SurgeX Security Plus Online Uninterruptible Power Supply

General Safety Instructions

Warnings in this manual appear in four ways:

• DANGER: A lightning bolt symbol ⚡️ in a triangle precedes the word "DANGER". Indicates imminently hazardous situations that WILL result in death, serious injury, or severe property damage if not avoided.
• CAUTION: An exclamation mark symbol ⚠️ in a triangle precedes the word "CAUTION". Indicates potentially hazardous situations that may result in injury or equipment damage if not avoided.
• WARNING: An exclamation mark symbol ⚠️ in a triangle precedes the word "WARNING". Indicates potentially hazardous situations that COULD result in serious injury or death, or severe property damage if not avoided.
• ATTENTION: An exclamation mark symbol ⚠️ in a triangle precedes the word "ATTENTION". Indicates situations and conditions that can cause operator injury and/or equipment damage.

Additional warning symbols may specify special hazards:

• Electrical Warning: A lightning bolt symbol ⚡️ in a triangle indicates high voltage locations that may cause serious injury or death.
• Explosion Warning: An explosion mark symbol ? in a triangle indicates conditions where molten or exploding parts may cause serious injury or death if proper precautions are not observed.

Protective Earth and Neutral Connections

Protective earth (Ground): ⏚

Neutral: N

Connection point for the neutral conductor on PERMANENTLY INSTALLED EQUIPMENT

Earth Ground: ⏚

Important Information for Users

To ensure correct operation, please read this manual carefully and keep it handy for future reference.

1. Before operating or connecting load equipment, ensure the UPS is connected to a properly grounded electrical supply.
2. The UPS has dangerously high voltages on its input and output connections, which can be life-threatening.
3. Do not disassemble the covers; there is a risk of electric shock.
4. In an emergency, immediately turn off the circuit breaker for the circuit supplying power to the UPS and the battery circuit breaker.
5. The UPS has two power sources: the input power supply and the UPS battery. For maintenance, both sources must be disconnected to de-energize the UPS. If only input power is disconnected, hazardous voltages may still exist from the battery.
6. Keep the UPS away from open flame and devices that may cause sparks to prevent damage or safety hazards.
7. Do not open or damage individual battery cases, as spillage of caustic electrolyte can occur, posing a danger to life, safety, and the environment.
8. Battery charging characteristics vary by brand and type. Use only manufacturer-approved replacement batteries. Consult the manufacturer before installing different brands or types.
9. The UPS has an internal EMI filter that produces leakage current to ground. Ensure the UPS is connected to a properly grounded input electrical source.
10. Contact the manufacturer or an authorized distributor for troubleshooting assistance.
11. Only factory-authorized service technicians should service or maintain the UPS.
12. This UPS meets FCC Class A electromagnetic compatibility requirements.
13. Dispose of depleted batteries properly. Contact your local recycling or hazardous waste center or the UPS manufacturer for disposal instructions.

1.0 Overview

The SurgeX Security Plus UPS is a high-frequency, double-conversion (true online) intelligent UPS designed for critical applications such as file servers, enterprise servers, microcomputers, telecommunication systems, data centers, and laboratory instrumentation. It provides high-quality, conditioned uninterruptible power, suitable for IT, LAN, banking, financial, and other mission-critical systems. The UPS connects to a single-phase AC input and provides single-phase AC output power.

1.1 Primary Functions and Operating Characteristics

1. Intelligent RS232 Communication: Utilizes RS232 data interface or USB port with power management software for three communication functions: host computer supervision and control, remote power ON/OFF control, and network discoverability via an optional internal SNMP adapter.
2. High Input Power Factor and Low Input THDI: Employs advanced active power factor correction (PFC) technology for improved input power factor and compatibility with the mains supply.
3. High Performance to Price Ratio: Features high-frequency pulse width modulation (PWM) technology for enhanced efficiency, reduced size and weight, and improved operational reliability.
4. Dependable Self-Protection Functions: Includes output over-voltage protection, battery low voltage protection, and input over-voltage protection to improve reliability and adaptability.
5. Wide Input Voltage Window: Operates within a broad input voltage range, ensuring high-quality power delivery even during low or high input voltage fluctuations, thereby reducing battery discharge cycles and extending battery life.

1.2 Precautions

Observe the following general safety precautions during operation or maintenance:

1. No user-serviceable parts are inside the UPS. Do not remove covers; servicing must be done by trained authorized technicians.
2. The UPS has an input EMI filter that produces leakage current to ground. Ensure connection to a properly grounded input electrical source.

1.3 Performance Specifications

Major specifications are detailed in individual specification sheets. Specifications are subject to change without notice.

Dimensions and Weights (Approximate):

• UPS-22100-88R: Height: 35.5 in (850.0 mm), Width: 13.8 in (349.76 mm), Depth: 38.6 in (980.6 mm), Unit Weight: 449.0 lbs (203.7 kg)
• UPS-22150-69R: Height: 42.3 in (1080.2 mm), Width: 15.75 in (400.0 mm), Depth: 44.39 in (1127.54 mm), Unit Weight: 739.0 lbs (335.2 kg)

Shipping Dimensions and Weights (Approximate):

• UPS-22100-88R: Height: 56.5 in (1435.1 mm), Width: 25.25 in (641.35 mm), Depth: 45.25 in (1149.35 mm), Shipping Weight: 641.5 lbs (291 kg)
• UPS-22150-69R: Height: 60.2 in (1530.0 mm), Width: 20.1 in (510.0 mm), Depth: 48.4 in (1230.0 mm), Shipping Weight: 807.0 lbs (366.0 kg)

2.0 Structure and Basic Principles

2.1 General Structure

2.1.1 Security Plus Front Panel and Rear Panel Structure

The operator panel layout is illustrated in Figure 2-1 and Table 2-1.

Figure 2-1: Depicts the front panel of the Security Plus UPS with an LCD display and control buttons.

2.1.2 Security Plus Display/Controls Operation

The LCD display and controls allow access to various UPS functions and information.

• Function Button Explanation: The NORMAL/BYPASS button starts/stops the inverter. When stopped, the UPS enters bypass mode. The SELECT button scrolls through displays and is held for 3 seconds to enter programming modes. The OK button confirms selections in programming mode.
• Display Content and Corresponding Operation: After startup, the UPS name and model number are displayed for 8 seconds. The display then shows the "OPERATION MODE" (NORM, BYP, BATT) or "FAULT" if a fault is detected.
• UPS Parameters Mode: Pressing the SELECT button cycles through parameter displays (Operation Mode, Output Voltage, Input Voltage, Input Frequency, Output Frequency, Load Percentage, Battery Voltage, Battery Charge Percentage, UPS State One, UPS State Two). The mode cancels after 30 seconds of inactivity.

Figure 2-2: Display Verbiage (10-15kVA) illustrates the operational flow between different modes (Battery, UPS Start Up, Online, Bypass, Shutdown) based on button presses and AC input conditions.

Figure 2-3: Parameters Setting Menu (10-15kVA) shows the menu structure for configuring settings like Inverter Off, Alarm Silence, Ground Fault, Sync Window (Narrow/Wide), and Output Voltage settings (e.g., 240VAC, 230VAC, etc.). It also details how to save settings by entering Bypass operation.

2.1.3 Security Plus Terminal Connection Block Illustration (10-15kVA)

Models are factory configured for 50 or 60Hz. For 10-15kVA models, input wires connect directly to the AC input circuit breaker.

Figure 2-5D: Shows the terminal connection block on the rear, detailing connections for DC, Input AC, and Output.

North American Connections (Figure 2-5D / Table 2-3): Specifies wiring for input voltages (208V, 240V at 60Hz) and output voltages (120V, 208V, 240V at 60Hz), including neutral and bypass jumper connections.

International Connections (Figure 2-5B / Table 2-4): Specifies wiring for input voltages (200V, 220V, 230V, 240V at 50Hz) and corresponding output voltages (200V, 220V, 230V, 240V at 50Hz), including neutral and bypass jumper connections.

2.1.4 RS232 Communications

Table 2-5: RS232 Pin-out and Signals details the pin assignments and signal descriptions for the RS232 interface, including transmit data, receive data, AC fail signals, common, battery low, and output AC fail signals. The maximum current carrying capacity of switch contacts is 3A/30VDC.

2.1.5 Communication Ports Maintenance

The USB and RS232 ports facilitate communication with computers or servers for monitoring. The remote contact interface port provides solid-state relay switch contacts via a DB9 connector. The EPO (emergency power off) contact is a normally closed 125 VAC circuit; a properly sized switch is required for wiring to the EPO circuit.

2.2 Basic Principles

In normal operation, AC input power is converted to a stabilized DC voltage by a power factor corrected (PFC) AC/DC chopper circuit, which then supplies a DC/AC inverter. The inverter converts DC back to regulated, sinewave AC power for the load, routed through an isolation transformer. A battery charger maintains the battery. During a power outage, the battery supplies power to the DC bus for the inverter, ensuring continuous power. In case of overload or fault, a static bypass switch automatically connects input power directly to the output transformer.

UPS Operational Modes:

• Figure 2-8: Normal Operation Mode: Shows AC input powering the PFC AC/DC converter, which supplies the DC/AC inverter. The inverter powers the load via the isolation transformer. The battery is charged by the DC/DC charger.
• Figure 2-9: Battery Operation Mode: Shows AC input failure. The battery supplies power to the DC/DC converter, which then supplies the DC/AC inverter, powering the load.
• Figure 2-10: Bypass Operation Mode: Shows AC input bypassing the inverter and directly powering the load via the isolation transformer, often during overload or fault conditions.

3.0 Equipment Installation

3.1 Site and Environment Requirements

The installation site must meet standards for safe and normal operation. If conditions are not met, site adjustments are necessary before installation.

3.1.1 Site Requirements

1. Installation site conditions should ensure safe and normal operation.
2. The equipment room requires appropriate fire prevention and detection devices.
3. The branch electrical circuit supplying the UPS must be dedicated, with its own circuit breaker and input power receptacle (if plug-connected).
4. Do not store flammable or explosive materials in the same room as the UPS.
5. The UPS must be properly grounded. Voltage between neutral and safety ground should not exceed 5V.
6. Ensure all construction in the installation area is completed before UPS installation. The UPS should be installed on a hardsurfaced floor in a tidy, dry, and dust-free environment.
7. The UPS does not include input over-current protection; refer to local and national electric codes for proper input circuit breaker sizing.

3.1.2 Environmental Requirements

• Ambient Temperature: 0° C to +40° C
• Relative Humidity: 0% RH to 95% RH, non-condensing
• Cooling Mode: Forced air cooling
• Orientation: Install upright, with no more than 5° departure from vertical.

3.2 Procedures for Dismantling Containers

After delivery, carefully unpack the UPS from its shipping container. Use accompanying instructions and Figure 3-3 for guidance. Check received items against the shipping list and inspect for hidden damage. Contact the freight carrier if damage is noted. If items are missing or incorrect, contact the distributor or manufacturer.

Note: Do not dispose of packing materials until the UPS is inspected, installed, and verified for proper operation.

Figure 3-3: Illustrates the unpacking process, showing the UPS on a pallet, shipping brackets, and the plywood ramp used to roll the unit off the pallet.

3.3 Installation of UPS

Ensure adequate space for operation, maintenance, and cooling: at least 30-50cm (12-20") around the enclosure and 50cm (20") above. Keep vent openings and fans clear for good ventilation, which also improves battery life. Installation in an air-conditioned environment is preferable.

1. Place the UPS on a smooth, level floor. Ensure it cannot tip over (max 5° tilt).
2. Ensure good ventilation by observing recommended spacing.
3. Avoid direct sunlight.
4. Protect from humidity and moisture.
5. Do not store corrosive, flammable, or explosive substances near the UPS.
6. Do not place articles on or around the UPS; ensure ventilation slots are clear.
7. Do not allow people to sit on the UPS.
8. Mounting brackets are not seismic; secure the UPS system to the building structure flooring before operation.
9. Bond mounting brackets to the UPS base and flooring using provided screws to secure the base.

4.0 Equipment Use and Maintenance

4.1 Preparation for Start-up

Confirm the following before use:

1. Input and output wiring connections are correct (refer to Section 2.1.3 or 2.1.4).
2. Verify the UPS is set for the correct voltage (check the label on the unit's rear). Refer to Section 2.1.3 or 2.1.4 for voltage setting changes.
3. Input voltage matches the selected configuration.
4. The battery circuit breaker on the rear is in the "OFF" position.
5. Confirm all connected loads (computers, instrumentation) are turned off.

4.2 Routine UPS Startup Sequence

1. Turn the main input circuit breaker to the ON position.
2. Turn the battery circuit breaker to the ON position.
3. The Line LED will illuminate when AC is applied. The Inverter (INV) LED will turn on shortly if the AC input is within specification, indicating normal operation and uninterruptible power supply.
4. If other conditions are displayed, refer to the troubleshooting sections (4.5 and 4.6).
5. Start connected loads sequentially, beginning with the highest power loads.

4.3 Routine UPS Shutdown

1. Press the NORMAL/BYPASS button to stop the UPS inverter; the UPS will enter bypass mode.
2. Turn off the main circuit breaker.
3. Turn off the battery circuit breaker.
4. To restart, follow the routine start-up instructions.

4.4 Important Battery Issues

If the UPS has been disconnected for an extended period, charge it for at least four hours before resuming operation. While it can be used during charging, battery runtime may be short during a power outage.

As long as the UPS is connected to a live power source with breakers ON, the battery remains charged.

1. Do not mix batteries of different capacity, type, or brand. Use only manufacturer-approved batteries. Consult the manufacturer before replacing batteries.
2. Clean the UPS exterior with a soft cloth and clear water only. Avoid oily substances, solvents, or abrasive cleaners.
3. Keep the UPS away from ignition sources and electrical equipment that may cause sparks.
4. Do not store flammable, explosive, or corrosive substances near the UPS or add-on battery cabinets.
5. If the UPS is routinely disconnected for long periods, connect it regularly and charge the battery to prevent self-discharge damage.

4.5 Frequent Trouble Causes

If the UPS fails to operate correctly after installation and start-up, consider these potential causes before assuming a UPS failure:

• Problem 1: Main supply and output normal, but buzzer sounds intermittently.
• Possible Cause: Unstable AC input due to poor connections at the breaker, receptacle, or terminal block.
• Solution: Check all input power connections.
• Problem 2: UPS started, output normal, but BYPASS light is illuminated.
• Possible Cause: Excessive load connected to the UPS.
• Solution: Reduce connected loads until the BYPASS light extinguishes. If overloaded, consider an additional UPS or one with higher capacity. (Note: High inrush loads may cause temporary bypass operation.)
• Problem 3: UPS displays and output normal after start-up, but output stops when load is connected.
• Possible Cause 1: Severe overload or output short circuit.
• Solution 1: Reduce load or check for short circuits caused by faulty adapters or equipment.
• Possible Cause 2: Incorrect load start-up sequence.
• Solution 2: Restart the UPS with no loads connected, then power on largest loads first, followed by smaller loads.
• Problem 4: UPS operates normally after start-up but shuts off after a period.
• Possible Cause: UPS is running on battery (no AC input or disconnected) and the battery is not fully charged.
• Solution: Turn off all switches, restart the UPS, verify AC power, and charge the battery for at least four hours. (Note: Long-term low battery voltage shortens service life.)
• Problem 5: After a period of normal operation, the buzzer sounds intermittently, and "battery low voltage" is displayed.
• Possible Cause: Very low input voltage causing the UPS to run on battery. Low battery condition triggers protection status.
• Solution: Determine the cause of the low input voltage.
• Problem 6: UPS starts and works, but fails to output power during an outage.
• Possible Cause: Battery not connected, battery circuit breaker is off, or battery is damaged.
• Solution: Verify battery connection, ensure battery circuit breaker is ON, and check battery for damage.
• Problem 7: "LINE" LED flashing with intermittent alarm buzzer.
• Possible Cause: Ground fault. The alarm checks for a neutral-to-ground bond.
• Solution: Press and hold SELECT until "Inverter Off: Yes?" appears. Press SELECT twice more until "Ground Fault: Disable?" appears. Press OK. Press NORMAL/BYPASS, wait 2 minutes, then press NORMAL/BYPASS again. Ensure LINE and INV LEDs are on.

4.6 Troubleshooting

4.6.1 Overview

In case of UPS failure, first inspect the UPS and surroundings for obvious reasons (e.g., high temperature, humidity, obstructed vents). Observe any messages on the front panel display. Simple troubleshooting suggestions are provided; for complex issues, contact your distributor or manufacturer.

4.6.2 Troubleshooting Steps

Problem: Buzzer gives long buzzing, fault light is on, UPS is powered through bypass, and inverter fails.

• Possible Cause 1: Output overload or short circuit leading to automatic shutdown.
• Solution 1: Locate and remove the source of overload or short circuit.
• Possible Cause 2: Driver or power transistor failure.
• Solution 2: Contact distributor or manufacturer.
• Possible Cause 3: Master control board failure.
• Solution 3: Contact distributor or manufacturer.
• Possible Cause 4: UPS Over-temperature protection.
• Solution 4: Turn off all loads, allow the UPS to cool, and restart according to routine start-up instructions.

Problem: UPS works when power supply is OK, but fails during a power failure.

• Possible Cause 1: Battery circuit breaker is open (Off).
• Solution 1: Close (turn on) the battery circuit breaker.
• Possible Cause 2: Battery failure.
• Possible Cause 3: Battery charger malfunction.
• Possible Cause 4: Poor contact between battery wires or terminals.
• Solution (for 2, 3, 4): Contact distributor or manufacturer.

Problem: Intermittent buzzing of the buzzer when UPS input is normal.

• Possible Cause: Abnormal input voltage exceeding the UPS's acceptable range.
• Solution: Contact an electrician to verify input voltage.

Problem: UPS works well with computer, but connected load crashes after power failure.

• Possible Cause: Neutral-to-ground voltage at UPS input is too high.
• Solution: Contact an electrician to correct excessive input neutral-to-ground voltage.

Problem: All panel indicator lamps are off.

• Possible Cause: Poor connection or malfunction of the display control panel.
• Solution: Contact distributor or manufacturer.

5.0 Battery Tray Replacement

5.1 Precautions

Battery servicing should be performed or supervised by knowledgeable personnel. Contact SurgeX for battery replacement. Replace batteries with the same type and number. CAUTION: Risk of explosion if battery is replaced with an incorrect type. Dispose of used batteries properly. Do not dispose of batteries in fire; they may explode. Do not open or mutilate batteries; released electrolytes are harmful.

CAUTION: Batteries pose a risk of electrical shock and high short-circuit current. Observe these precautions:

• Remove watches, rings, or metal objects.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not lay tools or metal parts on batteries.
• Disconnect charging source before connecting/disconnecting battery terminals.
• Determine if the battery is inadvertently grounded; if so, remove the source from ground.

5.1.1 Battery Tray Replacement (10 – 15 kVA)

Reference Figure 5-4 for the following steps:

1. Flip the DC circuit breaker on the rear panel to OFF.
2. Open the lower front door.
3. Remove the metal front panel with a screwdriver.

Figure 5-4: Shows the UPS with the front panel open, revealing battery trays and connectors.

CAUTION: Battery connectors extend past tray fronts; examine all connections before removing the front cover.

1. Remove battery retaining brackets.
2. Unplug the desired battery tray connector.
3. Lift the front of the tray and pull it straight out.
4. Lift the rear of the tray to remove it from the compartment.
5. Repeat steps 2-4 for additional trays.
6. Slide new SurgeX battery trays into empty slots.
7. Ensure trays are secure and reconnect battery tray connectors.
8. Replace metal bars.
9. Secure components with hardware.
10. Flip the DC circuit breaker on the rear panel to ON.

CAUTION: Examine battery cable connections for looseness or damage before connecting trays. Ensure clearance between connectors and cover plate before installing panels.

6.0 Packing, Transportation and Storage

6.1 Packing

The original packaging includes an inner cardboard carton within a plywood container, secured to a pallet. Reuse this material and shipping brackets for service or installation shipments. Follow these steps:

1. Place UPS on the shipping pallet.
2. Attach metal shipping brackets to the UPS frame near the pallet.
3. Bolt brackets to the pallet using provided bolts, washers, and nuts.
4. Cover the UPS with a protective plastic bag.
5. Place foam inserts and slide the heavy cardboard container over the UPS.
6. Place the plywood ramp on the cardboard container.
7. Place the outer plywood container over the UPS and inner carton, securing it to the pallet.

6.2 Transportation

Handle with care, avoiding impact or dropping. Observe packing and shipping notices on the carton. Do not stack cartons.

6.3 Storage

Store the UPS in a dry location, protected from moisture and rain. Ambient temperature: 0°C to 55°C; relative humidity: 20% to 80%. Keep away from harmful gases, corrosive chemicals, flammable or explosive materials, strong vibration, impact, and intense magnetic fields. For long-term storage (over 6 months), charge the battery every 3 months to prevent self-discharge damage.

6.4 Fuse Replacements

Fuse servicing requires an authorized technician. Use only replacement fuses of the same type and rating.

• Charger PCB fuses (F1, F2): 250V, 5.0 amp.
• Control PCB fuse: 125V, 0.25 amp.
• 2kVA/4kVA UPS: Power PCB fuses: F1 (250V, 2.0A), F2 (250V, 20.0A), F4/F5 (250V, 15.0A Littelfuse 314 Series).
• 3kVA/5.2kVA/6kVA UPS: Power PCB fuses: F1 (250V, 2.0A), F2 (250V, 25.0A), F4/F5 (250V, 20.0A Littelfuse 314 Series).

7.0 Mechanical Characteristics

7.1 Unit Dimensions/Weights

7.2 Shipping Dimensions/Weights

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