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Modular UPS System Installation and Operation Manual 10 kVA to

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1. 3 NOT VALID Us NLESS 27 TERMINAL BLOCK COVER 3 TB 0068 26 CORNER PROTECTORS 36 _CC 0133 25 BATTERY RAIL INSULATION 16 24 SHUNT TRIP CONNECTORS K6C SU 1 CB 0194 23 AUXILIARY CONNECTORS K6C AB 1 CB 0195 22 TERMINAL BLOCK 3 POLE 1 TB 0080 21 TERMINAL BLOCK 12 POLE 1 TB 0026 20 AUXILIARY SWITCH K5AS 1 CB 0193 19 SHUNT TRIP 24 V K58S 1 CB 0197 18 BREAKER 750 VDC 225 A 3 POLE 1 M225 17 BREAKER PLATE 1 PW 0001 16 FUSE HOLDER 2 FS 0079 15 FUSE 500 VDC 5A 2 FS 0077 14 BATTERY HARDWARE KIT 28 SEE DETAIL A 13 CABLE 4 0 GA MINIMUM 6 SUPPLIED BY CUSTOMER 12 CABLE 10 GA 25 LG 1 10 25NC 11 CABLE TOCA 207 LG 1 10 20NC 10 CABLE 10GA 13 L 2 10 12BN 9g CABLE 1 0 GA 30 LG 3 1 0 30EN 8 CABLE 1 0 GA 95 LG 1 1 0 95BE 7 CABLE 1 0 GA 35 LG 1 1 0 35BE 6 CABLE 1 0 GA 40 LG 1 1 0 40BE 5 CABLE 1 0 GA 45 IG 5 1 0 458 4 CABLE 1 0 GA 14 LG 2 1 0 14B 3 CABLE 1 0 GA 14 L 20 1 0 14B vs BATTERY 28 TC 12100S 1 CABINET 1 PWI NO DESCRIPTION DT PART NO SERIAL 60 uAlfsiz de PONER No DE Br ZE POWER BATTERY COMPANY INC 1 zem v BATTERY SYSTEM LAYOUT FOR Luis 1 PW1 CABINET 336 V WITH 28 12 V BATTERIES amp BREAKER APPROVED FILE NO PW1 0004 DRAWING NO 1PW1 28TC100S 336 M225 LIMITED FACTORY WA
2. components Control Panel 3 UPS Module 3 Rear side of User Control Panel 2 control panel mounted on UPS cabinet door Control Panel 1 F2 UPS Module 2 Customer Communication Syst Ree N ystem d configuration DIP switches Maintenance F2 SW1 1 Bypass Switch UPS Module 1 IA1 Parallel Isolator Switches IA2 used only for inverter output IA2 1 IA2 2 IA2 O imm Io ken o ben Parallel isolator Rear view of isolation NW4024 located Customer Ge eer of Power 2 S ER Connections SE Figure 6 1A Powerware 9320 C03 Controls and Indicators Powerware 9320 10 kVA and 20 kVA Installation and Operation 6 1 164201416 REV A 071103 Figure 6 1B identifies and shows the location of the controls and indicators on the Powerware 9320 CO2 UPS The descriptions provide a brief overview of the UPS controls and standard and optional features NOTE Read the Operation section of this manual and have thorough knowledge of UPS operation before attempting to operate any of the UPS controls or optional components Control Panel 2 PS age A I WP pees T Kl control panel l Control Panel 1 P Cl mounted on UPS cabinet door Rear side of User
3. Figure 10 1b X Slot Location on Front of Powerware 9320 C02 UPS Cabinet Powerware 9320 10 kVA and 20 kVA Installation and Operation 10 3 164201416 REV A 071103 This page left intentionally blank 10 4 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 11 1 Generator ON Facility The generator ON facility must use a normally open contact that closes to indicate that a generator is running and supplying input power to the UPS When used this facility disables the UPS static bypass and prevents the UPS from transferring the load into the generator power supply The user may also elect prevention of battery charging while on generator input Both or either of these features may be selected via the control panel See section 7 3 8 Set Up UPS Generator port X2 Generator alarm panel Figure 11 1 Generator ON Connection Powerware 9320 10 kVA and 20 kVA Installation and Operation 11 1 164201416 REV A 071103 This page left intentionally blank Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 12 1 General The components inside the UPS cabinet are secured to a sturdy metal frame All repairable parts and assemblies are located for easy removal and very little disassembly This design allows authorized service personnel to perform routine maintenance and servicing quickly You must schedule periodic performance check
4. Customer Communication Interfaces F2 p UPS Module 1 x2 For Glee System Hauf ME configuration DIP switches SW1 1 age Maintenance Bypass Switch AT Parallel Isolator Switches A2 used only for inverter output Internal Battery isolation ices Ql A EI TAL JDI i ae i IA2 1 IA2 2 oa t i DC Battery x B t f PEA Rear view of Circuit Breaker Parallel isolators Weien 3 1 NW4024 located DC Battery Bkr Prpass zi H i j i Dune on right side of a 8 LES distribution 2A 2B 2C 2N e WE section Customer Power Connections Figure 6 1B Powerware 9320 C02 Controls and Indicators Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 6 2 UPS Operational Controls The UPS has many standard features that provide cost effective and consistently reliable power protection 6 2 1 Control Panels Control Panels on the front of the UPS pictured in Fig 6 2 contains a LCD screen to display the current status of the UPS system There is an individual control panel for each module installed in the UPS cabinet You can view a statistical history and log of system events and display a real time representation of power flow through the system compon
5. S stands for Single Module The system consists only of one Module P01 stands for Parallel Module in a Multi Module system and 01 stands for the first Module MASTER in the Multi Module system P02 stands for Parallel Module in a Multi Module system and 02 stands for the second Module SLAVE in the Multi Module system P03 stands for Parallel Module in a Multi Module system and 03 stands for the third Module SLAVE in the Multi Module system 7 4 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 7 3 2 LCD Display Structure and Navigation The menu structure is shown in Figure 7 3 below Navigation through the menu is accomplished by using the ENTER pushbutton to go to the menu level or to activate an action then using the UP or DOWN arrows to select a specific function within each menu category The RESET pushbutton will immediately return to the highest screen Values shown are typical and will vary based on actual user conditions qf PRESS RESET RETURNS TO TOP LEVEL LOAD EVENT LOG e HH MM SS PROTECTED LOAD TO INV 02 27 02 HH MM SS LOAD TO BYP BATT RUN TIME MIN 10 0 OUTPUT FREQUENCY HZ 60 00 BYPASS FREQUENCY HZ 60 00 BATTERY VOLTAGE V 189 189 BATT CHARGE CUR A 0 0 0 0 DISCHARGE CURRENT A LOAD NOT PROTECTED 02 27 02 HH MM SS SE LOAD OFF SUPPLY FAIL iid We
6. In the OFF LINE mode the load is supplied from the utility supply through the bypass Using the control panel see Figure 7 2 the UPS may be easily transferred to Bypass Mode Cc CC LINE 2 BYPASS LED s green Co when shown BATTERY shaded C LINE 1 INV When the UPS is operating in Bypass Mode the efficiency of the system is higher In the event of a utility supply failure the load will automatically be transferred from utility to 7 10 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 inverter within 5 milliseconds The battery charger remains active in the Bypass Mode The Bypass Mode is recommended only if the loads can tolerate power interruptions of up to 5 ms the transfer time from Bypass Mode to ON LINE Mode CAUTION In order to provide the load with maximum protection it is always recommended that the load be supplied by the inverter ON LINE Mode 7 4 3 MAINTENANCE BYPASS Mode The Maintenance Bypass Mode is performed by means of the IA1 BYPASS SWITCH on the front of the UPS When the switch is in the O OFF position the Bypass Switch is OPEN This is the normal operating condition where the load is supplied by the inverter or via the static bypass When the switch is in the I ON position the Bypass Switch is CLOSED causing load power to be supplied directly from the utility source LED indication E can be d
7. 1 and protected with outer protective packaging material Figure 1 1 Powerware 9320 10 kVA or 20 kVA module 3 module UPS Cabinet Powerware 9320 10 kVA and 20 kVA Installation and Operation 1 3 164201416 REV A 071103 1 Carefully inspect the outer packaging for evidence of damage during transit CAUTION Do not install a damaged cabinet Report any damage to the carrier and contact your local sales or service office immediately 2 Use a forklift or other material handling equipment to move the cabinet to a convenient unpacking area Insert the forklift forks under the metal pallet supports on the bottom of the unit CAUTION Do not tilt cabinets more than 10 degrees from vertical 3 Set each cabinet on a firm level surface allowing a minimum clearance of 3 m 10 ft on each side for removing the cabinets from the pallets CAUTION First carefully remove the stretch wrap and remove accessory installation kit before removing outer main cabinet packaging Approximate weight of accessory kit is 25 Ibs 11 kg 4 5 NOTE Remove the packing material and discard or recycle them in a responsible manner After removing the protective covering inspect the contents for any evidence of physical damage and compare each item with the Bill of Lading If damage has occurred or shortages are evident contact the Powerware Customer Service Department immediately to determine the extent of the
8. NUT SPRING LOCK WASHER WASHER BOLT CABLE LUG CABLE A BATTERY TERMINAL ITEM DESCRIPTION AY CONTAINED IN BATTERY HARDWARE KIT HMP 2 NOTE ALL CONNECTIONS MUST BE RETORQUED ANNUALLY TO 35 IN LBS IMPORTANT NOTE ALL CONNECTIONS TO BE RETORQUED ANNUALLY malo RA PE GAMA ALL CONNECTIONS MUST BE CHECKED FOR PROPER TORQUE PRIOR TO START UP OR ENERGIZING OF SYSTEM IMPORTANT NOTES THE CUSTOMER AND OR CONTRACTOR SHALL BE RESPONSIBLE FOR INSTALLING THIS EQUIPMENT IN ACCORDANCE WITH ALL APPLICABLE CODES AND REGULATIONS IN HANDLING KEEP UPRIGHT WITHIN 15 DEGREES LOUVERS SIDE VIEW 29 53 31 50 TOP VIEW 70 87 U FRONT VIEW 18 19 20 Di SEE DETAIL B Co sek e L7 DETAIL B 168 VOC 24 VDC 144 VOC in iby LV 1 BREAKER E oa g barr AUXILIARY CONTACTS He Sib 20 OJH 5 AUXILIARY CONTACTS zoron mi hanis om X SHUNT TRIP 24 VDC a 336 VDC aan gs 336 VDC ELECTRICAL DIAGRAM PLACE CORNER PROTECTOR BETWEEN BATTERIES FOR VENTILATION PURPOSES 27 TERMI
9. provided that startup of the unit onsite has been performed by Invensys Powerware or its agent Equipment sold but not manufactured by Invensys Powerware and only the manufacturer of such equipment shall warrant this equipment and is not included as part of this warranty agreement Equipment repaired or replaced pursuant to this warranty will be warranted for the remaining portion of the original warranty subject to all the terms thereof This warranty is not valid unless an authorized Invensys Powerware Service Engineer or Agent performs startup and commissioning This warranty does not apply to any Unit that has been subject to neglect accident abuse misuse misapplication incorrect installation or that has been subject to repair or alteration not authorized in writing by Invensys Powerware personnel or performed by an authorized Invensys Powerware Service Engineer or Agent Purchaser shall be invoiced for and shall pay for all services not expressly provided for by the terms hereof including without limitation site calls involving an inspection that determines no corrective maintenance is required THIS WARRANTY IS THE PURCHASER S USER S SOLE REMEDY AND IS EXPRESSLY IN LIEU OF AND THERE ARE NOT OTHER EXPRESSED OR IMPLIED GUARANTEES OR WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PURPOSE WHICH ARE EXPRESSLY DISCLAIMED In no case will Invensys Powerware s liability under this Warranty exceed th
10. to SW2 9 1 U 2A 2B 2C 2N JD8 N 1A 1B 1C 1N 3A 3B 3C 3N Figure A 1b A 10 SW2 1 to SW2 9 Single Cabinet ON ON ON ON ON ON ON ON ON m 0 CO NJ Os Or BY Ww PO Front View of Model 9320 CO3 Powerware 9320 CO3 10 kVA or 20 kVA Modules Three modules per cabinet 30 to 60 kVA System Front View showing customer connections Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 Left view Front view Right view Fiabe etVac0n SS NWA006 GOOVC75A UNINTERRUPTIBLE POWER SUPPLY 10 kVA E Left view Front view Right view Main Fuse ruses PCB Rating Pal Tanson SS Tome aas UNINTERRUPTIBLE POWER SUPPLY 20 kVA Figure A 2 Powerware 9320 series 10 kVA and 20kVA Module Labels Powerware 9320 10 kVA and 20 kVA Installation and Operation A 11 164201416 REV A 07 11 2003 9320 Battery Cabinet A 12 9320 C03 Enclosure Rectifier mcdo ov sinduy 9g Indui 2 Inverter I OV Rectifier Booster ndino ov sindu oq ndu Inverter indino ov sindu 201 indui ov Rectifier Booster Inverter AC INPUT 9320
11. CAUTION All the operations in this section must be performed by authorized service technicians or by qualified internal personnel The Powerware 9320 may be shut down completely if the load does not need input power for an extended period of time The UPS system may be switched to Maintenance Bypass Mode for service or maintenance purposes or transferred to the ECO Mode if the load does not need the highest degree of protection and efficiency is to be maximized The load may be disconnected by means of the two ON OFF LOAD OFF pushbuttons for security or operational reasons CAUTION If the Powerware 9320 will remain deactivated for an extended period of time provision must be made for periodic recharge of the system batteries Powerware 9320 10 kVA and 20 kVA Installation and Operation 8 3 164201416 REV A 071103 CAUTION Activation of both ON OFF buttons simultaneously during normal operation will switch off the UPS output and no longer supply power to the load 1 Verify that the loads are shut down and that there is no need for power supply to the load 2 Ifthe loads are all disconnected press simultaneously the two ON OFF buttons on the UPS control panel for all UPS modules On each Display MAINS BYP FAULT will appear and the LED indicators will indicate as shown below LED Indicator Color LINE 1 Green LINE 2 OFF BYPASS OFF INVERTER OFF BATTERY Flashing Green 3
12. MEASUREMENTS PRESS ENTER 0 gt LOAD TO INVERTER RECTIFIER VOLTAGE V 208 208 208 COMMANDS oe LOAD TO BYPASS VOLTAGE V BYPASS 208 208 208 PERFORM OUTPUT VOLTAGE V BATT TEST 208 208 208 OUTPUT CURRENT A 28 28 28 UPS SERIAL NUMBER ACTIVE POWER kW M 15 15 15 REACTIVE POWER KVAR 4 4 4 APPARENT POWER KVA 17 17 17 OUTPUT POWER 50 0 50 0 50 0 BATT CAPACITY 98 UPS DATA DATE OF MANUFACTURE SET UP USER DATE TIME Figure 7 3 LCD Screen Navigation Chart each module has its own display Powerware 9320 10 kVA and 20 kVA Installation and Operation 7 5 164201416 REV A 071103 7 3 3 Main Menu Screen DESCRIPTION e Logging Control A log of the last 64 events is stored in the Power Management Display e Menu Measurements allow monitoring voltages power frequencies current battery run time and other information e Command Menu enables performance of Load to Inverter Load to Bypass and battery test functions e UPS Data Menu shows UPS serial number date of manufacture current time amp date e Set Up Menu allows user to set Date Time automatic battery test and gen set mode e Set Up Menu for service allows trained service personnel to troubleshoot and adjust system parameters 7 3 4 Event Log Screen DESCRIPTION Logging Control sample screen A log of the last 64 events is store
13. Rotate all Parallel Isolator Switches IA2 1 A2 2 A2 3 to the O OFF position Used in model 9320 C03 only 4 Open all battery breakers internal or external 5 Open the utility input supply breaker THE POWERWARE 9320 IS NOW VOLTAGE FREE 8 4 Load Transfer to Maintenance Bypass If it is necessary to perform service or maintenance on the UPS it is possible to transfer the UPS to MAINTENANCE BYPASS CAUTION BEFORE YOU ROTATE THE MAINTENANCE BYPASS SWITCH TO POSITION I ON MAKE SURE THAT THE LOAD HAS BEEN TRANSFERRED TO THE BYPASS MODE EVEN THOUGH THE UNIT IS IN BYPASS MODE LETHAL VOLTAGE IS STILL PRESENT WITHIN THE UPS CABINET CAUTION ALL THE OPERATIONS IN THIS SECTION MUST BE PERFORMED BY AUTHORIZED ELECTRICIANS OR BY QUALIFIED INTERNAL PERSONNEL The load is protected by the Powerware 9320 UPS system in normal operation all installed modules of the UPS are operating on inverter 8 4 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 1 Load transfer to Maintenance Bypass e Go to Menu COMMANDS and choose command LOAD TO BYPASS and transfer the load to utility supply on any of the control panels on the UPS cabinet On the LCD Display LOAD NOT PROTECTED will appear e Rotate the Maintenance Bypass Switch IA to I ON On LCD Display MANUAL BYP IS CLOSED will appear and the alarm will sound The LED indicators will indic
14. SIDE VIEW 18 19 20 17 Sri PLACE CORNER PROTECTOR BETWEEN BATTERIES FOR VENTILATION PURPOSES G6 OTES APPLICABLE CODES AND REGULATIONS IN HANDLING KEEP UPRIGHT WITHIN 15 DEGREES 29 53 31 50 TOP VIEW 70 87 8 FRONT VIEW SITE INSTALLED 168 VDC 15 16 SEE DETAIL B WIRING DIAGRAM BREAKER ES Ge unn pen DS No am ne Dr um wo unn covers enor ES 99 199 el Son me ae w i 168 VDC Z 168 VDC ELECTRICAL DIAGRAM e a a Zz of bi N fi SACE i h i e w on 21 95 x ECH Se oft J EH A W s 1 DETAIL A TERMINAL CONNECTION LG NUT db sl E SPRING LOCK WASHER 1 st E WASHER 1 D STUD POST d Cc CABLE LUG 1 B CABLE A BATTERY TERMINAL 1 ITEM DESCRIPTION QTY CONTAINED IN BATTERY HARDWARE KIT HMP 15 SEE BATTERY LABEL FOR TORQUE VALUES FOR PRC TC BATTERY SUFFIX S IMPORTANT NOTE A
15. The conduit landing plates are to be removed to add conduit landing holes as required Plate material is 14 gauge steel 2 mm thick The cabinets must be installed on a level floor suitable for computer or electronic equipment If perforated floor tiles are required for ventilation place them in front of the UPS Refer to Table J in Appendix A for equipment weight and point loading and Figure A 9 in Appendix A for air exhaust locations Details about control wiring are provided in each procedure for connecting options and features Figure A 1 and Tables G and H in Appendix A identify the control wiring terminations Powerware 9320 10 kVA and 20 kVA Installation and Operation 2 1 164201416 REV A 071103 2 2 UPS Cabinet Installation To install an UPS cabinet perform the procedures in the following paragraphs 2 2 1 Unloading the Powerware 9320 UPS Cabinet from the Pallet The UPS cabinet is bolted to a wooden shipping base using two steel angles To remove the shipping material perform the following procedure WARNING The UPS cabinet is heavy Refer to Table J in Appendix A for weight of cabinets If unloading instructions are not closely followed the cabinet may cause serious iniurv CAUTION Do not tilt cabinets more than 10 degrees from vertical Do not cut the outside protective cardboard packing box open Damage to the enclosed cabinet mav occur CAUTION Carefully open top of outer package and remove access
16. immediately and fasten with the provided four screws CAUTION While the UPS is operating in the maintenance bypass mode the load is not protected and in the event of a supply failure the load supply will be interrupted and the load will fail 8 6 2 Reinstalling a Module in a Capacity Multi Module System To replace a Faulty Module in a Capacity Multi Module System perform following steps Perform the following steps to install the new module in a Powerware 9320 1 If necessary remove UPS Module compartment protection covers CAUTION Two persons are needed to insert the module into the UPS Frame The weight of a 20 kVA module is 56 kg a 10 kVA module is 49 kg 2 Slide the UPS Module about into the dedicated UPS compartment Do not slide the UPS Module into the cabinet far enough to mate the rear connector 3 Connect Control Panel cable to connector JD7 4 Slide the UPS module to its final position and push firmly to assure good contact on the rear connector CAUTION This procedure must be followed in the order given because the rear UPS module connector will have working voltage applied 8 10 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 5 Tighten the four screws on the front of the module 6 Reconnect cables on connectors JD4 and JD7 7 Check if the LED LINE1 is green If yes the utility voltage is OK On the LCD LOAD OFF SUPPLY FAILURE
17. 164201416 REV A 071103 Ji Control Panel 3 Jb2 F2 CH EE UPS Module 3 7 swi Ja Ou Control Panel 2 Jor f H H JD4 ioi Control Panel 1 F2 i UPS Module 2 x2 X3 swi Ve OD 1 1 1 1 1 1 1 1 1 i 1 JD2 f 1 1 1 1 1 1 1 1 1 1 1 J57 TL A JD4 JD1 JD2 F2 d UPS Module 1 x2 x3 H swi P go7 LAN i X Slot for insertion of X Slot Cards JD4 IA2 1 IA2 2 IA2 3 l X6 Gem o mm O mm X Slot x w Parallel isolator Maintenance x5 Bypass 2A 2B 2C 2N Figure 10 1a X Slot Location on Front of Powerware 9320 C03 UPS Cabinet 10 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 Control Panel 2 F2 UPS Module 2 Control Panel 1 F2 UPS Module 1 Internal Battery Q1 IA2 1 IA2 2 I O mm O imm x Parallel isolators Maintenance x4 Bypass X5 DC Battery Bkr NW4024 X Slot for insertion of Rear view nc inside 1 X Slot Cards cabinet 2A 1A
18. 30 seconds without bypass 13 4 Environmental Specifications Dimensions W x H x D mm in 550 21 7 x 1800 70 9 x 750 29 6 modules Model 9320 C03 Weight Ibs kg 3x10kVA 3x20 kVA 558 253 598 271 Weight Ibs kg 2x10kVA 2x20 kVA modules Model 9320 C02 w maximum batteries 1171 531 1197 543 Operating temperature 0 to 40 C 32 to 104 F Operating Altitude 1500 meters 5000 feet with no derating Storage Temperature 0 to 50 C 32 to 122 F Relative Humidity Maximum 95 non condensing Audible Noise with 100 75 Load 65 63 dBA EMI Suppression IEC 62040 3 amp FCCA Electrostatic Discharge ESD Immunity IEC 801 2 Applicable Standards UL 1778 Computer Room Suitable 13 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 The information in this appendix will help you plan for and install your UPS system This appendix contains the following Table A Table B Table C Table D Table E Table F Table G Table H Table Table J Table K Table L Figure A 1 Figure A 2 Figure A 3 Figure A 4a Figure A 4b Power Wiring Installation Notes 9320 CO3 3 x 10 kVA and 9320 CO2 2 x 10 kVA Power Wiring Installation Notes 9320 CO3 3 x 20 kVA and 9320 CO2 2 x 20 kVA UPS Power Cable Terminations 9320 CO3 and 9320 CO2 Power Cable Conduit Requ
19. CO2 10 kVA or 20 kVA Modules Two modules per cabinet 20 to 40 kVA System Front View showing customer connections Powerware 9320 10 kVA and 20 kVA Installation and Operation A 9 164201416 REV A 07 11 2003 F2 UPS Module 3 Ji Jb2 x1 x2 x3 swi 1 H JD7 JD4 F2 UPS Module 2 JD1 JD2 X1 X2 w UI SW1 1 JD7 JD4 F2 UPS Module 1 IA1 Parallel isolator ypass IA2 1 IA2 2 IA2 3 X6 x2 O mm O mm O em a X3 X4 Maintenance x5 X slot Control Panel 3 Control Panel 2 Control Panel 1 Nw4024 Rear view inside 1 cabinet LABEL DATA IA1 IA2 1 2 3 JD1 JD2 SW1 1 SW2 1 to 9 Kal X2 K x4 X5 X6 JD11 Maintenance Bypass Parallel Isolator Mod 1 2 3 Smart Port RS232 SUB D9P F Isolated Relay outputs SUB b25 F Single Parallel Switch System Configuration Switches Emergency Power OFF EPO Generator ON Battery Temperature Module 1 Battery Temperature Module 2 Battery Temperature Module 3 Battery Breaker control EPO Serial communication port SW1 1 HIGH Module Type Parallel Module LOW Single Module SW2 1
20. K1 is opened the battery charger is turned off and the battery SCRs and both receive signals to turn on to provide battery power to the system Because the battery SCRs are electronic devices battery power is instantly available to the boost converter so that the inverter and customers load can be supported without interruption In a single feed installation where the bypass input is connected to the rectifier input the back feed protection contactor K4 will also open The opening of contactors K1 and K4 5 8 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 prevents static system voltage from bleeding backwards through the static switch and rectifier snubber components and re energizing the input source While in battery mode the UPS will enunciate an audible horn indicate the status change on the front panel display with the message MAINS NOT OK and make an entry into the alarm event history As the battery discharges the boost converter and inverter constantly make small adjustments to ensure a steady output The UPS will remain in this operating mode until the input power to the rectifier is again within the specified voltage or frequency acceptance window If the input power fails to return or is not within the acceptance parameters required for normal operation the battery will continue discharging until a DC voltage level is reached where the inverter output can no longer support the
21. LINE1 is green If yes the utility voltage is OK On the LCD LOAD OFF SUPPLY FAILURE will appear and the LED indicators will indicate as shown below LED Indicator Color LINE 1 Green LINE 2 OFF BYPASS OFF INVERTER OFF BATTERY Flashing Green Powerware 9320 10 kVA and 20 kVA Installation and Operation 8 7 164201416 REV A 071103 8 Make sure the bypass fuses F2 are inserted front of Module 9 Simultaneously press both ON OFF Buttons to start the UPS On LCD display LOAD NOT PROTECTED will appear and the LED indicators will indicate as shown below Load Not Protected Load Protected LED Indicator Color Color LINE 1 Green Green LINE 2 Green Green BYPASS Green OFF INVERTER OFF Green BATTERY Green Green 10 If LOAD NOT PROTECTED is displayed transfer load to Inverter Mode by means of COMMAND LOAD TO INVERTER 11 To test new module perform COMMAND LOAD to BYPASS then return to normal operation by performing COMMAND LOAD TO INVERTER 12 Close the corresponding Parallel Isolator Switch IA2 of the replacement Module switch to position ON NOTE Parallel Switch IA2 1 belongs to Module 1 Parallel Switch IA2 2 belongs to Module 2 Parallel Switch IA2 3 belongs to Module 3 Used on model 9320 C03 only THE LOAD IS NOW PROTECTED BY REDUNDANT POWER FROM THE 9320 UPS 8 6 UPS Module Replacement in a Capacity
22. Required 3 8 Ground Ground Powerware 9320 10 kVA and 20 kVA Installation and Operation A 3 164201416 REV A 07 11 2003 Table C cont UPS Power Cable Terminations 9320 CO2 Terminal Terminal Function Size of Pressure Tightening Torque Int Hex Function Termination NA Ib in Size in AC Input to A Phase A_ 1 12 4 0 Awg Slot UPS B Phase B_ 1 12 4 0 Awg Slot Mains C Phase C 1 12 4 0 Awg Slot N Neutral 1 12 4 0 Awg Slot AC Output A Phase A 1 12 4 0 Awg Slot to Critical B Phase B_ 1 12 4 0 Awg Slot Load C Phase C 1 12 4 0 Awg Slot N Neutral 1 12 4 0 Awg Slot DC Input Battery 1 12 4 0 Awg Slot from N Mid point 1 12 4 0 Awg Slot Battery to Battery 1 12 4 0 Awg Slot UPS Customer Protective Protective 4 16 1 Awg Slot Ground Ground Ground 8 Per NEC article 300 20 a all three phase conductors must be run in the same conduit Neutral and ground must be run in the same conduit as the phase conductors 9 Conduit is sized to accommodate one neutral conductor the same size as the phase conductor and one protective ground wire of the same size 10 Conduit sizes were chosen from NEC Table C1 type letters RHH RHW RHW 2 TW THW THHW and THW 2 Table D Power Cable Conduit Requirements Powerware 9320 CO3 amp C02 Powerware Terminal
23. UPS Module Static Switch 9320 UPS Module Static Switch 9320 UPS Module Static Switch AC OUTPUT N AB N Figure A 3 Oneline Drawing 9320 CO3 Notes Refer to National and Local Electrical Codes for acceptable external wiring practices Use 90 C copper wire Wire ampacities based from Table 310 16 of the NEC Wiring Provided by others oN Over current Protection Provided by others Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 Protective GND External Mains Input Battery Figure A 4a Power Terminals on Powerware 9320 CO3 Figure A 4b Power Terminals on Powerware 9320 CO2 Powerware 9320 10 kVA and 20 kVA Installation and Operation A 13 164201416 REV A 07 11 2003 550 mm lt 217 in 4 SSS SS S55 SS 1800 mm 70 9 in Conduit Landing Area panel supplied blank holes shown for illustration only Blank panel dimensions 127 mm 5 in high 494 mm 19 44 in long Figure A 5 9320 CO2 left and 9320 CO3 right Dimensions Rear View A 14 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 eg CN 750 mm RG TNA ERE 2 550mm 21 7 inches gt Figure A 6 9320 CO3 Cabinet Dimensions Powerware 9320 10 kVA and 20 kVA Installation and Operation A 15 164201416 REV A 07 11 2003 Figure A 7 9320 CO2 Cabinet without modules di
24. actual values will depend on user environment 7 3 6 Commands Screen DESCRIPTION LCD DISPLAY LOAD TO INVERTER Transfer Load to Inverter LOAD TO BYPASS Transfer Load to Bypass gt PERFORM BATT TEST Battery Test Powerware 9320 10 kVA and 20 kVA Installation and Operation 7 7 164201416 REV A 071103 7 3 7 UPS Data DESCRIPTION H Information displayed is installed at the time of manufacture e Manufacturing Date D EPROM Version e Actual Date and Time set by user under user set up menu 7 3 8 Set Up User DESCRIPTION Set up Date and Time Press ENTER to access Set up Battery test Press ENTER to access Set up operation with Gen Set Press ENTER to access e Command to prevent battery charger operation when on generator operation e Command to prevent use of static bypass when on generator operation LCD DISPLAY UPS SERIAL NUMBER M DATE OF MANUFACTURE DD MM YY EPROM VERSION V 000 DATE TIME DD MM YY HH MM SS LCD DISPLAY p SET UP DATE TIME DD MM YY HH MM SS gt SET UP BATT TEST DAY OF MONTH 1 31 HOUR OF DAY 0 23 REPETITIVE Y N Y N SET UP GEN SET OPER BATTERY CHARGE LOCK Y N BYPASS LOCK UNLOCK 7 8 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 7 3 9 Set Up Service DESCRIPTION LCD DISPLAY e This menu is reserved for authorized SET UP S
25. atthe bottom of the UPS cabinet not on modules Refer to switch Twisted manufacturers X1 1 wires 2 installation 14 18 instructions X1 2 gauge Table A 2 Remote EPO o a S REMOTE TWISTED T WIRES 2 X1 UPS N C O O Remote EPO switch rating is 24 VDC 1 Amp maximum NOTE This switch must be a dedicated switch not tied into any other circuits 4 Ifyou are installing multiple Remote EPO stations wire all EPO switches in series with each other 5 If required install appropriate sized conduit and wiring from the Remote EPO switch to trip circuitry of upstream protective devices A separate contact block with the appropriate normally open or normally closed contacts must be used for this function Remote EPO switch wiring must be in accordance with UL Class 1 requirements 6 Secure the UPS by reversing all steps taken to prepare it for Remote EPO installation 4 3 To Operate a Remote EPO 1 Activation of an EPO switch will interrupt the EPO circuit and immediately shut off UPS main circuit power to the load as well as the DC input from the battery supply 2 Even though the EPO switch is opened the UPS will not re energize until the normal startup procedure is followed which requires operator intervention at the UPS cabinet controls 4 2 Powerware 9320 10 kVA and 20 kVA Installation and Opation 164201416 REV A 071103 Section II Operation Powerware 932
26. damage and its impact upon further installation While awaiting installation protect the unpacked UPS cabinet from moisture dust and other harmful contaminants Failure to store and protect the UPS properly may invalidate the warranty Remove jacking screws 4X from accessory box and insert into threaded holes on metal shipping brackets Index all the screws down to the floor with a box end wrench to elevate the two wooden pallets Once elevated remove the wooden pallet by removing the nuts that attach them to the metal brackets Lower all jacking bolts to enable the shipping brackets to support the unit weight Once on the ground remove all 4 jacking bolts Remove the screws that hold the bracket to the unit legs Tilt the unit carefully not more than 10 degrees in order to remove the brackets Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 2 1 Preliminary Installation Information WARNING Only qualified personnel should perform installation All wiring and installation of the UPS system must be done in accordance with the most current NEC standards or local electrical code Refer to the following while installing the UPS system Refer to Appendix A of this manual for installation drawings and additional installation notes Dimensions in this manual unless otherwise noted are in millimeters and inches Do not tilt the cabinets more than 10 degrees during installation
27. pin DB 25P F Contact Function Mains failure Mains present Common Load on inverter Message Common Battery low BATT_LOW Battery OK Common Load on Mains BYPASS mode Message Common Common Alarm COMMON_ALARM _ No Alarm Condition Common Not Connected For future use For future use GND 12V Imax 100 mA Not Connected Not Connected Contacts are rated at 60 volts maximum DC or 30 volts RMS AC and 500 mA maximum current and should be supplied by a LVLE source in compliance with UL 1778 Powerware 9320 10 kVA and 20 kVA Installation and Operation A 7 164201416 REV A 07 11 2003 Table J Installed Equipment Weight Ibs kg 65 lbs for shipping weight Internal battery strings None 1 String 2 Strings 3 Strings 4 Strings Product Power Modules 9320 CO2 20 10 1x 10 324 147 507 230 690 313 873 396 1056 479 9320 CO2 40 20 1x 20 338 153 703 319 886 402 1069 485 9320 CO2 20 20 2x 10 439 199 805 365 988 448 1171 531 9320 CO2 40 40 2x 20 465 211 1197 543 9320 CO3 30 10 1x 10 329 149 9320 CO3 60 20 1x 20 342 155 9320 CO3 30 20 2x 10 443 201 9320 CO3 60 40 2x 20 470 213 9320 CO3 30 30 3x10 558 253 9320 CO3 60 60 3 x 20 598 271 5 The clearances required around the UPS system are s
28. pushbuttons are also used as a security ON OFF switch making it possible to quickly disconnect the load from the UPS in emergency situations Upon startup from initial install or power off disconnect the UPS starts in NORMAL inverter mode In subsequent startups the system will return to the mode previously used before shutdown except that ECO mode will require operator intervention to activate Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 7 3 CAUTION ACTIVATION OF THE ON OFF PUSHBUTTONS WHEN THE UPS IS NOT IN MAINTENANCE BYPASS MODE WILL INTERRUPT THE POWER SUPPLY TO THE CRITICAL LOAD If for security or emergency reasons it is necessary to immediately disconnect the load from the UPS press the two red ON OFF pushbuttons simultaneously In this case make sure that the maintenance bypass switch IA1 is in the O position Normal Off 7 3 Description of the LCD Screen 7 3 1 Status Screens DESCRIPTION LCD DISPLAY LOAD Load is protected by UPS power It is supplied by the inverter normal operation PROTECTED Load is not protected by UPS power It is LOAD supplied by utility power load on bypass NOT PROTECTED Load supply is completely interrupted UPS LOAD OFF has been switched off by ON OFF buttons SUPPLY FAILURE NOTE On the right hand side of the LCD there is a 3 digit indicator defining the Module Position in the Multi Module system
29. should contact Invensys Global Services Powerware 9320 10 kVA and 20 kVA Installation and Operation 12 1 164201416 REV A 071103 12 3 Performing Preventive Maintenance The UPS system requires very little preventive maintenance However the system should be inspected periodically to verity that the units are operating normally and that the batteries are in good condition Perform the following checks DAILY 1 Check the area surrounding the UPS system Ensure the area is not cluttered allowing free access to the unit 2 Ensure the air intakes vents on the bottom and exhaust opening s on the back of the cabinet are not blocked 3 Ensure the operating environment is within the parameters specified in Chapter 13 Product Specifications 4 Ensure the UPS is in Normal mode Proper LED indicators are illuminated and the LCD display shows LOAD PROTECTED If the alarm LED is illuminated or the Normal status LEDs are not illuminated contact Invensys Global Services Perform the following check MONTHLY 1 Review the Event Log for any operational issues that need attention ANNUAL maintenance Annual preventive maintenance should be performed only by authorized service personnel familiar with maintenance and servicing of the UPS system Contact Invensys Global Services for more information about service offerings BATTERY Test The battery test takes approximately 3 minutes and should be performed only if
30. system the UPS cabinet battery strings and options or accessories installed Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 Safety Considerations The UPS cabinet is designed for industrial or computer room applications and contains safety shields behind the doors However the UPS system is a sophisticated power system and should be handled with appropriate care following these guidelines Keep surroundings clean and free from excess moisture Do not operate the UPS system close to gas or electric heat sources The system is not intended for outdoor use The operating environment should be maintained within the parameters stated in the manual Keep the cabinet doors closed and locked to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit The UPS system contains its own power source Lethal voltages are present even when the UPS is disconnected from utility power WARNING Only AUTHORIZED SERVICE PERSONNEL should perform maintenance on or service the UPS system If service or routine maintenance is required Ensure all power is disconnected before performing installation or service Ensure the area around the UPS system is clean and uncluttered Battery maintenance or battery replacement should be performed only by authorized service personnel Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of
31. will appear and the LED indicators will indicate as shown below LED Indicator Color LINE 1 Green LINE 2 OFF BYPASS OFF INVERTER OFF BATTERY Flashing Green 8 Make sure the bypass fuses F2 are inserted front of Module 9 Simultaneously press both ON OFF Buttons to start the UPS 10 Insure that all modules are in the Bypass Mode COMMAND LOAD TO BYPASS for each module not in Bypass Mode 11 Verify all modules are on bypass by observing the LED indicators as shown below If not perform 12 Close Parallel Isolator Switch IA2 corresponding to the replaced module position ON All modules are now operating in parallel 13 Open Maintenance Bypass AT by turning it to position OFF The load is now supplied by the static circuit in all connected Check LED indicators on the corresponding control panels to verify this They should indicate as shown below Load on Bypass Load Protected LED Indicator Color Color LINE 1 Green Green LINE 2 Green Green BYPASS Green OFF INVERTER OFF Green BATTERY Green Green modules LED Indicator Color LINE 1 Green LINE 2 Green BYPASS Green INVERTER OFF BATTERY Green Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 8 11 14 Transfer load to inverter mode by means of COMMAND LOAD TO INVERTER on any one of the three c
32. will transfer the critical load to the internal bypass The critical load will be transferred automatically to the internal bypass if any of the following abnormal conditions occur on the output of the system If the output of the system exceeds acceptable voltage tolerances Critical load current exceeds the overload specifications of the inverter Inverter failure The transfer is initiated by turning on the static switch and blocking the IGBT gate signal This kind of transfer is normally referred to as a Make Before Break transfer The transfer takes place in less than 4 ms one quarter cycle to ensure loads on the systems output are not interrupted The static switch remains on until either the inverter is able to support the system output or the unit is placed into a maintenance position where repairs can be made If the UPS initiates its own transfer to bypass for any reason other than operator intervention the UPS will attempt to restart the inverter if not running already and attempt a retransfer back on line to support the output of the system Three attempts will be made within ten minutes to bring the inverter back on line automatically before the UPS will lock out any further attempts After three attempts have been made the UPS will remain in bypass and an alarm condition will be annunciated The UPS can also be transferred to bypass using the front panel controls Bypass mode is a normal operating mode not requiring an alarm conditio
33. 020 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 gi 5 1 Looking Inside the UPS System The Powerware 9320 is a continuous duty solid state transformerless at 208 VAC three phase true online system that provides conditioned and uninterruptible AC power to the UPS systems output The UPS supports process control data processing telecommunications PBX and research equipment The Powerware 9320 maintains power to the critical loads during commercial electrical power brownout blackout overvoltage undervoltage and out of tolerance frequency conditions The basic system consists of a rectifier battery charger DC booster inverter monitoring operation control panel integrated communications server and microprocessor controlled logic In this manual the power required by your equipment is called the critical load The UPS supplies the critical load with conditioned power that is synchronized with your utility power Figure 5 1 shows the main elements of the UPS Battery Charger Et UPS Module 1 UPS Moduke2 J UPS Module3 il Fig 5 1 Main Elements of the UPS System UPS Module 3 in 9320 C03 systems only Powerware 9320 10 kVA and 20 kVA Installation and Operation 5 1 164201416 REV A 071103 If utility power is interrupted or falls outside the parameters specified in Chapter
34. 13 Product Specifications the UPS uses a backup battery supply to maintain power to the critical load for a specified period of time or until the utility power returns For extended power outages the UPS is designed to operate with an alternative power system such as a generator or will shut down your critical load in an orderly manner if Powerware shutdown software is used In the event of a severe output overload or failure of a critical internal UPS component an emergency bypass consisting of a continuous duty static switch and backfeed protection contactor K4 is utilized The backfeed protection contactor is located in series with the static switch to ensure safety to anyone working upstream of the UPS system For manual transfers to bypass the static switch is also used The static switch is armed and ready during both types of transfers If maintenance of the UPS system is required an internal Maintenance Bypass switch provides a means of isolating the UPS Rectifier Booster Inverter components for servicing while still supplying power to the critical load The operation of the UPS is described in greater detail in the following paragraphs 5 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 5 2 Normal Battery and Bypass Modes The UPS system functions automatically to supply AC electrical power to the critical load There are four standard operation modes In Normal mode
35. 225 9320 CO2 2 x 10 kVA 15 100 9320 CO2 2 x 20 kVA 150 150 CAUTION To reduce the risk of fire connect only to a circuit provided with maximum input circuit breaker current ratings from Table E in accordance with the National Electric code ANSI NFPA 70 14 The input and bypass feeds should be symmetrical about ground 15 The line to line unbalanced output capability of the Powerware 9320 UPS is limited only by the full load per phase current values for AC output to critical load shown in Tables A and B 16 Output overcurrent protection and output disconnect switches are to be provided by the user Table F lists the maximum rating for output circuit breakers satisfying the criteria for both Table F Maximum Output Circuit Breaker Ratings Amperes Powerware Model At Rated Output voltage of 208 VAC 9320 CO2 2 x 10 kVA 70 9320 CO2 2 x 20 kVA 150 9320 CO3 3 x 10 kVA 110 9320 CO3 3 x 20 kVA 225 1 Use Class 1 wiring methods as defined by the NEC for control wiring Install the control wiring in separate conduit from the power wiring The wire should be rated at 150 volts 5 amperes minimum 2 Refer to tables G H and and to Chapters 2 4 and 11 of this manual for customer interface wiring Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 A 5 Table G Customer Interface Inputs and Outp
36. 8TC25 336 M60 SYSTEM SPECIFICATIONS SYSTEM MODEL NO 1PW1 28TC50S 336 M150 S24 A S UL SYSTEM RATING 26 37 KWB FOR RECOMMENDED GG SYSTEM CUTOFF VOLTAGE 285 6 FULL LOAD CURRENT 92 33 ADC FULL LOAD CURRENT PER SERIES OPEN CIRCUIT VOLTAGE 347 2 SHUNT TRIP 24 V INSTALLATION AN FLOAT VOLTAGE 378 MIN 4 MINUTES TO 1 70 VPC 386 4 MAX CIRCUIT 92 33 ADC 361 2 VDC D MAINTENANCE CAUTION REFER 1 O INSTALLATION STRUCTIONS IIS 1 PRIOR TO STALLING CABIN ALL RECOMMENDED CUSTOMER S C ON TABLE 310 16 OF N E C USIN INITIAL CO NECTION TORQUE VALUES ABLE GAUGES ARE BASED G 75 C CABLE INTERNAL BREAKER IS FOR OVERCURRENT PROTECTION ONLY 120 IN LB BREAKER USE INSULATED TOOLS FOR CABINET INSTALLATION 22 78 3 00 DOT 1 ERMINATIONS FOR CUSTOMER S C DO NOT ALLOW TOOLS OR CABLES TO REST ON BATTERIES ABLE ARE RATED FOR 75 C AMPACITIES OF CUSTOMER S CABLE MUST NOT CAUSE THIS RATING TO BE EXCEEDED TRI he glee BOTTOM VIEW RER EER BEE BEE REAR VIEW 93 X 61 31 32 X 01 3 32 PLE KNOCKOUTS TYP 0 625 TYP IMPORTANT THE CUSTOMER AND OR CONTRACTOR SHALL BE RESPONSIBLE FOR INSTALLING THIS EQUIPMENT IN ACCORDANCE WITH ALL LOUVERS
37. 9320 System WARNING All the operations in this section must be performed by properly trained personnel By opening removing or replacing the UPS modules and module covers you risk exposure to dangerous voltages Do not leave the UPS module compartment without an appropriate protective cover 8 6 1 Removing a Module from a Capacity Multi Module System If in a capacity system a UPS Module experiences a fault and there is not enough capacity left to protect the load by the remaining operating UPS Modules the load will automatically be transferred to bypass and will be supplied directly by the mains power supply 8 8 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 To extract the faulty module from the UPS Frame proceed as follows 1 Identify the faulty Module to be replaced See Section 9 3 for description of alarm conditions 2 Verify that all UPS modules are in bypass mode In the majority of the events the LED indicators on Control Panel of the Faulty Module will show LED Indicator Color LINE 1 Green LINE 2 Green BYPASS Green INVERTER RED BATTERY Green The LED indicators on the Control Panels of the other Operating Modules will show LED Indicator Color LINE 1 Green LINE 2 Green BYPASS Green INVERTER OFF BATTERY Green 3 Close the Maintenance Bypass Switch IA1 position ON On LCDs MANUAL BYP CLOSED w
38. ERVICE service engineers It is not to be accessed by End Users PASSWORD e Type in password NOTE Apart from the adjustment of voltages frequencies currents power and battery run time in the SET UP Service menu it is also possible to set and check the following parameters e UPS Rated Power e Module configuration S P01 PO2 e Single standard or Dual Input feed e F converter 50 60Hz or 60 50Hz e Sync window 2 4 Powerware 9320 10 kVA and 20 kVA Installation and Operation 7 9 164201416 REV A 071103 7 4 Operating Modes 7 4 1 ON LINE Mode INVERTER MODE The ON LINE Mode is the UPS Operating Mode in which the load is supplied through the RECTIFIER and INVERTER LED indicators are illuminated when shown shaded CC C LINE 2 BYPASS LED s green when shown La shaded BATTERY CC UC LINE 1 INV Using the control panel see Figure 7 2 the UPS can easily be transferred to the ON LINE mode The ON LINE mode provides the highest degree of protection especially in the event of a supply disturbance or failure This operating mode is always recommended if the critical loads computer systems will not tolerate any interruption of the supply even for a very short time In the unlikely event of an inverter fault or overload condition the UPS will transfer the load automatically and without interruption to the static bypass utility supply 7 4 2 OFF LINE Mode BYPASS or ECONOMY MODE
39. EV A 071103 system will be required The internal charger charges the entire battery system with a maximum current as indicated in Chapter 13 Product Specifications Note that the higher the battery capacity the longer the recharge time required to fully recharge the batteries 5 3 5 Static Bypass The bypass has a continuous duty SCR switch and a back feed contactor K4 in the Bypass circuit In normal mode the contactor connects the inverter to the output A contactor K2 provides isolation to the inverter when the system is on bypass 5 3 6 Maintenance Bypass A user accessible shrouded 4 wire Mechanical Maintenance Bypass switch is provided internal to the cabinet 5 12 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 6 1 General The UPS system should function automatically and require very little attention during normal operation The controls and indicators identified in this section are used during startup to monitor normal operation and during abnormal events Figure 6 1 identifies and shows the location of the controls and indicators on the Powerware 9320 C03 UPS The descriptions provide a brief overview of the UPS controls and standard and optional features NOTE Read the Operation section of this manual and have thorough knowledge of UPS operation before attempting to operate any of the UPS controls or optional
40. GE Sp E pal INSTALLING CABINET S E SC GALL RECOMMENDED CUSTOMER S CABLE GAUGES ARE BASED ON TABLE 310 16 OF N E C USING 75 C CABLE NN el TERNAL BREAKER IS FOR OVERCURRENT PROTECTION ONLY WS sx PINITIAL CONNECTION TORQUE VALUES 120 IN LB BREAKER GE k BATTERIES FOR VENTILATION PURPOSES a 1 jk USE INSULATED TOOLS FOR CABINET INSTALLATION DO NOT ALLOW TOOLS OR CABLES TO REST ON BATTERIES 6 ERMINATIONS FOR CUSTOMER S CABLE ARE RATED FOR 75 C DETAIL A AMPACITIES OF CUSTOMER S CABLE MUST NOT CAUSE THIS E GE NOTES GE RATING TO BE EXCEEDED ENEE vo THE CUSTOMER AND OR CONTRACTOR SHALL BE RESPONSIBLE yas oe FOR INSTALLING THIS EQUIPMENT IN ACCORDANCE WITH ALL TE WASHER 1 APPLICABLE CODES AND REGULATIONS en IN HANDLING KEEP UPRIGHT WITHIN 15 DEGREES 5 E ANNL il ITEM DESCRIPTION QTY CONTAINED IN BATTERY HARDWARE KIT HMP 15 SEE BATTERY LABEL FOR TORQUE VALUES yp amp FOR PRC TC BATTERY SUFFIX er 93 X 61 31 32 X 01 3 32 y TRIPLE KNOCKOUTS 7 22 78 TYP 29 53 IMPORTANT NOTE ALL CONNECTIONS TO BE RETORQUED ANNUALLY ALL CONNECTIONS MUST BE CHECKED FOR PROPER TORQUE H 7 SITE INSTALLED PRIOR TO START Up OR ENERGIZING OF SYSTEM 3 00 4 0 625 TYP 1 00 29 50 31 50 27 TERMINAL BLOCK COVER 3 TB 0068 BOTTOM VIEW TOP VIEW 26 CORNER PROTECTORS 36 _CC 0133 25 BATTERY RAIL INSULATION 16 WIRING DIAGRAM 24 SHUNT TRIP CONNECTORS K6C SU 1 CB 0194 23 AUXILIARY CO
41. Ge r ting Started 1 1 Installing the Up 1 1 1 1 1 Creating an Installation Plan 1 1 1 1 2 Preparing Your Site 0200000055 1 2 1 1 3 Environmental Considerations 1 2 1 1 4 Preparing for Wiring the UPS System 1 2 1 1 5 Inspecting and Unpacking Each Cabinet 1 3 2 Installing the UPS System 2 1 Preliminary Installation Information 2 1 2 2 UPS Cabinet Installation 2 2 2 2 1 Unloading the Powerware 9335 80kVA 120 kVA UPS Cabinet from the Pallet 2 2 2 2 2 Installing Remote Battery Power Wiring 2 2 2 2 3 Installing UPS External Power Wiring 2 3 2 2 4 Installing Customer Connections 2 4 2 2 5 Prepare for Installing Accessories 2 4 2 3 Battery Cabinet Installation 2 5 2 4 Initial Stamupy e Are dx der Ree teed mates 2 5 2 5 Completing the Installation Checklist 2 5 2 5 1 Installation Checklist 2 6 3 Installing and Connecting Batteries 3 1 Important Safety Instructions 3 1 3 2 Internal Battery Modules 3 2 4 Installing a Remote EPO Control 4 1 Installation Procedures 0000000 ees 4 1 4 2 To Install a Remote EPO 4 1 4 3 To Operate a Remote EPO 4 2 iii Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 Section Il Operati
42. LL CONNECTIONS TO BE RETORQUED ANNUALLY ALL CONNECTIONS MUST BE CHECKED FOR PROPER TORQUE PRIOR TO START UP OR ENERGIZING OF SYSTEM 27 TERMINAL BLOCK COVER 3 TB 0068 26 CORNER PROTECTORS 36 CC 0133 25 BATTERY RAIL INSULATION 16 24 SHUNT TRIP CONNECTORS K6C SU 1 CB 0194 23 AUXILIARY CONNECTORS K6C AB 1 CB 0195 22 TERMINAL BLOCK 3 POLE 1 TB 0080 21 TERMINAL BLOCK 12 POLE 1 TB 0026 20 AUXILIARY SWITCH KSAS 1 CB 0193 19 SHUNT TRIP 24 V K58S 1 CB 0197 18 BREAKER 750 VDC 150 A 3 POLE 1 M150 17 BREAKER PLATE 1 PW 0001 16 FUSE HOLDER z FS 0079 15 FUSE 500 VDC SA 2 FS 0077 14 BATTERY HARDWARE KIT 28 SEE DETAIL A 13 CABLE 1 0 GA MINIMUM 6 SUPPLIED BY CUSTOMER 12 CABLE 10 GA 25 LG 1 10 25NC 11 CABLE 10 GA 20 LG 1 10 20NC 10 CABLE 10 GA 12 LG 2 10 12BN 9 CABLE 2 GA 30 LG A 2 30EN 8 CABLE 2 GA 95 LG 1 2 95BE 7 CABLE 2 GA 35 LG 1 2 35BE 6 CABLE 2 GA 40 LG 1 2 40BE 5 CABLE 2 GA 45 LG 5 2 45B 4 CABLE 2 GA 14 LG 2 2 14B 3 CABLE 2 GA 10 LG 20 2 10B 2 BATTERY 28 TC 1250S 1 CABINET 1 Pw1 NO DESCRIPTION QTY PART NO SERIAL SOKVA ar Te POWEREY NO DATE BY SCALE POWER BATTERY COMPANY INC DRAWN BY BATTERY SYSTEM LAYO UT FOR Luis 1 PW1 CABINET 336 V WITH vor vuo we
43. NAL BLOCK COVER 3 TB 0068 26 CORNER PROTECTORS 40 CC 0133 25 BATTERY RAIL INSULATION 16_ 28 x 3 x 1 16 THK 24 SHUNT TRIP CONNECTORS K6C SU 1 CB 0194 23 AUXILIARY CONNECTORS K6C AB 1 CB 0195 22 TERMINAL BLOCK 3 POLE 1 TB 0080 21 TERMINAL BLOCK 12 POLE 1 TB 0026 20 AUXILIARY SWITCH _ K5AS 1 CB 0193 19 SHUNT TRIP 24 V K58S 1 CB 0197 18 BREAKER 750 VDC 100 A 3 POLE 1 M100 17 BREAKER PLATE 1 Pw 0001 16 FUSE HOLDER 2 FS 0079 15 FUSE 500 VDC 5A 2 FS 0077 14 BATTERY HARDWARE KIT 28 SEE DETAIL A 13 CABLE 2 GA MINIMUM 6 SUPPLIED BY CUSTOMER 12 CABLE 10 GA 25 LG 1 10 25NC 11 CABLE 10 GA 20 LG 1 10 20NC 10 CABLE 10 GA 12 LG 2 10 12NC 9 CABLE 6 GA 30 LG 3 6 30EN 8 CABLE 6 GA 90 LG 1 6 90CE 7 CABLE 6 GA 45 LG 1 6 45CE 6 CABLE 6 GA 25 LG 1 6 25CE 5 CABLE 6 GA 45 LG 5 6 45C 4 CABLE 6 GA 30 LG 2 6 30C 3 CABLE 6 GA 14 LG 20 6 14C 2 BATTERY 28 TC 1225L 1 CABINET 1 Pw1 NO DESCRIPTION PART NO WIRING DIAGRAM SERIAL 20KVA Ier wl pate sy Laos QTY 1 PONR POWER 1 DRAWN BY 2 Luis 3 NOT VALID UNLESS BATTERY SYSTEM LAYOUT FOR 1 PW1 CABINET 336 V WITH 28 12 V BATTERIES A BREAKER APPROVED FILE NO DRAWING NO PW1 0000 1PW1 2
44. NNECTORS K6C AB 1 CB 0195 22 TERMINAL BLOCK 3 POLE 1 TB 0080 IT TI 168 voc 24 voc 144 voc 21 TERMINAL BLOCK 12 POLE 1 TB 0026 d d d 20 AUXILIARY SWITCH K5AS 1 CB 0193 19 SHUNT TRIP 24 V K585 1 CB 0197 18 BREAKER 750 VDC 150 A 3 POLE 1 M150 17 BREAKER PLATE 1 PW 0001 16 FUSE HOLDER 2 FS 0079 15 FUSE 500 VDC 5A 2 FS 0077 LOUVERS 14 BATTERY HARDWARE KIT 28 SEE DETAIL A BREAKER 13 CABLE 1 0 GA MINIMUM 6 SUPPLIED BY CUSTOMER 12 CABLE 10 GA 25 LG 1 10 25NC x E 11 CABLE 10 GA 20 LG 1 10 20NC Spiga D SS SE 10 CABLE 10 GA _12 LG 2 10 12BN 9 0 9 CABLE Zo 30 LG 3 2 30EN si z 8 CABLE 2 GA 95 L 1 2 95BE E Z Eeer 7 CABLE 2 GA 35 LG 1 2 35BE ne 20 6 CABLE 2 GA 40 L 1 2 40BE st e 2 Jesis 5 CABLE 2 GA 45 LG 5 EE CAS 4 CABLE 2 GA 14 L 2 2 148 5 3 CABLE ZCA 13 L 20 2 128 2 BATTERY 28 TC 12505 1 CABINET 1 PWI Si tee voc NO DESCRIPTION QTy PART NO SERIAL 40 Ales E d 10s m e Revisions _ 1 07 02 POWER Y s No DE Ka ZE POWER BATTERY COMPANY INC i EE BATTERY SYSTEM LAYOUT FOR REAR VIEW SIDE VIEW FRONT VIEW e Luis 1 PW1 CABINET 336 V WITH vor vuo wel 28 12 V BATTERIES amp BREAKER Pwi 0003 1PW1 28TC50 336 M150 SYSTEM SPECIFICATIONS SYSTE SYSTEM RATING 52 75 RECOMMENDED SYSTEI SYSTE FULL LOAD CURRENT OPEN CIRCUIT VOLTAGE 347 2 SH
45. POW ERWARE 9320 Modular UPS System 10 kVA and 20 kVA Modules 10 kVA to 60 kVA System Installation and Operation Manual 164201416 Rev A IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for your Uninterruptible Power Supply UPS system You should follow these instructions during the installation and maintenance of the UPS options accessories and batteries This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference with the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense Powerware 9320 10 kVA and 20 kVA Installation and Operation ii 164201416 REV A 071103 Introduction ie er et et hee AR RE ctw ds viii Basic System Configurations ix Using This Manual ix Conventions Used in This Manual D Safety Considerations xi Getting Help cede veh eee Gea wae E eee dake eet xii Section Installation 1
46. RRANTY FOR THREE PHASE POWERWARE PRODUCTS Subject to the conditions herein Invensys Powerware Powerware warrants solely to the original end user the electronics the Unit and Powerware built battery cabinets against defects in material and workmanship for the warranty period of 12 months from the date of equipment start up or 18 months from date of shipment whichever occurs first Should service be necessary this warranty covers USA only The Powerware 9315 9330 9335 three phase UPS products are sold with a standard factory warranty described below start up and extended labor service All three phase UPS installations will have an authorized Invensys Powerware Service Engineer or Agent perform startup or the factory warranty and extended labor service will be void The included first year extended labor service provides for a complete 12 months of onsite labor for your UPS purchase Worldwide All parts requiring replacement for the Factory Warranty period If in the opinion of Invensys Powerware the Unit fails to meet published specifications and the defect is within the terms of this warranty the Unit will be repaired or replaced at the option of Invensys Powerware with no charge for replacement parts Labor required to make upgrades repairs or replacement installation is not included under the terms of this Limited Warranty except for labor and travel costs required during the first 90 days of this warranty USA only
47. TIONS IN HANDLING KEEP UPRIGHT WITHIN 15 DEGREES LOUVERS SIDE VIEW 29 53 31 50 TOP VIEW 70 87 8 FRONT VIEW SITE INSTALLED O 15116 SEE DETAIL B 168 VDC WIRING DIAGRAM BREAKER 2 a D D z con aun zeen fe 14 23 D D D Se 7 cou Y siner zeen 24 98 No enor C EI 99 199 Si ene O Sonn me ze w 168 VDC gege 168 VDC ELECTRICAL DIAGRAM A a a Zz of bi N l i SACE i Kc EE on 21 95 S SCH SC off Ged EH e W 1 DETAIL A TERMINAL CONNECTION LG NUT d sl E SPRING LOCK WASHER 1 st E WASHER 1 D STUD POST d Cc CABLE LUG 1 B CABLE A BATTERY TERMINAL 1 ITEM DESCRIPTION QTY CONTAINED IN BATTERY HARDWARE KIT HMP 15 SEE BATTERY LABEL FOR TORQUE VALUES FOR PRC TC BATTERY SUFFIX ei IMPORTANT NOTE ALL CONNECTIONS TO BE RETORQUED ANNUALLY ALL CONNECTIONS MUST BE CHECKED FOR PROPER TORQUE PRIOR TO START UP OR ENERGIZING OF SYSTEM
48. UNT TRIP 24 V INS MODEL NO 1PW1 28TC100S 336 M225 S24 A S UL KWB FOR FLOAT VOLTAGE 378 MIN CUTOFF VOLTAGE 285 6 184 67 ADC FULL LOAD CURRENT PER SERIES CIRCUIT 5 MINUTES TO 1 7 VPC 386 4 MAX 184 67 ADC 361 2 VDC ALLATION AND MAINTENANCE CAUTION REFER STAI TO INSTALLATION STRUCTIONS IIS 1 PRIOR TO ING CABIN ALL RECOM ON TABLE INTERNAL BREAKER INITIAL CO NECTION TORQUE VALUES ENDED CUSTOMER S CABLE GAUGES ARE BASED 310 16 OF N E C USING 75 C CABLE IS FOR OVERCURRENT PROTECTION ONLY 120 IN LB BREAKER USE INSULATED TOOLS FOR CABINET INSTALLATION 22 78 3 00 1 00 ERMINATIO DO NOT ALLOW TOOLS OR CABLES TO REST ON BATTERIES S FOR CUSTOMER S CABLE ARE RATED FOR 75 C AMPACITIES OF CUSTOMER S CABLE MUST NOT CAUSE THIS RATING TO BE EXCEEDED BOTTOM VIEW RER EER BEE BEE REAR VIEW 93 X 61 31 32 X 01 3 32 TRIPLE KNOCKOUTS TYP Re ee TYR 29 50 PLACE CORNER PROTEC OR BETWEEN BATTERIES FOR VENTILATION PURPOSES 181920 17 9 IMPORTANT NOTES THE CUSTOMER AND OR CONTRACTOR SHALL BE RESPONSIBLE FOR INSTALLING THIS EQUIPMENT IN ACCORDANCE WITH ALL APPLICABLE CODES AND REGULA
49. VDC nominal 168 168 INPUT 1 positive 1 negative 1 mid point Amps 107 160 C Minimum conductor size AWG each 1 0 4 0 AC AC Output to Critical Load Full Load Amps 112 168 OUTPUT Current 3 phase 1 neutral 1 ground D Minimum conductor size AWG each 1 0 4 0 Note Refer to Figure A 3 on system one line diagram for the bold letter callout locations 7 Terminals are UL rated at 90 C Refer to Table C for power cable terminations and Table D for conduit requirements Figure A 1 shows the location of power cable terminals inside the UPS Table C UPS Power Cable Terminations 9320 CO3 Terminal Function Terminal Function Size of Pressure Tightening Torque Int Hex Termination NA Ib in Size in AC Input to UPS A Phase A_ 1 6 350 kcmils 42 4 375 3 8 Mains B Phase B 1 6 350 kcmils 42 4 375 3 8 C Phase C 1 6 350 kcmils 42 4 375 3 8 N Neutral 1 6 350 kcmils 42 4 375 3 8 AC Output to A Phase A_ 1 6 350 kcmils 42 4 375 3 8 Critical Load B Phase B_ 1 6 350 kcmils 42 4 375 3 8 C Phase C 1 6 350 kcmils 42 4 375 3 8 N Neutral 1 6 350 kcmils 42 4 375 3 8 DC Input from Battery 1 6 350 kcmils 42 4 375 3 8 Battery to UPS N Mid point 1 6 350 kcmils 42 4 375 3 8 Battery 1 6 350 kcmils 42 4 375 3 8 Customer Ground Protective Protective 4 6 350 kcmils As
50. Wires in Minimum Conduit No of Product Model Conduit Size in Conduits Rectifier Input A B C N G 5 2 0 inches 1 9320 C03 Ext Battery Source N G 4 2 0 inches 1 30 kVA 3 x 10 Output A B C N G 5 2 0 inches 1 Rectifier Input A B C N G 5 3 0 inches 1 9320 C03 Ext Battery Source N G 4 2 5 inches 1 60 kVA 3 x 20 Output A B C N G 5 2 5 inches 1 Rectifier Input A B C N G 5 1 5 inches 1 9320 C02 Ext Battery Source N G 4 1 5 inches 1 20 kVA 2 x 10 Output A B C N G 5 1 5 inches 1 Rectifier Input A B C N G 5 2 5 inches 1 9320 C02 Ext Battery Source N G 4 2 0 inches 1 40 kVA 2 x 20 Output A B C N G 5 2 5 inches 1 11 External overcurrent protection is not provided by this product but is required by codes Refer to A and B for wiring requirements If an output lockable disconnect is required it is to be supplied by designated personnel 12 Table E lists the maximum rating for input circuit breakers A 4 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 13 Nominal battery voltage is computed at 2 volts per cell as defined by Article 480 of the NEC Rated battery current is calculated using the nominal computed voltage Table E Maximum Input Circuit Breaker Ratings Amperes Powerware Model Input Voltage Rating 208 VAC DC 9320 CO3 3 x 10 kVA 110 100 9320 CO3 3 x 20 kVA 250
51. a 3 Phillips head screwdriver Tilt the unit slightly to enable the steel bracket to be removed from beneath two legs Lower the unit down to the floor 4 Repeat the process for the other side by tilting the unit and removing the steel bracket See illustrated procedure packed on the outside of the shipping carton 5 The UPS cabinet may now be moved to its final position for installation 2 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 2 2 2 Installing External Battery Power Wiring The Powerware 9320 C03 contains no internal batteries and must therefore be used with an external battery system The Powerware 9320 C02 contains internal batteries how ever for extended runtime an external battery system will be required The procedure for wiring an external battery system to the 9320 is described as follows Also read the battery system manual to ensure proper interconnections on the battery side 1 If not already done open the UPS cabinet door using the provided operator handle and remove the bottom internal protective panel Retain hardware 2 Route battery cables from the battery cabinet through the conduit landing plate at the UPS cabinet bottom rear to the battery terminals at the bottom front of the cabinet Refer to Appendix A of this manual for wiring access information NOTE Remove the UPS cabinet input and output conduit landing plate to punch conduit holes as required When re
52. an 10 input THD at full load Power Factor Minimum 0 98 Battery Voltage 10 kVA modules 168 volt nominal center point connected to neutral 20 kVA modules 168 volts nominal center point connected to neutral Maximum Battery Charge Current Adjustable up to 12 amperes per module batteries to 400AH Powerware 9320 10 kVA and 20 kVA Installation and Operation 13 1 164201416 REV A 071103 13 3 UPS System Output DC Ripple less than 1 voltage ripple UPS Output Current C03 166 amperes cabinet maximum actual based on modules used UPS Output Current C02 110 amperes cabinet maximum actual based on modules used UPS Output Capacity 100 rated current at 0 8 power factor Output Voltage Regulation 1 5 10 100 load Output Voltage Harmonic Content Less than 1 Output Voltage Balance Each phase may be loaded to 100 current independently with voltage regulation within stated tolerance Output Voltage Phase Displacement 120 degrees between phases 0 01 degree Output Transients lt 4 for 0O 100 or 100 to 0 load change Frequency Regulation 0 1 free running Synchronous to Bypass No break transfer Frequency Slew Rate 1 Hz per second maximum Overload Capacity 25 C based on kVA rating 101 to 110 for 10 minutes 111 to 150 for 30 seconds Maximum Output Capability 150 RMS for
53. annot be guaranteed Call the authorized service center for assistance MAINS FAILURE The utility power supply is outside its prescribed tolerance The input power to UPS is too low or missing If site power appears to be OK check the input circuit breakers etc supplying the UPS OVERCURRENT OR There is a short circuit at the Check all output connections and repair SHORT CIRCUIT output of UPS on load side as required OVERLOAD Load exceeds the UPS rated Identify which piece of equipment is power causing the overload and remove it from the UPS OVERTEMPERATURE UPS temperature has exceeded Check that the ambient temperature of the the allowed value UPS is less than 40 C and that cooling air flow is not blocked If the ambient temperature is normal call the authorized service center for assistance BATTERY CHARGER The attached battery and the Call the authorized service center for OFF battery charger set up do not assistance correspond or battery charger fault INVERTER FAULT Inverter is faulty Call the authorized service center for assistance NON SYNCH The inverter and utility power are not synchronized The frequency of the input voltage to the UPS is outside operational limits and the UPS static bypass has been temporarily disabled BATTERY LOW The battery is nearly discharged Shutdown load connected to UPS before the UPS switches itself off to protect its batterie
54. ar load 9 2 1 4 9320 CO3 3 x 20 kVA 208 208 100 non linear load 18 3 2 7 A 8 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 go1 LABEL DATA Control Panel 2 Jb2 F2 TEn TE IA1 Maintenance Bypass UPS Module 2 SE TA2 1 2 Parallel Isolator Mod 1 2 swi t P BE BCE JD1 Smart Port RS232 SUB D9P F o7 Deeg Al Jb2 Isolated Relay outputs SUB D25 F zpa L_ EH SW1 1 Single Parallel Switch 1 SW2 1 to 9 System Configuration Switches j i x1 Emergency Power OFF EPO pa A E x2 Generator ON F2 SS it X3 Battery Temperature Module 1 UPS Module 1 x2 H it X4 Battery Temperature Module 2 WE A X6 Battery Breaker control EPO ses rt JIL JD11 Serial Communication Port JDA EEN i SW1 1 Module Type HIGH Parallel Module Internal Battery S LOW Single Module RS SW2 1 Single SCENE to SW2 9 Cabinet Ql rar gout al ar 1 ON SS xe i 2 ON l Om O m ae O ll JD42 3 ON Parallel isolators Maintenance or O 4 ON DC Battery Bkr Bypass x5 O 5 ON S Rear view 6 ON E inside x ye cabinet 7 ON 2A 2B 2C 2N z Bue 8 ON 9 ON N 1A 1B 1C 1N 3A 3B 3C 3N t Figure A 1a Front View of Model 9320 CO2 Powerware 9320
55. around the UPS is clean and uncluttered e Battery cabinet maintenance or battery replacement should be performed only by authorized service personnel e Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of the equipment e Always conform to the more detailed safety precautions described in Important Safety Instructions section of Chapter 12 Maintaining the UPS System Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 6 6 Symbols Controls and Indicators These symbols may appear on your UPS system or on labels inside the UPS Most international safety agents accept them Everyone in your organization who works with your system should understand the meaning of these symbols PROTECTIVE GROUNDING TERMINAL A terminal which must be connected to earth ground prior to making any other connection to the equipment A terminal to which or from which a direct current or voltage may be applied or supplied Z This symbol indicates the word phase ON The principal power switch is in the ON position OFF The principal power switch is in the OFF position CAUTION REFER TO MANUAL Stop and refer to the Operator s Manual for more information DANGER RISK OF ELECTRIC SHOCK There is a risk of electric shock present and you should observe associated warnings The UPS contains high voltages Powerware 9320 10 kVA and 20 kVA Installa
56. ate as shown below LED Indicator Color LINE 1 Green LINE 2 Green BYPASS Green INVERTER Red BATTERY Green e Press reset button to silence audible alarm 2 Simultaneously press both ON OFF pushbuttons on the UPS cabinet control panel for each of the installed modules e Onthe LCD Display MAIN BYP FAULT will appear and the LED indicators will indicate as shown below LED Indicator Color LINE 1 Green LINE 2 OFF BYPASS OFF INVERTER OFF BATTERY Flashing Green e Press reset button e On the LCD Display LOAD OFF SUPPLY FAILURE will appear 3 Rotate all Parallel Isolator Switches to O OFF 4 Open all battery breakers either internal or in external battery cabinets THE LOAD IS NOW SUPPLIED BY THE UTILITY SOURCE AND IS NOT PROTECTED Powerware 9320 10 kVA and 20 kVA Installation and Operation 8 5 164201416 REV A 071103 8 5 UPS Module Replacement in a Redundant 9320 System WA RNING All the operations in this section must be performed by properly trained personnel By opening removing or replacing the UPS modules and module covers you risk exposure to dangerous voltages Do not leave the UPS module compartment without an appropriate protective cover 8 5 1 Removing a Module from a Redundant Multi Module System If in a redundant parallel system a UPS module is faulty the load will continue to be protected by the remaining ope
57. ators Powerware 9320 10 kVA or 20 kVA module Control Panel UPS Control Panel LCD Screen and Pushbuttons LCD Screen Navigation Chart X Slot Location on Front of Powerware 9320 CO3 UPS Cabinet X Slot Location on Front of Powerware 9320 CO2 UPS Cabinet Generator ON Connection Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 vi Listof Tables Table 3 1 Internal battery combinations for 9320 CO2 UPS Table3 2 Estimated run time table for internal batteries 9320 CO2 Table4 1 Remote EPO Wire Terminations Table4 2 Remote EPO vii Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 Powerware 9320 UPS true double conversion online power protection can be utilized to prevent loss of valuable electronic information minimize equipment downtime and or minimize the adverse effect on equipment production due to unexpected power issues The Powerware UPS System continuously monitors incoming electrical power and removes the surges spikes sags and other irregularities that are inherent in commercial utility power Working with your building s electrical system the UPS System supplies clean consistent power that your sensitive electronic equipment requires for reliable operation During brownouts blackouts and other power interruptions optional battery strings provide emergency power to safeguard your operation The UPS system is housed in free sta
58. bles are properly sized and terminated A ground conductor is properly installed If the cabinet does not use all module mounting locations the provided protective covers are installed on the front and back of the cabinet Battery cabinet installation instructions have been completed Air conditioning equipment is installed and operating properly The area around the installed UPS system is clean and dust free It is recommended that the UPS be installed on a level floor suitable for computer or electronic equipment Adequate workspace exists around the UPS and other cabinets Adequate lighting is provided around all UPS equipment Any optional accessories are mounted in their installed location and properly wired Summary alarms and or building alarms are wired appropriately OPTIONAL Startup and operational checks performed by authorized service personnel All network connections are completed 2 6 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 3 1 Important Safety Instructions The Powerware 9320 C03 UPS does not contain batteries It must however be used with a properly configured battery cabinet or rack with a properly sized battery system for proper operation The Powerware 9320 C02 UPS uses internal batteries For extended runtime applications it may also be used with a properly configured battery cabinet or rack with a pro
59. connected loads When this occurs the unit will issue another set of audible and visual alarms indicating BATTERY IN DISCHARGE Unless the rectifier has a valid input soon the critical load will only be supported for about 3 minutes before the output of the system shuts down completely When this occurs the LCD display will show the message BATTERY DISCHARGED If at any time during the battery discharge the input power becomes available again contactors K1 and K4 are closed and the rectifier will begin to supply DC current to the boost converter and inverter The battery SCRs will be switched off while the battery charger is turned back on to begin recharging the battery At this point the unit returns to normal operation The systems total operating time on battery will depend on many factors Some factors that affect battery support times are battery type and capacity number of parallel strings environmental temperatures age of the battery and fluctuations in load demand during the discharge The greater the load the less support time the battery will provide Decrease the load and the battery support time will generally increase Powerware 9320 10 kVA and 20 kVA Installation and Operation 5 9 164201416 REV A 071103 5 2 4 Maintenance Bypass Mode An internal maintenance switch IA1 is used to safely supply utility power to the system output during periods of maintenance or repairs Before this switch is used the syste
60. ctrical power through the UPS system when the UPS is operating in Normal mode Normal Mode Battery Charger UPS Moduk 1 Battery Breaker mm Main Power Trickle Current Energized De Energized Figure 5 2 Path of Current Through the UPS in Normal Mode UPS Module 3 in 9320 C03 systems only During normal UPS operation power for the system is derived from a utility input source through the input contactor K1 and externally protected utility feed Load Protected appears on the LCD display and indicates the incoming power is within voltage and frequency acceptance windows Three phase AC input power is converted to DC using a full wave six pulse solid state rectifier block which supplies unregulated DC voltage to a boost converter which in turn supplies a higher regulated DC voltage to the inverter A separate internal battery charger is used to maintain the proper charge level on the battery during normal operation The battery charger derives its input from the booster output and provides regulated DC voltage and charge current to the battery The battery charge condition is monitored by the UPS and when abnormal reported by the status indicators located on the LCD display The battery is always connected to the UPS and ready to support the inverter should the utility input become unavailable 5 4 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 The DC bo
61. d and presented under the Event Log All events and alarms are displayed with their date and time of occurrence 7 3 5 Measurements Screen DESCRIPTION Battery Runtime remaining in minutes UPS Output Frequency Bypass Frequency LCD DISPLAY EVENT LOG MEASUREMENTS COMMANDS UPS DATA SET UP USER SET UP SERVICE LCD DISPLAY 02 27 02 17 03 30 LOAD TO INV 02 27 02 17 03 30 LOAD TO BYP 02 27 02 17 03 30 LOAD OFF LCD DISPLAY BATT RUN TIME MIN 10 0 OUTPUT FREQUENCY HZ 60 00 BYPASS FREQUENCY HZ 60 00 7 6 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 BATTERY VOLTAGE V Battery Voltage 189 189 BATT CHARGE CUR A Battery Charger Current a Kate R e DISCHARGE CURRENT A Discharge Current 0 0 5 Ma P RECTIFIER VOLTAGE V Rectifier Voltage all three phases 208 208 208 BYPASS VOLTAGE V Bypass Voltage all three phases 208 208 208 OUTPUT VOLTAGE V Output Voltage all three phases 208 208 208 OUTPUT CURRENT A Output Current all three phases 28 28 28 ACTIVE POWER kW Active Output Power all three phases 5 5 5 l REACTIVE POWER kVAR Reactive Output Power all three phases 1 1 1 APPARENT POWER KVA Apparent Output Power all three phases 6 6 6 OUTPUT POWER Output Power all three phases 80 80 80 Ss BATT CAPACITY Battery Capacity remaining 98 typical values shown
62. e E Ea ks 7 1 7 2 Using the Control Panel 7 2 7 2 1 Power Management Display 7 2 7 2 2 LED Indicators 7 2 7 2 3 Pushbutton Functions 7 3 7 2 4 ON OFF Shutdown and Startup Pushbuttons 7 3 7 3 Description of the LCD Screen 7 4 7 3 1 Status Screens 7 4 7 3 2 LCD Display Structure and Navigation 7 5 7 3 3 Main Menu Screen 7 6 7 3 4 Event Log Screen 7 6 7 3 5 Measurements Screen 7 6 7 3 6 Commands Screen 7 7 7 3 7 YRS Dalai eer eege eet dae eta eine eed 7 8 7 3 8 Set Up USEF tenis eran tebe ewe pe gee end 7 8 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 7 3 9 Set Up Service 7 4 Operating Modes 7 4 1 ON LINE Mode Inverter Mode 7 4 2 OFF LIINE Mode BYPASS or ECONOMY Mode 7 4 3 MAINTENANCE BYPASS Mode 7 4 4 Parallel Isolator IA2 8 UPS Operating Instructions 8 1 Operation vnc eee te E a ETNE bat 8 2 Start Up Procedure for the UPS 8 3 Shut Down Procedure forthe UPS 8 4 Load Transfer to Maintenance Bypass 8 5 UPS Module Replacement in a Redundant 9320 System 8 5 1 Removing a Module from a Redundant Multi Module System 8 5 2 Reinstalling a Module in a Redundant Multi Module System 8 6 Module Replacement in a Capacity 9320 System 8 6 1 Removing a Module from a Capacity Multi Module System 8 6 2 Reinstalling a Modul
63. e There are no alarm conditions e The battery is fully charged e Utility supply is present and normal The battery testing can be carried out independently of the operation mode OFF LINE or ON LINE and whether or not the load is connected The battery test procedure can be performed from the UPS front panel See Chapter 7 Using the Control Panel BATTERY Maintenance Contact Invensys Global Services for battery maintenance Only authorized service personnel should perform Battery replacement and maintenance 12 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 13 1 System Information The UPS systems are housed in freestanding cabinets with safety shields behind the front panels The UPS systems are available in 60 Hz configurations with a maximum rating of 60 kVA output per cabinet The following sections detail the input output environmental and battery specifications for each model 13 2 UPS System Input Operating Input Voltage Nominal 15 20 208 VAC for operation from 166 VAC to 239 VAC 60 Hz Operating Input Frequency Range 45 65 Hz continuous duty Current 9320 C02 Maximum Input 30 kVA Model 3 x 10 kVA modules 90 amperes Current 9320 C03 60 kVA Model 3 x 20 kVA modules 183 amperes Maximum Input 20 kVA Model 2 x 10 kVA modules 60 amperes 40 kVA Model 2 x 20 kVA modules 122 amperes Input Current Harmonic Content Less th
64. e in a Capacity Multi Module System 9 Responding to System Events 9 1 TE BIS eeler Zender arate inte th de bb ay Er 9 2 Menu Commands Event Log Measurements 9 3 Fault Identification and Correction 10 Communications 10 1 X Slot Communication Modules 11 Options 11 1 Generator ON Facility 12 Maintaining the UPS System 12 1 General 12 2 Important Safety Instructions 12 3 Performing Preventive Maintenance 13 Product Specifications 13 1 System Information 13 2 UPS System Input 13 3 UPS System Output 13 4 Environmental Specifications Appendix A Customer Information Warranty Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 o D D o rzJ Oo P Gi a oO Figure 1 1 Figure 4 1 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 6 1a Figure 6 1b Figure 6 2 Figure 7 1 Figure 7 2 Figure 7 3 Figure 10 1a Figure 10 1b Figure 11 1 Powerware 9320 10 kVA or 20 kVA module UPS Cabinet Typical Remote EPO Control Main Elements of the UPS System Path of Current through the UPS in Normal Mode Path of Current through the UPS in Bypass Mode Path of Current through the UPS in Battery Mode Path of Current through the UPS in Maintenance Bypass Mode Powerware 9320 CO3 Controls and Indicators Powerware 9320 CO2 Controls and Indic
65. e is displaved Distribution 40kVA 28x9Ah 56x9Ah 84x9Ah 112x9Ah 56x9Ah 84x9Ah 112x9Ah Table 3 1 Internal battery combinations for 9320 CO2 UPS 10 kVA 20 kVA 40 kVA 28 x9 Ah 8 N A N A 56 x9 Ah 21 8 N A 84x9 Ah 35 15 N A 112 x9 Ah 50 21 8 Table 3 2 Estimated run time with internal batteries 9320 C02 3 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 4 1 Installation Procedures D EMERGENCY OFF D Figure 4 1 Typical Remote EPO Control 4 2 To Install a Remote EPO NOTE Before installing a Remote EPO be sure you have prepared the UPS according to the instructions in Chapter 2 To Install a Remote EPO control 1 Securely mount the remote EPO switch Recommended locations include near operator s consoles or near exit doors Refer to Remote EPO switch manufacturers installation instructions for enclosure dimensions and wiring knockouts 2 Install wiring from the remote EPO switch using appropriate sized conduit through the Customer Interface conduit landing plate on the bottom rear of the UPS cabinet Refer to Figure A 9 for conduit landing area 3 Connect the Remote EPO wiring as shown in Tables 4 1 and 4 2 on the next page Powerware 9320 10 kVA and 20 kVA Installation and Operation 4 1 164201416 REVA 071103 Table 4 1 Remote EPO Wire Terminations From Remote To X1 connector on customer interface panel Remarks EPO Switch s
66. e replacement value of the Unit warranted Invensys Powerware s obligation under said warranty is expressly conditioned upon receipt by Invensys Powerware of all payments due it including interest charges if any During such time as Invensys Powerware has not received payment of any amount due it in accordance with the Contract terms under which the equipment is sold Invensys Powerware shall have no obligation under said warranty also during this time the period of said warranty shall continue to run and the expiration of said warranty shall not be extended upon payment of the overdue amount These limitations to said warranty apply even in the event that the equipment is sold initially by Invensys Powerware for resale to an ultimate end user In no event shall Invensys Powerware be liable for any indirect incidental special or consequential damages of any kind or type whatsoever or based on any claim or cause of action however denominated Invensys Powerware shall not be responsible for failure to provide service or parts due to causes beyond Invensys Powerware s reasonable control This limited warranty applies only to the original end user of the unit This factory warranty will not be in effect if the End User does not properly store the equipment including the trickle charge of batteries no later than the date indicated on the packaging before installation and does not cover shipping damages if FOB Factory Cost for replace
67. ed See the operation section of this manual for shutdown instructions Remove Customer Interface conduit landing plate from the UPS cabinet Drill or punch conduit holes for interface wiring Open UPS cabinet front door and remove the front safety shield panel to gain access to the wire way to bring wires from the conduit landing panel at the bottom rear of the cabinet Locate required connection points by referring to Figure A 1 in Appendix A Refer to Appendix A of this manual for wiring and termination requirements Reinstall Customer Interface conduit landing plate Install conduit and wiring When wiring is complete secure UPS by reinstalling all panels removed in previous ps Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 2 3 Battery Cabinet Installation The Powerware 9320 C03 has no batteries within the UPS cabinet The Powerware 9320 C02 contains internal batteries however for extended runtime an external battery system will be required See installation instruction provided with the battery cabinet for proper installation of that portion of the system WARNING It is very important to ensure that a proper protective device is installed between the battery system and the UPS DC input terminals See Tables A and B in Appendix A for proper wire and protective device sizing 2 4 Initial Startup Startup and operational checks should be performed only by authoriz
68. ed service personnel Contact service in advance usually a two week notice is required to reserve a preferred startup date 2 5 Completing the Installation Checklist The final step in installing your UPS system is completing the following Installation Checklist This checklist ensures that you have completely installed all hardware cables and other equipment Completing all items listed on the checklist will ensure a smooth installation You should make a copy of the Installation Checklist before filling it out and retain the original After your installation is complete a service representative will be able to verify the operation of your UPS system and commission it to support your critical load The service representative cannot perform any installation tasks other than verifying software and operating setup parameters Service personnel may request a copy of the completed Installation Checklist to be sure you have completed all applicable equipment installation NOTE The Installation Checklist MUST be completed prior to starting the UPS system for the first time Powerware 9320 10 kVA and 20 kVA Installation and Operation 2 5 164201416 REV A 071103 2 5 1 Installation Checklist All packing materials and restraints have been removed from each cabinet Each cabinet in the UPS system is placed in the installed location All conduits and cables are properly routed to the UPS and auxiliary cabinets All power ca
69. emove UPS Module completely by pulling it out horizontally 8 Insert new UPS Module see Section 8 5 2 or cover the open ing UPS Module Compartment with an appropriate protection cover immediately and fasten with the provided four screws 8 5 2 Reinstalling a Module in a Redundant Multi Module System WARNING All the operations in this section must be performed by properly trained personnel By opening removing or replacing the UPS modules and module covers you risk exposure to dangerous voltages Do not leave the UPS module compartment without an appropriate protective cover Perform the following steps to install the new module into a Powerware 9320 1 If necessary remove UPS Module compartment protection covers CAUTION Two persons are needed to insert the module into the UPS Frame The weight ofa 20 kVA module is 56 kg a 10 kVA module is 49 kag 2 Slide the UPS Module about Zo into the dedicated UPS compartment Do not slide the UPS Module into the cabinet far enough to mate the rear connector 3 Connect Control Panel cable to connector JD7 4 Slide the UPS module to its final position and push firmly to assure good contact on the rear connector CAUTION This procedure must be followed in the order given because the rear UPS module connector will have working voltage applied 5 Tighten the four screws on the front of the module 6 Reconnect cable on connector to JD4 7 Check if the LED
70. ents LED status indicators show the operating mode of the UPS and alert you to system events Panel push buttons provide navigation through the information and control screens The load ON OFF pushbuttons are located at the right of the control panel Both must be pressed simultaneously to activate the LOAD ON OFF function Below the LCD screen are the user control pushbuttons RESET UP DOWN and ENTER which provide access to the control and measurement functions of the UPS The control panel is described in detail in chapter 7 Using the Control Panel Sech 9320 ON OFF Display and Operation System Status LED System Status LEDs SE Figure 6 2 Powerware 9320 10 kVA to 20 kVA modules Control Panel 6 2 2 System and Load ON OFF Two load ON OFF pushbuttons are located on the right side of the LCD display Activating both pushbuttons simultaneously will effect immediate system shutoff of the controlled module This feature prevents accidental system shutdown if one of the pushbuttons is inadvertently depressed System turn on is achieved in the same manner by simultaneously depressing both buttons Operation of the system ON OFF pushbuttons is described in detail in Chapter 7 Using the Control Panel and Chapter 8 Powerware 9320 10 kVA and 20 kVA Installation and Operation 6 3 164201416 REV A 071103 UPS Operating Instructions For a parallel module 9320 system the DIP Switch SW1 1 located on the fron
71. hown in Table K Table K System Clearances From Front of Cabinet 36 inches working space From Back of Cabinet 6 inches for ventilation From Right or Left side of Cabinet 0 inches clearance 6 The basic environmental requirements for operation of the UPS system are 0 40 C 32 104 F Ambient Temperature Range Recommended Operating Range Maximum Relative Humidity 20 25 C 68 EI 95 The UPS ventilation requirements for heat removal are shown in Table L Table L Air Conditioning or Ventilation Requirements During Full Load Operation Powerware 9320 20 kVA and 40 kVA Powerware Model Input Output Voltage Heat Rejection BTU hr x 1000 hr kW 9320 CO2 2 x 10 kVA 208 208 linear load pf 0 8 4 9 0 7 9320 CO2 2 x 20 kVA 208 208 linear load pf 0 8 9 8 1 4 9320 CO2 2 x 10 kVA 208 208 linear load pf 1 0 5 4 0 8 9320 CO2 2 x 20 kVA 208 208 linear load pf 1 0 10 8 1 6 9320 CO2 2 x 10 kVA 208 208 100 non linear load 6 1 0 9 9320 CO2 2 x 20 kVA 208 208 100 non linear load 12 2 1 8 9320 CO3 3 x 10 kVA 208 208 linear load pf 0 8 6 8 1 0 9320 CO3 3 x 20 kVA 208 208 linear load pf 0 8 13 7 2 1 9320 CO3 3 x 10 kVA 208 208 linear load pf 1 0 8 1 1 2 9320 CO3 3 x 20 kVA 208 208 linear load pf 1 0 16 2 2 4 9320 CO3 3x10kVA 208 208 100 non line
72. icators will appear as follows 8 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 LED Indicator Color LINE 1 Green LINE 2 Green BYPASS Green INVERTER Red BATTERY Green 11 Connect load to the UPS output 12 Close external output circuit breakers in the load distribution panel Both MBP and static bypass should now be supplying the load e Verify on the LCD Display and LED indicators that the load is on Bypass 13 Rotate the Maintenance Bypass Switch IA1 to the O OFF position On the LCD Display MANUAL BYP OPEN will appear followed by LOAD NOT PROTECTED And inverter red light turns off 14 Using the Measurements menu see sections 7 3 2 and 7 3 5 Check the output power voltage current and frequency 15 Perform Load transfer to Inverter e Goto COMMANDS menu on UPS cabinet control panel and choose command LOAD TO INVERTER on any of the control panels to transfer the load to inverter output see sections 7 3 2 and 7 3 6 e Onall LCD Displays LOAD PROTECTED will appear 16 Repeat step 14 above to verify that all voltages currents power and frequency are correct 17 Once the above procedure is performed at initial start up subsequent start ups may be performed using only step 15 as long as other conditions are unchanged THE POWERWARE 9320 UPS NOW PROTECTS THE LOAD 8 3 Complete Shutdown Procedure for the UPS
73. ifferent LINE 2 BYPASS depending upon LED s green the status of the when shown UPS and LED shaded BATTERY condition before turning IA1 to the closed LINE 1 position unless noted CAUTION Before transferring the load to Maintenance Bypass using the IA1 switch always make sure that each module in the UPS cabinet is in the Bypass Mode Failure to observe this procedure can cause equipment damage CAUTION When the UPS is operated in the Maintenance Bypass mode through the Bypass Switch IA1 the load will not be protected in the event of a utility supply failure It is therefore strongly recommended that the user switch back to ON LINE INVERTER ON or BYPASS OFF LINE MODE as soon as possible Powerware 9320 10 kVA and 20 kVA Installation and Operation 7 11 164201416 REV A 071103 7 4 4 Parallel Isolator IA2 7 12 Each UPS module is provided with an output isolator switch IA2 which when opened isolates the corresponding unit from the PARALLEL BUS and from the LOAD Once IA2 is open there is no power coming from its inverter In redundant parallel configurations it is used to isolate a unit from the parallel system without the need of transferring the load to bypass This switch should always be in the I ON position except for servicing the UPS when in the maintenance bypass mode Rotating this switch to the O OFF position while the inverter is supplying power to the load w
74. ill appear the alarm will sound and the LED indicator will indicate as shown below LED Indicator Color LINE 1 Green LINE 2 Green BYPASS Green INVERTER RED BATTERY Green The load is now directly supplied by utility power and is not protected 4 Open the corresponding Parallel Isolator Switch IA2 of the faulty Module switch to position OFF NOTE Parallel Switch IA2 1 belongs to Module 1 Parallel Switch A2 2 belongs to Module 2 Parallel Switch IA2 3 belongs to Module 3 model 9320 CO3 only 5 On the faulty Module control panel press the two ON OFF Buttons simultaneously to shutdown the UPS Module Powerware 9320 10 kVA and 20 kVA Installation and Operation 8 9 164201416 REV A 071103 6 Disconnect cables from connectors JD4 and JD7 on the faulty module only 7 Unscrew the four screws on the front of the faulty UPS module 8 Pull Module forward slightly by means of the two black handles until the rear connectors are disconnected WARNING Before removing the UPS module completely wait 2 minutes until the internal DC capacitors are discharged CAUTION Two persons are needed to pull the module from the UPS Frame The weight of a 20 kVA module is 56 kg a 10 kVA module is 49 kg 9 Remove UPS Module completely by pulling it out horizontally 10 Insert new UPS Module see Section 8 5 2 or cover the opening UPS Module Compartment with an appropriate protection cover
75. ill dump the critical load WARNING Rotating the output isolator switch IA2 to the O open position when the maintenance bypass switch IA1 is in the O open position will interrupt power to the critical load POSITION EFFECT Normal Operation Load supplied by UPS UPS Module isolated from Parallel Bus for maintenance or module replacement UPS Module not supplying load Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 8 1 Operation The following procedures provide instruction for operating the UPS system Refer to Chapters 6 and 7 of this manual for a description of the UPS controls and monitor panel functions NOTE Before starting the UPS ensure all installation tasks are complete and authorized service personnel have performed a preliminary startup The preliminary startup verifies all electrical interconnections to ensure the installation was successful and the UPS operates properly 8 2 Start Up Procedure for the 9320 Modular UPS CAUTION All the operations in this section must be performed by authorized service technicians or by qualified internal personnel To start the UPS system for normal operation perform the following procedure 1 Ensure the UPS switches and external customer circuit breakers are set as follows UPS Utility Supply Breaker customer supplied O OPEN UPS Bypass Input Breaker d
76. installing ensure that the protective ground wire is reconnected if it has been removed for conduit hole punching in the plate 3 Connect positive negative and neutral DC power wiring from the external battery source to the DC input positive and negative and neutral battery center tap terminals in the UPS cabinet Refer to Appendix A of this manual for wiring and termination requirements and wiring access information 2 2 3 Installing UPS External Power Wiring 1 Open the front cabinet door using the provided removable operator handle packed separately with the UPS Remove the internal safety shield panel by removing the fastening hardware to gain access to the input and output terminals at the bottom front of the cabinet NOTE Remove the UPS cabinet input and output conduit landing plate to punch conduit holes as required When reinstalling ensure that the protective ground wire is reconnected if it has been removed for conduit hole punching in the plate 2 Route input and output cables through wireway to UPS terminal blocks Refer to Appendix A of this manual for wiring access information 3 For UPS input connect phase A B C Neutral N and earth ground G input power wiring from the source to the rectifier input terminals 1A 1B 1C in the UPS cabinet Refer to Appendix A of this manual for wiring and termination requirements terminal location and wiring access information DANGER Never connect the earth ground G t
77. ion about the UPS The menu driven LCD Screen enables access to the 1 EVENT LOG 2 MEASUREMENTS COMMANDS UPS DATA SETUP USER SERVICE SETUP Not accessable for users requires a field service technician NOTE See section 7 3 2 for further information OO Ww 7 2 2 LED Indicators 7 2 The LED indicators display the general status of the UPS Indicators show the power flow status and in the event of power failure or load transfer from inverter to bypass or vise versa the corresponding LED indicators will change color from green normal to red warning The LINE 1 and LINE 2 LEDs indicate the availability of the input power supply The INVERTER and BYPASS LEDs if green indicate which of the two power paths is supplying power to the critical load When the battery is supplying the load due to supply failure the BATTERY LED will be flashing The ALARM LED is a visual indication of any internal or external alarm conditions At the same time an audible alarm will be activated Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 INDICATOR INDICATOR STATUS MEANING ALARM OFF No alarm condition RED BUZZER Alarm condition RED Alarm condition persists LINE 1 GREEN Utility supply to rectifier available RED Utility supply to rectifier not available LINE 2 GREEN Bypass supply available RED Bypass supply not available or not OK BYPASS GREEN Load on bypass By
78. ircuit breaker internal or external 7 Scroll through the measurements menu and verify that battery polarity and voltage are proper and within prescribed limits see sections 7 3 2 and 7 3 5 The voltages should be about 189 and 189 8 Repeat the same procedure for Modules 2 and 3 9320 C03 only as listed above 9 Test Parallel Functions The load to the system should remain disconnected A All three UPS Modules are on INVERTER MODE B Close Parallel Isolator IA2 1 position ON of Module 1 On LCD THIS UPS IS NOW MASTER will appear in the event log C Close Parallel Isolator IA2 2 position ON of Module 2 On LCD THIS UPS IS NOW SLAVE will appear in the event log D Close Parallel Isolator A2 3 position ON of Module 3 9320 C03 only On LCD THIS UPS IS NOW SLAVE will appear in the event log E On output Terminal Block there is now UPS power and On all three LCD s LOAD PROTECTED will appear For first time start up only complete through step 18 On subsequent startups do only step 15 10 Perform load transfer to Maintenance Bypass to verify proper bypass operation e Use Menu COMMANDS on UPS control panel and choose LOAD TO BYPASS on any of the control panels on the UPS modules see sections 7 3 2 and 7 3 6 to transfer the load to the bypass source e Close Maintenance Bypass Switch IA1 to position I ON The LCD display will show MANUAL BYP CLOSED and the LED ind
79. irements 9320 CO3 and 9320 CO2 Maximum Input Circuit Breaker Ratings all models Maximum Output Circuit Breaker Ratings all models Customer Interface Inputs and Outputs all models Customer interface to JD2 Customer connections to JD1 Equipment Weight System Clearances Air Conditioning or Ventilation Requirements Front View of Powerware 9320 showing customer connections Label of Powerware 9320 Oneline diagram of Powerware 9320 Power terminal connections for Powerware 9320 CO3 Power terminal connections for Powerware 9320 CO2 Figure A 5 6 7 UPS Cabinet Dimensions Powerware 9320 10 kVA and 20 kVA Installation and Operation A 1 164201416 REV A 07 11 2003 Table A INPUT OUTPUT Ratings amp External Wiring Requirements for Powerware 9320 CO2 amp CO3 Modules kVA 2x10 3x 10 Ratings Units Rating 50 60 Hz Basic unit ratings at kVA 20 30 0 8 lagging PF load kW 16 24 INPUT OUTPUT 208 208 VOLTAGE AC Input to UPS 0 95 min PF Amps 60 90 AC 3 phase 1 neutral 1 ground INPUT Minimum conductor size AWG each 4 2 A Max amps include full load current plus battery recharge current DC DC Input Ext Battery source to UPS VDC nominal 168 168 INPUT 1 positive 1 negative 1 mid point Amps 54 80 C Minimum conductor size AWG each 2 1 0 AC AC Output to Critical Load Full Load Amps 56 84 OUTPUT Current 3 phase 1 neutral 1 gro
80. k in service Powerware 9320 10 kVA and 20 kVA Installation and Operation 5 5 164201416 REV A 071103 5 2 2 Bypass Mode The UPS automatically switches to Bypass mode if it detects an overload load fault or internal failure The bypass source supplies the commercial AC power to the load directly Figure 5 3 shows the path of electrical power through the UPS system when operating in the Bypass mode CAUTION The critical load is not protected while the UPS is in the Bypass mode Static Bypass Mode IA L qt Input Filter Rectifier Booster Inverter Tr W I ay Battery Charger Battery Battery UPS Module 1 Breaker UPS Module 2 UPS Module 3 Breaker Contactors Switches mm Main Power Closed K D 4 I gt Trickle Current C Energized Open OO H Fans De Energized Figure 5 3 Path of Current Through the UPS in Bypass Mode UPS Module 3 in 9320 C03 systems only 5 6 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 In BYPASS mode the output of the system is provided with three phase AC power directly from the systems input While in this mode the output of the system is not protected from voltage or frequency fluctuations or power outages from the source Some power line filtering and spike protection is provided to the load b
81. l 28 12 V BATTERIES amp BREAKER r cker FILE NO DRAWING NO Pw1 0003 1PW1 28TC50S 336 M150 G ES a SYSTEM MODEL NO 1PW1 28TC50S 336 M150 S24 A S UL il SYSTEM RATING 35 165 KWB FOR 9 MINUTES TO 1 7 VPC E 5 RECOMMENDED SYSTEM FLOAT VOLTAGE 378 MIN 386 4 MAX CH SYSTEM CUTOFF VOLTAGE 285 6 N FULL LOAD CURRENT 123 1 ADC L FULL LOAD CURRENT PER SERIES CIRCUIT 123 1 ADC i SACE OPEN CIRCUIT VOLTAGE 347 2 361 2 VDC SHUNT TRIP 24 V L ISNS l INSTALLATION AND MAINTENANCE ODPAR D on a 1819120 21 95 7 E 5 17 onor CAUTION REFER TO INSTALLATION a Ak el e INSTRUCTIONS IIS 1 PRIOR TO 3 q lL
82. l inrush current to no higher than rated current levels 5 3 2 Boost Converter A Boost Converter converts the raw DC input to a regulated DC link voltage of approximately 225 and 225 volts DC It is operated in the current mode and is controlled using a variable modulation technique with a frequency in the range of 7 kHz The neutral connection is maintained from the input to the output as a fixed connection 5 3 3 Inverter and Filter The inverter is a traditional current mode controlled hard switched IGBT 3 phase topology The IGBTs are modulated by a variable frequency current mode control technique at approximately 7 kHz An output filter filters out the high frequency switching components line to neutral 5 3 4 Batteries and Battery Charger The battery for the Powerware 9320 system is comprised of a positive string of 84 cells and a negative string of 84 cells each made up of fourteen 12 volt battery blocks The battery charger is divided into a positive side charger and a negative side charger each powered from the respective positive and negative controlled DC bus voltages The chargers operate automatically in the constant current or constant voltage mode based on battery condition The Powerware 9320 C03 has no batteries within the UPS cabinet The Powerware 9320 C02 contains internal batteries however for extended runtime an external battery Powerware 9320 10 kVA and 20 kVA Installation and Operation 5 11 164201416 R
83. m should be transferred to bypass This switch has two positions O OFF and lI ON When switched to I ON the bypass source supplies the commercial AC power to the load directly While on internal static bypass when a user rotates the maintenance switch from the O OFF to the I ON position the load is wrapped around the UPS and power is removed from the entire upper portion of the UPS allowing service work to be completed on the UPS safely Figure 5 5 shows the path of electrical power through the UPS system when operating in Maintenance Bypass mode CAUTION The critical load is not protected when the UPS is in the Maintenance Bypass mode DANGER LETHAL VOLTAGE PRESENT This unit should not be operated with the cabinet doors open or protective panels removed Do not make any assumptions about the electrical state of any cabinet in the UPS system Maintenance Bypass Mode IA K4 Static Switch Sch oi Input Filter Booster Inverter K1 K2 1A2 Iron Ei Ir D T al a I Battery Charger N Battery O O Battery UPS Module 1 Breaker UPS Module 2 UPS Module 3 Breaker Contactors Switches m Main Power Closed Shy Se oy Trickle Current E
84. mensions same as 9320 CO3 cabinet A 16 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 SYSTEM SPECIFICATIONS SYSTEM MODEL NO 1PW1 28TC25L 336 M100 S24 A S UL SYSTEM RATING 17 58 KWB FOR 6 MINUTES TO 1 7 VPC RECOMMENDED SYSTEM FLOAT VOLTAGE 378 MIN 386 4 MAX SYSTEM CUTOFF VOLTAGE 285 6 FULL LOAD CURRENT 31 33 ADC FULL LOAD CURRENT PER SERIES OPEN CIRCUIT VOLTAGE 347 2 SHUNT TRIP 24 V CIRCUIT 31 33 ADC 361 2 VDC INSTALLATION AND MAINTENANCE CAUTION REFER INSTAI ING CABIN GALL RECOM ON TABLE INTERNAL BREAKER INITIAL CO TO INSTALLATION INSTRUCTIONS IIS 1 PRIOR TO ENDED CUSTOMER S CABLE GAUGES ARE BASED 310 16 OF N E C USING 75 C CABLE IS FOR OVERCURRENT PROTECTION ONLY NECTION TORQUE VALUES 50 IN LB BREAKER USE INSULATED TOOLS FOR CABINET INSTALLATION DO NOT AL TERMINATIO LOW TOOLS OR CABLES TO REST ON BATTERIES S FOR CUSTOMER S CABLE ARE RATED FOR 75 C AMPACITIES OF CUSTOMER S CABLE MUST NOT CAUSE THIS RATING TO BE EXCEEDED 22 78 3 00 1 00 E T 93 X 61 31 32 X 01 3 32 TRIPLE KNOCKOUTS TYP Re ee TYR 29 50 BOTTOM VIEW EER BEE BEE REAR VIEW DETAIL_A TERMINAL CONNECTION
85. ment equipment installation material freight charges travel expenses and labor of Invensys Powerware representatives will be borne by the Purchaser user Any advice furnished the Purchaser before or after delivery in regard to use or application of Powerware equipment is furnished without charge and on the basis that it represents Invensys Powerware s best judgment under the circumstances The use of any such advice by the Purchaser is solely and entirely at its own risk Any other agreements such as Service contracts or Sales Concessions are not means to annul this Factory Warranty For comment or questions about this Limited Factory Warranty write to the Customer Quality Representative 3301 Spring Forest Road Raleigh NC 27601 or call 919 872 3020 Powerware 9320 10 kVA and 20 kVA Installation and Operation W 1 164201416 REV A 07 11 2003 This page left intentionally blank Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003
86. munications 6 4 4 Other Options Refer to Chapter 11 of this manual to review other options available for the Powerware 9320 and their use Powerware 9320 10 kVA and 20 kVA Installation and Operation 6 5 164201416 REV A 071103 6 5 Safety Considerations 6 6 The UPS enclosure is designed for industrial or computer room applications and contains safety shields However the system is sophisticated and should be handled with appropriate care following these guidelines e Keep surroundings clean and free from excess moisture e Do not operate the system close to gas or electric heat sources e The system is not intended for outdoor use e The system operating environment should be maintained within the parameters stated in this manual e Keep the system doors closed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit e The system contains its own power source Lethal voltages are present even when the system is disconnected from utility power e When servicing modules or UPS is operated with modules missing insure that proper protective covers are installed at both the front and rear of the section with the missing module s WARNING Only AUTHORIZED SERVICE PERSONNEL should perform service or maintenance on the UPS If service or routine maintenance is required e Ensure all power is disconnected before performing installation or service e Ensure the area
87. n However if the UPS is unable to return to Normal mode following an automatic transfer to Bypass mode an alarm condition is recorded Powerware 9320 10 kVA and 20 kVA Installation and Operation 5 7 164201416 REV A 071103 5 2 3 Battery Mode The UPS transfers to battery mode automatically if a utility power outage occurs or if the utility power does not conform to specified parameters In Battery mode the battery provides emergency DC power that the inverter converts to AC power Figure 5 4 shows the path of electrical power through the UPS system when operating in Battery mode Battery Mode LAT E et cH gt Static Switc Input Filter Rectifier Booster Inverter S Battery Charger UPS Module 1 UPS Module 2 UPS Module 3 Breaker Contactors Switches mm Main Power Closed Sy Se ol ge gt Trickle Current a Energized Open CEO CG H a De Energized Figure 5 4 Path of Current Through the UPS in Battery Mode UPS Module 3 in 9320 C03 systems only During a utility power failure the rectifier no longer has an AC utility source from which to supply the DC output current required to support the battery charger and boost converter The input contactor
88. nding cabinets The cabinet sections are matching in design and color and have safety shields behind the front panels for hazardous voltage protection The following illustration depicts a typical Powerware 9320 CO3 30 kVA and 60 kVA UPS System consisting of up to three parallel modules in a single cabinet Fewer than three modules may be used depending on application needs When a 9320 CO2 is used a maximum of two modules are possible with the third module space being used for internal batteries 9320 CO2 uses this space for internal batteries A maximum of two UPS modules may then be emploved CAUTION Blank Front Module Cover Panel When fewer than three d modules are installed in the 9320 cabinet insure that blank panels are installed both front and rear for proper protection from exposure to live electrical connections inside the cabinet in all unused module locations Blank Rear Fan Grill 750 mm 29 6 in Cabinet depth 1800 mm 70 9 in lt lt 700mm 27 6 in gt Control Panel 3 UPS Module 3 Control Panel 2 Control Parel 1 F2 UPS Module 2 O F2 UPS Module 1 J1 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 Operator Control Panels Rear view of NW4024 located at right side of distribution section Removable Conduit Landing Panel at bottom rear of cabinet See Appe
89. ndix for details viii Basic System Configurations These basic UPS system configurations are possible e A Single Cabinet UPS with External Battery Cabinet Single Utility Feed 9320 CO3 and a maximum of three UPS modules or a Single Cabinet UPS with internal batteries 9320 CO2 and a maximum of two UPS modules e One two or three installed modules applied in the case of two or three modules to provide either redundant or capacity operation When the 9320 CO2 is used only two modules are possible WARNING The UPS cabinet is factory pre configured as a one two or three module assembly Only AUTHORIZED SERVICE PERSONNEL should modify the UPS system configuration in the field 9320 CO3 only You can enhance any of these system configurations by ordering optional accessories such as Remote Emergency Power Off EPO control and X Slot communications connectivity features Using This Manual Your UPS functions automatically and requires very little attention during normal operation However you should read and understand the procedures described in this manual to ensure trouble free operation In particular you should be thoroughly familiar with the Remote Emergency Power Off procedure described in Chapter 4 of this manual The information in this manual is divided into the sections and chapters listed The system you are installing dictates which parts of the manual you should read Everyone should read the Introd
90. nergized Esc A Open CO gt H Fy De Energized Figure 5 5 Path of Current through the UPS in Maintenance Bypass Mode UPS Module 3 in 9320 C03 systems only 5 10 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 5 3 Functional Description The UPS is an online double conversion unit with a series power train An uncontrolled rectifier feeds a boost converter which in turn powers the inverter The internal static bypass utilizes a static switch and an independent maintenance bypass switch is also included internal to the UPS cabinet The unit input must be 4 wire in plus protective ground at the rectifier and 4 wire in plus ground at the bypass The output can be 4 wire plus GND or 3 wire plus GND depending on customer requirements The unit does not incorporate any galvanic isolation input to output The battery string comprises 168 cells 336 volts nominal arranged in a positive string of 84 cells and a negative string of 84 cells with the center of the series connected strings tied to system neutral The battery is charged by positive and negative side chargers which are powered from the output of the boost converter 5 3 1 Input Rectifier The Input Rectifier is a full wave bridge uncontrolled rectifier which produces unregulated DC of approximately 170 and 170 volts DC A pre charge system pre charges the DC bus prior to the input contactor being closed to contro
91. nt voltage 6 3 3 Installation Features Power wiring can be routed through the rear and bottom of the UPS cabinet with connections made to easily accessible terminal blocks at the bottom front of the cabinet External monitoring and communication control wiring must be installed in accordance with approved wiring methods Communication wiring can be routed through the top of each cabinet Communication option cards are quickly installed in the slot behind the front door panel X slot cards are hot pluggable 6 4 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 6 4 Options and Accessories Contact your sales representative for information about any of these available options 6 4 1 Remote EMERGENCY POWER OFF A REMOTE EMERGENCY POWER OFF pushbutton is an option to provide for situations where you must instantaneously control the UPS output The operation of the REMOTE EMERGENCY POWER OFF pushbutton is described in detail in Chapter 8 UPS Operating Instructions 6 4 2 Battery Cabinets A complete 9320 C03 UPS system requires one or more battery cabinets to provide the necessary DC backup power A complete 9320 C02 UPS system requires internal batteries and may use one or more battery cabinets to provide the necessary DC backup power Battery cabinets are designed to match with the UPS cabinet although they do not directly bolt together 6 4 3 Communications See Chapter 10 Com
92. o the Neutral connection N inside the UPS equipment cabinet A serious electric shock hazard or equipment failure could result Powerware 9320 10 kVA and 20 kVA Installation and Operation 2 3 164201416 REV A 071103 WARNING The Powerware 9320 UPS requires a neutral input and output power connection for proper operation unless the output is delta connected in which case only an input neutral is needed Internal input and output neutrals are permanently connected inside the cabinet WARNING Units are shipped as single feed only WARNING An insulated grounding conductor must be provided per NEC 4 5 2 2 2 2 7 8 ste 2 4 Connect ground phase A B C and Neutral power wiring from the output terminals 3A 3B 3C on the In Out Terminal Block to the critical load Refer to Appendix A of this manual for wiring and termination requirements and wiring access information Secure the UPS by reinstalling the safety shield panels and closing the front cabinet door latching the cabinet door with the removable door handle 4 Installing Customer Connections See Chapter 10 Communications 5 Prepare for Installing Optional Accessories NOTE If you are installing accessories including the Remote Emergency Power Off REPO switch you must install conduit between each device and the UPS cabinet for wiring these options Be sure the UPS system is turned off and all power sources are remov
93. on 5 Understanding UPS Operation 5 1 Looking Inside the UPS System 5 1 5 2 Normal Battery and Bypass Modes 5 3 5 2 1 Normal Mode 5 4 5 2 2 Bypass Mode 5 6 5 2 3 Battery Mode 5 8 5 2 4 Maintenance Bypass Mode 5 10 5 3 Functional Description 5 11 5 3 1 Input Rechter 5 11 5 3 2 Boost Converter 5 11 5 3 3 Inverter and Eiter 5 11 5 3 4 Battery and Battery Charger 5 11 5 3 5 StatiC BYPASS aie aot ea ee eae EG deg ae 5 12 5 3 6 Maintenance Bypass 002220000 5 12 6 Operational Controls and Features 6 1 Generals 23 cede okt Chere oie ede 6 1 6 2 UPS Operational Controls 6 3 6 2 1 Control Panel ee EE eh ete ee ee ee ee 6 3 6 2 2 System and Load ON OFF 6 3 6 2 3 Maintenance Bypass Switch 6 4 6 2 4 Cold Start Capability 2 6 4 6 3 UPS Standard Features 04 6 4 6 3 1 Customer Interface 0000 0 eee eee 6 4 6 3 2 Battery Management 6 4 6 3 3 Installation Features 000 eee eeee 6 4 6 4 Options and Accessories 6 5 6 4 1 Remote EMERGENCY POWER OFF 6 5 6 4 2 Battery Cabinets 6 5 6 4 3 Communications 6 5 6 4 4 Other Options 6 5 6 5 Safety Considerations 6 6 6 6 Symbols Controls and Indicators 6 7 7 Using the Control Panel 7 1 Description 55 34 Seeded bed ba ne e
94. only by authorized service personnel This service is usually offered as part of the service contract for your UPS Contact Global Services in advance usually a two week notice is required to reserve a preferred startup date 1 1 1 Creating an Installation Plan Before beginning to install the UPS system read and understand how this manual applies to the system being installed Use the procedures and illustrations in the following chapters to create a logical plan for installing the system Powerware 9320 10 kVA and 20 kVA Installation and Operation 1 1 164201416 REV A 071103 1 1 2 Preparing Your Site For your UPS to operate at peak efficiency your installation site should meet the environmental parameters outlined in this manual If you intend to operate the system at an altitude higher than 1500 meters 5000 feet contact your local sales or service office for important information about high altitude operation The operating environment must meet the weight airflow size and clearance requirements specified in Appendix A The basic environmental requirements of the UPS system are Ambient Temperature Range 0 40 C 32 104 F Recommended Operating Range 20 25 C 68 77 F Maximum Relative Humidity 95 non condensing The UPS cabinet uses forced air cooling to regulate internal component temperature Air inlets are in the bottom sides and front of the cabinet and outlets in the top of the cabinet You must allo
95. ontrol panels ON the LCD panel LOAD PROTECTED will appear and the LED indicator will indicate as shown below LED Indicator Color LINE 1 Green LINE 2 Green BYPASS OFF INVERTER Green BATTERY Green THE LOAD IS NOW PROTECTED BY THE 9320 UPS Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 9 1 Alarms In the event of an alarm condition the red LED Indicator Alarm and the audible alarm will turn on In this case proceed as follows A Silence the audible alarm by pressing the Reset button B Identify the cause of the alarm condition by means of the EVENT LOG in the MAIN menu C In case of alarm conditions please contact the Invensys Global Service Center D Fault identification and suggested corrective action is given on the following pages 9 2 Menu Commands Event Log and Measurements In Chapter 4 there is a detailed description of the Menu Commands Event Log and Measurements that can be operated and displayed on the LCD The List of Alarms and Messages are shown in Section 9 3 Powerware 9320 10 kVA and 20 kVA Installation and Operation 9 1 164201416 REV A 071103 9 3 Fault Identification and Correction The major alarm conditions that will be encountered are shown in the following table Alarm Condition Meaning Suggested Solution UPS FAULT There is a fault in the UPS and therefore normal operation c
96. or the UPS system Chapter 9 Responding to System Events lists all the alarm messages and notices that can occur during operation of the UPS system Chapter 10 Communications describes the communication feature available with the UPS system Chapter 11 Options describes the available options for this UPS system Chapter 12 Maintaining the UPS System contains maintenance instructions for the UPS system Chapter 13 Product Specifications provides detailed specifications for the UPS system Appendix A Customer Information contains important information on wiring requirements and recommendations and important diagrams of the cabinet s mechanical details and electrical access Warranty provides the Powerware warranty for this product Read through each procedure before you begin Perform only those procedures that apply to the UPS system you are installing or operating Conventions Used in This Manual The text in this manual uses these conventions Bold type highlights important concepts in discussions key terms in procedures and menu options Italic type highlights notes and new terms where they are defined Rectangular boxes containing bold type are warnings or cautions that pertain to the UPS system or its electrical connections In this manual the term UPS refers only to the UPS cabinet and its internal elements The term UPS system refers to the entire power protection
97. ory installation kit before removing outer packaging Approximate weight is 25 Ibs 11 kg 1 Remove accessory installation kit located at the top of the unit see figure 1 1 by opening top of outer box Remove the 4 jacking bolts from the accessory pack Use a forklift or other material handling equipment to move the cabinet to the installation area Insert the forklift forks under the unit and keep the unit elevated approximately 3 inches above the ground 2 Remove the outer stretch wrapping The two steel angles which connect the UPS cabinet to the wooden shipping base contain 2 threaded holes for inserting jacking bolts 3 Unbolt the wooden cross members on the shipping base by removing the four nuts 10 mm which fasten the wooden pallet to the steel brackets Remove the wooden cross members from the steel brackets Insert the jacking bolts into the holes and lower them to the ground in order for the weight of the unit to be supported by the 4 bolts Place small metal plates under the jacking bolts to prevent floor damage Ensure the unit does not tilt more than specified in the caution note above Remove the forklift or pallet jack once the unit is supported on thee jacking bolts Slowly lower the UPS by alternating between the four jacking bolts until the steel brackets are on the floor Remove the jacking bolts Detach the UPS cabinet from the angle steel by removing all of the M5 Phillips head machine screws that fasten them using
98. ost converter derives power from the unregulated DC rectifier and produces a higher stable DC voltage and current source for the inverter A fixed system neutral is also carried through the boost converter to allow full support of single phase AC loads from any phase of the inverter output The output neutral of the system is connected to the required neutral both from the main utility supply and the bypass supply and should never be bonded to protective earth ground at the UPS output The inverter produces three phase AC power to a customer load without the use of a transformer The inverter derives power from the boost converter regulated DC and utilizes IGBT devices and pulse width modulation PWM to produce a regulated and low harmonic content AC output The AC output of the inverter is delivered to the system output through the output contactor K2 If the utility AC power is interrupted or is out of specification the UPS automatically switches to Battery mode to support the critical load with no interruption When utility power returns the UPS returns to normal mode If the UPS becomes overloaded or unavailable the UPS switches to Bypass mode The UPS automatically returns to Normal mode when the overload condition is cleared and system operation is restored within specified limits If the UPS experiences an internal failure it switches automatically to Bypass mode and remains in that mode until the failure is corrected and the UPS is bac
99. pass or Eco mode OFF Bypass not operating or switched off INV GREEN Load on inverter RED Inverter fault or load not transferable to inverter OFF Inverter not operating switched off BATTERY GREEN Battery OK Battery charger OK RED Battery fault or battery completely discharged Flashing GREEN Battery nearly discharged or load OFF command issued Flashing RED Battery disconnected battery fuse open 7 2 3 Pushbutton Functions The pushbuttons allow the user to operate the UPS to perform settings and adjustments to start up and shutdown the UPS and to monitor on the LCD display the voltages currents frequencies and other variables of system operation KEYS FUNCTION ON OFF Turn on UPS system press both pushbuttons simultaneously or ON OFF shutdown the UPS press both pushbuttons simultaneously UP Move upwards through the menu DOWN Move downwards through the menu RESET Move to the top of the menu Cancel the audible alarm If the alarm condition was only transient the LED indicator ALARM will also extinguish otherwise it will remain on RED ENTER Confirms a chosen menu item 7 2 4 ON OFF Startup and Shutdown Pushbuttons By pressing simultaneously both ON OFF pushbuttons on the Control Panel the UPS can be switched on if currently OFF or shutdown immediately if currently ON Requiring both to be simultaneously depressed prevents accidental operation of the UPS The two main ON OFF
100. perly sized battery system for proper operation The standard batteries of the Powerware 9320 two module system are sealed maintenance free batteries internally mounted and will typically be connected at the time the UPS is commissioned The battery life depends very much on the ambient temperature A temperature range between 18 and 23 C will achieve the optimum battery life If the UPS is delivered without batteries Powerware is not responsible for any damage or malfunctioning caused to the UPS by incorrect wiring The installation of batteries should be performed or supervised by personnel knowledgeable of batteries and their associated precautions Keep unauthorized personnel away from batteries CAUTION Refer to the battery manufacturers installation manual for battery installation and maintenance instructions Powerware 9320 10 kVA and 20 kVA Installation and Operation 3 1 164201416 REVA 071103 3 2 Internal Battery Modules In the Powerware 9320 C02 there is space for up to 112 x 9 Ah batteries internally In the drawing below different Battery and Module configurations are shown The batteries may only be used as common batteries powering either one or two installed modules of the 9320 C02 See the Table below for the expected autonomy time NOTE Set up the correct number of battery blocks on Control Panel Menu Service Set Up as well as the number of battery strings used to insure the correct autonomy tim
101. rating modules running in On Line Mode Inverter Mode The faulty module may be replaced without having to transfer the load to bypass To extract the faulty module from the UPS Frame in a Redundant Multi Module Configuration proceed as follows 1 2 Identify the faulty Module with the Alarm condition and RESET the Alarm The audible alarm will stop If the Alarm conditions persist the LED Indicator ALARM is red there is a fault in the UPS Module Open the corresponding Parallel Isolator Switch IA2 of the faulty Module switch to position OFF NOTE Parallel Switch IA2 1 belongs to Module 1 Parallel Switch IA2 2 belongs to Module 2 Parallel Switch IA2 3 belongs to Module 3 Used in model 9320 C03 only On the faulty Module control panel press the two ON OFF Buttons simultaneously to shutdown the UPS Module Disconnect cables from connectors JD4 and JD7 on the faulty module only Unscrew the four screws on the front of the faulty UPS module Pull Module forward slightly by means of the two black handles until the rear connectors are disconnected WARNING Before removing the UPS module completely wait 2 minutes until the internal DC capacitors are discharged CAUTION Two persons are needed to pull the module from the UPS Frame The weight of a 20 kVA module is 56 kg a 10 kVA module is 49 kg 8 6 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 7 R
102. s MANUAL BYP IS CLOSED Maintenance Bypass closed Load supplied by utility power This alarm is only displayed if the UPS is on Maintenance Bypass 9 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 10 1 X Slot Communication Modules This section describes the several types of X Slot cards which can be used with the Powerware 9320 X Slot cards allow the UPS to communicate to a variety of environments and with different types of devices The Powerware 9320 is compatible with any X Slot card including but not limited to ConnectUPS SNMP WEB Card provides 10Base T Ethernet connectivity for web based remote monitoring in addition to SNMP capabilities ConnectUPS M SNMP Card provides 10Base T Ethernet connectivity for SNMP based remote monitoring Single Port Card provides one serial communication port USB Card provides a USB connection to your Windows PC Multi Server Card provides additional serial communication ports that can communicate with additional computers Modbus Card provides RS 485 and RS 232 Modbus RTU connectivity for integration with building management systems Relay Card provides dry relay contacts for AS 400 signal compatibility Individual x slot card documentation is supplied with the provided card or is available at Wwww powerware com Powerware 9320 10 kVA and 20 kVA Installation and Operation 10 1
103. s of your UPS system to keep it running properly Regular routine checks of operation and system parameters will enable your system to function efficiently for many trouble free years 12 2 Important Safety Instructions Remember that your UPS system is designed to supply power EVEN WHEN DISONNECTED FROM THE UTILITY POWER The UPS cabinet interiors are unsafe until the DC power source is disconnected and all capacitors are discharged After disconnecting the utility power and the DC power authorized service personnel should wait at least 5 minutes for capacitor bleed off before attempting internal access to the UPS cabinet WARNING All the operations in this section must be performed by properly trained personnel By opening removing or replacing the UPS modules and module covers you risk exposure to dangerous voltages Do not leave the UPS module compartment without an appropriate protective DANGER LETHAL VOLTAGE PRESENT This unit should not be operated with the cabinet doors open or protective panels removed Do not make any assumptions about the electrical state of any cabinet in the UPS system Since each battery string is an energy source in itself opening the Battery Circuit Breaker does not de energize the voltage within the battery string DO NOT ATTEMPT TO ACCESS ANY INTERNAL AREA OF THE BATTERY STRING YOURSELF VOLTAGES ARE ALWAYS PRESENT IN THE BATTERY STRING If you suspect that a battery string needs service you
104. t of each Module will be in the HIGH position WARNING To shut down a multi module system you must depress both ON OFF pushbuttons on every UPS module Activation of the ON OFF buttons when the UPS is not in maintenance bypass mode will interrupt the power supply to the load 6 2 3 Maintenance Bypass Switch An internal Maintenance Bypass Switch is provided to completely isolate the main power processing of the UPS during service The Maintenance Bypass Switch is described in detail in Chapter 8 UPS Operating Instructions 6 2 4 Cold Start Capability The 9320 UPS system cannot be powered up without a utility input initially present Accordingly it is not able to power a load if the system is not started first on utility power 6 3 UPS Standard Features 6 3 1 Customer Interface Computer Interface One serial communications port using the standard Powerware XCP interface is provided via a plug in interface card inserted in the communications slot on the front of the unit This interface is supplied as standard with each Powerware 9320 You can use this port to link the UPS to the features described in Chapter 10 Communications and Chapter 11 Options 6 3 2 Battery Management A two stage charging system ensures that the initial recharge is done in an optimal time with current limited constant current DC applied to the batteries When terminal voltage reaches a certain level the charger switches to consta
105. the critical load is supplied by the inverter which derives its power from rectified utility AC power In this mode the battery charger also provides charging current for the battery if needed e In Battery mode the critical load is supplied by the inverter which derives its power from the battery DC power e In Bypass Economy mode the critical load is directly supported by utility power via the static switch In this mode the critical load is not protected e In Maintenance Bypass mode the critical load is directly supported by utility power but the UPS can be shut down for maintenance The operator switching the Maintenance Bypass Switch to the Bypass position accomplishes this however the critical load is not protected The UPS continually monitors itself and the incoming utility power and automatically switches between these modes as required with no operator intervention except for the Maintenance Bypass mode The sophisticated detection and switching logic inside the UPS ensures that operating mode changes are automatic and transparent to the critical load System events are alarms and notices that are displayed on the LCD monitor panel They may or may not require operator intervention See Chapter 9 The following descriptions provide the differences in UPS operating modes Powerware 9320 10 kVA and 20 kVA Installation and Operation 5 3 164201416 REV A 071103 5 2 1 Normal Mode Figure 5 2 shows the path of ele
106. the equipment Getting Help If you need to schedule initial startup need regional locations and telephone numbers have a question about any of the information in this manual or have a question this manual does not answer please call Invensys Global Service at xi United States 1 800 843 9433 Canada 1 800 461 9166 Outside the U S Call your local representative Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 Section I Installation This page left intentionally blank Getttng Atorted 1 1 Installing the UPS The complete UPS cabinet is shipped on a single pallet Use a forklift or a pallet jack rated to handle the weight of the cabinets refer to Table J in Appendix A for cabinet weights to move the packaged cabinet to the installation site or as close as possible to the site before unloading from the pallet This is the basic sequence of the installation steps Create an installation plan for the UPS system Chapter 1 Prepare your site for the UPS system Chapter 1 Inspect unpack and unload the UPS cabinet Chapter 1 Wire the system Chapter 2 Install features accessories and or options as applicable Chapter 4 and 10 Complete the installation checklist Chapter 2 NS OF oP ON OS Have authorized service personnel perform preliminary operational checks and startup NOTE Startup and operational checks should be performed
107. tion and Operation 6 7 164201416 REV A 071103 6 8 This page left intentionally blank Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 7 1 Description This chapter describes the UPS Control Panel including controls and indicators and how to monitor UPS operation The control panels are located on the front of the UPS see Figure 7 1 Each UPS module in the 9320 cabinet has an individual Control Panel Figure 7 1 UPS Control Panel The Control Panel contains 1 the main power ON OFF switches 2 a flat Liquid Crystal Display LCD screen 3 4 a horizontal row of navigation pushbuttons an array of multi color LED status indicators Refer to Chapter 8 UPS Operating Instructions for use of the operational controls Powerware 9320 10 kVA and 20 kVA Installation and Operation 7 1 164201416 REV A 071103 7 2 Using the Control Panel The Control Panel provides an operator interface with the UPS system Figure 7 2 identifies the display and pushbutton areas discussed in the following sections as well as LED indicators that provide a visual display of system operating status CI CI ON OFF eee ae c LINE 1 INV reset All ewe Figure 7 2 LCD Screen and Pushbuttons 7 2 1 Power Management Display The 2 x 20 character LCD Screen simplifies the communication with the UPS and provides the necessary monitoring informat
108. ual source customer supplied O OPEN UPS Battery Cabinet Breaker customer supplied O OPEN UPS Maintenance Bypass Switch ATI O OFF UPS Parallel Isolator Switches IA2 1 IA2 2 A2 3 O OFF Verify Position of DIP Switch SW 1 1 on each module system ON UP position Verify Position of DIP Switch SW 2 9 for single cabinet system ON positions Used in the 9320 C03 only 2 Close the UPS utility supply breaker Screen event MAIN RECTIFIER FAULT appears 3 Observe LED Line 1 indicator turns green and battery indicator LED flashes green Screen event LOAD OFF SUPPLY FAILURE appears 4 Press both ON OFF pushbuttons on the Module 1 control panel simultaneously to turn on the UPS module LOAD NOT PROTECTED will appear on the LCD screen and LED indicators will display as follows Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 8 1 LED Indicator Color LINE 1 Green LINE 2 Green BYPASS Green INVERTER OFF BATTERY Flashing Green If module does not transfer to inverter automatically 5 Perform Command LOAD TO INVERTER see sections 7 3 2 and 7 3 6 On LCD Display LOAD PROTECTED will appear and the LED indicators will display as follows LED Indicator Color LINE 1 Green LINE 2 Green BYPASS OFF INVERTER Green BATTERY Flashing Green 6 Close any battery cabinet c
109. uction Chapters 1 2 7 and 8 Introduction The introduction provides a brief description of the UPS system a description of the content of each chapter safety and text conventions used in the manual and reference information Section Installation e Chapter 1 Getting Started tells you how to prepare your site for the installation of your UPS system It discusses equipment environmental requirements inspecting and unpacking cabinets e Chapter 2 Installing the UPS System describes how to install the UPS cabinets and optional equipment e Chapter 3 Installing and Connecting Batteries provides battery safety installation and connection information e Chapter 4 Installing a Remote EPO Control contains information for installing the optional Remote Emergency Power Off REPO control ix Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 Section Il Operation Chapter 5 Understanding UPS Operation provides information on understanding how your UPS works Chapter 6 Operational Controls and Features describes the standard and optional operational features and controls of the UPS system Chapter 7 Using the Control Panel describes the controls and indicators found on the Control Panel and shows the various information screens displayed on the LCD screen Chapter 8 UPS Operating Instructions contains startup and shutdown procedures f
110. und D Minimum conductor size AWG each 4 2 Note Refer to Figure A 3 on system one line diagram for the bold letter callout locations Read and understand the following notes while planning your installation 1 Refer to national and local electrical codes for acceptable external wiring practices 2 Material and labor for external wiring requirements are to be provided by designated personnel 3 For external wiring use conductors rated for 90 C operation See the appropriate column in Tables A and B 4 Wire ampacities are chosen from Table 310 16 of the NEC 5 A neutral feeder is required for both the main and bypass inputs to this system sized to provide for harmonic currents generated by non linear loads per NEC in Tables A and B 6 Refer to section 1 of this manual for installation instructions A 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 Table B INPUT OUTPUT Ratings amp External Wiring Requirements for Powerware 9320 CO2 amp CO3 Modules kVA 2x 20 3 x 20 Ratings Units Rating 50 60 Hz Basic unit ratings at kVA 40 60 0 8 lagging PF load kW 32 48 INPUT OUTPUT VOLTAGE 208 208 AC Input to UPS 0 95 min PF Amps AC 3 phase 1 neutral 1 ground 122 183 INPUT Minimum conductor size AWG each 2 0 250 kemil A Max amps include full load current plus battery recharge current DC DC Input Ext Battery source to UPS
111. ut no active power conditioning or battery support is available to the output of the system in the bypass mode of operation The internal bypass is comprised of a solid state silicon controlled rectifier SCR static switch SSW and a back feed protection contactor K4 The static switch is rated as a continuous duty device that is used anytime the boost converter and inverter is unable to support the applied load The static switch is wired in series with the back feed protection contactor and together are wired to enable the inverter and rectifier to be bypassed when this path is active The static switch as an electronically controlled device can be turned on immediately to pick up the load from the inverter The backfeed protection contactor is normally always closed ready to support the static switch unless the bypass input source becomes unavailable During an outage transfers to bypass are prohibited and for the safety of those who may be working on the power lines upstream from the UPS the back feed protection contactor is opened preventing system output voltage from bleeding across the static switch snubber components to the bypass input source In the bypass mode the static switch is turned on to supply the load current directly from the bypass supply with the inverter ready to take over the load if the bypass supply should vary outside preset limits If the inverter is unable to support the load on the output of the system the UPS
112. uts Terminal Name Description X1 Emergency Power Off X1 1 and X1 2 no polarity X2 Generator On X2 1 and X2 2 no polarity X3 X4 X5 Not used Not used X6 Battery Shunt trip breaker control X6 1 and X6 2 12V amp com JD 2 1 Utility Fail Alarm NO Utility Fail Alarm JD 2 2 Utility OK Utility Present JD 2 3 Common Common JD 2 4 Load on Inverter message NO Load on inverter message JD 2 5 Load on inverter message NC Load not on inverter message JD 2 6 Common Common JD 2 7 Battery Low Alarm NO Battery voltage low alarm JD 2 8 Battery OK Battery voltage OK JD 2 9 Common Common JD 2 10 Load on utility bypass mode Load on utility oypass JD 2 11 Load on utility oypass NC Load not on utility bypass JD 2 12 Common Common JD 2 13 Common Alarm NO Common alarm JD 2 14 No alarm condition No alarm JD 2 15 Common Common JD 2 16 Not used Not used JD 2 17 Not used Not used JD 2 18 Not used Not used JD 2 19 Not used Not used JD 2 20 Not used 12 volt customer input Not usedAux Signal power input JD 2 21 Not usedGround customer input Not usedGround input JD 2 22 Ground Ground JD 2 23 12 volts 12 volts Imax 100 ma JD 2 24 Not used Not used JD 2 25 Not used Not used A 6 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 07 11 2003 Table H Definition of pin connections on JD2 25
113. w clearance in back of the cabinet for proper air circulation Refer to Table K of Appendix A for clearance requirements 1 1 3 Environmental Considerations The life of the UPS system is adversely affected if the installation does not meet the following guidelines 1 The system must be installed on a level floor suitable for computer or electronic equipment 2 The system must be installed in a temperature controlled indoor area free of conductive contaminants Failure to follow guidelines may invalidate the UPS warranty 1 1 4 Preparing for Wiring the UPS System For external wiring requirements including the minimum AWG size of external wiring refer to Tables A and B in Appendix A for the Powerware 9320 10 kVA or 20 kVA modules UPS The power wiring connections for this equipment are rated using copper wire at 90 C Note that wiring to an external battery cabinet if used may be either 75 C or 90 C rated Control wiring for EPO and optional accessories such as building alarm and monitoring interface should be connected at the customer interface connections inside the front of the UPS using NEC class 1 wiring methods 1 2 Powerware 9320 10 kVA and 20 kVA Installation and Operation 164201416 REV A 071103 1 1 5 Inspecting and Unpacking Each Cabinet The first task in preparing for installation is inspecting and unpacking the UPS The UPS and accessory cabinets are shipped bolted to wooden pallets as shown in Figure 1

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