Operator&#39
Operator’s Guide
UPS-1250 DC Output Series
Military Grade Uninterruptible Power Supply
UPS-1250-S-1U
N+M Redundancy
UPS-1250-E-2U
Made in USA
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
User Serviceable Parts................................................................................................................................................6
Section II
General Product Information
Product Description....................................................................................................................................................7
Product Topology.........................................................................................................................................................8
Part Numbering Scheme and Options.............................................................................................................. 10
Electrical Characteristics...................................................................................................................................... 11
Product Specifications............................................................................................................................................ 12
1U Mechanical Diagram........................................................................................................................................ 13
2U Mechanical Diagram........................................................................................................................................ 14
UPS Efficiency............................................................................................................................................................. 15
Total Output Power that can be derived from the AC INPUT.................................................................. 17
Power Cable Wiring Diagram.............................................................................................................................. 20
Power Cable Wire Size............................................................................................................................................. 21
Section III
Operation
Set-Up............................................................................................................................................................................ 22
Start-Up........................................................................................................................................................................ 23
Shut-Down................................................................................................................................................................... 23
Power Cable Connections/Disconnections While Operating................................................................... 24
Cooling System........................................................................................................................................................... 25
Front Panel Indicators............................................................................................................................................ 26
LEDs....................................................................................................................................................................... 26
Audible alarm.................................................................................................................................................... 31
Hot Swapping the Battery Pack........................................................................................................................... 31
Operating Environment.......................................................................................................................................... 32
006-0007097 12/22/17 Rev B
2 of 52
UPS-1250DC Guide
www.synqor.com
Section IV
Multiple UPS Configurations
Parallel Connection of DC OUTPUTS – Droop Share Option................................................................... 33
N+M Redundancy - Ideal Diode......................................................................................................................... 33
Connection of the AC INPUTS and/or DC INPUTS...................................................................................... 34
3-Phase AC INPUT Source............................................................................................................................ 34
Section V
Battery Pack
Battery Technology................................................................................................................................................... 35
Electronic Circuitry within the Battery Pack................................................................................................. 35
Battery Capacity........................................................................................................................................................ 36
Storage of the Battery Pack................................................................................................................................... 37
Battery Pack Replacement ................................................................................................................................... 37
Handling the Battery Pack.................................................................................................................................... 38
Section VI
Control Interface Details
Control Cable Connections.................................................................................................................................... 39
Internal User I/O Circuits.............................................................................................................................. 40
Remote On/Off Switch Connections.......................................................................................................... 40
Digital Input/Output Control Signals................................................................................................................ 41
RS232 Serial Interface............................................................................................................................................. 42
Ethernet Interface..................................................................................................................................................... 43
Section VII
Maintenance
Battery........................................................................................................................................................................... 44
Fans................................................................................................................................................................................ 44
Cleaning........................................................................................................................................................................ 44
Section VIII
Trouble-Shooting Guide
Fault Conditions........................................................................................................................................................ 45
006-0007097 12/22/17 Rev B
3 of 52
UPS-1250DC Guide
www.synqor.com
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 DC INPUT cable and connector:
▪ 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 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:
▪ 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 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.
006-0007097 12/22/17 Rev B
4 of 52
UPS-1250DC Guide
www.synqor.com
Section I
Warnings
•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.
006-0007097 12/22/17 Rev B
5 of 52
UPS-1250DC Guide
www.synqor.com
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 SynQor 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 37.
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.
User Serviceable Parts
UPS-1250 DC Output Series fans are user replaceable with kits available from SynQor. Please
contact the SynQor factory for obtaining fan replacement kits and instructions (Replaceable Fan
Module SYN-9450). The UPS-1250 DC Output Series has no other user serviceable parts inside of
it. DO NOT REMOVE the cover of the unit or any of its connectors. Other than the fan assembly
replacement, only factory trained personnel should perform repairs.
006-0007097 12/22/17 Rev B
6 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
Product Description
The SynQor UPS-1250 DC Output 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, rackmountable package. It provides voltage 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-1250 DC Output Series products can draw power from an AC input having a wide range
of voltage and frequency levels, or from an 28 V nominal DC input. The AC input has priority over
the DC input. The UPS provides up to 1250 W of DC output power at 28 volts nominal.
The electronic circuitry within the UPS-1250 DC Output 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-1250 DC Output 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 UPS-1250 DC
Output Series products comply with a wide range of testing according to MIL-STD-810G.
The UPS-1250 DC Output 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 33 lbs. and the latter 52 lbs.
The SynQor UPS-1250 DC Output Series products are designed and manufactured in the U.S.A.
006-0007097 12/22/17 Rev B
7 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
Product Topology
The SynQor UPS-1250 DC Output 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 28 V mid-bus within the UPS that draws power
from one of up to three power sources: the AC INPUT, the 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
AC to DC
w/ PFC
and
ISOLATION
DC
INPUT
ELECTRONIC
SWITCH
BATTERY
with
CHARGER
and
ELECTRONIC SWITCH
ISOLATED
DC-DC
CONVERTER
IDEAL
DIODE
DC
OUTPUT
BULK ENERGY
STORAGE
CAPACITOR
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.
006-0007097 12/22/17 Rev B
8 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
The DC output can deliver up to 1250 W. The DC output is isolated from the AC input.
Bulk energy storage capacitors are connected to the mid-bus to help smooth imbalances in
power flow between the inputs and output 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
006-0007097 12/22/17 Rev B
9 of 52
UPS-1250DC Guide
www.synqor.com
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
1250
Battery Pack
Height
Size
S
1U
AC Input
Frequency
DC Regulation
Type
DC Output
Voltage
L
R
28
DC Input Reserved
D
Options
00
E00
000: None
S: Standard 1U: 1.73” L: 47-65 Hz R: Fully Regulated
28 V
0CE: CE Marking
UPS 1250: 1250 W
28:
D: DC Input 00: N/A
E: Extended 2U: 3.33” W: 47-800 Hz D: Semi-Regulated
Output
E00: Ethernet/SNMP
ECE: Ethernet/SNMP & CE Marking
Not all combinations make valid part numbers, please contact SynQor for availability. See the Product Summary web page for more options.
*Note:Order “D: Semi-Regulated” option to place multiple UPS units in parallel
Examples:UPS-1250-S-1U-LR28D00-000, UPS-1250-S-1U-WR28D00-E00
UPS-1250-S-1U-LD28D00-0CE (Parallelable with CE mark)
The UPS-1250 DC Output Series of products provide up to 1250 W of total output power
(DC). They come in two different physical formats:
•A 1U high, 33 lb. rackmount unit that uses the standard battery pack that provides >10 minutes
of battery run-time at full power
•A 2U high, 52 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 47-800 Hz range (for 400 Hz and Variable Frequency systems)
•The output voltage of the UPS-1250 DC Output Series can be 28 volts nominal.
•There is a DC INPUT that is specified to comply with MIL-STD-704F and MIL‑STD‑1275D for 28
V systems.
•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.
006-0007097 12/22/17 Rev B
10 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
Electrical Characteristics
INPUT CHARACTERISTICS
Operating AC Input
Voltage
Frequency
80-265 Vrms*
47-65 Hz
(47-800 Hz Optional)
Input Power Factor
>0.98 at 47-65 Hz
>0.97 at 400 Hz
>0.93 at 800 Hz
20 A (full load, 85 Vrms)
25 A
Maximum Input Current Continuous
AC Input Circuit Breaker Rating
(* Power Derating to 80% below 90 Vrms)
Operating DC Input
Voltage
22-33 V
Continuous Maximum Input Current
62 A (full load, 22 V)
Transient Maximum Input Current
75 A
OUTPUT CHARACTERISTICS
Output Power Continuous
1250 W
DC Output - Fully Regulated
Voltage Setpoint (Nominal)
28 V
Voltage Setpoint Accuracy
± 3%
Voltage Regulation (Over Load & Temperature) ± 5%
Operating Output Current Range
0 - 45 A
Overload Current Maximum ( < 1 sec)
60 A
DC Output - Semi-Regulated (Parallelable)
Voltage Setpoint (Nominal)
28 V
-11%
Voltage Regulation
28 V at 0 A
25 V at 50 A
Operating Output Current Range
0 - 50 A
Overload Current Max ( < 1 sec)
60 A
MECHANICAL CHARACTERISTICS
1U Standard Battery Pack Chassis
Chassis Width
17”W
Chassis Depth
22.25”D
Chassis Height
1.73”(1U)H
Case Material
Aluminum
Total Weight
33 lbs. (with chassis & battery)
Optional 2U Extended Battery Pack
Chassis Width
17”W
Chassis Depth
22.25”D
Chassis Height
3.33”(2U)H
Case Material
Aluminum
Total Weight
52 lbs. (with chassis & battery)
Connectors
AC Input Connector
MS3470L14-4P
User I/O Ports
HD DB15 Female
Configuration I/O Port
HD DB15 Male
Ethernet Port
Amphenol RJF22N00,
Code B
DC Input Connector
MS3470L18-8P
DC Output Connector
MS3470L18-8S
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.
006-0007097 12/22/17 Rev B
ENVIRONMENTAL CHARACTERISTICS MIL-STD-810G
Temperature Methods 501.5, 502.5
Operating Temperature
-20 °C to +55 °C
Non-operating Temperature
-20 °C to +65 °C
Altitude Method 500.5
Operating
0 - 18,000 ft
Non-operating
0 - 40,000 ft
Environmental Tests
Shock/Drop
Method 516.6, Procedures 1,4,6
Temperature Shock
Method 503.5, Procedure 1
Vibration
Method 514.6, CAT 5, 7, 8, 9, 24
Fungus
Method 508.6
Salt Fog
Method 509.5
Sand and Dust
Method 510.5, Procedures 1,2
Method 506.5 Procedure 1
Rain
Method 507.5 Procedure 2
Humidity
Method 528 Procedure 1
Mechanical Vibrations of
Shipboard Equipment
RELIABILITY CHARACTERISTICS MIL-HDBK-217F
MTBF
100 kHrs
MIL-217F Ground Benign, Ta=25 °C
ELECTROMAGNETIC CAPABILITY MIL-STD-461F
CE101
30 Hz - 10 kHz
CE102
10 kHz - 10 MHz
CS101
30 Hz - 150 kHz
CS106
10 kHz - 40 GHz
CS114
10 kHz - 200 MHz
CS116
10 kHz - 100 MHz
RE101
30 Hz - 100 kHz
RE102
10 kHz - 18 GHz
RS101
30 Hz - 100 kHz
RS103
2 MHz - 40 GHz
* Regarding MIL-STD-461 CE-101, the 50 uH series inductance of a standard LISN
adversely affects the input ripple of the UPS (DC input only). Such a large series
source inductance (50 uH in each power lead) is not generally encountered in a
28 V DC source of such high power rating. Therefore, testing for CE-101 (DC input)
was conducted with 3 different configurations: two using 50 uH LISNs and a 54 mF
capacitor connected across the input to the UPS, and one using 5 uH LISNs for
which no additional capacitor was added.
These configurations all passed CE-101 for all frequencies.
11 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
Product Specifications
The following three pages show the electrical and mechanical specifications of the UPS‑1250‑S‑1U
high and the UPS-1250-E-2U Series of products. Data sheets showing these specifications and
other information can be found at the web site http://www.synqor.com/UPS.
Status LED
Status Indicator Panel
UPS-1250-S-1U
1.73"
1U
On/Off
Air intakes
17.00"
UPS-1250-S-1U with DC & AC Input/DC Output
DC Output
Exhaust
Fan
Ethernet
Port
Option
User User Ground
I/O Config Stud
Port
Port (1/4-20)
DC
Input
Exhaust
Fan
AC
Input
AC Circuit
Breaker
AC
Input
AC Circuit
Breaker
UPS-1250-E-2U
3.33"
2U
On/Off
Status Indicator Panel
Air intake
17.00"
UPS-1250-E-2U with DC & AC Input/DC Output
DC Output
006-0007097 12/22/17 Exhaust
Fan
Ethernet
Port
Option
Rev B
User User Ground
I/O Config Stud
Port
Port (1/4-20)
12 of 52
DC
Input
Exhaust
Fan
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
1U Mechanical Diagram
19.450″
[494.03]
22.25″
[565.15]
18.700″
[474.98]
9.750″
[247.65]
0.75″
[19.1]
0.75″
[19.1]
1.5″ [38.1]
17.00″
[431.8]
POWER OUT
ON
POWER IN
LOAD
CHARGE
FAN
BATT
UPS BATT
MADE IN USA
OFF
006-0007097 12/22/17 Rev B
13 of 52
UPS
1.73″ [43.9]
UNIT
MOUNTING
HOLES
8-32
.250
x26
UPS-1250DC Guide
0.625″
[15.875]
0.55″
[13.9]
0.313″
[7.9502]
www.synqor.com
Section II
General Product Information
2U Mechanical Diagram
19.450″
[494.03]
18.700″
[474.98]
22.25″
[565.15]
9.750″
[247.65]
0.75″
[19.1]
0.75″
[19.1]
1.5″ [38.1]
17.00″
[431.8]
POWER OUT
POWER IN
LOAD
CHARGE
FAN
3.33″
[84.582]
BATT
MADE IN USA
UPS BATT
UNIT
MOUNTING
HOLES
8-32 .250”
x52
2.375″
[60.325]
ON
UPS
OFF
006-0007097 12/22/17 Rev B
14 of 52
0.55″
[13.9]
2.062″
[52.375]
1.749″
[44.425]
0.313″
[7.9502]
UPS-1250DC Guide
0.625″
[15.875]
www.synqor.com
Section II
General Product Information
UPS Efficiency
Figure 1 shows the typical efficiency with which the UPS-1250 DC Output Series uninterruptible
power supplies delivers power to its DC OUTPUT from a 22, 28, and 33 volts input.
Efficiency vs. Output Power
94
92
90
88
Efficiency
(%)
86
28 V
84
33 V
22 V
82
80
0
250
500
750
1000
1250
Output Power (W)
Figure 1
006-0007097 12/22/17 Rev B
15 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
Figure 2 shows the typical efficiency with which the UPS-1250 DC Output Series uninterruptible
power supplies delivers power to its DC OUTPUT from 115 VAC and 230 VAC input.
Efficiency vs. Output Power
86
84
82
80
78
115 Vac
Efficiency
(%)
76
230 Vac
74
72
70
0
250
500
750
1000
1250
Output Power (W)
Figure 2
006-0007097 12/22/17 Rev B
16 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
Total Output Power that can be derived from the AC INPUT
The total UPS output power for the UPS-1250 DC Output Series is rated at 1250 W 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 (<90 Vrms) 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 >22 Vdc) or its internal battery. Figure 3 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.
UPS Output Power vs. Air Temperature
1400
1200
1000
Output
Power
(Watts)
VAC(IN) >105 VRMS or VDC(IN) >22 V or
power drawn from the battery
800
600
VAC(IN) = 90 VRMS and VDC(IN) <22 V and
power not drawn from the battery
400
VAC(IN) = 80 VRMS and VDC(IN) <22 V and
power not drawn from the battery
200
0
25
30
35
40
45
50
55
Air Temperature (°C)
Figure 3
•If the AC INPUT voltage is above 105 Vrms, then the UPS can deliver its full rated output power
of 1250 W 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 90 Vrms and 80 Vrms then the total output power that can be
derived from the AC INPUT linearly decreases from 1250 W at 90 Vrms to 1000 W at 80 Vrms
006-0007097 12/22/17 Rev B
17 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
(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 1125 W at 85 Vrms 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 >22 V) or the
internal BATTERY PACK.
•If the AC INPUT voltage is 90 Vrms AND the ambient air temperature is above 45oC (113oF),
the total output power that can be derived from the AC INPUT linearly decreases from 1250
W at 45oC (113oF) to 1000 W at 55oC (131oF). For example, the total output power that could
be derived from the AC INPUT would be 1125 W at an AC INPUT voltage of 90 Vrms 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.
•When the AC INPUT voltage is between 105 Vrms and 90 Vrms 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 97.5 Vrms would be 1250 W
up to an ambient temperature of 50oC (122oF) and then derate to 1125 W at 55oC (131oF).
Furthermore, there is a limited (and uncommon) range of AC INPUT voltage between 132 Vrms
and 160 Vrms in which the total output power that can be derived from the AC INPUT is also
derated, as shown in Figure 4.
006-0007097 12/22/17 Rev B
18 of 52
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
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 4
Note that the full rated output power of 1250 W 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 90 Vrms.
006-0007097 12/22/17 Rev B
19 of 52
UPS-1250DC Guide
www.synqor.com
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
DC INPUT
Pin
Function
G, F, E
+Vin
B, C, D
Vin Return
A, H
No Connect
DC OUTPUT
Pin
Function
G, F, E
+VOUT
B, C, D
VOUT Return
A, H
No Connect
006-0007097 12/22/17 Rev B
A
D
B
C
A
G
B
H
F
E
C
D
A
B
G
H
C
F
D
20 of 52
E
UPS-1250DC Guide
www.synqor.com
Section II
General Product Information
Power Cable Wire Size
SynQor recommends the following cables for use with the UPS-1250 DC Output Series:
AC Input:
DC Input:
DC Output:
SYN-9101
SYN-9104
SYN-9102
SYN-9151
SYN-9154
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 Ring Connectors, 10’
UPS connection to NATO Connector, 10’
UPS connection to Harwire Termination, DC Output, 10’
UPS connection to Fork Connectors, DC 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 DC Output
cables because the current flowing through it is very high (as high as 65 A for the UPS-1250 DC Output Series)
and the voltage across it is already relatively small (as low as 22 V). In fact, a common problem that arises
(when the DC INPUT cable has too small a wire) is that the voltage seen at the DC INPUT of the UPS falls below
the minimum specified value of 22 V even though the voltage at the source of the DC power is greater than 22
V. 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-1250 DC Output Series:
• The AC INPUT cable has 3 wires (one for the ground) of 12 AWG
• The DC INPUT cable has 6 wires (three for each connection) of 12 AWG
• The DC OUTPUT cable has 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”.
006-0007097 12/22/17 Rev B
21 of 52
UPS-1250DC Guide
www.synqor.com
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 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.
•An overcurrent protect and disconnect device should be installed on the DC INPUT circuit.
An example of a suitable device is a Carling Technologies, C-series, 80 A 65 VDC, CA1-B0-14680-321-J circuit breaker. (www.carlingtech.com)
•VERIFY that the 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.
006-0007097 12/22/17 Rev B
22 of 52
UPS-1250DC Guide
www.synqor.com
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 output (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 output 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.
006-0007097 12/22/17 Rev B
23 of 52
UPS-1250DC Guide
www.synqor.com
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 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. If the UPS is turned on and delivering power to several loads
and then another load is connected, 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.
006-0007097 12/22/17 Rev B
24 of 52
UPS-1250DC Guide
www.synqor.com
Section III
Operation
Cooling System
The SynQor UPS-1250 DC Output 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 longterm 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.
006-0007097 12/22/17 Rev B
25 of 52
UPS-1250DC Guide
www.synqor.com
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. LED A1 is permanently disabled. There is no AC outlet on the unit.
POWER OUT
LOAD
FAN
A0
A1
B0
B1
B2
B3
C0
D0
D1
E0
E1
E2
E3
F0
CHARGE
POWER IN
006-0007097 12/22/17 Rev B
26 of 52
UPS-1250DC Guide
BATT
C1
F1
UPS BATT
www.synqor.com
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
Power-Out Indicators (LEDs in positions A0 and A1)
The LED in position A0 indicates the status of the DC OUTPUT, according to the table below:
LED Appearance
006-0007097 12/22/17 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
Rev B
27 of 52
UPS-1250DC Guide
www.synqor.com
Section III
Operation
Load Power Indicators (LEDs in positions B0 – B3)
The LEDs in positions B0 through B3 indicate the output power of the UPS 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
006-0007097 12/22/17 Rev B
28 of 52
NA
Battery Charge =100%
NA
Battery Charge =100%
(Cell Balancing
is Occurring)
UPS-1250DC Guide
www.synqor.com
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
006-0007097 12/22/17 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
Rev B
29 of 52
UPS-1250DC Guide
www.synqor.com
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
006-0007097 12/22/17 Rev B
30 of 52
UPS-1250DC Guide
www.synqor.com
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 greater than or approaching 100%
Rated Power
Three
Fault Appears on the DC 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.
006-0007097 12/22/17 Rev B
31 of 52
UPS-1250DC Guide
www.synqor.com
Section III
Operation
Operating Environment
The SynQor UPS-1250 DC Output Series is designed for the extreme environmental conditions
of military and aerospace applications. All the electronic circuitry and the battery pack are
contained in a sealed, weather-proof, shock-proof chamber constructed of die-cast aluminum.
Only the redundant, water-proof cooling fans are exposed to the environment. 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
006-0007097 12/22/17 Rev B
32 of 52
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; 1-2000 Hz
▪ Operating
▪ 20 g/20 ms; 40 g/11 ms; 75 g/6 ms
▪ 48 inch drop in transit case
▪ 30 degree tilt and drop
▪ Operating
UPS-1250DC Guide
www.synqor.com
Section IV
Multiple UPS Configurations
Parallel Connection of DC OUTPUTS – Droop Share Option
UPS units with the optional droop share feature are directly parallelable between multiple
modules. See the table below for example part numbers. 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 units.
Parallel Unit Ordering Information
Regulation Type
Example PN
Regulated Output (No Paralleling)
-R
UPS-1250-S-1U-LR28D00-000
Droop Share Output
-D
UPS-1250-S-1U-LD28D00-ECE
N+M Redundancy - Ideal Diode
The ideal diode on the DC OUTPUT provides N+M redundancy when multiple units are placed
in parallel. An N+M redundant system consists of N units to supply the maximum load, and M
additional units to provide redundancy. Typically, one additional unit is used for redundancy
giving “N+1 redundancy”.
During normal operation, all N+M units will deliver power to the load. Should one unit fail, the
remaining units will increase their output current to continue to power the load. The failed unit
can be removed and replaced to restore the redundancy level of the system to its original design.
The replacement unit can be inserted into a live, operating system, but for safety reasons it is
recommended that all units in the system be disabled first.
In addition to N+M redundancy, the ideal diode prevents power from flowing into the unit during
normal operation. This ensures that power cannot circulate between multiple units when the
outputs are in parallel. The droop characteristic of the DC output ensures the load is shared
evenly (-D ordering option).
006-0007097 12/22/17 Rev B
33 of 52
UPS-1250DC Guide
www.synqor.com
Section IV
Multiple UPS Configurations
Connection of the AC INPUTS and/or DC INPUTS
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 INPUT 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.
Note that the UPS input circuit breaker disconnects the unit from the AC input bus should a UPS
experience a hardware fault on its input stage.
3-Phase AC INPUT Source
When three UPS units are used (with their DC OUTPUTS connected in parallel), 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 UPS units are droop share models and the DC OUTPUTS 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 are regulated output models, the DC OUTPUTS cannot be directly paralleled. 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 DC OUTPUT. This load power may or may not
be balanced.
006-0007097 12/22/17 Rev B
34 of 52
UPS-1250DC Guide
www.synqor.com
Section V
Battery Pack
Battery Technology
The battery packs for the UPS-1250 DC Output Series contain Lithium Polymer rechargeable
batteries. For a given amount of energy storage they are much smaller and lighter than a leadacid 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-1250-S 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-1250-E 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
006-0007097 12/22/17 Rev B
35 of 52
UPS-1250DC Guide
www.synqor.com
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-1250-S 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-1250-E unit. It has approximately 500 watthours 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
006-0007097 12/22/17 Rev B
36 of 52
UPS-1250DC Guide
www.synqor.com
Section V
Battery Pack
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
1250-S Series
(1U; 33 lbs.)
Battery Packs
1250-E Series
(2U; 52 lbs.)
BAT-0200-S-1U-000
(200 Watt Hours)
Standard Battery Pack
BAT-0500-E-2U-000
(500 Watt Hours)
Extended Battery Pack
Other Options also available, check the website or contact [email protected] for further information.
Always use the proper SynQor battery pack.
006-0007097 12/22/17 Rev B
37 of 52
UPS-1250DC Guide
www.synqor.com
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 Fully Regulated
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 SynQor 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 37.
006-0007097 12/22/17 Rev B
38 of 52
UPS-1250DC Guide
www.synqor.com
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 not used for this product.
The designation/location of the pins for the User I/O female high-density DB15 connector is
shown below:
006-0007097 12/22/17 Rev B
39 of 52
UPS-1250DC Guide
www.synqor.com
Section VI
Control Interface Details
Internal User I/O Circuits
+5V
1N4148
50k Ohms
Output Pin
2N3904
1N4148
4, 5
I/O Circuits
+5V
100 Ohms
8
500 Ohms
PS2581L
Signal Common Pin
User I/O Rear Panel Connector
15 Pin DSUB Female
+5V Pin
Input Pin
1N4148
Remote On/Off Switch Connections
+5V
100 Ohms
8
+5V Pin
I/O Circuits
500 Ohms
12
PS2581L
REMOTE_START
Input Pin
1N4148
OUTPUT OFF
500 Ohms
13
PS2581L
1N4148
OUTPUT ON
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.
006-0007097 12/22/17 Rev B
40 of 52
UPS-1250DC Guide
www.synqor.com
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)
+5 V
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 DC Output voltage
is within range
Open collector* output where “low” indicates that the UPS is at
or above its maximum temperature
*with an internal 50 kΩ Pull-up Resistor to 5 V and ESD Protection Diodes.
006-0007097 12/22/17 Rev B
41 of 52
UPS-1250DC Guide
www.synqor.com
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 RS232
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.
Status LED
Status Indicator Panel
UPS-1250-S-1U
1.73"
1U
On/Off
Air intakes
17.00"
UPS-1250-S-1U with DC & AC Input/DC Output
DC Output
006-0007097 12/22/17 Exhaust
Fan
Ethernet
Port
Option
Rev B
User User Ground
I/O Config Stud
Port
Port (1/4-20)
42 of 52
DC
Input
Exhaust
Fan
UPS-1250DC Guide
AC
Input
AC Circuit
Breaker
www.synqor.com
Section VI
Control Interface Details
Readback information that is available:
• AC Input Voltage
• AC Input Current
• AC Input Frequency
• DC Input Voltage
• 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
• Alarm enable / disable
• Fan diagnostics
For a detailed description of the terminal interface see the SynQor website at:
http://www.SynQor.com/UPS/documents/UPS_User_Commands.pdf
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
006-0007097 12/22/17 Rev B
43 of 52
UPS-1250DC Guide
www.synqor.com
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 SynQor 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 37.
Fans
The fans on the rear panel have sealed bearings that do not require any maintenance. Fan
assemblies are user replaceable with kits available from SynQor. Please contact the SynQor
factory for obtaining fan replacement kits.
Cleaning
The UPS-1250 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.
006-0007097 12/22/17 Rev B
44 of 52
UPS-1250DC Guide
www.synqor.com
Section VIII
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
A0
A1
B0
B1
B2
B3
C0
D0
D1
E0
E1
E2
E3
F0
CHARGE
POWER IN
006-0007097 12/22/17 Rev B
45 of 52
BATT
C1
F1
UPS BATT
UPS-1250DC Guide
www.synqor.com
Section VIII
LED
Trouble-Shooting Guide
Indication
•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.
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
A0:
DC OUTPUT
Power LED
Possible Problem(s)
•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 DC Output load is higher than 1250 W.
•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
006-0007097 12/22/17 Rev B
46 of 52
UPS-1250DC Guide
www.synqor.com
Section VIII
LED
Trouble-Shooting Guide
Indication
B3 is BLINKING RED
•Total UPS load power is greater than or approaching 1250 W. 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.
B0 – B3:
LOAD POWER
LEDs
F0:
UPS Cooling
System LED
F1:
Battery Pack
Temperature
LED
Possible Problem(s)
006-0007097 12/22/17 Rev B
47 of 52
UPS-1250DC Guide
www.synqor.com
Section VIII
LED
C0:
Fan Service
Required LED
C1:
Battery
Pack Service
Required LED
All 16
LEDs:
Audible
Alarm:
(pattern
repeats every
5 seconds)
Trouble-Shooting Guide
Indication
LED is AMBER
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 1250 W.
•Loads should be reduced if this condition persists.
Three tones
•The DC OUTPUT has experienced either a short circuit or a load
having a start-up surge current characteristic that the UPS could not
start. The DC OUTPUT has therefore turned OFF.
•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.
006-0007097 12/22/17 Rev B
48 of 52
UPS-1250DC Guide
www.synqor.com
Section VIII
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 DC 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 DC
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.
If there is more than one load of the DC 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.
006-0007097 12/22/17 Rev B
49 of 52
UPS-1250DC Guide
www.synqor.com
Section VIII
Trouble-Shooting Guide
▪ 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 DC OUTPUT, and then an additional load of the DC 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 DC OUTPUT to be triggered, and the DC 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 DC OUTPUT and initiate a new start-up sequence (after 4 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 65 A at full power) and the DC INPUT voltage is so low (as low as 22 V).
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.
▪ 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 22 V minimum, but the voltage
drop across the cable is large enough for the voltage at the DC INPUT of the UPS to fall below
22 V, 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.
006-0007097 12/22/17 Rev B
50 of 52
UPS-1250DC Guide
www.synqor.com
Section VIII
Trouble-Shooting Guide
▪ 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 80 Vrms 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.
006-0007097 12/22/17 Rev B
51 of 52
UPS-1250DC Guide
www.synqor.com
Operator’s Guide
UPS-1250 DC Output Series
Military Grade Uninterruptible Power Supply
Made in USA
006-0007097
12/22/17
Rev 
B
1.888.567.9596 (USA only) | SynQor Headquarters 155 Swanson Road, Boxborough, MA 01719-1316 USA |
www.synqor.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement