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17.

Remove the (4) batteries from the left side Bay 1. Next remove the (4) batteries from 
the left side Bay 2. Finally, remove the (4) batteries from the left side Bay 3. Now 
install (4) new batteries ( with the terminals up) into Bay 3. Install (4) more new 
batteries (with the terminals up) into the left side Bay 2.  Install the final (4) new 
batteries 

(WITH THE TERMINALS OUTWARD)

into the left side Bay 1. 

USE CARE

NOT TO SHORT THE BATTERY TERMINALS TO THE CHASSIS METAL PARTS.

18.

Reinstall (2) of the left side battery hold down brackets over the batteries on 
Bays 2 & 3 and secure with the screws removed in step 10.

19.

Reinstall (3) small battery jumpers between BATT17 positive to BATT18 negative, 
BATT18 positive to BATT19 negative and BATT 19 positive to BATT20 negative. Next,
reinstall the RED (B) wire to the BATT20 positive terminal. Reinstall the black jumper 
to the BATT17 negative terminal. You may have to slide the batteries out sleightly to 
get at the terminals to reinstall the wiring.

20.

Reinstall the (1) remaining battery hold down bracket over the batteries located on the
left side Bay 1 and secure with the remaining screw removed in step 10.

21.

Reinstall the (6) small jumpers between BATT9 positive to BATT10 negative, 
BATT10 positive to BATT11 negative, BATT11 positive to BATT12 negative,
BATT13 positive to BATT14 negative, BATT14 positive to BATT15 negative,
BATT15 positive to BATT16 negative.

22.

Reinstall (1) of the long jumpers removed in step 13 from BATT13 negative to
the BATT12 positive terminal. Now reconnect the black wire coming from the right 
side BATT8 positive, to the BATT13 negative terminal. Connect the black jumper 
connected to the BATT17 negative terminal to the BATT16 positive terminal. The left 
side battery wiring is now complete go to the next step.  

23.

Reinstall the (6) small battery jumpers between BATT5 positive to BATT6 negative, 
BATT6 positive to BATT7 negative, BATT7 positive to BATT8 negative,
BATT1 positive to BATT2 negative, BATT2 positive to BATT3 negative, and
BATT3 positive to BATT4 negative.

24. 

Reinstall (1) of the remaining long jumpers removed in step 13 to the BATT5 negative 
terminal and the other end to the BATT4 positive terminal. Now reconnect the black 
wire coming from the Battery Circuit Breaker to the BATT1 negative terminal. 
DO NOT RECONNECT THE RED WIRE TO THE BATT20 POSITIVE TERMINAL
AT THIS TIME AS UPS DAMAGE MAY RESULT.

25.

Using a voltmeter set to the 300Vdc scale, place the positive (red) lead on BATT1 
negative (BLACK) terminal and the positive (RED) terminal on the BATT20 positive 
terminal. The meter should read 235 - 276Vdc. If you do not get the correct voltage 
reading recheck steps 18-24. 

DO NOT PROCEED UNTIL THE CORRECT METER

READING IS OBTAINED.

26.

Reconnect the RED wire coming from the main circuit board loBATT to the 
BATT20 positive terminal.

7

Summary of Contents for SG5K-1TX

Page 1: ...ormation 2004 Falcon Electric Inc All rights reserved All other brand names and trademarks are the property of their respective owners The information stated in this document is subject to change without notice 2004 02 05 Falcon Falcon Electric and UPS Plus logos are registered trademarks of Falcon Electric Inc FALCONElectric Inc 5116 Azusa Canyon Rd Irwindale California 91706 626 962 7770 Fax 626...

Page 2: ...r computer room environments the batteries should be replaced every three to five years In critical applications replace the batteries every two years When replacing the UPS batteries use the same number and type of batteries Exercise extreme caution when servicing the 240Vdc batteries in the UPS and External Battery Banks due to the risk of electrocution The batteries approved for the Falcon SG 5...

Page 3: ...ARE HANDLING AND RECYCLING OF SEALED LEAD ACID BATTERIES LIMITATION OF LIABILITY FALCON ELECTRIC INC ASSUMES NO LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGE DUE TO THE THIRD PARTY SERVICING OR REPLACEMENT OF BATTERIES IN FALCON PRODUCTS INCLUDING BUT NOT LIMITED TO LIABILITY FOR INJURY LOSS OF LIFE PROPERTY DAMAGE LOSS OF USE LOSS OF DATA LOSS OF TIME INCONVENIENCE OR COMMERCIAL LOSS O...

Page 4: ...that powers input to the UPS Next turn the circuit breaker powering the UPS to the OFF position 5 To verify the UPS has been properly disconnected from all energy sources return to the UPS and turn the UPS Input Power Switch to the up or ON position THE UPS SHOULD NOT POWER UP Next depress the button marked ON OFF on the UPS front control panel again THE UPS SHOULD NOT POWER UP Now turn the UPS In...

Page 5: ...move the side panel and set aside 8 The batteries are located on both sides of the UPS chassis Please take a few minutes to acquaint yourself with the positions of the batteries inside the UPS and the photos on the next page It is important to locate all of the battery and associated wiring locations prior to starting the battery removal installation process REMOVE ONE OF THE SHORT BATTERY INTERCO...

Page 6: ...Down Brackets Mounting Screws 3 Places Detail of the opposite end of the Battery Bracket secured by a screw shown with the screw removed Detail of Battery Bracket tab in slot mounting Batteries on right side of the UPS Additional batteries on the left side of the UPS BATT8 BATT7 BATT6 BATT5 BATT4 BATT3 BATT2 BATT1 BATT9 BATT10 BATT11 BATT12 BATT13 BATT14 BATT15 BATT16 BATT20 BATT19 BATT18 BATT17 M...

Page 7: ...tive terminal 13 Remove the long jumper wires from between the BATT5 negative and BATT4 positive terminals Also from between the BATT12 positive and BATT13 negative terminals 14 You are now ready to remove the old batteries from the chassis and install the new ones To avoid confusion when reinstalling the new batteries please take a few minutes to observe the positions of the old batteries prior t...

Page 8: ...BATT14 negative BATT14 positive to BATT15 negative BATT15 positive to BATT16 negative 22 Reinstall 1 of the long jumpers removed in step 13 from BATT13 negative to the BATT12 positive terminal Now reconnect the black wire coming from the right side BATT8 positive to the BATT13 negative terminal Connect the black jumper connected to the BATT17 negative terminal to the BATT16 positive terminal The l...

Page 9: ...PS is operating normally from the utility power source switch off the Battery Circuit Breaker located on the UPS rear panel Locate the BATT BATT terminals on the bottom of the main PSDR board see page 5 for the board location Using a Voltmeter set to the 300Vdc scale measure the battery charger voltage at these test points The voltage should be 274Vdc 2Vdc If this voltage is close but not within t...

Page 10: ...s removed in step 4 and tighten 35 If the UPS is model SG1K 1T reinstall the battery fuse and cap 36 Connect the UPS to an utility power source 37 Turn on the UPS power switch located on the rear panel The UPS should power up and function normally as defined in the Owner s Manual 38 Leave the UPS turned on for 24 hours to allow the batteries to fully charge 9 ...

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