UPS User Guide
Operator’s Guide
UPS-1500 Series
Military Grade Uninterruptible Power Supply
UPS-1500-S-1U
UPS-1500-E-2U
Made in USA
Advancing The Power Curve
1.888.567.9596 (USA only) | SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA |
®
www.synqor.com
Table of Contents
Section I
Warnings
Hazardous Voltages....................................................................................................................................................4
Hazardous Energies....................................................................................................................................................5
Battery Pack...................................................................................................................................................................6
Protection from the Environment..........................................................................................................................6
No User Serviceable Parts.........................................................................................................................................6
Section II:
General Product Information
Product Description....................................................................................................................................................7
Product Topology.........................................................................................................................................................8
Part Numbering Scheme and Options.............................................................................................................. 10
Product Specifications............................................................................................................................................ 11
Electrical Characteristics...................................................................................................................................... 13
1U Mechanical Diagram........................................................................................................................................ 14
2U Mechanical Diagram........................................................................................................................................ 15
UPS Efficiency............................................................................................................................................................. 16
Total Output Power that can be derived from the AC INPUT.................................................................. 16
Power Cable Wiring Diagram.............................................................................................................................. 19
Power Cable Wire Size............................................................................................................................................. 20
Warranty...................................................................................................................................................................... 21
Section III:
Operation
Set-Up............................................................................................................................................................................ 23
Start-Up........................................................................................................................................................................ 24
Shut-Down................................................................................................................................................................... 24
Power Cable Connections/Disconnections While Operating................................................................... 25
Cooling System........................................................................................................................................................... 26
Front Panel Indicators............................................................................................................................................ 27
LEDs....................................................................................................................................................................... 27
Audible alarm.................................................................................................................................................... 32
Hot Swapping the Battery Pack........................................................................................................................... 32
Operating Environment.......................................................................................................................................... 33
Visit our website for
more information
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Section IV
Multiple UPS Configurations
General Considerations.......................................................................................................................................... 34
Parallel Connection of DC Outputs.................................................................................................................... 35
Possible configurations of the AC OUTPUTs................................................................................................... 36
Multi-unit Configurations.............................................................................................................................. 36
Parallel Connection of the AC Outputs............................................................................................................. 37
Two UPS units with AC OUTPUTs Paralleled........................................................................................ 37
Three UPS units with AC OUTPUTs Paralleled..................................................................................... 38
Series Split-Phase Connection of AC Outputs ............................................................................................... 39
Series 3-Phase Connection of AC Outputs ...................................................................................................... 40
Connection of the AC and/or DC INPUTS....................................................................................................... 41
3-phase AC INPUT Source............................................................................................................................. 41
Multi-unit AC Output On/Off Control....................................................................................................... 42
AC Output Neutral Grounding..................................................................................................................... 42
Wiring Caution.......................................................................................................................................................... 42
Section V:
Battery Pack
Battery Technology................................................................................................................................................... 43
Electronic Circuitry within the Battery Pack................................................................................................. 43
Battery Capacity........................................................................................................................................................ 44
Storage of the Battery Pack................................................................................................................................... 44
Battery Pack Replacement ................................................................................................................................... 44
Handling the Battery Pack.................................................................................................................................... 45
Section VI:
Control Interface Details
Control Cable Connections.................................................................................................................................... 46
Internal User I/O Circuits.............................................................................................................................. 47
Remote On/Off Switch Connections.......................................................................................................... 47
Digital Input/Output Control Signals................................................................................................................ 48
RS232 Serial Interface............................................................................................................................................. 49
Ethernet Interface..................................................................................................................................................... 51
Section VII
Maintenance
Battery........................................................................................................................................................................... 52
Fans................................................................................................................................................................................ 52
Cleaning........................................................................................................................................................................ 52
Section VIII
Trouble-Shooting Guide
Fault Conditions........................................................................................................................................................ 53
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Section I
Warnings
Hazardous Voltages
The INPUT AND OUTPUT POWER connectors and cables of the SynQor UPS may have
voltages that are unsafe. INJURY OR DEATH ON CONTACT may result. Appropriate safety
precautions should be taken. All connections should be made in accordance with LOCAL
ELECTRICAL CODES.
•The UPS CHASSIS should be connected to earth or system ground with Ground Stud on
the rear panel, see mechanical diagrams.
•For the AC INPUT cable and connector:
▪ Do not assume that a hazardous voltage is not present at the terminals of the AC input
connector, even if the UPS appears to be off.
▪ Do not make contact with the terminals of the AC input connector.
▪ Always connect the cable to the UPS before it is connected to the source of AC power.
▪ Always disconnect the AC input cable from the source of AC power before disconnecting
it from the UPS.
▪ If the AC input cable is connected to the source of AC power and not connected to the
UPS, do not contact the exposed terminals of the AC input cable.
▪ Do not assume that the source of AC power is not present.
▪ Connections between the AC input cable and the source of AC power should not
be accessible.
•For the AC OUTPUT cable and connector:
▪ Do not assume that a hazardous voltage is not present at the terminals of the AC output
connector, even if the UPS appears to be off.
▪ Do not make contact with the terminals of the AC output connector.
▪ Connect the AC output cable to the UPS before the UPS is turned on.
▪ If connection of the load to the AC output cable has exposed conductors, make this
connection before connecting the AC output cable to the UPS.
▪ Connections between the AC output cable and the load should not be accessible.
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Section I
Warnings
•For the DC INPUT cable and connector (if present):
▪ The rated DC input voltage of the UPS is below the level considered hazardous.
▪ The DC input terminals of the UPS are isolated from the AC input and AC outputs with
reinforced safety insulation.
▪ 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.
•For the DC OUTPUT cable and connector (if present):
▪ The rated DC output voltage of the UPS is below the level considered hazardous.
▪ The DC output terminals of the UPS are isolated from the AC input and AC outputs with
reinforced safety insulation.
▪ However, never assume the terminals of the DC output connector or the wires of the
DC output cable are safe to contact, even if the UPS appears to be off.
•For the BATTERY PACK (if not inserted into the UPS):
▪ When the battery pack is not inserted into the UPS, the battery is internally disconnected
from the power pins of the battery pack’s connector.
▪ Even if this disconnection were not present, the DC voltage of the battery is below the
level considered hazardous.
▪ Do not apply external voltages to the pins of an exposed battery pack connector. It is
not possible to charge the battery pack from an external source, and excess voltages
could damage internal control circuitry.
Hazardous Energies
The INPUT AND OUTPUT POWER connectors and cables of the SynQor UPS may be the source
of high levels of energy. Do not inappropriately make electrical contact between any terminal
of a connector and another, or between any wire of a cable and another, or between any
terminal or wire and the UPS’s chassis or ground. DAMAGING ELECTRICAL ARCS may result.
Care should be taken to avoid accidental electrical contacts of this sort.
When the BATTERY PACK is not inserted into the UPS, the battery is internally disconnected
from the power pins of the battery pack’s connector. 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.
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Section I
Warnings
Battery Pack
The individual LITHIUM POLYMER BATTERIES contained in the SynQor battery pack are sealed
units that are further mechanically protected by the battery pack’s chassis and electrically
protected by the battery pack’s electronic circuitry. Under normal conditions they do not pose a
hazard, but they should not be physically, thermally or electrically abused.
The TRANSPORT of the battery pack must comply with applicable regulations of the locality. See “Battery Pack - Handling the Battery Pack”.
The battery pack should be DISPOSED in accordance with applicable regulations of the locality
or RETURNED to a factory-authorized Service Center.
Emergency response contact information for battery damage, leaks, smoke, or fires can be
found at the following link: http://www.SynQor.com/UPS/documents/Contact.pdf. Please
contact the factory for all other questions regarding the UPS battery pack.
CAUTION: Do not dispose of batteries in a fire. The batteries may explode.
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 42
Protection from the Environment
The SynQor UPS is a ruggedly built product having its electronics and battery contained in
sealed chambers. It is capable of withstanding harsh levels of mechanical acceleration, shock
and vibration, temperature and pressure variations, and exposure to water, salt, sand and dust
within the levels specified in the data sheet. THESE LEVELS SHOULD NOT BE EXCEEDED.
Do not obstruct the air intake in the front of the UPS or the fan exhausts in the rear panel of
the UPS while the UPS is operating.
No User Serviceable Parts
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.
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Section II:
General Product Information
Product Description
The SynQor UPS-1500 Series is an advanced technology military-grade uninterruptible power
supply (UPS) that uses lithium polymer batteries and highly efficient power electronic circuitry
to achieve a high power level and battery run-time in a low-profile, low-weight, rack-mountable
package. It provides voltage and frequency conditioning, electrical isolation, and power flow
smoothing between the power inputs and its power outputs. It provides battery backed-up
power when other power sources are not present.
A communication/control port is available to permit monitoring and control by a host computer
system. Front panel LEDs and an audible alarm provide information on the status of the UPS
and the battery pack.
The UPS-1500 Series products can draw power from an AC input having a wide range of voltage
and frequency levels, or from an optional 28V nominal DC input. The AC input has priority over
the DC input. The UPS provides up to 1500VA and 1250W of AC output power at 115Vac. The pure sine wave AC output voltage can drive any non-linear load with a crest factor up to
2.5, and any load power factor from 0.0 to 1.0. There are two optional DC outputs at various
voltage and power levels available. The total AC plus DC output power is limited to 1250W.
The electronic circuitry within the UPS-1500 Series products is designed, qualified and screened
according to SynQor’s MIL-COTS Standards. It complies with the requirements of MIL-STD-704F,
MIL-STD-1399-300B, MIL-STD-1275D and MIL-STD-461F, as well as IEC‑EN61000 specifications
for world-wide commercial utility applications.
The UPS-1500 Series products are designed and manufactured to withstand the harsh
environments and use encountered in military applications. The electronic circuitry and battery
are contained in a sealed chamber constructed from a die-cast aluminum chassis that is weatherproof and shock-proof. Redundant, water-proof fans on the rear panel draw cooling air over
the heat-sink fins below the sealed chamber. Military-grade circular connectors are used, and
optional attached connector covers are available for when the cables are not attached. The UPS1500 Series products comply with a wide range of testing according to 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. The former weighs
approximately 32 lbs. and the latter 50 lbs.
The SynQor UPS-1500 Series products are designed and manufactured in the U.S.A.
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Section II
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. There is
a seamless transfer from any power source to another so that there is no disruption in the
output voltage waveform.
As the figure below shows, there is a nominal 28V mid-bus within the UPS that draws power
from one of up to three power sources: the AC INPUT, the optional DC INPUT or the battery
(with that order of priority based on availability). EMI filters are present at all external
inputs and outputs.
AC
INPUT
DC
INPUT or
DC2 OUTPUT
AC to DC
w/ PFC
and
ISOLATION
ISOLATED
INVERTER
AC
OUTPUT
ELECTRONIC
SWITCH /
Non-Isolated
DC-DC Converter
ISOLATED
DC/DC
CONVERTER
DC
OUTPUT
(OPTIONAL)
(OPTIONAL)
BATTERY
BULK ENERGY
STORAGE
CAPACITOR
with
CHARGER
and
ELECTRONIC SWITCH
Power flows from the AC INPUT through an AC-DC converter that has Power Factor Correction
(PFC) and high-frequency safety isolation. Power flows from the DC INPUT through an
electronic switch that is closed when the AC INPUT power is absent and the DC INPUT voltage
is within its specified range. Otherwise, a second electronic switch is closed to connect the
battery to the mid-bus.
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Section II
General Product Information
The AC OUTPUT is created by an inverter that draws power from the mid-bus. This inverter
provides high frequency safety isolation and a pure-sinusoidal output voltage waveform.
Optional DC outputs at various voltage and power levels are available. The DC1 option is limited
to 500W. The DC2 option can deliver up to 1250W output. When the DC2 option is selected, DC
Input is not available. The DC1 and DC2 outputs are isolated from each other and the AC output.
Bulk energy storage capacitors are connected to the mid-bus to help smooth imbalances in
power flow between the inputs and outputs of the UPS.
There is a battery charger circuit that draws power from the mid-bus. It ensures the batteries
are normally fully charged and that the various cells are equalized. 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.
UPS in Transit Case Option
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Section II
General Product Information
Part Numbering Scheme and Options
This table shows the part numbering scheme for the full line of SynQor UPS products:
UPS Output Power
UPS
1500
1500:1500VA
1250W
UPS
3000:3000VA
2500W
Battery Pack
Size
Height
AC Input
Frequency
E
2U
L
AC Output
AC Output AC Output
Set Point
Voltage Neutral Wire
Frequency
1
G
DC Input
D
S:Not Installed
D:DC Input
M:DC2 Out 24VDC
w/Droop Share
S:Standard 1U:1.73" L: 47-65Hz 1:115Vrms G:Grounded 5:50Hz P:DC2 Out 24VDC
6:60Hz
E:Extended 2U:3.48"
no sharing
W:47-800Hz 2:230Vrms F:Floating 4:400Hz
N:No Battery
R:DC2 Out 28VDC
w/Droop Share
V:DC2 Out 28VDC
no sharing
DC Output
Voltage
Additional
Options
28
000
00:None
12:12V
15:15V
24:24V
28:28V
40:40V
50:50V
000: Standard
0CE: CE Marking
E00: Ethernet /
SNMP
ECE: Ethernet /
SNMP &
CE Marking
6
The DC Input is not available if a DC2 Option is selected. DC2 Options P & V are only available on the UPS-1500.
Not all combinations make valid part numbers, please contact SynQor for availability. See the Product Summary web page for more options.
Part Number Examples:
UPS-1500-E-2U-L1G6D28-000, UPS-1500-S-1U-L2G5S00-000
UPS-1500-S-1U-L2G5S00-0CE (230V output with CE marking)
The UPS-1500 Series of products provide up to 1500VA and 1250W 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
•A 2U high, 50 lb. rackmount unit that uses the extended battery pack that provides >24
minutes of battery run-time at full power
Each format has various options that can be specified according to the part numbering scheme
shown in the table:
•The allowable frequency of the AC INPUT can either be in the 47-65 Hz range (for 50 Hz and/
or 60 Hz systems) or in the 360-800 Hz range (for 400 Hz and Variable Frequency systems)
•The output voltage of the UPS-1500 Series can be 115VRMS or 230VRMS
•The AC output can be configured with its neutral wire internally grounded to the chassis
of the UPS or left floating for shipboard applications
•The initial set-point frequency of the AC OUTPUT voltage can be 50 Hz, 60 Hz or 400 Hz. Regardless of the initial set-point frequency, the actual frequency can be set through the
communications/control port. Note: This feature is not yet available .
•There is an optional DC INPUT that is specified to comply with MIL-STD-704F and
MIL‑STD‑1275D for 28V systems.
•Two optional DC OUTPUT capabilities are available: DC1 with up to 500W capability, and
DC2 with up to 1250W capability an optional droop share.
•RS232 serial port and logic-level I/O communication are included in the standard model. An Ethernet port providing web and SNMP interfaces is an available option.
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Section II
General Product Information
Product Specifications
The following three pages show the electrical and mechanical specifications of the UPS‑1500S‑1U
high and the UPS-1500E-2U Series of products. Data sheets showing these specifications and
other information can be found at the web site http://www.synqor.com/UPS.
UPS-1500-S-1U
Status LED
Front Panel
Status Indicator Panel
1.73"
1U
On/Off
17.00"
Air Intake
Rear Panel
UPS Units with DC Input / DC1 Output Options
17.00"
1.73"
1U
DC1
Output
Option
AC
Output
Exhaust
Fan
Ethernet User CONFIG Ground DC
Port
I/O
Port
Stud
Input
Option
(1/4-20) Option
Exhaust
Fan
AC
Input
AC
Circuit
Breaker
Rear Panel
UPS Units with DC1 Output / DC2 Output Options
17.00"
1.73"
1U
DC1
Output
Option
AC
Output
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Exhaust
Fan
Ethernet User CONFIG Ground DC2
Port
I/O
Port
Stud Output
Option
(1/4-20) Option
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Exhaust
Fan
AC
Input
AC
Circuit
Breaker
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Section II
General Product Information
UPS-1500-E-2U
Status LED
Front Panel
Status Indicator Panel
2U
3.33"
On/Off
17.00"
Air Intake
Rear Panel
UPS Units with DC Input / DC1 Output Options
8.5cm
2U
DC1
Output
Option
AC
Output
Exhaust
Fan
Ethernet
Port
Option
User CONFIG Ground DC
I/O
Port
Stud
Input
(1/4-20) Option
17.00"
Exhaust
Fan
AC
Input
AC
Circuit
Breaker
AC
Input
AC
Circuit
Breaker
Rear Panel
UPS Units with DC1 Output / DC2 Output Options
DC1
Output
Option
AC
Output
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Exhaust
Fan
Ethernet
Port
Option
User CONFIG Ground DC2
I/O
Port
Stud Output
(1/4-20) Option
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Exhaust
Fan
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Section II
General Product Information
Electrical Characteristics
INPUT CHARACTERISTICS
ENVIRONMENTAL CHARACTERISTICS MIL-STD-810G
Operating AC Input
MTBF
100kHrs
MIL-217F Ground Benign, Ta=25°C
Voltage
80-265Vrms*
Temperature Methods 501.5, 502.5
Frequency
47-65Hz
Operating Temperature
-20°C — +55°C
(47-800Hz Optional)
Storage Temperature
-20°C — +65°C
>0.98 at 47-65Hz
Altitude Method 500.5
>0.97 at 400Hz
Operating
>0.93 at 800Hz
Non-operating
Maximum Input Current Continuous
20A (full load, 85Vrms)
Electromagnetic Capability
AC Input Circuit Breaker Rating
25A
CE101
30 Hz - 10 kHz
CE102
10 kHz - 10 MHz
Input Power Factor
(* Power Derating to 80% below 90Vrms)
Operating DC Input (Optional)
0 - 15,000 ft
0 - 40,000 ft
MIL-STD-461F
CS101
30 Hz - 150 kHz
Voltage
22-33V
CS106
10 kHz - 40 GHz
Continuous Maximum Input Current
62A (full load, 22V)
CS114
10 kHz - 200 MHz
Transient Maximum Input Current
75A
CS116
10 kHz - 100 MHz
OUTPUT CHARACTERISTICS
RE101
30 Hz - 100 kHz
Total Output Power Continuous
1250W (1500VA)
RE102
10 kHz - 18 GHz
Maximum DC1 Output Power
510W
RS101
30 Hz - 100 kHz
Maximum DC2 Output Power
1250W
RS103
2 MHz - 40 GHz
(Note: Available AC power is reduced by power delivered to the DC output)
Environmental Tests
AC Output
Shock/Drop
Method 516.6, Procedures 1,4,6
AC Output Waveform
Pure Sinusoidal
Vibration
Method 514.6, CAT 5, 7, 8, 9, 24
Voltage
115Vrms ± 3%
Fungus
230Vrms ± 3%
Salt Fog
60Hz ± 0.5%
Sand and Dust
50Hz ± 0.5%
Rain
Method 506.5
400Hz ± 0.5%
EMI
MIL-STD-461F
26A (115Vrms)
Humidity
Frequency
Peak Load Current
13A (230Vrms)
Mechanical Vibrations of
Load Power Factor
0-1.0 (leading or lagging)
Shipboard Equipment
Total Harmonic Distortion
2% (1000W resistive load)
MECHANICAL CHARACTERISTICS
Chassis Size (H x W x D)
Voltage Regulation (Over Load & Temperature) ± 3%
(Other Options Available)
Method 507.5
Method 528
1.73"(1U) x 17" x 21.6"
12V at 42A
=504W
Case Material
15V at 34A
=510W
Total Weight
24V at 21A
=504W
28V at 18A
=504W
40V at 12.5A
=500W
50V at 10A
=500W
Optional 2U Extended Internal Battery Pack
3.33"(2U) x 17" x 21.6"
Chassis Size (H x W x D)
Aluminum
Case Material
49 lbs. (with chassis & battery)
Total Weight
Connectors
AC Input Connector
MS3470L14-4P
DC Input Connector
MS3470L18-8P
AC Output Connector
MS3470L14-4S
DC1 Output Connector
MS3470L14-4SW
DC2 Output Connector
MS3470L18-8S
User I/O Ports
HD DB15 Female
Configuration I/O Port
HD DB15 Male
Cooling Exhaust Fans
Sound Pressure Level (SPL)
54 dB(A)
Air Flow
0.67(m3/min) 23.7 CFM
Two fans in system, above specs are for each fan separately.
DC2 Output (optional)
Voltage Setpoint
± 3%
No Sharing
Voltage Regulation (Over Load & Temperature) -2%
Common Voltage/Power combinations (DC2)
24V at 50A
=1200W
28V at 44.6A =1250W
Droop Share (Output droops vs. load to allow passive sharing among modules.)
24V Option
Voltage Regulation (Over Load & Temperature) -15%
26V at 0A
22V at 50A
=1100W
28V Option
Voltage Regulation (Over Load & Temperature) -13%
30V at 0A
26V at 48.1A =1250W
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Method 509.5
Method 510.5, Procedures 1,2
Standard 1U Battery Pack
DC1 Output (optional)
Common Voltage/Power combinations (DC1)
Method 508.6
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Section II
General Product Information
1U Mechanical Diagram
19.450"
21.60"
18.700"
9.750"
.750"
.75"
1.50"
UNIT
MOUNTING
HOLES
8-32 .250
x26
17"
MADE IN USA
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.55"
.625"
.313
1.73"
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Section II
General Product Information
2U Mechanical Diagram
19.450
18.700
21.60
9.750
.750
.75
1.50"
UNIT
MOUNTING
HOLES
8-32 .250
x52
2.375
3.33
MADE IN USA
UPS
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1.749
.625
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Section II
General Product Information
UPS Efficiency
Figure 1 shows the typical efficiency with which the UPS-1500 series uninterruptible power
supplies delivers power to its AC OUTPUT from a 230Vrms AC INPUT, an 115Vrms AC INPUT or
a 28V DC INPUT:
Efficiency vs. Output Power
for Each Input Source
95.0%
90.0%
28 Vdc
230 Vac
115 Vac
85.0%
Efficiency
80.0%
75.0%
70.0%
0
200
400
600
800
Ouput Power (Watts)
1000
1200
1400
Figure 1
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 1250W for an ambient temperature as high as 55oC (131oF). It draws this power first from the AC INPUT (if its voltage is within range) and then the DC
INPUT (if its voltage is within range) and then from the internal BATTERY PACK (if it has
sufficient charge).
However, when the AC INPUT voltage is at the low end of its range (<90Vrms) or the ambient
temperature is at the high end of its range (>45oC/113oF) the UPS will not be able to deliver its
full rated output power in the steady-state without switching over to either the DC INPUT (if it
is available and >22Vdc) or its internal battery. Figure 2 indicates the total steady-state output
power that the UPS can derive from the AC INPUT under these extreme conditions. See Figure
3 for information on transient conditions.
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Output Power vs. Air Temperature
1400
1200
1000
Output
Power
(Watts)
VAC(IN) >105VRMS or VDC(IN) >22V
800
600
VAC(IN) = 90VRMS and VDC(IN) <22V
400
VAC(IN) = 80VRMS and VDC(IN) <22V
200
0
25
30
35
40
45
50
55
Air Temperature (°C)
Figure 2
•If the AC INPUT voltage is above 105Vrms, then the UPS can deliver its full rated output
power of 1250W from the AC INPUT for an ambient temperature as high as 55oC (131oF)
without needing to switch over to the optional DC INPUT or the internal BATTERY PACK.
•If the AC INPUT is between 90Vrms and 80Vrms then the total output power that can be
derived from the AC INPUT linearly decreases from 1250W at 90Vrms to 1000W at 80Vrms
(except for at the high end of the ambient temperature range – see below). For example,
the total output power that could be derived from the AC INPUT would be 1125W at
85Vrms as long as the ambient temperature is not above 50oC (122oF). If the total output
power is greater than this derated value, the UPS will switch to the DC INPUT (if it is
available and >22V) or the internal BATTERY PACK.
•If the AC INPUT voltage is 90Vrms AND the ambient air temperature is above 45oC (113oF),
the total output power that can be derived from the AC INPUT linearly decreases from
1250W at 45oC (113oF) to 1000W at 55oC (131oF). For example, the total output power
that could be derived from the AC INPUT would be 1125W at an AC INPUT voltage of
90Vrms and an ambient temperature of 50oC (122oF). A higher output power than this
would cause the UPS to switch over to its DC INPUT or the internal BATTERY PACK.
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Section II
General Product Information
•When the AC INPUT voltage is between 105Vrms and 90Vrms AND the ambient temperature
is between 45oC and 55oC, the total output power that can be derived from the AC INPUT
can be calculated by linearly interpolating between the curves shown. For example, the
total output power that can be derived from the AC INPUT when the voltage is 97.5Vrms
would be 1250W up to an ambient temperature of 50oC (122oF) and then derate to 1125W
at 55oC (131oF).
Furthermore, there is a limited (and uncommon) range of AC INPUT voltage between 132Vrms
and 160Vrms in which the total output power that can be derived from the AC INPUT is also
derated, as shown in the graph below.
Output Power vs. AC Input Voltage
(without switching over to the DC input or the battery)
1400
1200
1100W
1000
Steady state
Output
Power 800
(Watts)
15s transient
132V
2s transient
600
400
200
0
60
80
100
120
140
160
180
200
220
240
260
280
Input Voltage (Vrms)
Figure 3
Note that the full rated output power of 1250W can be derived from the AC INPUT having a voltage
within this uncommon range for 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
INPUT voltage drops below 90Vrms.
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Section II
General Product Information
Power Cable Wiring Diagram
Looking at the rear panel, the UPS connector terminals have the following functions and locations:
Pin
A
B
C
D
AC INPUT
Function
Line
Neutral
No Connect
Ground
A
D
B
C
A
Pin
G, F, E
B, C, D
A, H
DC INPUT
Function
+Vin
Vin Return
No Connect
G
B
H
F
C
E
Pin
A
B
C
D
AC OUTPUT
Function
Line
Neutral
No Connect
Ground
D
A
D
B
C
DC1 OUTPUT
Pin
Function
C, D
+VOUT
A, B
VOUT Return
A
D
B
C
A
DC2 OUTPUT
Pin
Function
G, F, E
+VOUT
B, C, D
VOUT Return
A, H
No Connect
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G
H
C
F
D
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Section II
General Product Information
Power Cable Wire Size
SynQor recommends the following cables for use with the UPS-1500 Series:
AC Input:
AC Output:
DC Input:
DC1 Output:
DC2 Output:
SYN-9101
SYN-9104
SYN-9102
SYN-9131
SYN-9130
SYN-9151
SYN-9154
SYN-9171
SYN-9172
SYN-9174
SYN-9175
UPS connection to NEMA 5-20 Plug, 10’
UPS connection to NEMA 5-15 Plug, 10”
UPS connection to Hardwire Termination, 10”
UPS connection to NEMA 5-20 Receptacle, 10’
UPS connection to Hardwire Termination, 10’
UPS connection to Ring Connectors, 10’
UPS connection to NATO Connector, 10’
UPS connection to Fork Connectors, 10’
UPS connection to Hardwire Termination, 10
UPS connection to Harwire Termination, DC2 Output, 10’’
UPS connection to Fork Connectors, DC2 Output, 10’’
Other options may be available. Contact [email protected] or visit the website: http://www.synqor.com for
more information. If it is necessary to develop custom cables for your application, please read through the
following section for some important considerations. Damage caused by improper wiring of cables will not be
covered under SynQor’s warranty.
Both the input and output cables of the UPS carry substantial current, and since the wires in these cables have
resistance the current flowing through them causes a voltage drop from one end of the cable to the other. In
other words, the voltage across the cable at its downstream end is smaller than the voltage across the cable at its
upstream end. Mathematically, the amount that the voltage drops is equal to the resistance of the cable’s wire
multiplied by the current flowing through the wire. It is therefore important to make sure that the resistance of
the cable’s wire is small enough to keep this voltage drop to an acceptably small value.
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 65A for the UPS-1500 Series) and the
voltage across it is already relatively small (as low as 22V). 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 22V even though the voltage at the source of the DC power is greater than 22V. Under this
condition the UPS will switch to the internal battery pack for its power source even though the voltage at the DC
source of power appears to be available and at a proper level.
The resistance of a wire depends directly on its length. A wire twice as long as another will have twice the
resistance, holding all other things constant. The resistance also depends on the reciprocal of the cross-sectional
area of the wire, which in turn depends on the square of the wire’s diameter. A wire with half the diameter of
another will therefore have four times the resistance, holding all other things constant.
Therefore, the longer a cable is, the more important it is that the wire’s diameter be large. Alternatively, a cable
can have multiple pairs of wires to achieve a larger “effective wire diameter”. This second approach gives a more
flexible cable. For 10 ft long cables, SynQor recommends that for the UPS-1500 Series:
• The AC INPUT cable have 3 wires (one for the ground) of 12 AWG
• The DC INPUT cable have 6 wires (three for each connection) of 12 AWG
• The AC OUTPUT cable have 3 wires (one for ground) of 12 AWG
• The DC1 OUTPUT cable have 4 wires (two for each connection) of 12 AWG
• The DC2 OUTPUT cable have 6 wires (three for each connection) of 12 AWG
Additional details about the effects of a resistance-related voltage drop are included in “Trouble-Shooting
Guide - Cable wire resistance is too high”.
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Section II
General Product Information
Warranty
SynQor warrants that the UPS product, including all accessories, but excluding battery pack,
will be free from defects in materials and workmanship and will perform in accordance with its
specifications (as set forth in the SynQor Operator’s Guide and applicable datasheet) for one
(1) year following the date of shipment to the customer.
SynQor warrants that UPS battery pack will be free from defects in materials and workmanship
and will perform in accordance with its specifications (as set forth in the SynQor Operator’s
Guide and applicable datasheet) for the earlier of (i) one (1) year from the date of shipment
to the customer, and (ii) three hundred (300) charge, discharge cycles, whichever comes
first, provided, in each case, that the battery pack is stored and operated in accordance with
conditions specified in the SynQor UPS Operator’s Guide and any applicable datasheet.
UPS products and battery packs repaired or replaced pursuant to this warranty shall be
warranted for the non-expired portion of the warranty applying to the original equipment.
This warranty does not apply to (i) products damaged by abuse, misuse, neglect, improper
testing, accident or tampering, (ii) products subjected to adverse operating environments, (iii)
products operated outside the limits of their electrical specifications, (iv) products repaired
or modified by third parties or products which have been caused to fail by any product or
component not supplied by SynQor, (v) products which have been used in a manner contrary
to the specifications or guidelines set forth in the SynQor UPS Operator’s Guide or product
datasheet, or (vi) improper performance of products as installed in Buyer applications where
such products performed in accordance with product specifications prior to installation.
If SynQor determines that the product is defective SynQor will, at its option, repair or replace
the product or refund all or part of the purchase price therefor. Replacement product may
be new or refurbished equipment. To obtain a replacement or repaired product under this
warranty, the Buyer must contact SynQor Sales within the warranty period to obtain a Return
Material Authorization and shipping instructions. The Buyer must return the product in the
original packaging and pay all charges incurred in shipping the product back to SynQor. In
shipping the product back to SynQor, the Buyer assumes all risk of damage or loss in transit.
If SynQor determines that the product is defective, SynQor will pay any shipping charges in
sending the replacement or repaired product to the Buyer.
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Section II
General Product Information
THIS WARRANTY IS BUYER’S SOLE AND EXCLUSIVE REMEDY FOR ANY CLAIM, WHETHER IN
CONTRACT, TORT OR OTHERWISE, AND IS IN LIEU OF ANY OTHER WARRANTY, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT LIMITED TO, ANY WARRANTY
OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY WARRANTY OF
NONINFRINGEMENT OF THE INTELLECTUAL PROPERTY RIGHTS OF THIRD PARTIES. ALL SUCH
WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED.
Limitation on Liability and Remedy.
SynQor shall have no liability for any indirect, incidental, special or consequential damages
in connection with the transactions contemplated hereby or arising from the use or inability
to use the product, including without limitation, damages due to business interruption, lost
profits or lost goodwill, claims of third parties, or injury to person or property, whether based
upon breach of contract, negligence, strict liability, tort or other legal theory. In no event shall
SynQor’s total liability arising from the sale or use of, or inability to use, SynQor’s product
exceed the price paid for the product net of discounts and rebates. Neither party may bring a
cause of action under this warranty more than two (2) years after the cause of action arose.
Limitation on Use.
SynQor’s products are not authorized for use and should not be used, without the specific
prior written approval of an authorized officer of SynQor making specific reference hereto, in
any nuclear facility or application, or any other application in which failure or malfunction of
the product could reasonably result in loss of or harm to human life, or catastrophic damage
to property or the environment. Buyer will indemnify and hold SynQor harmless from any loss,
cost or damage resulting from Buyer’s use of the products in any such prohibited activity.
The foregoing is excerpted from SynQor’s Terms and Conditions of Sale - Military Power Systems,
available at this link: http://www.SynQor.com/Company - SalesTsandCs.html.
If there is a conflict between what is described in this Operator’s guide and SynQor’s online terms and
conditions, the online version shall govern.
PATENTS
SynQor holds numerous U.S. patents, one or more of which apply to most of its power converter products. Any that apply to the product(s) listed in this document are identified by marking on the
product(s) or on internal components of the product(s) in accordance with U.S. patent laws.
SynQor’s patents include the following:
5,999,417
6,222,742
6,545,890
6,594,159
6,731,520
6,894,468
6,896,526
6,927,987
7,050,309
7,072,190
7,085,146
7,119,524
7,269,034
7,272,021
7,272,023
7,558,083
7,564,702
7,765,687
7,787,261
8,023,290
8,149,597
8,493,751
8,644,027
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Section III:
Operation
Set-Up
The recommended procedure for setting up the UPS is the following:
•Insert the BATTERY PACK (if not already present) and tighten its screws.
•Make sure the AC BREAKER on the rear panel of the UPS is in the OFF position.
•Connect the ground wire to the ground stud on the rear panel of the UPS.
•Connect all OUTPUT cables, first to the UPS and then to the various loads.
•VERIFY that the optional DC OUTPUT cable is connected to the UPS and the load with
the correct polarity.
•Connect the USER I/O cables.
•Connect all INPUT cables, first to the UPS and then to the various sources.
•VERIFY that the optional DC INPUT cable is connected to the UPS and the source of DC
power with the correct polarity.
•Turn on the sources (if they have an upstream breaker).
•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.
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Section III:
Operation
Start-Up
•VERIFY that all connections to the UPS are correct.
•If either the AC source or the DC source (or both) is present and within specifications,
the color of the LED above the ON/OFF switch will be amber. This indicates that the
UPS is in standby mode and ready to turn on. The battery pack LEDs will also be
appropriately illuminated.
•Momentarily push the ON/OFF switch on the front panel of the UPS upward. The
switch can then be released and it will return to its normal (neutral) position.
•The UPS will immediately enable its outputs (assuming there is no fault condition). The color of the LED above the ON/OFF switch will change to green. The LEDs on the
battery pack will indicate the amount of power being delivered to the load and the
input source from which this power is being drawn.
Note: If no input power sources are available the UPS can still be turned on. It will draw power
from the internal battery for as long as the battery has charge left in it. This is sometimes
referred to as a “COLD START” in the industry. Under this condition, the LED above the ON/
OFF switch and the battery pack’s LEDs will initially all be off. When the ON/OFF switch is
pushed to the ON position, all of these LEDs will be appropriately illuminated.
Shut-Down
•Shut down the equipment connected to the UPS.
•Push the ON/OFF switch on the front panel of the UPS downward and hold it in this position for 1 second (or more). The color of the LED above the ON/OFF switch will
change to amber (if one or both input power sources are present) or it will be off
(if no power sources are present). The switch can then be released to return to its
normal position.
•The UPS will disable its outputs and shut down.
•The battery pack LEDs will either be appropriately illuminated (if one or both input
power sources are present) or they will be off (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.
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Section III
Operation
Power Cable Connections/Disconnections While Operating
For safety reasons, it is highly recommended that the input and output power cables be
connected to the UPS before the source of AC or DC input power is turned on, and before the
UPS is turned on (see Section I: Warnings and the SET-UP section above). Similarly, it is highly
recommended to first turn off the UPS and the sources of input power before any power
cables are disconnected from the UPS.
However, the SynQor UPS is capable of having any of its input or output power cables connected
at any time (if safely done), including when the UPS is turned on and delivering power to the
load. For instance:
•Even if the UPS is turned on, one can connect or disconnect the input power cables
without harming the UPS or disrupting power delivery to the load. If no input power
source is available, the UPS will draw power from the battery pack. When there is an
external source of power connected to the UPS, the unit will draw power from that
source, choosing the AC INPUT source first, if present, and then the optional DC input
source. The transfer from one source of power (including the battery) to another is
seamless.
•Even if the UPS is turned on, one can connect or disconnect an output power cable
without harming the UPS or disrupting power delivery to a load that might be connected
to the other output.
NOTE that disconnecting an input or output power cable while that cable is handling power will likely
cause an arc to form as the terminals are pulled apart. This arcing is not harmful to the UPS, although
if done enough times it will degrade the connector to the point where it will need to be replaced. This
problem is particularly acute for the DC INPUT cable because its current is so high. Disconnecting this
cable while a large current is flowing is not recommended.
ALSO NOTE that when the UPS is turned on and delivering power to a load, and then another piece of
equipment is connected to the same output, it is possible that this connection will momentarily disrupt
the quality of the UPS’s output voltage. For instance, consider the case where the AC OUTPUT power
cable has a terminal strip that allows several loads to be connected to it. If the UPS is turned on and
delivering power to several of these loads and then another load is connected to the terminal strip, it is
possible that this new load will momentarily draw a large surge of current as it starts up. If this happens,
the output of the UPS could reach its maximum current limit, and the UPS will reduce its output voltage
to keep the current from getting any larger. This reduction in voltage will be corrected once the new load
reaches its normal mode of operation, but in the mean time the reduction of the 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.
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Section III
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. Similarly, care should be taken to avoid obstructing the fan blades.
The speed of the cooling fans is automatically controlled to provide adequate UPS cooling
while extending the life of the fan bearings. Under low ambient temperature and/or low UPS
output power the fans will be driven at a low speed. If the ambient temperature and output
power are such that the UPS cannot otherwise maintain its specified maximum temperature
for its internal circuitry, the fans will momentarily be driven at a speed that exceeds their rated
long-term running speed. There is an LED on the front panel of the battery pack that indicates
the speed of the fans.
If the ambient temperature is low enough (for the level of power being delivered to the
load), the fans may not be on. This is not a malfunction. It is done to preserve the life of
the fans. If the fans are off, check the Fan Service Required LED on the front panel of the
battery pack. If it is GREEN, the fans are functioning properly and simply not needed under
the present conditions.
The fans are weather-proof and water-proof.
The UPS has two fans to provide redundancy for these exposed, moving components. With
only a single operating fan the UPS is still able to deliver 100% rated power at an ambient
temperature as high as 40oC, and it is able to deliver 80% of its rated power at an ambient
temperature as high as 55oC.
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Section III
Operation
Front Panel Indicators
To indicate the status of the UPS and its battery pack, there is one LED above the ON/OFF
switch on the left side of the front panel of the UPS and an additional 16 LEDs on the front
panel of the battery pack. There is also an audible alarm. These indicators are described in
this section.
LEDs
LED above the ON/OFF switch
This LED has four possible indications, according to the table below:
LED Appearance
Description
Indication
Green
UPS is Running
(Outputs are Enabled)
Amber
UPS is on Standby
(Outputs are Enabled)
Red
UPS has a Fault Condition
Off
UPS is Off
LEDs on the Battery Pack
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
FAN
BATT
A0
A1
B0
B1
B2
B3
C0
C1
D0
D1
E0
E1
E2
E3
F0
F1
POWER IN
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Section III
Operation
• Power-In Indicators (LEDs in positions D0 and D1)
The LED in position D0 indicates the status of the optional DC INPUT and the LED in position D1 indicates
the status of the AC INPUT, according to the table below:
LED Appearance
Description
Indication
Green
Input is Ready to Provide Load Power
Pulsing Green
Input is the One Presently Selected as the Source of
Power
Amber
Input has Returned within Range and Diagnostic Tests are
Being Performed
Off
Input is Not within Range
(Or the DC Input Option is not Installed)
• Power-Out Indicators (LEDs in positions A0 and A1)
The LED in position A0 indicates the status of the optional DC OUTPUT and the LED in position A1 indicates
the status of the AC OUTPUT, according to the table below:
LED Appearance
006-0006205 03/17/15 Rev N
Description
Indication
Green
UPS is On and the Output Voltage is
Within Range
Amber
UPS is On but the Output Voltage is
Out of Range
Red
UPS is Off and the Output Voltage is Within Range
Off
UPS is Off
(Or the DC Output Option is not Installed)
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Section III
Operation
• Load Power Indicators (LEDs in positions B0 – B3)
The LEDs in positions B0 through B3 indicate the total output power of the UPS (The AC OUTPUT power
plus the optional DC OUTPUT power) according to the table below:
LED Appearance
Description
Indication
B0 Dimmed Green;B1-B3 Off
Total Load Power <25%
B0 Green; B1 Dimmed Green; B2-B3 Off
Total Load Power <50%
B0, B1 Green;
B2 Dimmed Green; B3 Off
Total Load Power <75%
B0, B1, B2 Green;
B3 Dimmed Green
Total Load Power <100%
B0; B1; B2 Green;
B3 Blinking Red
Total Load Power ≥100%
• Battery State-of-Charge Indicators (LEDs in positions E0 – E3)
The LEDs in positions E0 through E3 indicate the state-of-charge of the internal battery pack, as well as
whether the battery pack is on standby or being charged (Blinking Amber) or discharged (Blinking Red),
according to the table below.
LED Appearance
Standby
Discharging
Charging
NA
NA
Indication
Battery Charge <10%
Battery Charge <25%
Battery Charge >25%
Battery Charge >50%
Battery Charge >75%
NA
NA
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NA
Battery Charge =100%
NA
Battery Charge =100%
(Cell Balancing
is Occurring)
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Section III
Operation
• UPS Cooling System Indicator (LED in position F0)
The LED in position F0 indicates the temperature and status of the cooling system for the UPS according
to the table below:
LED Appearance
Description
Indication
Green
Moderate UPS Temperature
(Fans Running at 33%)
Blinking Green
Warm UPS Temperature
(Fans Running at 67%)
Amber
Elevated UPS Temperature
(Fans Running at 100%)
Red
Maximum UPS Temperature
(Fans Running at 110%)
• Battery Pack Temperature Indicator (LED in position F1)
The LED in position F1 indicates the temperature of the battery pack (and its availability to be charged or
discharged because of its temperature) according to the table below:
LED Appearance
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Description
Indication
Blinking Red
Battery is too Cold to be Charged or Discharged
Blinking Amber
Battery is too Cold to be Charged
Green
Battery Temperature is Within its Specified
Operating Range
Amber
Battery is too Hot to be Charged
Red
Battery is too Hot to be Charged or Discharged
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Section III
Operation
• Fan Service Required Indicator (LED in position C0)
The LED in position C0 indicates whether the two cooling fans in the rear panel of the UPS are OK or if
their performance is degraded, according to the table below:
LED Appearance
Description
Indication
Green
Both Fans are OK
Amber
One or Both Fans Have Recently Had Degraded Performance
and Diagnostic Tests are Being Performed
Red
One or Both Fans Presently Have Degraded Performance
• Battery Pack Service Required Indicator (LED in position C1)
The LED in position C1 indicates whether the battery pack is OK or if its storage capacity has been degraded
compared to its rated value, according to the table below:
LED Appearance
Description
Indication
Green
Battery Pack is OK
Amber
Battery Pack’s Calculated Maximum Storage Capacity is
<75% of its Rated Value
Red
Battery Pack’s Calculated Maximum Storage Capacity is
<50% of its Rated Value
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Section III
Operation
Audible alarm
For critical situations a pattern of audible tones will be repeated every 5 seconds, according to the table
below. This audible alarm can be silenced by holding the ON/OFF switch on the front panel in the “UP”
position until a chirp is heard. A new alarm condition will cause the audible alarm to be reactivated.
Contact Factory for instructions on how to permanently silence the alarm.
Number of Tones in Pattern
Indication
One
UPS is Drawing Power From the Battery Pack
Two
Load Power is Above 100% Rated Power
Three
Fault Appears on the AC Output
UPS Must be Turned Off and Back On to Reset Fault
Four
UPS is Drawing Power From the Battery Pack and the
Remaining Charge is <10%
Hot Swapping the Battery Pack
The battery pack can be removed from the UPS and it, or another one, can be inserted into the UPS
without disrupting the delivery of power to the load as long as a source of input power is available. This
feature is referred to as “hot swapping” in the industry. It can be used to replace a battery pack that
needs servicing, or to replace a drained battery pack with a spare, fully charged one if additional back-up
protection must be ensured before the drained battery pack will have time to be recharged. 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.
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Section III
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, waterproof cooling fans are exposed to the environment. Protection circuitry ensures that the battery is not
charged or discharged if it is too hot or too cold. The UPS will shut down if it is too hot.
The UPS (with cables connected or connector covers installed and the battery pack installed) has been
qualified to the following requirements of MIL-STD-810G:
MIL-STD-810G
Test Method
Name
Procedure
500.5
Low Pressure
I, II and III
501.5
High Temperature
I and II
502.5
Low Temperature
I and II
503.5
Temperature Shock
I
506.5
Rain
I
507.5
Humidity
NA
▪ 4” rain/hour
▪ 40 mph wind velocity
▪ >95%
508.6
Fungus
NA
▪ 28 day test
509.5
Salt Fog
NA
510.5
Sand and Dust
I and II
514.6
Vibration
Category 5
514.6
Vibration
Category 7
▪ General Exposure
514.6
Vibration
Category 8
▪ C-130 Aircraft level
514.6
Vibration
Category 9
▪ General Exposure
514.6
Vibration
Category 24
516.6
Shock
I, IV and Vi
528
Mechanical Vibrations of
Shipboard Equipment
I
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Details
▪ 15,000 ft. operating
▪ 40,000 ft. storage
▪ +55oC operating
▪ +65oC storage
▪ -20oC operating
▪ -20oC storage
▪ 10 cycles; >10oC/minute
▪ 5% salt solution
▪ 2 cycles (24 hr wet/24 hr dry)
▪ 20 mph blowing dust
▪ 40 mph blowing sand
▪ 5Hz (300 RPM)
▪ Loose Cargo
▪ PSD = 0.4 g2/Hz; 1-2000Hz
▪ Operating
▪ 20g/20ms; 40g/11ms; 75g/6ms
▪ 48 inch drop in transit case
▪ 30 degree tilt and drop
▪ Operating
www.synqor.com
Section IV
Multiple UPS Configurations
General Considerations
Up to three SynQor UPS units (all having identical model numbers) can be combined in various
ways to achieve:
•Higher output power
•Higher output voltage
•Multiple output phases
•A balanced or unbalanced load for a 3-phase ac input source
To implement these configurations, which will be described in more detail in the pages that
follow, a configuration-specific CONFIGURATION cable is required to cause the units to work
together properly. These CONFIGURATION cables are available from SynQor, and the proper
part number for any configuration is given in the pages that follow.
Configuration-specific OUTPUT and/or INPUT cables will also be required. They can be
assembled by the user following the wiring diagrams shown below, or they can be ordered
from SynQor using the proper part number given in the pages that follow.
When multiple UPS units are combined, none of them will enable their AC outputs until all of
them have been “turned on” (either by actuating their front-panel “on” switches or by sending
the appropriate signal over their USER I/O cables). If any UPS unit is “turned off” all of the UPS
units will disable their outputs. If any UPS unit cannot deliver output power because it cannot
draw power from its AC INPUT, its DC INPUT or its BATTERY, or because there is an internal
fault, then all of the UPS units will disable their outputs.
Note: When combining UPS units into the configurations described in this section, each UPS
must internally have the neutral wire of its AC OUTPUT floating, rather than connected to its
chassis. This requires that all the UPS units have the “F” option (rather than the “G” option)
regarding the AC OUTPUT neutral wire connection. Check the UPS part numbers to be sure
this is the case.
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Section IV
Multiple UPS Configurations
Parallel Connection of DC Outputs
The DC1 outputs are not parallelable between multiple modules. A direct parallel connection
of DC1 outputs from different modules will result in a circulating power between the two MPC
devices. Diode-ORing devices added externally at the DC1 outputs will prevent any circulating
power. However, the outputs will still not necessarily share the load current equally.
DC2 outputs with the optional droop share feature are directly parallelable between multiple
modules. Internal devices prevent circulating power between multiple units. The droop
characteristic provides current sharing between parallel connected modules. Care should
be taken to equalize the resistive drops between each unit and the load to maintain close
matching of output current between multiple devices.
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Section IV
Multiple UPS Configurations
Possible configurations of the AC OUTPUTs
Multi-unit Configurations
The chart below shows four possible ways the AC OUTPUTs of multiple SynQor UPS units can be
connected together. Each configuration will be discussed in more detail in the following pages.
Number
of UPS
Units
Output
Configuration
Phasor
Diagram
# of
Output
Phases
Output Voltage
Output
Current
per phase
Total Output
Power
Configuration
Cable
L1
2
Parallel
3
Parallel
2
Series
Split-Phase
1
L-N:1 x Vrated
2 x Irated
2 x Prated
SYN-9311
1
L-N:1 x Vrated
3 x Irated
3 x Prated
SYN-9315
2
L-N:1 x Vrated
L-L: 2 x Vrated
1 x Irated
2 x Prated
SYN-9313
3
L-N:1 x Vrated
L-L: 1.73 x Vrated
1 x Irated
3 x Prated
SYN-9317
L1
L2
L3
3
3 Phase-Y
L2
L1
L1
120°
Note that the chart shows the SynQor part number for the CONFIGURATION cable required for
each configuration.
The chart shown above focuses on how the AC OUTPUTs of multiple UPS units could be
connected. 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.
When ordering, select the “F: Floating” option for UPS units configured in this manner.
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Section IV
Multiple UPS Configurations
Parallel Connection of the AC Outputs
Two or three SynQor UPS units can have their AC OUTPUTs connected in parallel to deliver two
or three time the output power and output current of a single unit.
Two UPS units with AC OUTPUTs Paralleled
For two UPS units having their outputs connected in parallel, the wiring diagram for the AC
OUTPUT cables and the CONFIGURATION cable is shown below:
CONFIGURATION cable SYN-9311
AC OUTPUT
REAR PANEL
AC OUTPUT
REAR PANEL
L1
L1
N
PEGND
N
L1 N PEGND
TO LOAD
PEGND
When ordering, select the “F: Floating” option for UPS units configured in this manner.
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 115Vac or 230Vac.
UPS AC Output Voltage
115Vac
230Vac
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Minimum Wire Size
#14AWG (2.5mm2)
#16AWG (1.5mm2)
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Red Cable Section
Minimum Wire Size
#10AWG (6mm2)
#12AWG (4mm2)
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Section IV
Multiple UPS Configurations
Three UPS units with AC OUTPUTs Paralleled
For three UPS units having their outputs connected in parallel, the wiring diagram for the AC
OUTPUT cables and the CONFIGURATION cable is shown below:
CONFIGURATION cable SYN-9315
REAR PANEL
AC OUTPUT
REAR PANEL
AC OUTPUT
AUX
AUX
AUX
L1
L1
N
REAR PANEL
AC OUTPUT
N
PEGND
L1
PEGND
N
PEGND
L1 N PEGND
TO LOAD
When ordering, select the “F: Floating” option for UPS units configured in this manner.
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 115Vac or 230Vac.
UPS AC Output Voltage
115Vac
230Vac
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Minimum Wire Size
#14AWG (2.5mm2)
#16AWG (1.5mm2)
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Red Cable Section
Minimum Wire Size
#10AWG (6mm2)
#12AWG (4mm2)
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Section IV
Multiple UPS Configurations
Series Split-Phase Connection of AC Outputs
Two UPS units can have their AC OUTPUTs connected in series to create an output voltage that
is twice that of the output voltage of the individual UPS units. For instance, if the UPS units
each create an 115Vac output, the series configuration will create a 230Vac output at twice
the power level of a single unit. Or, if the UPS units each create a 230Vac output, the series
configuration will create a 460Vac output at twice the power level of a single unit.
The center node between the two outputs in the series configuration should be considered
the “neutral” wire, and therefore kept at a potential close to Protective Earth Ground (PEGND).
The other two AC OUTPUT wires (one from each UPS unit) are electrically “hot” (meaning at
a high potential relative to the neutral or PEGND). One will be phase- shifted by 180 degrees
(one-half cycle) from the other, meaning that when one hot wire is at its positive peak the
other is at its negative peak, and vice versa. The voltage between these two hot wires is
therefore twice that of either hot wire compared to the neutral wire. This configuration is
called “Split-Phase”. When ordering, select the “F: Floating” option for UPS units configured
in this manner.
The wiring diagram for the AC OUTPUT cables and the CONFIGURATION cable for the SplitPhase configuration is shown below:
CONFIGURATION cable SYN-9313
AC OUTPUT
Line 2
Line 1
AC OUTPUT
REAR PANEL
L1
L2
N
REAR PANEL
PEGND
N
PEGND
L2 N L1 PEGND
TO LOAD
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
115Vac or 230Vac.
UPS AC Output Voltage
115Vac
230Vac
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Cable Minimum Wire Size
#14AWG (2.5mm2)
#16AWG (1.5mm2)
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Section IV
Multiple UPS Configurations
Series 3-Phase Connection of AC Outputs
Three UPS units can have their AC OUTPUTs connected such that they share a common
“neutral” and then controlled such that their output voltages are phased by 120 degrees (onethird cycle) from each other. This creates a three-phase output where the line-to-neutral
voltage is the rated voltage of the individual UPS units (e.g. 115Vac or 230Vac line-to-neutral)
and the line-to-line voltage is 1.73 times higher (e.g. 200Vac or 300Vac line-to-line).
The wiring diagram for the AC OUTPUT cables and the CONFIGURATION cables for the 3-Phase
configuration is shown below:
CONFIGURATION cable SYN-9317
AC OUTPUT
Line 2 REAR PANEL
Line 1 REAR PANEL
AC OUTPUT
L2
N
Line 3
AC OUTPUT
L1
PEGND
N
L2 L1 L3 N PEGND
TO LOAD
REAR PANEL
L3
PEGND
N
PEGND
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
115Vac or 230Vac.
UPS AC Output Voltage
115Vac
230Vac
Cable Minimum Wire Size
#14AWG (2.5mm2)
#16AWG (1.5mm2)
The “neutral” wire of the 3-phase AC OUTPUT should be kept at a potential close to Protective
Earth Ground (PEGND).
When ordering, select the “F: Floating” option for UPS units configured in this manner.
Note: The three connectors of the SYN-9317 CONFIGURATION CABLE are labeled “Line 1”, “Line
2” and “Line 3”. The UPS unit that receives the “Line 1” connector will have an AC OUTPUT
that is phased 120 degrees (one-third cycle) ahead of the UPS unit that receives the “Line 2”
connector, which in turn will have an AC OUTPUT that is phased 120 degrees (one-third cycle)
ahead of the 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.
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Section IV
Multiple UPS Configurations
Connection of the AC and/or DC INPUTS
Whether there are two or three UPS units in the multiple-unit configuration, there are several
ways that the AC and/or DC INPUTS can be connected to sources of power:
•They could be connected to the same AC and/or DC source, respectively.
•They could be connected to different AC and/or DC sources, respectively.
All that is necessary is to ensure that the input voltage falls within the specified range of the
AC and/or DC INPUTS of the individual UPS units.
Furthermore, the individual AC and/or DC INPUT cables can be first combined into a single cable
(of appropriate minimum wire size), or they can be left as separate cables, each connected to
the desired AC or DC source.
3-phase AC INPUT Source
When three UPS units are used (with their AC OUTPUTs connected either in parallel or in a
3-phase configuration), each UPS unit’s AC INPUT can be connected to a different phase of a
3-phase source. There are two different ways to do this:
•each UPS unit’s AC INPUT can be connected from a line (i.e., L1 or L2 or L3) of the ac
source to the neutral wire of the 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)
Either connection scheme is acceptable, as long as the resultant input voltage falls within the
specified range of the AC INPUT of the individual UPS units.
If the AC OUTPUTs of the three UPS units are connected in parallel, they will automatically
share the total load power equally. Therefore, the power that they each draw from their
respective AC INPUT phases will be balanced with each other. If, on the other hand, the three
UPS units have their AC OUTPUTs connected in a manner to create a 3-phase AC OUTPUT, then
the power flowing through each UPS, and therefore the power drawn from each AC INPUT
phase, will depend on the load power drawn from each AC OUTPUT phase. This load power
may or may not be balanced.
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Section IV
Multiple UPS Configurations
Multi-unit AC Output On/Off Control
In multi-unit operation, all combined front panel “on” switches must be actuated before any
AC output will turn on. Any “off” front panel switch actuation will cause all AC outputs to
turn off. In addition, the “remote-on” or “remote-off” rear panel signal inputs may be utilized
for coordinated AC output on/off control. If any single UPS no longer has a valid input power
source (e.g., no AC or DC input and depleted battery), the combined AC output will shutdown.
AC Output Neutral Grounding
UPS units combined in multi-unit configurations must have the neutral floating “F” factory
option to prevent the possibility of circulation protective earth currents. If a grounded
output neutral is required, then the output neutral should be connected to protective
earth ground (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
following wiring diagrams.
Wiring Caution
WARNING: LETHAL VOLTAGES MAY BE PRESENT ON UPS AC OUTPUT CONNECTIONS.
ALWAYS REMOVE BATTERY PACKS AND INPUT POWER BEFORE MAKING MULTIUNIT 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 .
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Section V:
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. As such they are very suitable for a UPS application. Lithium
Polymer batteries are used in many military applications.
Electronic Circuitry within the Battery Pack
The SynQor battery pack has electronic circuitry within it that:
•
•
•
•
•
controls the charging (including the equalization charging) of the battery
separates the battery cells into multiple segments
provides protection of the battery
runs diagnostics on the battery
controls the battery pack’s front panel LED indicators
The purpose of separating the battery cells into multiple segments is to allow the battery
pack to remain useful even if one of its battery cells fails. In a normal battery configuration,
the failure of a single cell would disable the entire battery. The SynQor battery packs are
designed with their battery cells arranged in segments that can be disconnected from the
other segments by the internal electronic circuitry. Therefore, if a battery cell fails in one
segment, the battery pack can still operate with the remaining segments (at a reduced battery
run-time) until the battery pack can be serviced.
The Standard Battery Pack (that fits in the UPS-1500S units) has 3 segments, so a failure of
a battery cell would still allow at least 2/3rds of the battery pack’s run-time to be available. The Extended Battery Pack (that fits in the UPS-1500E units) has 7 segments, so a failure of a
battery cell would still allow at least 6/7ths of the battery pack’s run-time to be available.
The protection features provided by the electronic circuitry include:
•
•
•
•
Maximum Current Limit when the battery is being charged/discharged
Charging/Discharging Limit to avoid over-charging/discharging of the battery
Charging/Discharging Disable if the battery is too hot or too cold
Disconnect of the battery from the battery pack’s terminals when the pack is not
inserted into the UPS
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Section V
Battery Pack
Battery Capacity
The SynQor UPS battery packs come in two versions: a Standard Battery Pack and a thicker,
heavier Extended Battery Pack that provides a longer battery run-time.
The Standard battery pack fits into the 1U high UPS-1500S unit. It has approximately 200 watthours of energy storage and a recharge time of <2 hours. It has 3 battery segments and weighs
10.5 lbs. Its run-time, as a function of UPS load power, is:
Total UPS Output Power
Standard Battery Run-Time
100% Rated Power
> 10 Minutes
80% Rated Power
> 13 Minutes
60% Rated Power
> 21 Minutes
The Extended battery pack fits into the 2U high UPS-1500E unit. It has approximately 500
watt-hours of energy storage and a recharge time of <4 hours. It has 7 battery segments and
weighs 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
Storage of the Battery Pack
The storage temperature range of the battery pack (whether it is inserted in the UPS or stored
separately) is -20oC to +65oC (-4oF to +150oF). Care must be taken to ensure this range is not
exceeded or the battery’s energy storage capacity and/or life may be degraded.
Battery Pack Replacement
Battery Packs
Standard Battery Pack
Extended Battery Pack
1500S Series
(1U; 32 lbs.)
1500E Series
(2U; 50 lbs.)
3000S Series
(2U; 64 lbs.)
2 battery packs required
BAT-0200-S-1U-000
(200 Watt Hours)
3000E Series
(4U; 98 lbs.)
2 battery packs required
BAT-0200-S-1U-000
(200 Watt Hours)
BAT-0500-E-2U-000
(500 Watt Hours)
BAT-0500-E-2U-000
(500 Watt Hours)
Other Options also available, check the website or contact [email protected] for further information.
Always use the proper SynQor battery pack.
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Section V
Battery Pack
Handling the Battery Pack
The operating temperature range of the battery pack is -20oC to +55oC (-4oF to +130oF). The
battery pack’s internal electronic circuitry will disable the battery if the cell temperatures are
outside this temperature range. The SynQor UPS is equipped with internal battery heaters
which activate to keep the cells above 0oC in cold ambient temperatures.
The storage temperature range of the battery pack is -20oC to +65oC (-4oF to +150oF). Long
term storage outside this temperature range will lead to a permanent reduction in the
battery’s energy storage capapcity.
When the battery pack is not inserted into the UPS, the internal electronic circuitry disconnects
the battery from the pack’s power terminals. Nevertheless, care should be taken to avoid
making metal contact with (or between) any of these terminals.
The battery pack has its own aluminum chassis that protects its battery cells and internal
electronic circuitry from the environment when the pack is not inserted into the UPS.
However, care should be taken to ensure this chassis and the exposed power terminal strip is
not subjected to extreme mechanical shock or to excessive moisture.
UPS battery packs must be shipped per Federal DOT Regulations as a Class 9 Packing Group II
Hazardous Material. The battery pack must not be installed in the UPS when being shipped,
and it must be packaged in the original SynQor Shipping Carton (including inner protective
inserts) which has been approved for shipping this product. The shipping carton must be
appropriately labeled per applicable Federal DOT Requirements. A UPS may be shipped using
standard shipping methods if it does not contain a battery pack. Please contact SynQor for
further assistance.
The battery pack should be disposed in accordance with applicable regulations of the locality
or returned to a factory-authorized Service Center.
Emergency response contact information for battery damage, leaks, smoke, or fires can be
found at the following link: http://www.SynQor.com/UPS/documents/Contact.pdf. Please
contact the factory for all other questions regarding the UPS battery pack.
CAUTION: Do not dispose of batteries in a fire. The batteries may explode.
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 42.
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Section VI:
Control Interface Details
Control Cable Connections
There are two high-density (three-row) DB15 connectors located on the rear panel of the UPS:
The User I/O female DB15 connector on the left is for an optional connection to a host/system
computer so that it can control the UPS and receive information regarding the status of the UPS.
The Configuration male DB15 connector on the right is for a connection between one SynQor
UPS and another when, for instance, they have their outputs connected in parallel and they
therefore need to communicate and coordinate with each other.
The designation/location of the pins for the User I/O female high-density DB15 connector is
shown below:
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Section VI
Control Interface Details
Internal User I/O Circuits
+5V
1N4148
50k Ohms
2N3904
Output Pin
1N4148
4, 5
Signal Common Pin
User I/O Rear Panel Connector
15 Pin DSUB Female
I/O Circuits
+5V
100 Ohms
8
+5V Pin
500 Ohms
PS2581L
1N4148
Input Pin
Remote On/Off Switch Connections
+5V
100 Ohms
8
+5V Pin
I/O Circuits
500 Ohms
PS2581L
1N4148
500 Ohms
PS2581L
1N4148
12
REMOTE_START
Input Pin
OUTPUT ON
OUTPUT OFF
13
Remote On/Off Switch
SPDT Momentary
(ON) OFF (ON)
SHUTDOWN
Input Pin
Note: A 2PDT or 3PDT switch may be substituted for single control of 2 or 3 UPS machines, respectively.
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Section VI
Control Interface Details
Digital Input/Output Control Signals
There are 2 input and 5 output digital signals available on the User I/O female high-density
DB15 connector. The pin assignments and functions of these digital I/O signals are as follows:
Signal
Pin Number
Function
Bias voltage with minimal current drive usable as a pull-up voltage
for the open collector output signals (100Ω source resistance)
+5V
8
GND
4 and 5
LOW_BATT
6
ACIN_GOOD
7
ON_BATT
9
OUT_OK
14
OVER_TEMP
15
REMOTE_START
12
Drive this line “high” with ≥ 5mA to enable the UPS outputs
SHUTDOWN
13
Drive this line “high” with ≥ 5mA to disable the UPS outputs
Ground reference for all digital inputs and outputs
Open collector* output where “low” indicates battery charge
level is <10%
Open collector* output where “low” indicates AC Input voltage is
within range
Open collector* output where “low” indicates the UPS is drawing
power from its battery
Open collector* output where “low” indicates AC Output voltage
is within range
Open collector* output where “low” indicates that the UPS is at
or above its maximum temperature
*with an internal 50kΩ Pull-up Resistor to 5V and ESD Protection Diodes.
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Section VI
Control Interface Details
RS232 Serial Interface
The same User I/O female high-density DB15 connector also provides for an RS232 interface
between the UPS and the host/system computer. The interface has a 115.2k baud with eight
data bits, no parity bit and one stop bit. The pin assignments and functions for this RS2332
interface are as follows:
Signal
Pin Number
Function
GND
4 and 5
Ground reference for RX and TX signals
RX
3
RS232 DCE/UPS Device Receive signal
TX
2
RS232 DCE/UPS Device Transmit signal
The RS232 port provides readback of UPS’s state, as well as the configuration and control
of the UPS’s operation. The port can be used from a standard terminal interface, or from a
custom computer application. UPS-1500-S-1U
Status LED
Front Panel
Status Indicator Panel
1.73"
1U
On/Off
Air intake
17.00"
Rear Panel
UPS Units with DC Input / DC1 Output Options
4.4cm
DC1
Output
Option
AC
Output
Fan Exhaust
Ethernet
Port
Optional
Ground
DC
User CONFIG Stud
Input
I/O
Port (1/4-20)
Option
Fan Exhaust
AC
Input
AC Circuit
Breaker
Rear Panel
UPS Units with DC1 Output / DC2 Output Options
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Section VI
Control Interface Details
Readback information that is available:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
AC Input Voltage
AC Input Current
AC Input Frequency
DC Input Voltage
AC Output Voltage
AC Output Current
AC Output Power
AC Output Frequency
DC Output Power
Total Output Power
Battery Voltage
Battery State of Charge
Battery Predicted Run Time
Number of Battery Cycles
External Switch Input Status
Fan RPM
Internal Temperatures
Parameters that are controllable through the interface:
• Output enable / disable
• Fan diagnostics
• Alarm enable / disable
For a detailed description of the terminal interface see the SynQor website at:
http://www.SynQor.com/UPS/documents/UPS_User_Commands.pdf
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Section VI
Control Interface Details
Ethernet Interface
The optional Ethernet interface provides a web page based user interface for monitoring and
control of the UPS. The user can configure email alerts for UPS alarm conditions. The interface
also exposes an SNMP interface compliant to RFC-1628.
The Ethernet interface supports 10BASE-T and 100BASE-T standards. It utilizes a standard RJ45 connector, also allowing a metallic sealable circular military outer housing. The interface
supports auto-negotiation, polarity correction, and Auto-MDIX (detection and use of straight
through or cross-over cables).
IP address assignment can be done via DHCP or user entry of a static address. The interface
also supports a direct connection between the 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 at: http://www.synqor.com/ups/documents/UPS_Ethernet_SNMP_UG.pdf
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Section VII
Maintenance
Battery
The lithium polymer battery cells in the battery pack do not need any maintenance. In particular,
unlike a lead acid battery a lithium polymer battery does not need to re-charged on a regular
basis to avoid degradation of its energy storage capacity. Care should only be taken in ensure
that they are not stored at a temperature outside their specified storage temperature range of
-20oC to +65oC (-4oF to +150oF).
Emergency response contact information for battery damage, leaks, smoke, or fires can be
found at the following link: http://www.SynQor.com/UPS/documents/Contact.pdf. Please
contact the factory for all other questions regarding the UPS battery pack.
CAUTION: Do not dispose of batteries in a fire. The batteries may explode.
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 42.
Fans
The fans on the rear panel have sealed bearings that do not require any maintenance.
Cleaning
The UPS-1500 unit has a sealed chamber for its electronics and the battery pack that is weatherproof. Only the fans on the rear panel are exposed to the environment, and these fans are also
weather-proof. The unit can therefore be cleaned without concern of getting liquids inside
the chamber. NOTE, however, that if the cables have been removed from the connectors the
connectors should have their covers installed. If they are not, then care should be taken to not
get excess liquid on the connector terminals. ALSO NOTE that care should be taken to not get
excess liquid on the switch of the AC BREAKER on the back panel.
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.
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Trouble-Shooting Guide
Fault Conditions
The SynQor UPS has no user-serviceable parts within it. If it has an internal malfunction only
a factory trained personnel should attempt to repair it.
There are, however, several external conditions that could cause the UPS to not operate as
desired. These external conditions can likely be corrected by the user.
The 16 LEDs on the front panel of the battery pack are the best and first place to look to
determine what might be wrong with the UPS. The table on the next several pages is therefore
organized by what these LEDs indicate, and for each indication there is a listing of what might
possibly be wrong.
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
FAN
BATT
A0
A1
B0
B1
B2
B3
C0
C1
D0
D1
E0
E1
E2
E3
F0
F1
POWER IN
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Section VIII
LED
Indication
LED is OFF
D1:
AC INPUT
Power LED
LED is a STEADY
GREEN and not a
PULSING GREEN.
UPS is instead
running off the
optional DC INPUT
or the BATTERY
D0:
DC INPUT
Power LED
A1:
DC OUTPUT
Power LED
Possible Problem(s)
•The AC INPUT power source is not turned on.
•The AC INPUT cable is not connected or it is wired wrong.
•The AC Breaker on the rear panel is OFF.
•The AC INPUT voltage is either too low or too high.
•The AC INPUT voltage is within its proper range but the UPS is not
selecting it for its source of power.
•The AC INPUT voltage and the total load power may exceed the
power derating curves given earlier in this Guide.
•The AC INPUT cable may have too much series resistance. Thicker
wire should be used.
LED is OFF
•The optional DC INPUT is not available on this unit.
•The DC INPUT power source is not turned on.
•The DC INPUT cable is not connected or it is wired wrong.
•The DC INPUT cable is connected to the DC source with the
wrong polarity.
•The DC INPUT voltage is either too low or too high
•The DC INPUT cable may have too much series resistance. Thicker
wire should be used.
LED is OFF
•The UPS is OFF and needs to be turned ON.
LED is AMBER
•The AC OUTPUT load is higher than 1250W or 1500VA by enough
to trigger the power limit circuitry.
•The AC OUTPUT load crest factor is too high.
•The AC OUTPUT is shorted within the cable or a load.
•Some other source of power is connected to the AC OUTPUT.
LED is RED
•The UPS has been turned OFF, but due to a malfunction within the
UPS it is still running and providing an AC OUTPUT voltage.
•Some other source of voltage is connected to the AC OUTPUT and
is powering it when the UPS is not.
LED is OFF
•The optional DC OUTPUT is not available on the unit.
•The UPS is OFF and needs to be turned ON.
LED is AMBER
•The DC OUTPUT load is higher than 500W.
•The DC OUTPUT is shorted within the cable or a load.
•Some other source of power is connected to the DC OUTPUT.
LED is RED
•The UPS has been turned OFF, but due to a malfunction within the
UPS it is still running and providing an DC OUTPUT voltage.
•Some other source of voltage is connected to the DC OUTPUT and
is powering it when the UPS is not
AC OUTPUT
Power LED
A0:
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LED
Indication
F0:
•Total UPS load power is greater than 1250W. The UPS may still be
delivering its specified output voltage because the load power is not
high enough to trigger the power limit circuitry.
B0 – B3 are all OFF
•No power is being delivered to the load.
•The UPS is OFF and needs to be turned ON.
•The loads or output cables are not connected.
•The loads are all turned off.
•The loads are simply not drawing any appreciable power at the time.
LED is BLINKING
GREEN
•Indicates that the fans are running at 67% of their rated speed. There is no problem.
LED is AMBER
•Indicates that the fans are running at 100% of their rated speed. There is no problem, but the unit is operating at a high ambient
temperature and a high load combination.
LED is RED
•Fans are running at 110% of rated speed to keep the unit cool. The
maximum recommended temperature may be exceeded, but the
fans are keeping things cool enough to avoid triggering the overtemperature shut-down circuitry.
LED is BLINKING
RED
•The battery is too cold to be charged or discharged without damage. •If the UPS is running from the AC INPUT or the DC INPUT the battery
will eventually be warmed up and this condition will go away.
LED is BLINKING
AMBER
•The battery is too cold to be charged without damage, but it can be
discharged if the UPS needs to draw power from it.
•If the UPS is running from the AC INPUT, the DC INPUT or the
battery, the battery will eventually be warmed up and this
condition will go away.
LED is STEADY
AMBER
•The battery is too hot to be charged without damage, but it can be
discharged if the UPS needs to draw power from it.
•If the ambient temperature is within its specified range the battery
will eventually cool down and this condition will go away.
LED is STEADY RED
•The battery is too hot to be charged or discharged without damage.
•If the ambient temperature is within its specified range the battery
will eventually cool down and this condition will go away.
UPS Cooling
System LED
F1:
Battery Pack
Temperature
LED
Possible Problem(s)
B3 is BLINKING RED
B0 – B3:
LOAD POWER
LEDs
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LED
C0:
Fan Service
Required LED
C1:
Battery
Pack Service
Required LED
All 16
LEDs:
Audible
Alarm:
(pattern
repeats every
5 seconds)
Indication
LED is AMBER
Trouble-Shooting Guide
Possible Problem(s)
•One or both fans have recently had degraded performance but seem
to be ok now. The UPS is running a diagnostic test.
LED is RED
•One or both fans presently have degraded performance, even if they
are running, and service is recommended at the earliest convenient
time.
•Ensure that the fan blades are not obstructed from turning
LED is AMBER
•The battery pack’s calculated maximum energy storage capacitor is
<75% of its rated value. The UPS’s battery run-time will therefore be
similarly reduced.
•The battery pack should be replaced at the earliest convenient time
if this derated battery run-time is unacceptable.
LED is RED
•The battery pack’s calculated maximum energy storage capacitor is
<50% of its rated value. The UPS’s battery run-time will therefore be
similarly reduced.
•The battery pack should be replaced at the earliest convenient time.
All LEDs are OFF
•The battery pack is not fully inserted into the UPS with its thumb
screws tightened.
•The terminal on the battery pack is damaged or dirty.
•The battery pack is defective and needs to be replaced.
One tone
•The UPS is drawing power from the battery pack and is discharging it.
•Sources of power should be restored or preparations made to shut
down the loads
Two tones
•The total UPS load power is above 1250W.
•Loads should be reduced if this condition persists.
Three tones
•The AC OUTPUT has experienced either a short circuit or a load
having a start-up surge current characteristic that the UPS could not
start. The AC OUTPUT has therefore turned OFF. The DC output may
still be powered. •To reset, the UPS must be turned OFF and then ON.
Four tones
•The UPS is drawing power from the battery pack and its remaining
charge is <10% of its rated charge.
•Sources of input power should be restored or the loads should be
shut down.
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Trouble-Shooting Guide
Two other conditions should be mentioned:
•The fans are off when the UPS is running
It is normal for the fans to be off, even if the UPS is running and delivering power to the load,
as long as the temperature of the UPS is low enough. If the Fan Service Required LED (C0) is
green, both of the fans are OK, even if they are not running.
•The UPS does not turn off when the ON/OFF switch is pushed down
When the ON/OFF switch on the front panel is pushed down, the UPS does not respond to this
signal for approximately 1 second. This is done to ensure that the UPS is not accidently turned
off. If the user does not hold the ON/OFF switch in the OFF position for a full second before
releasing it, the UPS will not turn off.
Other possible situations that are the result of external issues that a user could
likely correct are related to:
•Loads that draw a large surge of current at start-up
Some AC loads draw a very large amount of current when an input voltage is first applied to
them. This might happen when the UPS is first turned on if the load is already connected
to the UPS. Or it may happen when the load itself is turned on and/or connected to the AC
OUTPUT of a UPS that is already running. Common examples of such loads are motors and
incandescent lights, but some electronic equipment can also display this characteristic.
Several problems could arise with such a load:
▪ The UPS fails to start the load:
The SynQor UPS is designed to try various start-up routines when it is first turned on to
overcome the problem of surge currents with some loads. There are five such routines
(or repetitions of a given routine) that are tried. If the load is not started after these five
routines are attempted, the UPS will turn OFF. To get the UPS to try again, the user should
again push the ON/OFF switch on the front panel to the ON position.
If the UPS cannot start the load, then it may be possible that a custom start-up routine could
be devised to work with this particular load. Contact the factory for more information.
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Trouble-Shooting Guide
If there is more than one load of the AC OUTPUT that displays this start-up surge
characteristic, and the UPS is not capable of starting with all of them connected and
switched on, it may be possible to switch on each load in turn. For instance, if the UPS
cannot start up with a load consisting of a large bank of incandescent lights, then it may
be able to start if various sections of the lights are switched on in sequence.
▪ A newly started load disturbs the existing UPS loads.
A common problem can occur when the UPS is running and powering one or more loads
connected to its AC OUTPUT, and then an additional load of the AC OUTPUT is turned on. If this newly started load draws a large surge current at start-up, it can cause the current
limit of the UPS’s AC OUTPUT to be triggered, and the AC OUTPUT voltage will then drop. This drop could cause the existing loads to be disturbed. Furthermore, if the voltage drops
far enough, the UPS will turn off it AC OUTPUT and initiate a new start-up sequence (after
0.1 seconds). This latter action would cause the power flow to the existing loads to be
interrupted.
If this disruption of existing loads is a problem, then the solution is to make sure the
loads that display this start-up surge characteristic are all started first, or that all loads are
started at the same time.
•Cable wire resistance is too high:
As mentioned in the section “Power Cables Wire Size”, the resistance of a power cable’s wires
gives a voltage drop from the upstream to the downstream end of the cable. This voltage
drop, if large enough, will cause the either UPS to determine that the voltage at its AC INPUT
or its DC INPUT is below its minimum specified value, even though the corresponding voltage
at the source of AC or DC power is within the specified range.
This problem is particularly possible for the DC INPUT, since the DC INPUT current is so high (as
much as 65A at full power) and the DC INPUT voltage is so low (as low as 22V).
The phenomenon that may be displayed is the following.
▪ Assume the AC INPUT source is not present, but the DC INPUT source is. ▪ The UPS, before it turns on, does not draw any power or current from the DC INPUT, and
therefore the voltage drop across the DC INPUT cable is zero.
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Trouble-Shooting Guide
▪ The UPS sees that the voltage at the DC INPUT is within its specified range, and enables
its outputs.
▪ As the load then draws power, the UPS begins to draw current from the DC INPUT cable. This current causes a voltage drop to appear across the cable.
▪ If the voltage at the DC source is close to, but still above, its 22V minimum, but the voltage
drop across the cable is large enough for the voltage at the DC INPUT of the UPS to fall
below 22V, then the UPS will determine that the DC INPUT is out of range and will switch
over to drawing power from the internal Battery Pack.
▪ Since the UPS no longer draws current from the DC INPUT, the voltage drop across the DC
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.
▪ The cycle above repeats itself for a total of three times, at which point the UPS stops
trying to draw power from the DC INPUT for one minute. After this one minute another
set of 3 cycles are repeated, followed by another stop for one minute, and so on.
This same problem can also occur for the AC INPUT if the voltage at the AC source is close to
the specified 80Vrms minimum limit. In this case the UPS will try ten times before stopping for
a one minute interval.
The solution to this problem is to make sure that the cable has wires of sufficient diameter,
or “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.
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Operator’s Guide
UPS-1500 Series
Military Grade Uninterruptible Power Supply
Made in USA
006-0006205 03/17/15 Rev N
Advancing The Power Curve
1.888.567.9596 (USA only) | SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA |
®
www.synqor.com
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