Allen-Bradley Bulletin 1609 User manual

User Manual

Bulletin 1609 Uninterruptible Power Supply

Catalog Numbers 1609-D and 1609-B

Important User Information

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety

Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1

available from your local Rockwell Automation® sales office or online at http://www.rockwellautomation.com/literature/ ) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and Figures in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and Figures.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

WARNING: This is a category C2 UPS product. In a residential environment, this product may cause radio interference, in which case the user may be required to take additional measures.

Additional Resources

Preface

These documents contain additional information concerning related products from Rockwell Automation

Resource

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Product Certifications website, http://www.ab.com

Publication Number:

1609-UM007_-EN-P

Publication Number:

1609-UM008_-EN-P

Publication Number:

1609-IN012_-EN-P

Publication Number:

1609-IN013_-EN-P

Publication Number:

1609-IN014_-EN-P

Publication Number:

1609-IN015_-EN-P

Description

Provides general guidelines for installing a Rockwell

Automation industrial system.

Provides declarations of conformity, certificates, and other certification details.

Bulletin 1609 UPS Management Software

User Manual

Network Management Card - Cat. No. 1609-ENET

User Manual

Bulletin 1609-D

Installation Instructions

Bulletin 1609-B


Surge Protective Device (Cat. No. 1609-SPD)


Network Management Card (Cat. No. 1609-ENET)


You can view or download publications at http:/www.rockwellautomation.com/literature/ . To order paper copies of technical documentation, contact your local Allen-Bradley distributor or

Rockwell Automation sales representative.

Rockwell Automation Publication 1609-UM009A-EN-P - January 2013

3

Preface

Notes:

4


Table of Contents

Bul. 1609-D Installation Instructions

Battery Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mount the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hardwire UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Selection of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Connect Power and Equipment to the UPS . . . . . . . . . . . . . . . . . . . . . . . . . 10

Bul. 1609-D Block Figure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Bul. 1609-B Installation Instructions

Battery Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mount the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hardwire UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Selection of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Connect Power and Equipment to the UPS . . . . . . . . . . . . . . . . . . . . . . . . . 14

1609-B Block Figure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Bul. 1609-EXBAT Installation

Instructions

Battery Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mount the 1609-EXBAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Selection of Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connect the 1609-EXBAT to the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General Information 1609-D and

1609-B

Recommended Battery for use with the UPS . . . . . . . . . . . . . . . . . . . . . . . . 19

Dry I/O Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

USB Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Manual or Remote Enable/Disable of UPS Output Selection . . . . . . . . . 20

Manual Enable/Disable/Self-test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Remote Enable/Disable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Display LED Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Troubleshooting

UPS LED Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Output Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Output Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Over Temperature from the Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Over Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Over Voltage from The DC/DC Converter of Inverter . . . . . . . . . . 23

Over Voltage from The Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Under Voltage from The Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Over Voltage from the Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Under Voltage from the Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fan Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Charger Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

TMOV Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Missing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Replace Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24


5

Table of Contents

Troubleshooting (continued)

Specifications

Dimensions

Service Instructions

UPS Management Software Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .25

UPS Network Managemenr Card Troubleshooting . . . . . . . . . . . . . . . . . .26

Bul. 1609-D Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Bul. 1609-B Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Bul. 1609-D Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Bul. 1609-B Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Bul. 1609-EXBAT Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Bul. 1609-BRK Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Service Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6


Battery Wiring and

Installation

-Bulletin 1609-D Installation Instructions

ATTENTION: Do not service the 1609-SPD without disconnecting the power sources due to electric shock hazard for risk of severe injury or death.

1. To access the battery compartment remove the three screws and the battery door.

2. Remove the battery container, jumpers, and wire harness from the battery compartment. Place the battery container and batteries onto a flat surface.

Use the provided jumper wires to connect the batteries in series. Connect the positive terminal (red) of the battery to the negative terminal (black) of another battery. See photo below for details.

3. Connect the red wire of the harness to the positive terminal (top red) and the black wire of the harness to the negative terminal (bottom black). See photo below for details.


7

Bulletin 1609 UPS

Battery Wiring and

Installation (cont.)

4. Fold the battery container and seal it with tape.

5. To connect the batteries to the UPS, insert the batteries into the battery compartment, open the white connector retainer and connect the two cables together as shown in the photo below.

6. To complete the battery installation, close the white connector retainer and reattach the battery door with the three screws

(torque of 8.7+/-1.7 lb-in).

8

Mount the UPS

The UPS-D is designed to mount on the back of the panel or to the floor of the enclosure. The UPS mounts to a bracket assembly (1609-BRK) that allows it to mount to either the panel or floor (see Figure 1 below).

Figure 1 - Mounting the UPS


Hardwire UPS

Selection of Cables

Bulletin 1609 UPS

Wiring of the UPS should be performed by a qualified electrician using the appropriate wire gauges.

Table 1 - AC Main Input/Output Wiring for UPS:

Item Specification

Wire Size 14 AWG

Minimum temperature

Wire conductor material

Tightening torque for terminals

75 °C

Copper only

4.4 lb-in.

Table 2 - DC Input / Output Wiring for External Battery Cabinet:


Wire Size 10 AWG

Minimum temperature



75 °C

Copper only

12 lb-in.

WARNING: To reduce the risk of fire, connect only to a circuit with 20 amperes maximum branch circuit overcurrent protection in accordance with the National

Electric Code, ANSI/NFPA 70.

A disconnect switch shall be provided by others for AC output circuit.

To reduce the risk of fire, connect only to a circuit with branch circuit overcurrent protection for 20 amperes rating in accordance with the National Electric Code,

ANSI/NFPA 70.


9

Bulletin 1609 UPS

Connect Power and

Equipment to the UPS

WARNING: This UPS features Surge Protection Device (SPD) is located on the left front of the unit. Disconnect all power sources before servicing due to Electric Shock Hazard for risk of severe injury or death.

1. Connect the appropriate input power to the UPS's input (Line, Neutral and Ground) terminals (see Figure 2).

2. Connect the specified equipment to the UPS's output (Line, Neutral and

Ground) terminals (see Figure 2).

Figure 2 - System Wiring

1609-D Block Figure

3. Connect any additional optional accessories (1609-ENET card).

L

AC

Input

E

Breaker

N

Input

Filter

Backfeed

Relay

AVR

AC to DC

Backfeed

Relay

AC to AC Inverter

Relay

+

-

DC to DC DC to AC

L

E

AC

Output

N

10


Battery Wiring and Installation

Bulletin 1609 UPS

1609-B Installation Instructions

ATTENTION: Disconnect the 1609-SPD before servicing, due to electric shock hazard for risk of severe injury or death.

Note: Batteries are not included with the 1609-B UPS

1. To access the battery compartment remove the three screws and the battery door.

2. Remove the battery container, jumpers, and wire harness from the battery compartment. Place the battery container and batteries onto a flat surface.

Use the provided jumper wires to connect the batteries in series. Connect the positive terminal (red) of the battery to the negative terminal (black) of another battery. Connect the red wire of the harness to the positive terminal (top red) and the black wire of the harness to the negative terminal (bottom black). See photo below for details.



11

Bulletin 1609 UPS

Battery Wiring and Installation (cont.)

4. To connect the batteries to the UPS, insert the batteries into the battery compartment, open the white connector retainer and connect the two cables together as shown in the photo below.

5. To complete the battery installation, close the white connector retainer and reattach the battery door with the three screws (torque of 8.7+/-1.7 lb-in).

12


Mount the UPS

Bulletin 1609 UPS

The 1609-B UPS products are designed to mount to a heavy duty DIN-rail

(see Figure 3 below). The 1609-B UPS products are also designed with an optional bracket assembly (Cat 1609-BRK) that allows it to mount to either the panel or floor (see Figure 4 below).

Figure 3 - Standard DIN-Rail Mount

Figure 4 - Optional Panel or Floor Mount

Hardwire UPS


Wiring of the UPS should be performed by a qualified electrician using the appropriate wire gauges.

Table 3 - AC Main Input / Output Wiring for UPS

Item

Wire Size

Minimum Temperature

Wire Conductor Material

Specification

14 AWG

75 °C

Copper only

Tightening Torque for Terminals 4.4 lb - in.

WARNING: To reduce the risk of fire, connect only to a circuit with 20 amperes maximum branch circuit overcurrent protection in accordance with the National


A disconnect switch shall be provided by others for AC output circuit.

To reduce the risk of fire, connect only to a circuit with branch circuit overcurrent protection for 20 amperes rating in accordance with the National Electric Code,

ANSI/NFPA 70.


13

Bulletin 1609 UPS

Connect Power and

Equipment to the UPS

WARNING: This UPS features Surge Protective Device (SPD) located on the top of the unit. Please disconnect all power sources before servicing due to Electric

Shock Hazard for risk of severe injury or death.

1. Connect the appropriate input power to the UPS's input (Line, Neutral and Ground) terminals (see Figure 5).

2. Connect the specified equipment to the UPS's output (Line, Neutral and

Ground) terminals (see Figure 5).


1609-B Block Figure

L

INPUT

N G L

OUTPUT

N G

L

AC

Input E

N

AC Input

AC Output

Input

Filter

Backfeed

Relay

Backfeed

Relay

Inverter

Relay

+

-

AC to DC (Charger) DC to DC DC to AC (Step Wave)

L

E

AC

Output

N

14


Battery Wiring and Installation

Bulletin 1609 UPS

1609-EXBAT Installation Instructions

Only use battery wires that have been provided with the 1609-EXBAT.

WARNING: A disconnect switch shall be provided by others for DC output circuit. To reduce the risk of fire, connect only to a circuit with branch circuit overcurrent protection for 35 amperes rating in accordance with the National


Before connecting a battery pack to UPS, the emergent disconnecting device shall be provided between the UPS and battery pack.

1. To access the battery compartment remove the six screws and the battery door.

2. Remove the battery container, jumpers and wire harness from the battery compartment. Place the battery container and batteries onto a flat surface.

Use the provided jumper wires to connect the batteries in series. Connect the positive terminal (red) of the battery to the negative terminal (black) of another battery. See photo below for details.


15

Bulletin 1609 UPS


3. Connect the shorter set of red and black wires of the harness to the top terminals (red - to - red and black - to - black). Connect the longer set of red and black wires of the harness to the bottom terminals (red - to - red and black - to - black) and route the wires through the cut-out hole. See photo below for details.


5. Insert the batteries into the battery compartment in the orientation as shown in the photo below.

6. Open the white connector retainer and connect the two cables together as shown in the photo below.

16



Bulletin 1609 UPS

7. To complete the battery installation, insert the surplus wire harness into the free space, close the white connector retainer and reattach the battery door with the six screws (torque of 8.7+/-1.7 lb-in).

Mount the 1609-EXBAT

The 1609-D UPS can be used with the External Battery Unit (1609-EXBAT).

The 1609-EXBAT unit is designed to mount to a heavy duty DIN-rail (see

Figure 6) or the optional mounting bracket assembly (1609-BRK) which allows it to mount to either the panel or floor (see Figure 7).

Figure 6 - Heavy Duty DIN Rail Mount

Figure 7 - Panel or Floor Mount


17

Bulletin 1609 UPS


Connect 1609-EXBAT to the UPS

Table 4 - DC Input/Output Wiring for External Battery Cabinet


Wire Size 10 AWG

Minimum temperature



75 °C

Copper only

12 lb-in.

To install the 1609-EXBAT unit with the 1609-D UPS, connect the three 10

AWG wires from the 1609-EXBAT terminals to the 1609-D UPS terminals marked as ‘EXTERNAL BATT PACK (36V)’. (See Figure 8)

Dispose of used batteries according to the battery instructions.


18


Recommended Battery for Use with the UPS and 1609-EXBAT

Bulletin 1609 UPS

General Information 1609-D and 1609-B UPS Units

Rockwell Automation battery catalog numbers 1609-SBAT and 1609-HBAT consist of the battery manufacturers listed below:

Manufacturer

B & B Battery (USA)

GS Yuasa International Ltd.

Shenzhen Center Power Tech Co., Ltd.

Shenzhen Ritar Power Co., Ltd.

CSB Battery Co., Ltd.

MH Number

MH19884

MH12970

MH25860

MH28539

MH14533

Type

HRLS 5.5-12

BP 5-12

HR 5.5-12

SHR7-12

NPH5-12

CP1250

RT1250

HR1221W

Rating

12V DC, 2.75 Ah

12V DC, 5.0 Ah

12V DC, 2.75 Ah

12V DC, 3.375 Ah

12V DC, 5.0 Ah

12V DC, 5.0 Ah

12V DC, 5.0 Ah

12V DC, 5.25 Ah

Not for use in a computer room as defined in the Standard for the Protection of Electronic Computer/Data Processing Equipment, ANSI/NFPA 75.

Dispose of used batteries according to the battery instructions.

Dry I/O Contacts

There is one Remote Enable/Disable Switch connection and 3 Dry I/O Contacts available on the front of the UPS. Do not apply external power to the Remote

Enable/Disable Switch; however, the 3 sets of Dry Contacts require external power supplies (Contacts Rating is 1A/24V DC). Each of the dry contacts is used to provide a remote status indication of the UPS, as follows:

8 7 6 5 4 3 2 1

•1 and 2 On Battery Contact (NO)

•3 and 4 Low Battery Contact (NO)

•5 and 6 Fault (Indicates UPS has faulted see trouble shooting section)

•7 and 8 Remote On/O (Shorted (closed) for ON, Open for OFF)

USB Communication Port

The UPS supports a USB communication port for the end user to connect with a computer. The user may monitor all the UPS status through the USB port if the 1609 UPS Management

Software is installed in the computer. The software is stored in the CD and can be found in the accessory bag.


19

Bulletin 1609 UPS

Manual or Remote

Enable/Disable of UPS Output Selection

The 1609 UPS output is designed to be manually or remotely enabled or disabled. User is required to enable or disable the remote function switch on the front panel.

REMOTE FUNCTION

Manual Enable/Disable/

Self-test

Remote Enable/Disable

DISABLE ENABLE

• Selected 'DISABLE' for Manual Enable/Disable the UPS's Output.

• Selected 'ENABLE' for Remote Enable/Disable the UPS's Output.

The Power Button on the front of the UPS is used to manually enable or disable the output of the 1609-D UPS.

To enable the 1609-D UPS, press and hold the power button until one beep is heard.

To disable the 1609-D UPS, press and hold the power button until three beeps are heard, then release immediately (takes approximately 3 seconds).

To perform a self-test, press and hold the power button until two beeps are heard, then release immediately. (The UPS must operate for at least 4 hours before executing this function)

An external switch connected to the Dry I/O terminals 7 and 8 is required to remotely Enable or Disable the UPS output.

8 7 6 5 4 3 2 1

To enable the UPS, close the switch that is connected to the Dry I/O terminals 7 and 8.

SW

24 Vdc

To Disable the UPS, open the switch that is connected to the

Dry I/O terminals 7 and 8.

20


Display LED Indicators

Bulletin 1609 UPS

Indicator LED Indicator Title

Online

AVR Trim ➊

AVR Boost ➊

On Battery

Description

The UPS is supplying utility power to the connected equipment

(see Troubleshooting).

The UPS is compensating for a high utility voltage


The UPS is compensating for a low utility voltage


The UPS is supplying battery power to the connected equipment.

Overload The connected equipment is drawing more than the UPS power rating allows (see Troubleshooting).

Replace Battery/Disconnect The battery is disconnected or must be replaced


➊ Applies to 1609-D only


21

Bulletin 1609 UPS

Troubleshooting

Button Function

UPS Output Enable

UPS Output Disable

Self-Test

Explanation

Press and hold the button until one beep is heard, then release immediately

Press and hold the button until three beeps are heard, then release immediately

Press and hold the button until two beeps are heard, then release immediately (The UPS must operate for at least 4 hours before executing this function)

Problem

No LED illuminates /

No alarm

No UPS output

UPS Operates on battery although input utility voltage exists

Input line utility power circuit breaker trip

Possible Cause

UPS output is disabled or input utility power is not present

The UPS has not been enabled

Solution

Have qualified electrician trouble shoot the input utility power system and make the necessary corrections.

Manually Enable - Make sure the Remote Function selector switch is in the Disable position, then press and hold the UPS Power button until one beep is heard and release immediately.

Remotely Enable - Make sure the Remote Function selector switch is in the Enable position and verify that there is an adequate connection to the remote on/off dry

I/O connection (terminals 7 & 8)

The system may experience high, low or distorted input utility voltage

Reduce the UPS sensitivity by using the 1609 UPS

Management software.

If the problem persists, move or connect the UPS with a known good quality utility power source.

The system may have experienced an overload

Verify that the circuit breaker is sized properly.

Verify the load connected to the output of the UPS. Ensure that the load does not exceed the output rating of the UPS.

FAULT LED illuminates

ONLINE LED illuminates, but no UPS output is available

An internal fault has been detected Refer to the UPS LED Fault Indicators below to identify the specific fault that occurred and possible resolution.

The UPS output connection may not be connected properly

Disable the UPS output and have qualified electrician troubleshoot the output connection system and make the necessary corrections.

The battery did not provide expected runtime

The batteries might be weak or the lifespan is due

No communication between the

UPS and your PC

Wrong cable

The connection cable is not firmly connected

Charge the batteries for 8 hours and retest the runtime.

If the runtime is still less than expected after charging, replace the batteries even if the Replace Battery LED doesn’t illuminate.

Verify cable used.

Reconnect the communication cable firmly.

PC Communication Port may have been used by another process or is defective

There is interference on the connection cable

Check if there is other software or service accessing the

Communication Port on your PC, or connect it to a different communication port.

Lay the cable differently or away from other cables and reconnect the cable.

22


Bulletin 1609 UPS

UPS LED Fault Indicators

No.

Fault

1 Output Short Circuit

GRN

RED

General Clear Fault Procedure

Press and hold the button until three beeps are heard then release immediately to turn the UPS off then press and hold the button again until one beep is heard then release to enable the output.

Description

The UPS has detected a short circuit on the Output of the UPS and disabled its output.

Solution

Have a qualified electrician troubleshoot the load connected to the output to the UPS and remove the short circuit if present.

2 Output Overload

GRN

RED

3 Over Temperature from the

Heatsink

GRN

RED

The UPS has detected an overload and disabled its output.

To clear fault, follow the General Clear Fault Procedure described above. If the problem persists, contact

Technical Support.

Verify the load connected to the output of the UPS. Ensure that the load does not exceed the output rating of the UPS. If the load exceeds the rating of the UPS please remove excess load or select the appropriate size UPS. If the problem persists, contact Technical Support.

To clear fault, follow the General Clear Fault Procedure described above.

The UPS has detected an over temperature of the heatsink and disabled its output.

Have a qualified electrician checked the ambient temperature to make sure that it does not exceed 40 °C

(1609-SBAT) or 50 °C (1609-HBAT). If it is over temperature, make the necessary correction to the system. This issue may be corrected by improving the room ambient temperature (add ventilation or provide air conditioning).


4 Over Ambient Temperature

RED

GRN

The UPS has detected an over ambient temperature and disabled its output.

Have a qualified electrician checked the ambient temperature to make sure that it does not exceed 40 °C

(1609SBAT) or 50 °C (1609-HBAT). If it is over temperature, make the necessary correction to the system. This issue may be corrected by improving the room ambient temperature (add ventilation or provide air conditioning).


5 Over Voltage from The DC/DC

Converter of Inverter

The UPS has detected an over voltage of the DC/DC

Converter and disabled its output.

Have a qualified electrician verify that the quality of utility voltage is within specification.

To clear the fault, follow the General Clear Fault Procedure described above.

If the fault is still present after attempting to clear fault, contact Technical Support.

RED

6

GRN

Over Voltage from The Inverter

RED

GRN

The UPS has detected high voltage on the inverter and disabled its output.




7 Under Voltage from The Inverter The UPS has detected low voltage on the inverter and disabled its output.

RED

GRN





23

Bulletin 1609 UPS

No.

Fault

8 Over Voltage from The Output of AVR

Description

The UPS has detected an over voltage on the output of AVR and disabled its output.

Solution

Have qualified electrician verify that the quality of the output voltage and the input utility voltage are within its specification.

To clear fault, follow the General Clear Fault Procedure described above and if the problem persists, contact Technical Support.

RED

BLINK

GRN

9 Under Voltage from The Output of AVR

The UPS has detected low voltage on the output of

AVR and disabled its output.



RED

BLINK

GRN

10 Fan Failure

RED

GRN

11 Charger Failure

The UPS has detected that the fan of the UPS has failed and disabled its output.

To clear fault, follow the General Clear Fault Procedure described above and if the Fan Failure persists, contact Technical Support.

The UPS has detected that the battery charger circuit has failed; however, the

UPS will continue running.

Clear this fault by removing the input utility voltage and batteries then plug the batteries back in place and turn the input utility voltage back on. Enable the UPS output to verify the fault.

If the Charger Failure persists, contact Technical Support.

12 TMOV Failure

GRN

BLINK

GRN

GRN

BLINK

GRN

13 Missing Battery

GRN

BLINK

RED

14 Replace Batteries

GRN RED

The UPS has detected that the MOV circuit has failed; however, the UPS will continue enabling the output.

Schedule to have a qualified electrician replace the MOV board (1609-SPD).

Remove the input utility power before service on this 1609-SPD due to risk of electrical shock.

The UPS has detected that the batteries are missing; however, the UPS will continue enabling the output.

Have a qualified electrician verify the battery connection for good contact and charge the batteries for

24 hours.

To clear fault, follow the General Clear Fault Procedure described above. If the battery status still indicates Missing Battery, new batteries are required.

The UPS has detected that the batteries are bad; however, the UPS will continue running.

Have a qualified electrician verify the battery connection for good contact and charge the batteries for

24 hours.

To clear fault, follow the General Clear Fault Procedure described above. If the battery status still indicates Replace Battery, new batteries are required.

24


Bulletin 1609 UPS

Bulletin 1609 UPS

Management Software

Troubleshooting

General Clear Fault Procedure


Status Indications Indication Description

Buzzer Alarm The UPS has detected a fault and generate a buzzer alarm.

Test In Progress

UPS Fault

Battery Low

The UPS is currently in a test mode.

Solution

Verify the type of fault from the Status Indicators or the LEDs on the UPS for further troubleshooting.

Do not interrupt the UPS testing. The UPS is doing battery test.

The UPS has detected a fault and disabled its output.

Verify the type of fault from the Status Indicators or the LEDs on the UPS for further troubleshooting.

To clear fault, follow the General Clear Fault Procedure described above and if the fault persists, contact Technical Support.

The UPS has detected that the batteries are low.

The batteries must be charged for 24 hours and re-verify the battery status. If the batteries still indicate to be low, replace the batteries.

Power Failed

Overheat

Overload

The UPS has detected that the input utility voltage has failed.

The ambient temperature is greater than 60 °C, or some internal components are over temperature.

The UPS has detected that output load of UPS is greater than 110%.

Verify that the input utility voltage is within the UPS’s input specification.

If it is not, make the necessary correction to the input utility power system.

Have a qualified electrician checked the ambient temperature to make sure that it does not exceed

40 °C(1609-SBAT) or 50 °C (1609-HBAT). If the temperature exceeds the UPS rating, make the necessary correction to the system. This issue may be corrected by improving the room ambient temperature (add ventilation or provide air conditioning).

To clear fault, follow the General Clear Fault Procedure described above and if the fault persists, contact Technical Support.

Verify that the load does not exceed the load specification. If it is, remove the excess load from the

UPS’s output and clear its fault. If the problem persists, have a qualified electrician troubleshoot the UPS Load System and make the necessary corrections or select the appropriate size of UPS. If the problem persists, contact Technical Support.

Load Warning

Load Severity

UPS Disconnect

Output Abnormal

The output load over the warning threshold.

The output load over the severity threshold.

The UPS has detected a communication loss between the UPS and the computer.

To indicate the output voltage is abnormal.

Verify the output load. If it is close to 100% load, remove the excess load or select the appropriate size of UPS.

Verify the output load. If it is actually at 100% load, remove some of the non-essential load or select the appropriate size of UPS.

Please check the USB cable between computer and UPS for secure connection or replace the cable with a known good cable.

If communication is established, re-open the UPS Management software. If the problem persists, contact Technical Support.



Output Off

UPS System Off

The UPS is operating in standby mode, or UPS is faulted.

The UPS system is in the standby state.

If it is identified as the UPS fault shutdown then turn the UPS off, and then turn UPS on again to reset the fault. If the fault persists, contact Technical Support.

If it is identified as the UPS fault shutdown then turn the UPS off. Turn UPS on again to reset the fault. If the fault persists, contact Technical Support.

Apply the input utility voltage to the UPS.

Awaiting Power

Battery Need Replace

Battery Depleted

The battery is depleted and the UPS awaits the return of input utility voltage.

The UPS has detected that the battery is bad or opened.

Have a qualified electrician verify the battery connection for good contact and charge the batteries for 24 hours.

To clear fault, follow the General Clear Fault Procedure described above. If the battery status still indicates Battery Need Replace, new batteries are required.

The UPS has detected that the batteries are depleted.


To clear fault, follow the General Clear Fault Procedure described above. If the battery status still indicates Battery Depleted, new batteries are required.


25

Bulletin 1609 UPS

Bulletin 1609

Network Management Card

Troubleshooting

Status Indications

UPS Disconnect

Buzzer Alarm

Input Out Of Range

Battery Low

Battery Depleted

Battery Need Replace

Test In Progress

Test Fail

Output Off

UPS System Off

UPS Shutdown

Output Over Voltage

Output Under Voltage

Overload

Over Temperature

Fan Abnormal

Inverter Abnormal

Charger Abnormal

General Clear Fault Procedure


Indication Description

The communication between UPS and the 1609-ENET card has been disconnected.

Solution

Check the 1609-ENET LEDs for the communication status and the operation of UPS.

If the UPS is operating normal but the LEDs of the 1609-ENET card are not working properly, make sure the cable is securely connected from the 1609-ENET card to the computer.

If the LEDs of the 1609-ENET card is still not working properly, apply a known good 1609-ENET card to verify whether the failure is on the UPS or the 1609-ENET.

Please verify the type of fault from the Status Indicators or the LEDs on the UPS for further troubleshooting.

The UPS has detected a fault and generated a buzzer alarm.

The UPS has detected that the input utility voltage is out of range.

The UPS has detected that the batteries are low.

The UPS has detected that the batteries are depleted.

The UPS has detected that the battery is bad or opened.

The UPS is currently in a test mode.

The UPS has detected that the battery is bad.

The UPS is operating in standby mode or fault shutdown.


To clear fault, follow the General Clear Fault Procedure described above. If the battery status still indicates

Battery Need Replace, new batteries are required.

Do not interrupt the UPS testing.

Verify that the battery is not disconnected or replace the batteries with a brand new set of batteries. Ensure the UPS ran for at least 4 hours before test.

If it is identified as the UPS fault shutdown then turn the UPS off, and then turn UPS on again to reset the fault

If the fault persists, contact Technical Support.

The UPS system is in the standby state.


The UPS was commanded to shut down or fault shutdown.


The UPS has detected that the output voltage is above the UPS’s output specification.

The UPS has detected that the output voltage is below the UPS’s output specification.


To clear fault, follow the General Clear Fault Procedure described above and if the problem persists, contact

Technical Support.


To clear fault, follow the General Clear Fault Procedure described above and if the problem persists, contact

Technical Support.

The UPS has detected that the UPS’s output load is greater than 110%.

The UPS has detected that the ambient temperature is greater than

60 °C, or some of the internal components are over temperature.

Verify that the load does not exceed the load specification.

If it is, remove the excess load from the UPS’s output and clear the fault. If the problem persists, have a qualified electrician troubleshoot the UPS Load System and make the necessary corrections or select the appropriate size of UPS. If the problem persists, contact Technical Support.

Have a qualified electrician check the ambient temperature to make sure that it does not exceed 40°C (1609-

SBAT) or 50°C (1609-HBAT). If it is over, make the necessary correction to the system. This issue may be corrected by improving the room ambient temperature (add ventilation or provide air conditioning).

Following the General Clear Fault Procedure to clear this fault.

The UPS has detected that the UPS’s fan has failed.

The UPS has detected that the UPS inverter circuit has failed.

The UPS has detected that the UPS battery charger circuit has failed.

Verify that the input utility voltage is within the UPS’s input specification.

If it is not, makes the necessary correction to the input utility power system.

The batteries must be charged for 24 hours. After charging batteries verify the battery status. If the batteries still indicate that they are low, replace the batteries.


To clear fault, follow the General Clear Fault Procedure described above. If the battery status still indicates

Battery Depleted, new batteries are required.

To clear fault, follow the General Clear Fault Procedure described above and if the Fan Failure persists, contact

Technical Support.


To clear fault, follow the General Clear Fault Procedure described above and if the Inverter Failure persists, contact Technical Support.

Clear this fault by removing the input utility voltage and batteries. Plug the batteries back in place and turn the input utility voltage back on. Enable the UPS output to verify the fault.

If the Charger Failure persists, contact Technical Support.

26


Bulletin 1609 UPS

Bul. 1609-D Specifications

Input

Output

Online

On Battery

Short Circuit Protection

Efficiency

V nom.

Capacity

Voltage Range, default

Voltage Range, widest online

Current nom.

Capacity Frequency

PFC

V nom.

Capacity

Output Voltage Range, default

Output Voltage Range, widest online

Transfer Point Accuracy

V nom

Frequency

THD

Crest Factor

On Battery (Typical with resistive load)

1609-D600N

120V

600 VA (390 W)

90...145V

90...145V

5.5 A

50/60 Hz ± 3 Hz

1609-D1000N

120V

1000 VA (650 W)

90...145V

90...145V

8.8 A

None None

120V

600 VA (390 W)

108...132 V

108...132 V

± 3 %

120V (sine wave)

50/60 Hz ± 0.5Hz

≤ 10% Full Linear Load

2.2:1

75%

Online - Typical with resistive load excluding AVR mode) 86%

50/60 Hz ± 3 Hz

1000 VA (650 W)

94%

Protection Surge

Overload (Shutdown after 10 s)

380 Joules

> 110...130%

Regulatory

Overload (Shutdown immediately)

Output Short Online/Battery

Thermal Protection

Safety

130%

Premises branch circuit over-current protection/Shutdown

UPS inside temperature ≥ 60 ºC

UL1778, CSA C22.2 No. 107.3, EN/IEC62040-1

Battery Pack

Environment

EMC

Markings

Run Time

Type

Voltage

Charger

Recharger Time

Lifetime

Temperature

FCC & CE (EN 62040-2)

UL, cULus, FCC, CE, C-Tick

≥5 min (at 25 °C, full R load) ≥3.5 min (25 °C, full R load)

1609-D1500N

120V

1500 VA (980 W)

90...145V

90...145V

13 A

50/60 Hz ± 3 Hz

None

1500 VA (980 W)

95%

≥2.5 min (at 25 °C, full R load)

Sealed Lead Acid Battery 12V/5Ah (for 0...40 °C B.B. BP5-12) 12V/5.5Ah (for 0...50 °CB.B. HRL5.5-12)

36V

Current limited, constant voltage float charger

Less than 8 hr to 90% capacity after discharge with full load

2...3 years at 25 °C ambient temperature

Operating Standard Battery 0...+40 °C (+32...+104 °F) Hi-Temperature Battery 0...+50 °C (+32...+122 °F)

Non-operating/Storage -15...+45 °C (+5...+113 °F)

Altitude

Humidity

Heat Output

Operating 0...6600 feet (0... 2000 meters)

Operating/Storage 5...95% RH (Non-condensing)

On Line, Full load: 217 BTU/hr

On Line, Full load, Charging:

296 BTU per hour

On Battery: Full Load: 1331 BTU per hour

On Line, Full load: 142BTU/hr


221 BTU per hour

On Battery: Full Load: 2218BTU per hour

On Line, Full load: 176BTU/hr


256BTU per hour

On Battery: Full Load: 3344BTU per hour

Mechanical

Audible Noise

Approximate Dimensions L*W*H In. (mm)

Approximate Weight lbs (kg)

< 50 dBA @ Front Side 1 Meter

8.66 x 16.14 x 10.24 (220 x 410 x 260)

29.7 (13.5) 30.1 (13.7) 31 (14.1)


27

Bulletin 1609 UPS

Bul. 1609-B Specifications

Input V nom.

Capacity

Voltage Range, default

Voltage Range, widest online

Current nom.

Capacity Frequency

1609-B600N

120V

600 VA (360 W)

96...138V

1609-B1000N

120V

1000 VA (600 W)

96...138V

5.4 A

50/60 Hz ± 3 Hz

8.9 A

50/60 Hz ± 3 Hz

None None

Output

Online

On Battery

Short Circuit Protection

Efficiency

PFC

V nom.

Capacity

Output Voltage Range, default

Output Voltage Range, widest online

Transfer Point Accuracy

V nom

Frequency

THD

Crest Factor

On Battery (Typical with resistive load)

120V

600 VA (360 W)

96...138V

96...138V

± 3%

120V (step wave)

50/60 Hz ± 1 Hz

47.5% (step wave)

2.5:1

80% Typical with resistive load

Online - Typical with resistive load excluding AVR mode) 94% Typical with resistive load

1000 VA (600 W)

47.6% (step wave)

Protection Surge

Overload (Shutdown after 10 s)

380 Joules (Total performance rated with 10*1000 μ s pulse)

> 110...130% - shutdown after 5 sec

Overload (Shutdown immediately)

Output Short: Online

Output Short: Battery

Thermal Protection

130% shutdown immediately

Premises branch circuit over-current protection

Shutdown

UPS inside temperature ≥ 70 °C

Regulatory

Battery Pack

Safety

EMC

Markings

Run Time

Type

UL1778, CSA C22.2 No. 107.3-05, EN/IEC62040-1

FCC & CE (Class A)

UL, cULus, FCC, CE, C-Tick

≥5 min (at 25 °C, full load = 360W, PF = 0.6...0.75)

Sealed Lead Acid Battery

12V/5Ah (for 0...40 °C: B.B. BP5...12)

12V/5.5 Ah (for 0...50 °C: B.B. HRL5.5...12)

24V

≥2 min (at 25 °C, full load = 600W, PF = 0.6...0.75)

Environment

Voltage

Charger

Recharger Time

Lifetime

Temperature

Current limited, constant voltage float charger

Less than 12 hrs to 90% capacity after discharge with full load

2...3 years at 25 °C ambient temperature

Operating Standard Battery 0...+40 °C (+32...+104 °F) Hi-Temperature Battery 0...+50 °C (+32...+122 °F)

Non-operating/Storage -15...+45 °C (+5...+113 °F)

Mechanical

Altitude

Humidity

Heat Output

Audible Noise

Approximate Dimensions L*W*H In. (mm)

Approximate Weight lbs (kg)

Operating 0...6600 feet (0... 2000 meters)

Operating/Storage 5...95% RH (Non-condensing)


On Line, Full load, Charging: 160 BTU per hour


< 45 dBA @ Front Side 1 Meter

6.1 x 11 x 7.09 (155 x 300 x 180)

14.5 (6.6)


On Line, Full load, Charging: 231 BTU per hour


14.7 (6.7)

28


Appendix

A

1609 UPS Dimensions

1609-D UPS Dimensions

375

U N I N T E R R U P T I B L E

P O W E R S U P P LY

1 6 0 9 - D

200

257

220

1609-B UPS Dimensions

339

300

196

U N I N T E R R U P T I B L E

P O W E R S U P P LY

1 6 0 9 - B

140

1609-EXBAT Unit Dimensions

339

300

140

196

178

178

197

140 140


187

170

160

187

170

160

29

Appendix A 1609 UPS Dimensions

1609-BRK Dimensions

(1609-D orientation)

1609-BRK Dimensions

(1609-B orientation)

40 227

382

302

7

110

175

33

30


125

Service Instructions

1609 UPS Dimensions Appendix A

If the UPS requires service, do not return it to the distributor. Follow these steps:

1. Servicing of batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries.

2. When replacing batteries, replace with the same number of the 1609 battery packs supplied by Rockwell Automation.

WARNING: Do not dispose of battery in a fire. The battery may explode. Do not open or mutilate the battery or batteries. Released electrolytes are harmful to the skin and eyes. It may be toxic. A battery can present a risk of electrical shock and high short circuit current.

3. Review the problems discussed in the Troubleshooting section of this manual to eliminate common problems.

4. If the problem persists, contact Rockwell Automation Customer Support at 440-646-5800.

5. Pack the UPS in its original packaging.

– Pack the UPS properly to avoid damage in transit. Never use Styrofoam beads for packaging.

– Damage sustained in transit is not covered under warranty.

ATTENTION: Always disconnect the battery(s) before shipping, in compliance with U.S. Department of Transportation (DOT) and IATA regulations. The battery(s) may remain in the UPS.

The following precautions should be observed when working on batteries:

• Remove watches, rings, or other metal objects.

• Use tools with insulated handles.

• Do not lay tools or metal parts on top of batteries.

• Determine if battery is inadvertently grounded. If inadvertently grounded, remove source from ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock can be reduced if such grounds are removed during installation and maintenance.


31

Appendix A 1609 UPS Dimensions

32


Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products.

At http://www.rockwellautomation.com/support , you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase for FAQs, technical information, support chat and forums, software updates, and to sign up for product notification updates.

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer

TechConnect SM support programs. For more information, contact your local distributor or Rockwell Automation representative, or visit http://www.rockwellautomation.com/support/ .

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/support/americas/phone_en.html

, or contact your local Rockwell

Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States

Outside United States

Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process.

Please contact your local Rockwell Automation representative for the return procedure.

Documentation Feedback

Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002 , available at http://www.rockwellautomation.com/literature/ .

Publication 1609-UM009A-EN-P - January 2013

Copyright © 2013 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

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