Allen-Bradley Bulletin 1609 User manual

41063-222-01 (1) 990-1868 12/2004

Installation and Operation

1609 Industrial Uninterruptible Power Supply

User Manual

Mount the UPS

This unit is designed to mount on a heavy duty DIN rail or on the back panel of an enclosure. For details on

DIN rail installation refer to the DIN rail installation guide included in the DIN rail package. The DIN rail kit is

not included.

When mounting on the back panel of an enclosure, select screws that are appropriate for the weight of this unit

and the mounting surface material.

Six screws must be used when mounting this unit in an enclosure. Three screws in the top of the bracket and

three screws in the bottom of the bracket. Failure to follow these instructions may result in damage to the unit.

Battery Installation

The UPS battery is shipped in a separate carton.

Refer to the installation guide included with the replacement battery for installation instructions.

Top Brack et

Bottom Bracket

Front Panel

Connect Power and Equipment to the UPS

Hardwiring should be performed by a qualified electrician. Use appropriate size wires.

1. The UPS features a transient voltage surge-suppression (TVSS) screw located on the front panel.

The TVSS screw is used for connecting the ground lead on surge suppression devices such as telephone

and network line protectors.

Prior to connecting the grounding cable, ensure that the UPS is NOT connected to utility or battery

power.

2. Hardwire the UPS.

– In 230 V applications the UPS must be protected with a circuit breaker that complies with

European standards for branch rated protection per the country of installation.

– In 208 V applications, the 1609-U500E must be protected by a dual pole, 10 A branch rated

circuit breaker with UL489 rating.

– The 120 V 1609-U500N has supplementary circuit breaker protection. The unit should be

protected by a single pole, 15 A branch rated circuit breaker with a UL489 rating. Allen-Bradley

part number 1492-MCAA115 is suggested. Ensure that the branch circuit breaker is off prior

to wiring the unit.

3. Connect equipment to the UPS.

4. Add optional accessories to the SmartSlot located on the front panel.

5. Turn on all connected equipment. To use the UPS as a master on/off switch, be sure all connected

equipment is switched on.

6. Press the button on the front panel to start the UPS.

– The battery charges to 90% capacity during the first four hours of normal operation.

–Do not expect full battery run capability during this initial charge period.

7. For optimal computer system security, install PowerChutemonitoring software included with the UPS.

PUSH

RESET

1 EPO

2 EPO COM

3 NC

4 COM

5 NO

6 NC

7 COM

8 NO

LOW

BATTERY

INPUT

208/220-240V ~ 50/60Hz , 7A M AX

OUTPUT

325W, 2.7A MAX

0V~ 50/60Hz, 500VA

LINENEUTRALGR OUND LINENEUTRALGR OUND

Te st

120 V model depicted.

INPUT

L1L2/N

OUTPUT

L2/N

INPUT

OUTPUT

LINENEUTRAL LINENEUTRAL

208/230 V

models

120 V

models

Connectors

Communication Port

Contact Closure Port

Output Contact Ratings:

Emergency Power Off

The emergency power off (EPO) feature is user configurable. EPO provides immediate de-energizing of

connected equipment from a remote location, without switching to battery operation.

Use a normally-open contact to connect the EPO COM terminal to the EPO terminal.

The EPO interface is a Safety Extra Low Voltage (SELV) circuit. Connect it only to other SELV

circuits. The EPO interface monitors circuits that have no determined voltage potential. Such closure

circuits may be provided by a switch or relay properly isolated from the utility. To avoid damage to the

UPS, do not connect the EPO interface to any circuit other than a closure type circuit.

Use one of the following cable types to connect the UPS to the EPO switch.

• CL2: Class 2 cable for general use.

• CL2P: Plenum cable for use in ducts, plenums, and other spaces used for environmental air.

• CL2R: Riser cable for use in a vertical run in a floor-to-floor shaft.

• CLEX: Limited use cable for use in dwellings and for use in raceways.

• For installation in Canada: Use only CSA certified, type ELC (extra-low voltage control cable).

• For installation in other countries: Use standard low-voltage cable in accordance with national and

local regulations.

Parameter Value

nominal switching capacity 1 A @ 30 VDC

maximum switching power 30 W

maximum switching voltage 60 VDC

maximum switching current 2 ADC

maximum carrying current 2 ADC

surge ratings 2 kV per Bellcore TA-NWT-001089

1.5 kV per FCC part 68

SERIAL PORT A standard serial interface cable is incompatible with the UPS.

Use the cable supplied with the unit.

1 EPO

2 EPO COM

3 NC

4 COM

5 NO

6 NC

7 COM

8 NO

LOW

BATTERY

The relays are connected from the common (COM) to the normally

closed (NC) pins.When the unit enters a low battery or on battery state,

the appropriate relay will transition and connect the common (COM) to

the normally open (NO) pin.

The Contact Closure Port connection will automatically disable when a

Network Management Card or the Serial Port connection are used.

Operation

UPS Display Panel

Display Panel Indicators and Function Buttons

Indicator

LED Indicator Title Description

On-Line The UPS is supplying utility power to the connected equipment

(see Troubleshooting).

AVR Trim The UPS is compensating for a high utility voltage (see Troubleshooting).

AVR Boost The UPS is compensating for a low utility voltage (see Troubleshooting).

On Battery 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/Battery

Disconnected

The battery is disconnected or must be replaced (see Troubleshooting).

INPUT

208/220-240V~ 50/60Hz, 7A MAX

OUTPUT

325W, 2.7A MAX

0V~ 50/60Hz, 500VA

LINENEUTRAL

GROUND

LINENEUTRAL

GROUND

Tes t

INPUT

208/220-240V~ 50/60Hz, 7A MAX

OUTPUT

325W, 2.7A MAX

0V~ 50/60Hz, 500VA

L2/N L1

L2/N

Tes t

120 V

models

208/230 V

models

Operation

Diagnostic Utility

Vo l t a g e

The UPS has a diagnostic feature that indicates the utility voltage.

The UPS starts a self-test as part of this procedure. The self-test does not

affect the voltage display.

Press and hold the button to view the utility voltage bar graph indicator.

After a few seconds, this five-LED Battery Charge indicator on the

right of the display panel will show the utility input voltage.

Refer to the figure on the left for the voltage reading (values are not listed on

the UPS).

The indicator on the UPS shows the voltage is between the displayed value

on the list and the next higher value (see Troubleshooting).

Feature

Button Feature Title Function

Power On Press this button to turn on the UPS. Continue reading for additional

capabilities.

Power Off Press this button to turn off the UPS.

Self-Test Automatic: The UPS performs a self-test automatically when tuned on, and

every two weeks thereafter (by default). During the self-test, the UPS

briefly operates the connected equipment on battery.

Manual: Press and hold the button for a few seconds to initiate the

self-test.

Cold Start When there is no utility power and the UPS is off, the cold start feature will

switch the UPS and connected equipment onto battery power

(see Troubleshooting).

Battery

Charge

User Configurable Items

UPS settings

Settings are adjusted through PowerChutesoftware or optional Network Management Card.

Function Factory

Default

User Selectable

Choices Description

Automatic

Self-Test

Every 14 days

(336 hours)

• Every 7 days

(168 hours)

• On start up only

• No self-test

Set the interval at which the UPS will execute a

self-test.

UPS ID UPS_IDEN Up to eight characters

(alphanumeric)

Uniquely identify the UPS (i.e. server name or

location) for network management purposes.

Date of Last

Battery

Replacement

Manufacture

Date

mm/dd/yy Reset this date when you replace the battery

module.

Minimum Capacity

Before Return from

Shutdown

0 percent • 0%

• 15%

• 30%

• 45%

• 60%

• 75%

• 90%

Specify the percentage to which batteries will

be charged following a low battery shutdown

before powering connected equipment.

Voltage Sensitivity High sensitivity High sensitivity

Medium sensitivity

Low sensitivity

The UPS detects and reacts to line voltage

distortions by transferring to battery operation

to protect the connected equipment.

In situations of poor power quality, the UPS

may frequently transfer to battery operation. If

the connected equipment can operate normally

under such conditions, reduce the sensitivity

setting to conserve battery capacity and service

life.

Alarm Delay

Control

Enable • Enable

• Mute

•Disable

Mute ongoing alarms or disable all alarms

permanently.

Shutdown Delay 90 seconds • 0 s

• 90 s

• 180 s

• 270 s

• 360 s

• 450 s

• 540 s

• 630 s

Set the interval between the time when the UPS

receives a shutdown command and actual

shutdown.

User Configurable Items

Low Battery

Warning

2 minutes 2, 5, 8, 11, 14,

17, 20, 23 minutes

PowerChute software interface provides

automatic, unattended shutdown when

approximately two minutes of battery operated

run time remains.

The low-battery warning beeps are continuous

when two minutes of run time remain.

Change the low battery warning interval setting

to the time that the operating system or system

software requires to safely shut down.

Synchronized

Turn-on Delay

0 seconds • 0 s

• 60 s

• 120 s

• 180 s

• 240 s

• 300 s

• 360 s

• 420 s

Specify the time the UPS will wait after the

return of utility power before start up (to avoid

branch circuit overload).

High Transfer Point 120 V models:

127 VAC

230 V models:

253 VAC

• 127 VAC

• 130 VAC

• 253 VAC

• 257 VAC

• 133 VAC

• 136 VAC

• 261 VAC

• 265 VAC

To avoid unnecessary use of the battery where

utility voltage is chronically high, set the high

transfer point higher if the connected

equipment can tolerate this condition.

Low Transfer Point 120 V models:

106 VAC

230 V models:

208 VAC

• 97 VAC

• 100 VAC

• 196 VAC

• 200 VAC

• 103 VAC

• 106 VAC

• 204 VAC

• 208 VAC

To avoid unnecessary use of the battery where

utility voltage is chronically low, set the low

transfer point lower if the connected equipment

can tolerate this condition.

The 1609-U500E ships ready for 230 V

sources. When operating the UPS in 208 V

applications, the UPS low transfer voltage

settings are adjusted through PowerChute

software or the Network Management Card.

The proper setting for low transfer voltage is

196 V.

Refer to the PowerChute user guide or the

Network Management Card instructions for

setting adjustment details.

Output Voltage

230 V models 230 VAC • 220 VAC

• 230 VAC

• 240 VAC

230 V models only: Sets the output voltage of

the UPS while operating on battery.

Function Factory

Default

User Selectable

Choices Description

Storage, Maintenance, Transport

Storage

Store the UPS covered in a cool, dry location with the batteries fully charged.

At 5° to 86° F (–15° to 30° C), charge the UPS battery every six months.

At 86° to 113° F (30° to 45° C), charge the UPS battery every three months.

Replacing the Battery Module

This UPS has an easy-to-replace, hot-swappable battery module. Replacement is a safe procedure, isolated

from electrical hazards. You may leave the UPS and connected equipment on during the replacement

procedure.

Ensure battery replacement every 2-4 years.

Standard (40C) battery; Allen-Bradley catalog number: 1609-500SBAT.

High Temperature (50C) battery; Allen-Bradley catalog number: 1609-500HBAT.

Once the batteries are disconnected the connected equipment is not protected from power outages.

Refer to the appropriate replacement battery installation guide for battery module installation instructions. See

your dealer or contact Rockwell Automation at 440-646-5800 for information on replacement battery modules.

Be sure to deliver the spent battery(s) to a recycling facility or ship it to the address specified

in the replacement battery literature.

Troubleshooting

Use this chart to solve minor installation and operation problems. Refer to Rockwell Automation Tech Support

at 440-646-5800 for further support.

Problem and/or Possible Cause Solution

UPS will not turn on

The battery is not connected properly. Check that the battery connector is fully engaged.

button not pushed. Press the button once to power-up the UPS and connected equipment.

The UPS is not connected to utility

power supply.

Check that the UPS is properly connected to utility power.

UPS will not turn off

The UPS is experiencing an internal

fault

Do not attempt to use the UPS. Unplug the UPS and have it serviced

immediately.

UPS beeps occasionally

Normal UPS operation when running

on battery.

None: The UPS is protecting the connected equipment. Press the

button to silence this alarm.

UPS is not providing expected backup time

The UPS battery(s) are weak due to a

recent power outage or battery(s) are

near the end of their service life.

Charge the battery(s). Batteries require recharging after extended outages.

Batteries can wear faster when put into service often or when operated at

elevated temperatures. If the battery(s) are near the end of their service life,

consider replacing the battery(s) even if the replace battery LED is not yet

illuminated.

Left half, Right half, or Center section of front panel is flashing

The UPS is experiencing an internal

fault.

Do not attempt to use the UPS. Unplug the UPS and have it serviced

immediately.

All LEDs are illuminated and the UPS emits a constant beeping

The UPS is experiencing an internal

fault.

Do not attempt to use the UPS. Unplug the UPS and have it serviced

immediately.

Front panel LEDs flash sequentially

The UPS has been shut down remotely

through software or an optional

accessory card.

None: The UPS will restart automatically when utility power returns.

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