CASTLE EX SERIES

USER MANUAL
Thanks for choosing Santak products!
All warnings and operation instructions in the manual and on the machine
should be strictly followedˈand this user manual should be kept properly
for future reference. Do not attempt to operate the UPS until reading
through all safety information and operating instructions of this manual
carefully.

This manual applies to the Castle EX series products, including:

3C3 EX 20KS/3C3 EX 20KS-ISO

3C3 EX 30KS/3C3 EX 30KS-ISO

3C3 EX 40KS/3C3 EX 40KS-ISO

3C3 EX 60KS/3C3 EX 60KS-ISO

3C3 EX 80KS/3C3 EX 80KS-ISO

 S o l e m n S t a t e m ent

Supervision Code Statement

To ensure consumer rights and safe electricity application, help you purchase authentic
SANTAK UPS, the following items should be heeded:
1. Make sure of
2. SANTAK Electronics (Shenzhen) Co. Ltd. never grants authorization in any form to
any company to manufacture UPS;
3. Labeled on all SANTAK is an Āelectronic supervision codeā (Āelectronic
supervision codeā is a code of product identication advocated by SIQSAQ in order to
strike at fake commodities).

Inquiry method:
Website inquiry: Access the website:www.95001111.com (Product Identification,
Authentication and Tracking System) and input the supervision code;
Tel inquiry: Call 95001111 to check (you may call 010-95001111 and follow the
instructions to enquire the identication);
Message inquiry: Send text message to 106695001111 (available to both China Mobile
and Unicom);
Any questions, you may call the telephone number at 95001111 or log on to
www.95001111.com. for further details or lodge your complaints.

Copyright Statement

SANTAK is dedicated to a continued effort of technological innovation and provision

of improved products and services to satisfy customersÿ needs. Product design and
technical specications are subject to upgrading without notice. Actual product may differ
from photo.
Please access www.santak.com to download the latest version of product instructions.

All Rights Reserved © 2008-2009 SANTAK Electronics (Shenzhen) Co., Ltd.

 S a f e t y I n s t r u c t i o ns

Operation Safety
1. Prior to the application, please read ĀSafety Instructionsā carefully to ensure correct
and safe application. Please keep the user manual properly.
2. During operation, attention should be paid to all warning symbols and operations
should be followed strictly as required.
3. Equipment is not supposed to be used in environment that directly exposed to the
sunlight or raindrops or in humid environment.
4. The equipment should not be installed close to area of thermal sources or any area
where there is presence of devices such as electric heaters and furnaces.
5. Make sure the safety space should be left for proper ventilation and product
maintenance when placing UPS. Refer to the instructions during installation.
6. Dry and non-conductive items should be used for cleaning.
7. In case of a re hazard, dry powder extinguisher should be used properly. Using liquid
re extinguisher may result in electric shock hazard.
8. Storey bearing capacity of machine and batteries should be taken into consideration
prior to installation.
9. Using this device, please ensure that the load power is match with the rated power of
UPS and the battery specications.

Prohibitions
1. There is high voltage presented inside the UPS, non-licensed company or technical
personnel is not allowed to open the case cover arbitrarily, otherwise there might be a
danger of electric shock and loss of warranty eligibility.
2. When applied to the following equipment, please contact the dealer or Santak in
advance since there might be special requirements and design for the application, setting,
management and maintenance:
AˊPrecision industrial, scientic and medical instruments and equipment;
BˊEquipment that might endanger physical safety such as elevator etc;
CˊLoad equipment with large startup current and negative power;
3. Do not place battery to re in order to avoid possible explosion.
Electric Safety
1. Before electricity is switched on, make sure earthing is properly done and wire and
battery polarity are correctly connected.
2. Battery protection device must be configured with over-current breaker of rated
specications.
3. When UPS relocation or wire reconnection is necessary, AC and battery should be
switched off and UPS should be completely turned off, otherwise there might be a danger
of electric shock because output terminal might be still electried.
4. Please use Santak specied appendix devices and accessories.
5. Prior to connecting the power distribution system to the UPS, make sure the rated
quadrupole over-current breaker is installed to break off all the input lines and thus
prevent a risk of electric shock.

Battery Safety
1. Battery service lifetime will be shortened as ambient temperature rises. Replace
batteries periodically to guarantee normal UPS performance and sufcient back-up time.
2. Only personnel with proper expertise can carry out the maintenance of accumulator
batteries.Replacement of accumulator batteries requires a match of same type and model
with equal quantity.
3. As accumulator batteries may contain potential electric shock and short-circuit current
danger, to avoid accidents that might be thus resulted, the following warnings should be
observed during battery replacement:
A. Do not wear watches, rings or similar metallic items;
B. Use insulated tools;
C. Put on rubber shoes and gloves;
D. Do not place metallic tools or similar metallic parts on the batteries;
E. Switch off load connected to the batteries before dismantling battery connection
terminals.
4. Do not expose accumulator battery to fire in order to avoid possible explosion that
might endanger physical safety.
5. Non-professionals are not allowed to open or destroy accumulator batteries for
electrolytes in batteries contain strong acid and other dangerous substances which will
cause damages to both human skins and eyes. Should electrolytes come into any contact
with human body unintentionally, rinse with clean water and seek medical advice.
6. Do not cause battery positive and negative polarity short circuit otherwise electric shock
or inammation may occur.

Maintenance
1. Working environment and storage means can affect the service term and reliability of
this product to some extent. Therefore, the product is not suitable for performance in the
following environment:
A. Locations where temperature exceeds the maximum or goes below the minimum
temperature as required by technical specications or humidity is improper (temperature
range: 0-40ć ; relative humidity range: 0-95%).
B. Locations where vibration and collision are constant;
C. Locations where metallic dustsˈcorrosive substances as well as salts and
inammable gases are present.
2. For long-term inaction, UPS (without batteries) should be kept in dry environment
with temperature ranging from -25-55ć . Before start-up, ambient temperature should be
brought back to 0 or above for a certain period of time (above 2 hours).
3. Keep good ventilation; otherwise, it will lead to internal temperature rise, shorten the
lifetime of the components and thus shorten the lifetime of the UPS.
4. For long-term inaction, the battery should be charged once every three moths in normal
temperature environment and once every two moths in high temperature environment
with no less than 10 hours; no-load discharge is not allowed, and the battery continuous
discharge time should not exceed 14 hours.
 Contents
C h a p t e r 1 B r i e f i n t r o d u c t i o n ......................................................................1
1.1 Product introduction........................................................................................................1
1.2 Frequently used symbols.................................................................................................2

C h a p t e r 2 E x t e r i o r a p p e a r a n c e .......................................................................3
2.1 Unpacking inspection......................................................................................................3
2.2 Exterior gure..................................................................................................................5
2.3 Panel instructions............................................................................................................6

C h a p t e r 3 I n s t a l l a t i o n i n s t r u c t i o n s ...............................................................8
3.1 Installation Notice...........................................................................................................8
3.2 Installation space.............................................................................................................8
3.3 Installation and wiring connection diagram...................................................................10
3.4 Requirements of wiring cables and protect device for Castle EX series UPS.....................14
3.5 Parallel UPS installation................................................................................................15
3.6 Procedures of connecting battery bank to UPS.............................................................18

C h a p t e r 4 O p e r a t i o n .............................................................................................19
4.1 Single UPS operation.....................................................................................................19
4.2 Parallel UPS operation................................................................................................... 26

C h a p t e r 5 C o m m u n i c a t i o n I n t e r f a c e ..........................................................28

C h a p t e r 6 O p t i o n a l a c c e s s o r i e s .........................................................32
6.1 Power Feedback Module...............................................................................................32
6.2 Transformer...................................................................................................................32
6.3 Double Charge Boards...................................................................................................33
6.4 Temperature Sensor.......................................................................................................33
6.5 Dustproof Net...............................................................................................................33
6.6 IP21 Option...................................................................................................................34

Chapter 7 Transportation, Maintenance and Troubleshooting................35

Appendix 1Techinial parameters and specifications............................37

A p p e n d i x 2 L i g h t r e f e r e n c e t a b l e ..........................................................38

A p p e n d i x 3 Wa r r a n t y...................................................................................40
 C h a p t e r 1 B r i e f i n t r oduc ti on

1.1 Product introduction


  
"
pure-online and three phase input and three phase output UPS.This series provides perfect
solution for power source protection and successfully solves problems such as blackout,
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   &      
be widely used in computer equipment, communications equipment and other controlling
equipments, and under the impact of the load for a particular election can be installed
accessories to deal with complex industrial environment. Therefore, Castle EX Series
 
"
 
 
 
   "   '

Manifold function of Castle EX series products to provide high-quality power supply

guarantee for your device:
Advanced DSP digital control technology to effectively improve product performance
and system reliability
N + X parallel redundancy ( support sharing batteries in parallel)
Excellent performance of industrial environment protection
Economy and security of ECO mode of operation allows UPS efciency of more than
98%
High-denition LCD interface for human-machine interaction, intuitive and convenient
operation
Powerful communication interface and remote monitoring
Abundant optional accessories, can be exibly congured according to actual demands.

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1.2 Frequently used symbols

The following symbols will be frequently used in this User Manual as well as in the
process of actual application; therefore, correct identication and understanding of their
connotations prove necessary.

2
 C h a p t e r 2 E x t e r i o r a p pearanc e

2.1 Unpacking inspection

1. Unpack and there should be:

1) UPS
2) Winpower Disc
3) Accessories including user manualǃRoHS card and two keys of the door

2. Check whether the UPS is damaged during the process of transportation or not. Should
any damage be observed or parts be found missing, do not start the machine. Contact the
forwarder and distributor immediately.

Note: Make sure that the heights of the door and some other obstacles are
appropriate.

1)Remove the top cover plate by unlocking the 2˅Remove the packing cardboards from the
wood screws with a sleeve. sides of the unit.

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3˅Remove the foam and plastic bag around the 4˅Move the frame smoothly from the pallet to
unit. the ground or the reserved position for installation
with a forklift.

Note: 1) 3C3 EX 20KS/30KS/40KS and ISO models

are provided with brake pads, rotate the wrench
(NO.19) clockwise until the brake pad revolves to
the ground, which can prevent the unit from moving.

2) For 3C3 EX 60KS/80KS models, remove the iron brackets xing the UPS with
a wrench rstly, then move the frame smoothly from the pallet to the ground, and
x the UPS with the iron brackets again.

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2.2 Exterior gure

Exterior gure of 3C3 EX 20KS/30KS/40KS UPS

Front view Front view(without front panel)

Rear view(3C3 EX 20K) Rear view(3C3 EX 30KS/40KS)

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Exterior gure of 3C3 EX 60KS/80KS UPS

Front view Front view(without front panel)

top view bottom view

2.3 Panel instructions

The LCD panel is the human-machine interface used to carry

out the visual operations of the UPS, including the power-on,
power-off, status display, fault alarm, parameter setting etc. And
all the operations of the UPS can be realized through the LCD
panel after installing the UPS. It consists of three parts: the LED
indicators, LCD and function keys. Please refer to the table
below for the description of the LED indicators and function
keys.

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Note: Please refer to Appendix 2 for detailed information of LED in accordance
with the UPS status.

Status LED Indicator: Display the current UPS operating mode or status.

Identier LED Indicator Color Status

ķ AC green UPS is powered directly by AC
ĸ Inverter green UPS is powering through the inverter
Ĺ Battery yellow Line input fault, UPS is powering by batteries
ĺ Bypass green UPS is powering the load by AC through bypass
LED will solid on with continuous warning tone or ash
Ļ Fault red with intermission warning tone in case of UPS abnormal
function

LCD display screenüļ˖Display detailed UPS information

Function Keys: selecting and opening menu items, accessing information and changing
system parameters etc.

Identier Key Name Function

Select a menu or conrm an operation; conrm the present
Conrm/
Ľ input password letter and enter the next password letter input
Enter
process; back to the main menu from the status screen.
ľ Page Down Switch to next screen display under the same menu.
Ŀ Ʒ Page UP Return to last screen display under the same menu.
Return to previous menu or cancel a certain operation; cancel
ŀ Esc Escape the input password; back to the status screen from the main
menu.

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 C h a p te r 3 I n s t a l l a t i o n i ns truc ti ons

3.1 Installation Notice

1) The installation of Castle EX series products must be performed in compliance with the
electrical code by professional personnel.
2) Install the UPS in a clean and stable environment that is free of vibration, dust, high
humidity, ammable gas, and ammable liquid or caustic substance.
3) To ensure normal UPS performance, ambient temperature should range between 0-40ć .
If temperature exceeds 40ć , maximum load should be decreased progressively by 12%
of the rated amount along with every increase of temperature by 5ć . The maximum am-
bient temperature for normal UPS performance should not exceed 50ć .
4) It is suggested that battery pack should work within a temperature range from15ć to
25ć .
5) Altitude for normal UPS function should not exceed 1000m. Should UPS be intended
for application above 1000m, progressive decrease of rated output should be applied as
listed in the following chart:

Altitude(m) 1000 1500 2000 2500 3000 3500 4000 4500 5000
Derating
100ˁ 95ˁ 91ˁ 86ˁ 82ˁ 78ˁ 74ˁ 70ˁ 67ˁ
coefcient

3.2 Installation space

3C3 EX 20KS/30KS/40KS series utilizes forced fan cooling and installation spot should
make allowance for ventilation. Meanwhile, inside maintenance should be carried out
from the front side and therefore maintenance space should also be considered in advance.
Refer to the following gure for installation space:

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3C3 EX 60KS/80KS series adopt the bottom air inlets and top air outlets to ensure good
ventilation, do not put any sundries at the top of the UPS, and the ventilation spacing
above the UPS should be no less than 500mm, otherwise the UPS internal temperature
will rise dramatically. Do not install the UPS under the outtake of an air conditioner,
otherwise, the water may drop into the UPS and thus cause UPS fault or a re. There must
be at least 1000mm of space reserved in front of and behind the UPS for internal and main
power part maintenance,please refer to the gure below for installation space:

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3.3 Installation and wiring connection diagram

3C3 EX 20KS/30KS/40KS standard models are integrated with dual power input, and 3C3
EX 60KS/80KS standard models with single power input. The switch between the single
power and dual power supply can be carried out by customer service engineers according
to customerÿs request. All the operations should only be carried out by the technical
personnel of the company or authorized by the company. Do not open the case cover
arbitrarily; otherwise, electric shock may occur.

3C3 EX 20KS/30KS/40KS wiring connection:

1. Wiring connection diagram:

2. Single power input:

Only connect the AC (3ž4W) to the Main 1.
(1)Ground wire should be connected to the UPS ground terminal;
(2)Connect the AC input cable to the terminal block ķ ;
(3)Connect the AC three-phase input lines to the bypass three-phase input lines ĸ
(4)Connect the four load power wires to the terminal block Ĺ

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 single power input(3ž4W):20kVA~40kVA connection diagram

Notes:
Please make sure that the input power is three-phase with 4 wires, and the
input voltage is within the allowable voltage range (refer to Appendix 1).
Make sure the input power is the positive phase sequence and battery polarities
are correctly connected.

3. Dual power input:

For dual power input, the conducting wire between AC input terminal and bypass input
terminal must be removed rstly.
(1) Ground wire should be connected to the UPS ground terminal;
(2) Connect the four AC input wires to the terminal block ķ ;
(3) Connect the four bypass input wires to the terminal block ĸ , N lines of the main 1
and main 2 are connected to the same terminal block;
(4) Connect the four load power wires to the terminal block Ĺ

dual power input(3ž4W):20kVA~40kVA connection diagram

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Notes:
Please make sure that the input power is three-phase with 4 wires, and the
input voltage is within the allowable voltage range (refer to Appendix 1).
Make sure the input power is the positive phase sequence and battery polarities
are correctly connected.

3C3 EX 20KS/30KS/40KS wiring connection:

1. Wiring connection diagram:

2. Single power input:

Only connect the AC (3ž4W) to the main input terminal.

(1) Ground wire should be connected to the UPS ground terminal;
(2) Connect the AC input cable to the terminal block ķ ;
(3) Connect the four load power wires to the terminal block ĸ

single power input(3ž4W):60kVA~80kVA connection diagram

12
Notes:
Please make sure that the input power is three-phase with 4 wires, and the
input voltage is within the allowable voltage range (refer to Appendix 1).
Make sure the input power is the positive phase sequence and battery polarities
are correctly connected.

3. Dual power input:

Customers may choose the dual power input according to their needs, and the installation
of the bypass input switch is carried out by the customer service engineers.
(1) Ground wire should be connected to the UPS ground terminal;
(2) Connect the AC input cable to the terminal block ķ ,and the bypass input wire to the
terminal block ĸ ;
(3) Connect the four load power wires to the terminal block Ĺ

dual power input(3ž4W):60kVA~80kVA connection diagram

Notes:
Please make sure that the input power is three-phase with 4 wires, and the
input voltage is within the allowable voltage range (refer to Appendix 1).
Make sure the input power is the positive phase sequence and battery polarities
are correctly connected.

13
3.4 Requirements of wiring cables and protect device for Castle EX
series UPS

External batteries of Castle EX Series UPS require serial connect positive and negative
of each group of 14-16 batteries (12VDC per battery) with the same capacity, nominal
voltage for each group being168VDC-192VDC. Battery capacity and number of group
can be selected at your option. Battery pack must be equipped with DC switch and input
fuse, and overload and line voltage should also be taken into consideration for wire
diameter selection. Please refer to the table below for details:

Input Output Battery positive Ground

Machine N wire
Rated power live wire live wire /N negative wire wire
Model diameter
diameter diameter diameter diameter
3C3 EX 10AWG/ 10AWG/ 8AWG/ 8AWG/ 8AWG/
20kVA/16kW
20KS 6mm2 6mm2 10mm2 10mm2 10mm2
3C3 EX 8AWG/ 8AWG/ 6AWG/ 6AWG/ 6AWG/
30kVA/24kW
30KS 10mm2 10mm2 16mm2 16mm2 16mm2
3C3 EX 6AWG/ 6AWG/ 4AWG/ 4AWG/ 4AWG/
40kVA/32kW
40KS 16mm2 16mm2 25mm2 25mm2 25mm2
3C3 EX 4AWG/ 4AWG/ 2AWG/ 2AWG/ 2AWG/
60kVA/48kW
60KS 25mm2 25mm2 35mm2 35mm2 35mm2
3C3 EX 2AWG/ 2AWG/ 1AWG/ 1AWG/ 1AWG/
80kVA/64kW
80KS 35mm2 35mm2 50mm2 50mm2 50mm2

Bypass
Machine AC input Battery N wire AC input Battery
input
Model breaker switch switch fuse input fuse
breaker
3¶50A/ 3¶63A/ 3¶125A/ 1¶80A/
3C3 EX 20KS 63A 690V 30A 600V
380VAC 380VAC 250VDC 220VAC
3¶63A/ 3¶80A/ 3¶150A/ 1¶100A/
3C3 EX 30KS 80A 690V 30A 600V
380VAC 380VAC 250VDC 220VAC
3¶80A/ 3¶100A/ 3¶200A/ 1¶150A/ 100A
3C3 EX 40KS 30A 600V*2
380VAC 380VAC 250VDC 220VAC 690V
3¶150A/ 3¶150A/ 3¶300A/ 1¶200A/ 100A
3C3 EX 60KS 100A 690V
380VAC 380VAC 250VDC 220VAC 690V*2
3¶175A/ 3¶175A/ 3¶400A/ 1¶250A/ 100A
3C3 EX 80KS 100A 690V
380VAC 380VAC 250VDC 220VAC 690V*2

14
Remark:
1. Prior to connecting the power distribution system to the UPS, make sure the
rated triploid-pole over-current breaker is installed to break off all the input lines
and the N line breaker can be congured individually.
2. When single-phase current exceeds 100A, switches of protective atmosphere
should be equipped with arc control devices,It should be D-curve air switch with
UL certication according to the customer requirement;
3. Battery positive/negative/N wire size: indicates UPS and battery bank wire size;
red wire signies the positive polarity and black wire the negative, while blue wire
the neutral.
4. There should be the same length of the battery wires (positive, negative and N)
of being no more than 40m.

3.5 Parallel UPS installation

1. Redundancy introduction
N+X is currently the most reliable power supply structure, in which N indicates the
minimum UPS number required for the total load and X is the redundant UPS number,
namely, the malfunctioning UPS number that the system can simultaneously bear. The
larger X is, the higher reliability of system will be. For instance, if the total loads of a
customer register 55kVA, we can use Castle 20KS for N+X design. With N taking up 3,
X can be selected in accordance with reliability degree or cost requirement. Supposing
customer selects X=2 and equalized UPS power supply is 11kVA for each unit, when one
set of UPS breaks down with malfunction, the remaining four sets will provide power
with almost 14kVA equalized current; if two sets of UPS fail, the remaining three sets of
UPS are supposed to provide power supply with almost 18kVA equalized current. The
maximum allowance of this system is for two sets of UPS going down at the same time,
the chances of which are much smaller than those of one UPS malfunction. Therefore, the
reliability degree can be largely enhanced, making it an optimal mode for application in
locations where high degree of reliability is always a focus.

15
2. Castle EX Series UPS is capable of direct parallel connection, which only requires
the parallel connection wires (optional) for 2 to 8 sets of UPS in parallel connection in
order to realize power redundancy (N+X)(60KS/80KS support six sets of UPS parallel
connection). Ventilation spacing between machine anks should be a minimum of 10cmˈ
input wiring for each set of UPS should follow the requirements for that of single unit.
Each UPS input/output should be connected to the same input patch board, from which
wires are distributed for load as illustrated in following gure:

Remark:
1˅Common battery pack is applicable in parallel configuration; each battery pack
should be of the same model and the same batch from the same manufacturer.
2) Requirement of output wiring length:
ķ When the lead from the output terminal of each set of UPS to the output patch
board is less than 20m, wire difference should be less than 20%;
ĸ When the lead from the output terminal of each set of UPS to the output patch
board is longer than 20m, wire difference should be less than 10%.

16
3.Parallel machine wire connection drawing:
3C3 EX 20KS/30KS/40KS UPS

3C3 EX 60KS/80KS UPS

17
3.6 Procedures of connecting battery bank to UPS

The rated over-current protection breaker should be installed between the battery bank and
the UPS, please refer to the wiring table at the last section for the specication.
(1) Make sure that there are no voltages present on the input and output terminals, and
there is no voltage output of the external battery socket;
(2) Turn off the battery breaker;
(3) Remove the panel on the terminal bay and connect Ā+ā, ĀNā and Ā-Ā wires
from UPS terminal bay to Ā+ā, ĀNā and Ā-Ā of the battery box; make sure the
battery polarities are correctly connected;
(4) Use multimeter (DC Voltage) to measure the voltage of positive and negative batteries
as well as positive and negative polarity, then close the cover of the terminal block.

3C3 EX 20KS/30KS/40KS battery connection diagram 3C3 EX 60KS/80KS battery connection diagram

Remark: Battery connection and replacement should be operated under the

system shutdown, Non-professionals are not allowed to carry out the task
otherwise electric shock may occur.

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 C h a p t e r 4 O p e r a ti on

4.1 Single UPS operation

1. Make sure A, B and C phase sequences are correctly connected and then supply power
to UPS.
2. Turn on the breaker of the battery bank (make sure that the Ā+ā, ĀNā and Ā-ā of
terminal bay are in accordance with those on the output of the battery bank).
3. Switch on Āinput breakerā (Line input breaker: Main ĉ ; bypass input breaker:
Main Ċ ; line input breaker for 60K/80K standard models) on the UPS and fans start to
rotate for UPS self-inspection. Main menu can be accessed within about 4sec and then
operations should be carried.

Remark: the following drawing takes 3C3 EX 20KS as an example and statistics
are only for reference.

1) Power on 2) Automatic access within about 4s

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3) Press ESC to access or automatically 4) Press ͩ to obtain the below information
access within 1min with no button being
pressed

5) Press ͩ again to obtain the below 6) Press ͩ again to obtain the below
information information

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7) Press ͩ again to obtain the below 8) Press ͩ again to obtain the below
information information

Remark: when malfunction occurs, Āxā will appear at the lower right corner of
the picture while when warning occursĀ āwill appear at the same position (as
illustrated in the below picture with battery mode as an example).

4. Start-up action (press ESC to exit the above picture)

1) Switch-on picture 2) Press ENTER

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3) Select ĀYes, Conrmā to switch on 4) Normal Switch-on
the machine

5) Battery power supply (switch off line input breaker)

5. Switch-off action (press ESC to exit above picture)

22
1) Switch-off picture 2) If it is in single machine mode, the
following will appear

3) If it is in parallel machine mode, the 4) Press ENTER

following will appear

5) Select ĀYes, Conrmā to switch off the machine

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Remark: If you intend to switch off only one set of UPS among the parallel
machine system, select Āsingle machine switch-offā; if switch-off is intended for
the entire parallel machine system, select Āparallel machine switch-offā.

6. Help

1) Help picture 2) Press ENTER on help picture

3) Press ENTER on SERVICE HOTLINE picture

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7. Setting action (press ESC to exit the above picture)

You are able to access Setting picture by using user combination (default: 1234, subject to
personal modication) so as to set the following programs.

1) Setting picture (bypass power supply) 2) Press ͩ

3) Input Password display 4) Input password and press ENTER

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8. Castle EX Series is capable of DC start-up without AC input, panel display being
similar to switch-on picture with AC supply. DC switch-on and off are available by
following instructions appearing in the pictures:
Firstly, activate DC switch-on function set under the bypass mode
Make sure thatĀ+ā,Ā-āandĀNāwires of batteries are properly connected to UPS
Switch on batteries
Lightly touch ENTER
Manually conduct switch-on order within about 40s after LCD self-inspection

Remark: UPS will be switched off automatically if there is no operation within 40s
after LCD self-inspection is completed!

4.2 Parallel UPS operation

Castle EX Series is capable of direct parallel connection, customers can add additional
machines on line to realize power redundancy and follow single machine operation
instructions for general operation. Before parallel operation, the customer service
engineers will change the stand-alone mode into the parallel mode through the LCD
display panel. Then connect the parallel lines of UPS and switch on the UPS input in
sequence, turn on the system through any of the single machine, then all the single
machines will display ĀUPS is loading onā, and then switch to inverter output.

Ł Normal switch on: Follow the operation ł If parallel operation fails,the

for single UPS and switch on the machine: following will appear:

26
Ń Select to switch off one of the single machines or the parallel system:

Remark: After turning on in Line mode, all UPSs will transfer to INV mode; Turn
off: when turn-off is conducted under INV mode, all UPSs will simultaneously
turn off inverter and then transfer to the bypass mode, if turn off the UPSs one by
one, all UPSs will simultaneously transfer to the bypass mode after the last UPS
completes turn-off action.

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 C h a p t e r 5 C o m m u n i c a t i o n Interfac e

Castle EX Series provides Intelligent Slot, Expanded Slot, PARALLEL, EXT.BATTERY

TEMP PROBE, AS400, EPO, RS485 and RS232 as well as SERVICE Supervising
Communication Interface exclusively available to Santak technical personnel.

3C3 EX 20KS/30KS/40KS

3C3 EX 60KS/80KS

1. Intelligent slot: suitable for WebPower card (optional) of remote supervising

management, enabling you to realize remote supervising management on UPS by
accessing Internet. (Intelligent slot adapter card is divided into long card and short card;
Castle EX Series requires the latter.)

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2. Expanded slot: only applicable for 20KS/30KS/40KS models, and available only to
users with special requirements and not for standard conguration.
3. PARALLEL: communication connections for parallel conguration, 8 sets of UPS in
parallel for 20KS/30KS/40KS models and 6 for 60KS/80KS models.
4. EXT.BATTERY TEMP PROBE: temperature interface for external battery cabinet,
capable of battery temperature supervision so as to realize battery intelligent management.
5. Standard AS400 interface: provides dry-contact interface for UPS supervising,
the contact signals can reflect the UPS operation states so as to realize power source
management (See Appendix for AS400 Port pin denition).
6. EPO: emergency power off, which provides users having emergency power-off need
with direct UPS output off function. (See Appendix for EPO external wiring diagram)
7. Standard RS485 Interface: capable of UPS supervising management when parallel
machine, providing complete control over UPS power supply (See Appendix for RS485
port Pin denition).
8. SERVICE Interface: available only to Santak internal technical professionals and not
open to users.
9. Standard RS232 Interface: applicable to WinPower management software (See
Appendix for RS232 port Pin denition).

AS400 PORT˖

Pin# Description I/O

1 UPS Fail Output
2 Summary Alarm Output
3 GND GND
4 Remote Shutdown Input
5 Common +12V
6 Bypass Output
7 Battery Low Output
8 UPS ON Output
9 Line Loss Output

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EPO external wiring diagram˖

RS485 PORT˖

Pin# Description I/O

3 RXDA Input
4 RXDB Input
5 TXDB Output
6 TXDA Output

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RS232 PORT˖

Pin# Description I/O

2 TXD Output

3 RXD Intput

5 GND Output

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 C h a p t e r 6 O p t i o n a l a c c e ss ori es

6.1 Power Feedback Module

Power feedback module is an optional spare part specially designed for Castle EX series
to provide perfect solution for high BUS voltage by feeding back the regenerative energy
to the power system or battery. And it is applicable to special elds in complex industrial
environment with reliable operation and exible installation, such as high-speed elevators,
mining elevators, rolling mill, motor, tension control system of wind mechanism and
principle bearing drive system of lathes etc.

6.2 Transformer

When the UPS is applied to load devices, there might be disturbances or malfunctions
caused by the Neutral to Ground voltage. However, the installation of the special
transformer to the output will make the Neutral-to Ground voltage be less than 1V;
besides, the installation of the special transformer to the input will avoid three times of
harmonic of the power system and reduce disturbances, thus prevent the load devices
from disturbing by other devices connected to the power system. It is recommended to
connect the transformer to the input or output according to application requirements.
(Internal transformer for 3C3 EX 20KS/30KS/40KS-ISO models and external for 3C3 EX
60KS/80KS-ISO models; please refer to this manual for operation instructions).

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6.3 Double Charge Boards

Castle EX Series UPS is capable of improving the charge capability and speed by
battery capacity expansion. It is exible to install an additional charge board in parallel
connection with the standard charge board since there is space for double charge boards
reserved.

6.4 Temperature Sensor

For battery with short lifetime and being sensitive to temperature, the temperature sensor
can be used to detect the temperature change, enable the temperature compensation
function of charge voltage, the battery charge voltage will be adjusted automatically to
prolong the lifetime of the battery.

6.5 Dustproof Net

Dustproof net is an optional spare part specially designed

for Castle EX Series UPS to work in dust environment
(dust diameter no less than 1.0mm, especially metallic
and metalloid dusts) in order to upgrade UPS frontal
protection grade to IP51 with flexible installation and
maintenance.

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6.6 IP21 Option

Castle EX 60~80K Series UPS adopts top perforation and top and bottom ventilation, it is
recommended to install the IP21 option to prevent objects with diameter larger than 12mm
and water drops.

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 Chapter 7 Transportation, Maintenance and
Troubleshooting

Move UPS
Make preparation for UPS relocation according to the following steps.
Remark: special equipment (folklift) is needed for loading and unloading due to the heavy
weight of UPS.
1. Switch off all equipments connected to UPS.
2. Turn off UPS AC switch and battery pack switch.
3. Disconnect all wires from UPS terminal bay.

Maintenance
Castle EX Series UPS requires minimum maintenance.
1. If battery is switched off, loaded equipments will not be covered for power-off
protection.
2. Under normal circumstance, batteries should be found in poor performance,
replacement should be done as soon as possible only by qualied personal with proper
training. Users are not allowed to replace without authorization.

Remark:
A. Prior to battery replacement, switch off UPS and remove it from AC.
B. Take off metallic articles such as rings and watches.
C. Use screw drivers equipped with insulated handles and do not place tools or
other metallic substances on the batteries.
D. Short circuit or reverse connection is forbidden for battery polarity connection.
3. It is not recommended to replace batteries individually. Complete replacement
should follow instructions given by battery suppliers.
4. Make sure UPS vent are properly ventilated and clean side frames and fan
vents from dusts every half a year (switch off AC and battery power prior to
cleaning).

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Troubleshooting
Should maintenance prove necessary, the following steps should be followed :
1. Check if UPS input wiring is done properly.
2. Check if all air switches are tripped off.
3. Check if voltage input is within specied range.
Please refer to ĀReference Table of LED indicators and LCD displayā of this User
Manual rst and then conduct proper treatment.

Table of Malfunctions
Symptom LCD Display or Possible cause Solution
Remove some load. Loading level
Overloaded in bypass or
shall be less than the nominal
inverter mode
power capacity.
The fault LED is lit,
Check that the input wiring and
periodic beeps Mains out of tolerance
input voltage are normal
Check the battery breaker and the
Battery disconnected
battery wiring
The fault LED is lit,
UPS fault
continuous beeps
Contact SANTAK customer
Battery discharging time Battery exhausted
service center
less than 1/3 of initial
discharging time Charger fault

LCD panel has no Long press ESC 3S,LCD

display replacement.

If problems still exist, please contact SANTAK service hotline at 400-830-3938/800-830-

3938 and provide the following information:
MODEL and SERIAL NO of the UPS˗

Failure date
Detailed failure description (including LCD malfunction, indicator condition, buzzer
information, power and load capacity etc.).

36
App e n d i x 1
Te c h i n i a l p a r a m e t e r s a n d s p e c i fi c ati ons
Model 3C3 EX 20KS 3C3 EX 30KS 3C3 EX 40KS 3C3 EX 60KS 3C3 EX 80KS
Power Rating 20KVA/16KW 30KVA/24KW 40KVA/32KW 60KVA/48KW 80KVA/64KW

Connection 3-Phase + N+G

Frequency 40-70Hz
Power factor  0.99 ķ
Input
Utility voltage 380h(-45%~ +25%)VAC˄when input voltage<75%, output power derating is
range required˅
Bypass Voltage
380h(-15%~ +15%)VAC 380h(-20%~ +15%)VAC ĸ
range
Line voltage 380h(1f1%)VAC or phase voltage 220h(1f1%)VAC(with balanced
Voltage rating
load)
Power factor 0.8
50Hzf8%˄track bypass frequency input ;when input frequency exceeds f8%
Output Frequency
or under the mode of battery power supply, frequency output should bef0.1%of
tolerance
nominal˅
 10min 110%<Load  125%
Overload time
 1min 125%<Load  150ˁ
Double-conversion
Up to 93% Up to 94%
Efciency mode
ECO mode Up to 98% Ĺ
Ambient
0~40ć
temperature
Operating Storage
–25~55ć (without battery)
Environment temperature
Ambient humidity 0-95%
Altitude  1000m

Nominal 28 Pcs f168VDC/f189VDC

battery
voltage/Rated 30 Pcs f180VDC/f202.5VDC
charging
voltage 32 Pcs f192VDC/f216VDC
N.W/Contain
82Kg/208Kg 110Kg/275Kg 114Kg/314Kg 282Kg 306Kg
transformer
Weight
G.W/Contain
122Kg/248Kg 160Kg/325Kg 164Kg/364Kg 356Kg 380Kg
transformer
UPS Dimension(W*D*H)˄mm˅ 420h643h956 470h710h1150 470h710h1150 600h800h1850 600h800h1850

Safety National Standard GB4943

Standard TCL certication YD/T1095
ESD GB/T 17626.2 Level 4
RS GB/T 17626.3 Level 3
EMS
EFT GB/T 17626.4 Level 4
SURGE GB/T 17626.5 Level 4
Radiation and
GB 7260.2
Conduction
EMI
WARNING: This is a product for commercial and industrial application in the second environment-
installation restrictions or additional measures may be needed to prevent disturbances.

Remark:
ķ 3C3 EX 20KS-40KS  0.99 at 50% load;3C3 EX 60KS-80KS  0.99 at full load.
ĸ f15ˁ default;-20% ̚ˇ 15ˁ regulate.
Ĺ ECO mode is supported by 3C3 EX20KS-40KS only in single machine mode ;ECO mode is supported by 3C3 EX
60KS-80KS in single and parallel machine mode.

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Ap p e n d i x 2 L i g h t r e f e r e n c e t a bl e

Indicator
NO Working condition Bypass Line Inverter Battery Buzzer
Fault LED
LED LED LED LED
1 Standby Mode
One
One beep
ǂ Normal ǂ ǂ ǂ ǂ ashing
every 8 sec
every 8 sec
One
One beep
ǂ Fault ǂ ǂ ǂ ǂ ashing
every 4 sec
every 4 sec
One One beep
ǂ Overload ǂ ǂ ǂ ǂ ashing every 1 sec
every 1 sec
2 Bypass Mode
One One beep
ǂ Normal ƽ ǂ ǂ ǂ ashing every 2 min
every 2 min
One
One beep
ǂ Fault ƽ ǂ ǂ ǂ ashing
every 4 sec
every 4 sec
One One beep
ǂ Overload ƽ ǂ ǂ ǂ ashing every 1 sec
every 1 sec
3 Line Mode
ǂ Normal ǂ ƽ ƽ ǂ ǂ None
One
One beep
ǂ Fault ǂ ƽ ƽ ǂ ashing
every 4 sec
every 4 sec
One One beep
ǂ Overload ǂ ƽ ƽ ǂ ashing every 1 sec
every 1 sec
4 Battery Mode
One
One beep
ǂ Normal ǂ ǂ ƽ ƽ ashing
every 4 sec
every 4 sec
One One beep
ǂ Low battery voltage ǂ ǂ ƽ ƾ ashing every 1 sec
every 1 sec
One One beep
ǂ Overload ǂ ǂ ƽ ƽ ashing every 1 sec
every 1 sec
5 Battery Self Diagnosis Mode
ǂ Normal ƾ ƾ ƾ ƾ None None
One
One beep
ǂ Fault ƾ ƾ ƾ ƾ ashing
every 4 sec
every 4 sec

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 One One beep
ǂ Low battery voltage ǂ ǂ ƽ ƾ ashing every 1 sec
every 1 sec
One One beep
ǂ Overload ǂ ǂ ƽ ƽ ashing every 1 sec
every 1 sec
6 Fault Mode
ǂ Normal ǂ ǂ ǂ ǂ Long light Long beep
7 Converter Mode
ǂ Normal ǂ ƽ ƽ ǂ None None
One
One beep
ǂ Fault ǂ ƽ ƽ ǂ ashing
every 4 sec
every 4 sec
8 ECO Mode
One
One beep
ǂ Normal ƽ ǂ ashing ǂ None
every 1 min
every 1 min
One
One beep
ǂ Fault ƽ ǂ ǂ ǂ ashing
every 4 sec
every 4 sec

Should any display or warning message excluded in the above table be found,please
contact distributor or call EATON Hot line for advice.
ƽ Indicator light is on
ƾ Indicator light ashes

Warning include one or more than one of these:

1.EPO active 13.Battery over temperature
2.Line loss 14.Fan over restrict
3.Neutral loss 15.BUS capacitor over restrict
4.Line phase error 16.Fan failure
5.Bypass loss 17.Fan disconnected
6.Bypass phase error 18.Low temperature Battery
7.Battery open 19.communication disconnected
8.Low battery voltage 20.Auxiliary charger failure
9.Over charger 21.Bypass N wire cut
10.Battery reverse 22.Battery N wire cut
11.Charger failure 23.Address conict
12.Battery over restrict

Remark:
In fault mode,there is output presented with normal bypass and the bypass LED
will lit(except ECO fault or output short circuit).

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A p p e n d i x 3 Wa r r a n t y

Our company promises: SANTAK its products to be offered free warranty service for
three years from the date of purchase.

To obtain service under warranty via a valid guarantee offered by dealers;

To obtain service under warranty via serial number.

As a user of SANTAK, if your UPS fails, please contact our 400/800 hotline for the
following service:

Three-year warranty (covering batteries purchased from SANTAK);

24-hour toll-free helpline (See the hot line number at the warning label located on the
cabinet cover);
Nationwide warranty;
Technical support on our web site;
Toll-free on-site service.

This limited warranty does not apply to conditions as follows:

Man-made fault;
Out of warranty;
The nished product of which the serial number is changed or lost;
Damage or loss resulted from force majeure or external causes;
Disassembly or modications to the unit with no authorization;
Disobeying provisions of operating/using the unit;
Battery over discharged or man-made damage.

614-06799-02

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CASTLE EX SERIES
20/30/40KVA
USER MANUAL