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Powerware 9395 UPS and Plus 1 UPS 650825 kVA User's Manual

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1.
2. B E s 8 8 Protective Cage j ce pre U KI NP gigs PG L I SINE lora po O 1o73 2 3 Ph Location of J50 J51 J61 and J70 cm PB Coiled Harnesses q oT T A p UM cdo TI mim H F iy L g Wiring Access H EE qu l i 1 Location of P61 ENT F Lr ES Harness O o 2 e H Pr al o o p 0000000 4 4 pl Ho o ay E Front E bl a O o p 000000 4 Front 4 9 o ni lt UPM Wireway a O o 0000000 4 to o d b al o o Location of P50 o yee dl i a O P51 and P70 o 1 a 0 Harnesses E EE li Location of RJ 45 gr f i Coiled CAN Cable Elo A eb Yea AG 6 n f Hi os c G E e A B ISBM Section Right Side View UPM Section Left Side View Figure 4 14 UPS Intercabinet Interface Harness Locations 4 16 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION
3. A B A B A B O O O O O O Ga C e ga Co El E6 El E6 El E6 E2 urs E7 E2 Urs 2 E7 E2 ur E7 E3 Fuse E8 E3 Fuse E8 E3 Fuse E8 O CBI E12 O CBI E12 O B1 E12 C optional C optional optional 2 2 T Ki 5 KI K b CB4 CB4 CB4 ISI Le O duae O Ue rs O Rectifier Rectifier Rectifier Static m Static J Static Y switch Y switch Y switch Fuse Fuse Fuse 53 K5 K5 ruse ruse ruse eo eo oe Fuse Fuse Fuse Inverter a Inverter ap Inverter e So an K3 K3 K3 0 e e Battery Battery Battery Converter Converter Converter Fuse Fuse Fuse poro K2 basa K2 coe K2 C E4 E5 C Q E4 E5 C Q E4 E5 Battery Breaker Battery Breaker Battery Breaker a x Un Lo oi Lo oi Lo ol ny E9 E9 E9 E10 BATTERY SYSTEM 10 BATTERY SYSTEM F10 BATTERY SYSTEM CABINET E11 Not supplied E11 Not supplied E11 Not supplied Optional E12 6 with the UPS E12 6 with the UPS E12 with the UPS MOB 1 D D D FN O M0B2 UN e MOB 3 EN O 04 A AC Input to UPS Re
4. o T oT TO T o v v Y o 5 P El e 3 B b age o b 3 B E b n o Oa E e N TA 7 v v v v d UT O Oa io e 9 Oa D A NE DOODOS000000000000000000 DOOOOSOOD000000000000000 ss ss ol HE H EEHEHHE H HEEHEHHE 00000 0 0 0 0 00 0 0 0 0 0 0 0 0 0 0 0 1 ODODOODODDODDODODODODD0D b ol pprap HE sil ssl BREE posos sesos il ssl sl ssl ll ssl BECEHCEHHGEHHESHGEERHERUR ssl il ssl EECHEHHEHHEEEEHERHEEH ssl ssl DODDDODODDODDODDODODOD0O 000 0000 0 0 0 0 0 0 0 0 00 00 0 0 0 0 0 1 11 DODODODODDODDODDODODOD0O 000 00 0 0 0 0 0 0 0 0 0 0 00 01 0 0 0 0 0 0 1 CA HHBEHHHEHHHEEHHEEEHHEEH HHHEEHHHEHHHEHHHEHEHHEEH er O sil ims amas sss sas sme sine O00000000000000099909909 ala jaja e O ssl sl Li b Soap soso sesos BECEHCEHHERHESHSCERHERUR ssl sl T a a e O ssl sl BBBBEEEHEBREEBREDEREHERG BEEEHGEHEEBREEBERERERREEH 6l 9 ssl ssl U DODODODODDODDODDDODODOD0O 9010000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0000000 0 0 000 0 0 0 0 0 0 0 0 0 0 0 90100000 0 0 0 0 0 0 0 0 00 010 0 0 0 0 0 1 EHBHEHEHEHHHEEHH
5. U 5 10 Ground Terminal o C Jo USE NEC CLASS 2 UC XN WRING METHODS ES X Terminal TB1 T O YA o Y Signal Connections f f from the UPS O 5 TE corem WIRE ity 7C RATED zr Terminal TB3 120 Vac Power JA Ye Pan JI O CD Do Figure 5 7 Remote Monitor Panel Il and Relay Interface Module Il Terminal Locations o O O e lt Ground Terminal pae TER Pa 5 NO TB1 2 Lol ppy ll E o o lt O RDX 7 2 N a RDX a er oO MC EI aye 120 Vac from N O RDX ZTE AA TT Critical Bus LL LAS SY PS Can Card J3 i aAa y 2 Gu RMP Il RIM Il or SCM Il Twisted Pair Figure 5 8 Remote Monitor Panel Il Relay Interface Module Il or Supervisory Contact Module II Wiring Table 5 5 RMP Il RIM Il or SCM Il Wiring Terminations From To Tightening Torque Remarks UPS CAN Card RMP II RIM II or SCM Il Nm Ib in J3 6 TX TB1 5 RDX 0 9 8 Use twisted pair J3 7 TX TB1 4 RDX 0 9 8 N A TB3 Line 0 9 8 N A TB3 Neutral 0 9 8 N A Ground Terminal 2 7 24 Maximum EA
6. AC Input to AC Input to Battery Aux Building Alarms UPS Rectifier Bypass 3 Wire A B C 3 or 4 Wire A B C 48V Battery Alarm Relays Rotation Rotation Bypass Shunt Trip a Breaker Remote EPO para T A y B CB4 5 E E1 E2 E3 E6 E7 pd NF Ng a E8 E12 O o Interface Board Single feed Kit 4 Input Breaker Not supplied Static Y CB1 o with the UPS Switch d optional Fuse J Backfeed Contactor K5 Input Input Input nput Contactor Contactor Contactor Contactor K1 K1 K1 K1 Rectifier Rectifier EE Rectifier Rectifier Fuse Fuse Fuse Fuse e e e e Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Inverter Inverter Inverter Inverter ce ee SN e Output Output Output Output Contactor Contactor Contactor Contactor K3 K3 K3 K3 AC Output e e e e to Critical E9 D Load Battery Battery Battery Battery E10 Converter e Converter Converter Converter au Fuse Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPM 4 UPM 1 UPM 2 UPM 3 FI UPM CABINET E4 ES E4
7. AC Input to UPS Rectifier 3 Wire A B C 48V Battery Alarm Relays Rotation Shunt Trip XS A Remote EPO Interface E1 E2 zu Interface Board Input Breaker O CB1 O optional e Input Input Input Contactor Contactor Contactor K1 K1 K1 E Rectifier BG Rectifier t Rectifier Fuse Fuse Fuse e e e Fuse Fuse Fuse Fuse Fuse Fuse Inverter Inverter Inverter CS TA YON Output Output Output Contactor Contactor Contactor K3 K3 K3 AC Output to o Critical Load E9 F10 D Battery Battery Battery E11 E12 Converter Converter Converter Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPS UPM 1 UPM 2 UPM 3 CABINET E4 E5 E4 E5 E4 E5 ON 4 A cen er o oh o o o o Battery Battery Battery Breaker Breaker Breaker BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM Not supplied with the UPS pp So Not supplied with the UPS Not supplied with the UPS NOTE Callout letters A B C and D map to Table 3 5 on page 3 10 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require
8. AC Input to Battery Aux Building Alarms UPS Rectifier 3 Wire A B C 48V Battery Alarm Relays Rotation j Bypass Shunt Trip Su Breaker Remote EPO a Y A CB4 MI MN ur VT TRUE Le NA had E1 E2 E3 Interface Board Input Breaker CB1 O optional Input Input Input nput Contactor Contactor Contactor Contactor K1 K1 K1 K1 Rectifier Rectifier EE Rectifier Rectifier Fuse Fuse Fuse Fuse e e e e Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Inverter Inverter Inverter Inverter ce ee SN e Output Output Output Output Contactor Contactor Contactor Contactor K3 K3 K3 K3 AC Output e e e to Critical E9 D Load Battery Battery Battery Battery E10 Converter e Converter Converter Converter ay Fuse Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPM 4 UPM 1 UPM 2 UPM 3 FI UPM CABINET E4 E5 E4 E5 E4 E5 UPS CABINET FN CN CX ug m 0 o 4 i QO o 4ili O o 4ili O o 4ili Battery Battery Battery Battery Breaker Breaker Breaker Breaker BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM Not supplied with the UPS Not supplied with the UPS Not supplied with the UPS Not supplied
9. a a E T Fa b dh 3 8 b dh Pp 2b la 9 b dp dh a a a a v v v v 5 e lag Uv E EX E vd ak d e EA ISBM Air Filters o e b dp 4 re O E i D b dp E b dp E b dp E La a a a a jl a a a gt o o o o ar o o o Figure 9 1 ISBM Section Air Filter Locations CAUTION AX Verify washed filters are thoroughly dry before reinstalling d Push the washed or new foam filters over the screw heads on the cabinet mounted studs until seated against the cabinet e Reinstall the UPM section front panels removed in Step a and secure with the retained hardware f Reinstall the ISBM section front panel removed in Step b and secure with the retained hardware EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 9 3 UPS MAINTENANCE 9 4 xdi Cp E J ES e EJ w d 9 o dg 9 o y Y P Ha I FH UPM Air Filters d d CL ca 1 CL a s o L IL IL J Q o o o gt oe 07 4 d o CI o o o o d Wr ar d E HR NO J o e o Wig o o n o o o o
10. a PE ca 7 END LASS a fm aS 58 7 HIRING METHODS E E N 2 31 0 31 OO o TLS we ch 9 f 100 5 J Th 70 3 AO qu 7 50 s T A Surface Mount using 10 Pan B Hi ue euer 88 9 Head Screws for Hanging 2 ity we RAB 3 50 Mount with vent holes facing up ui le lt 1 Elm T 6 TA NN ng ANS J f 0 25 NS e 215 9 _ m 70 5 Dimensions are in millimeters inches 8 50 1 12 5 16 Figure 5 13 Relay Interface Module Il Dimensions EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INSTALLING OPTIONS AND ACCESSORIES e 251 1 00 3 07 11 25 EA x E 215 9 e2 Knockouts Provided on Five Surfaces Flush Mount using 10 Pan Head Screws Mount with vent holes facing up EX T Eq RO URL T Surface Mount using 10 Pan Head Screws for Hanging Mount with vent holes facing up
11. O pooo00000 omy O Tei em 4 1 1 PI1 Interface Board o i l o O Front 4 o Oo q H o 4 c e Ta P6 F bg pii 1 a gt Oral rem lh E H 1 T ISBM Section Right Side Inside View Figure 4 15 P11 Interface Board Location LI I I I I II I1 LI II I I II I I1 po O Lol fe PI1 Interface Board pep EX oad 5 E a J39 Inverter CAN Comnector Q Figure 4 16 J39 Location on PI1 Interface Board EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 17 UPS SYSTEM INSTALLATION 4 5 4 6 4 7 4 8 4 18 Field Installed UPM Installation If installing a Plus 1 model install the FI UPM using the instructions in the Powerware 9395 Field Installed UPM Mechanical Installation Manual listed in paragraph 1 8 on page 1 7 After the FI UPM is installed proceed to paragraph 4 6 if installing a battery system otherwise proceed to paragraph 4 7 Battery System Installation If installing a battery system install the customer supplied battery system according to the battery and battery system manufacturer s instructions and all applicable codes and regulation
12. ISBM SECTION UPM SECTION Figure 1 1 Powerware 9395 UPS 650 825 kVA 1 1 2 Control Panel The control panel located on the front of the UPS contains a liquid crystal display LCD and pushbutton switches to control the operation of the UPS and to display the status of the UPS system See Chapter 7 UPS Operating Instructions for additional information 1 1 3 Customer Interface Building Alarm Monitoring Up to five inputs in the UPS are available to connect the facility s alarm system contacts Some system configurations may limit the number of inputs available The UPS uses these inputs to monitor the building alarms in addition to the UPS status See Chapter 8 Communication for additional information 1 2 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INTRODUCTION e Alarm Contact One alarm contact is provided for connection to equipment at the facility such as a light an audible alarm or a computer terminal The equipment connected to this contact alerts you to a UPS alarm See Chapter 8 Communication for additional information e X Slot Communication Bays Four communication bays are standard equipment One to four optional X Slote connectivity cards can be installed in the UPS module at any time X Slot cards are quickly installed at the front of the UPS and are hot pluggable See Chapter 8 Communica
13. CA aan SI U v v s v v ab f 3 a 1 E js po pa ab f er 7 oo o HR o E P 00000 P B oo 1 p a a a a e hase A o o o o om dom rum AC Output o o 5llala o Phase B from UPMs v o v v deBo o O 6 nase O O 0 o See Figure 4 13 H H i o for detail e IJ bf oOo 8 f 8 e hase C le a off o P e A eutral from UPMs H lt m lo e See Figure 4 13 for detail D aho e zribnenaanaennaonaanadan pcboonsonsoosoooosooodos J SSS Se SSS Se SSS SES See se 000 SSS 0050053 PF kag AC Input Breaker CB1 simiiimi n mnia ujm nju mm mm ujm ui un BSCS OD S0S0S0S00000S0g000 ararat atarata ta atalara taataa Taata las DODOODODOdo 100000000 EEBOBBEBUI IDICICIEICIE EIE 0 01 0 0 o oy o 0 00000 08000 0000 0 0 0 0 00 0 00 0 0 000 08 000 000 0 0 0 0 0 0 0 00 0 0 0 0 0 F nl nal o Ga NAG Joe o o o HEEEEHEEHEH HEEHEEHH HEEHEEHEEHEHEEHEEHEEHH DODODODODDODDDODOD0DOD0D 000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 B BBBEEHBOHBHEH IHBBHEHEH HEHHEHHHEHEHHHEHEBHEHEH o Q Q DODODODODDDDDDODODODODDO OO000DODDDDDODOODODDDDDO i H ct SSH SEES See BEES SEBS SEE Se SHES SoS SSH Se Se See SESE SEES Hee SS SSH SHES See SS SEBS SHE See Hee Se SSB EE Se Se See EE CR SESE SEE Se See SS E o o o sl las 6 6 SSH Ee SHE SSS Se las EEEHHHHHBEEBHEHEHEBEEBEH Jail aa ii 6 9 69 090 DODODDOODDODDDODODDDODOD 000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ul A p
14. Ww g Y d 6 b d FI UPM Air Filter CD CDI 1 1 L A To 05 e o op Figure 9 3 FI UPM Air Filter Location PERIODIC Maintenance Periodic inspections of the UPS should be made to determine if components wiring and connections exhibit evidence of overheating Particular attention should be given to bolted connections Maintenance procedures should specify that the bolted connections be retorqued to values listed in this manual ANNUAL Maintenance Annual preventive maintenance should be performed only by authorized service personnel familiar with maintenance and servicing of the UPS system Contact an Eaton service representative for more information about service offerings BATTERY Maintenance Contact an Eaton service representative for battery maintenance Battery replacement and maintenance should be performed only by authorized service personnel NOTE There is no manual DC disconnect device within the UPS Install batteries in accordance with the battery and battery system manufacturer s instructions EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 9 5 UPS MAINTENANCE 9 4 Recycling the Used Battery or UPS Contact your local recycling or hazardous waste center for information on proper disposal of the used battery or UPS e Do not dispose of the battery or batteries in a fire Batteries may explode Proper disposal of batteri
15. Breakers Contactors Trickle Current E O Closed Battery TON O Breaker Energized G 9 Open De Energized Battery NOTE On an UPS configured as an IOM the bypass input static switch bypass breaker CB4 and K5 are not present Figure 6 4 Path of Current Through the UPS in Battery Mode 6 6 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION 6 3 Single UPS Unit System Oneline Configurations The system oneline drawings in this section show the simplified internal structure of the UPS battery supply and basic maintenance bypass Voltage Oneline Drawing UPS Model System Type Input Output 9395 825 650 400 400 Single Reverse Transfer UPS Three UPM Common Figure 6 5 on page 6 8 9395 825 750 480 480 Rectifier Feed Common Battery Dual Feed 9395 825 825 Configuration 9395 825 650 Single Reverse Transfer UPS Three UPM Common Figure 6 6 on page 6 9 9395 825 750 im a Rectifier Feed Separate Battery Dual Feed 9395 825 825 Configuration 9395 825 650 400 400 Single Reverse Transfer UPS Four UPM Common Figure 6 7 on page 6 10 9395 825 750 480 480 Rectifier Feed Common Battery Dual Feed 9395 825 825 Configuration 9395 825 650 Single Reverse Transfer UPS Four UPM Common Figure 6 8 on page 6 11 9395 825 750 Ha re Rectifier Feed Separate Battery Dual Feed 9395 825 825 Con
16. Figure 3 12 UPS Cabinet as Shipped on Pallet UPM Section EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 23 UPS INSTALLATION PLAN AND UNPACKING This page intentionally left blank 3 24 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Chapter 4 UPS System Installation 4 1 Preliminary Installation Information Installation should be performed only by qualified personnel Refer to the following while installing the UPS system Chapter 3 for cabinet dimensions equipment weight wiring and terminal data and installation notes Do not tilt the cabinets more than 10 during installation Remove the conduit landing plates to add conduit landing holes as required Plate material is 16 gauge steel 1 5 mm 0 06 thick If pe rforated floor tiles are required for ventilation place them in front of the UPS 4 2 Unloading the UPS Sections from the Pallet The ISBM and UPM sections are bolted to separate wooden pallets supported by wood skids To remove the pallets The UPS sections are heavy see Table 3 1 on page 3 2 If unpacking and unloading instructions are not closely followed the cabinets may tip and cause serious injury CAUTION To preve cabinet Lift a nser cabin Forks DO End f kept i Do not tilt cabinets more than 10 from vertical L
17. Figure 9 2 UPM Section Air Filter Locations 3 If the UPS is a Plus 1 model check the Field Installed UPM FI UPM air filter located behind the front panel and wash or replace as necessary See Figure 9 3 for the filter location The FI UPM filter size is 20 x 44 x 0 25 Contact an Eaton service representative for replacement filter To remove the filter a Remove one top screw and two bottom screws securing the FI UPM front panel refer to the Powerware 9395 Field Installed UPM Mechanical Installation Manual Lift the panel straight up to remove it from the panel hanger bracket at the top of the cabinet b Pull the foam filter over the screw heads on the cabinet mounted studs and remove the filter from the cabinet Verify washed filter is thoroughly dry before reinstalling c Push the washed or new foam filter over the screw heads on the cabinet mounted studs until seated against the cabinet d Reinstall the FI UPM front panel removed in Step a and secure with the retained hardware 4 Record maintenance results and any corrective actions in a suitable log EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 9 3 9 2 3 9 2 4 9 2 5 Installing Batteries UPS MAINTENANCE e el
18. O CB4 5 Rectifier Static Switch Fuse Fuse Fuse Inverter JN K3 Battery Converter Fuse m K2 C E4 E5 Battery Breaker KIN O HI El BATTERY SYSTEM E11 Not supplied E12 with the UPS D UP CB1 optional ue et K1 uU Rectifier E6 s2 E Fuse F8 E12 O CM Static Switch Fuse Fuse Fuse JN Inv K3 erter E10 E11 E12 Battery Converte ri Fuse K E4 E5 Battery Breaker mn o oq BATTERY SYSTEM D Not supplied with the UPS UNDERSTANDING UPS OPERATION A AC Input to UPS Rectifier B AC Input to Bypass C DC Input from Battery D UPS AC Output to Tie Cabinet E Output to Critical Load Overcurrent Protection provided by customer NOTE This oneline does not show each UPM in the UPSs but represents each UPS in the distributed bypass system The internal structure of each UPS is shown Figure 6 5 through Figure 6 8 starting on page 6 8 N
19. WARNING f y USE MEC CLASS 2 a 7 WIRING METHODS cL ron RD RD pus REFER TO INSTALLATION ee MANUAL FOR PRESSURE TERRINAL TORQUE VALUES Dimensions are in millimeters inches TO Figure 5 14 Supervisory Contact Module Il Dimensions EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 5 17 INSTALLING OPTIONS AND ACCESSORIES This page intentionally left blank 5 18 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Section ll Operation Chapter 6 Understanding UPS Operation 6 1 UPS System Overview The Powerware 9395 UPS is a continuous duty solid state transformerless at 480 Vac three phase true online system that provides conditioned and uninterruptible AC power to the UPS system s output and critical load The basic system consists of a rectifier battery converter inverter monitoring operation control panel integrated communication server and digital signal processor DSP logic Figure 6 1 shows the main elements of the UPS system Battery System Input Breaker Input CB1 Contactor AC Input to ieee KI Rectifier o Q Charger Battery Breaker C co Battery o Battery Contactor K2 Bat Rectifi
20. e o o o o O 6 On o OF o O N O N O N O N O o O o O o O O i O WwW O WwW O WwW O O O O O a a O a O eO N O N O N O N O 9 9 9 UPS 1 UPS 2 UPS 3 UPS 4 CAN Bridge Card J3 CAN Bridge Card J3 CAN Bridge Card J3 CAN Bridge Card J3 If Installed If Installed NOTE External CAN connections between UPSs require shielded twisted pair wire Figure 5 4 Distributed Bypass System UPS CAN Wiring without MOBs Table 5 2 CAN Bridge Card Wiring Terminations Em NG UPS 3 CAN Bridge Card UPS 4 CAN Bridge Card UPS 1 CAN Bridge Card UPS 2 CAN Bridge Card If Installed If Installed J3 8 L J3 8 L J3 8 L J3 8 L J3 9 H J3 9 H J3 9 H J3 9 H J3 10 Shield J3 10 Shield J3 10 Shield J3 10 Shield EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 5 5 INSTALLING OPTIONS AND ACCESSORIES Twisted Pair Twisted Pair Twisted Pair TB1 TB1 TB1 TB MES ING 110 110 210 210 210 210 310 zO 310 310 410 410 410 410 5 Q 510 5 O 5 O 6 O 6 0 6 O 6 O 710 71O 710 7 O 8 O 8 O 8 O 80 9 O 9 O 9 O 9 O 10 O 10 10 O 10 O TB2 TB2 TB2 TB2 1 Q 1 CX 1 CX 1 CX 2 G1 2 G 23 O 2 G 3 NG 310 31O 3 0 4 O Twisted Pair 4 O Twisted Pair 4 O Twisted Pair 4 O Twisted Pair O 510 b 5 O 6 610 610 6 0 71O 71O 71O 71O 8 O 8 0 8 0 8 O 9 0 9 0 9 0 9
21. gt e a a lo al i O Figure 7 1 UPS Controls and Indicators ISBM Section Shown EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 1 UPS OPERATING INSTRUCTIONS 7 1 1 Control Panel The control panel is used to set up and control the UPS and to monitor UPS operation For a description of the UPS control panel functions see paragraph 7 2 7 1 2 Circuit Breaker Optional circuit breaker CB1 is used to control the AC input to the UPS rectifier NOTE CB1 is supplied with an extension handle to assist in operating the breaker This handle can not be installed permanently and must be removed for the front door to close Self stick hook and loop fastener strips are provided tied to the handle for mounting the handle in a convenient location such as next to the breaker on the bottom internal safety shield panel when not in use Remove the backing from each strip and attach one strip to the handle and the other strip to any smooth surface 7 2 Using the Control Panel The following paragraphs describe the UPS control panel including controls and indicators and how to monitor UPS operation The control panel see Figure 7 2 is located on the front door of the UPS E T N Powerware PRESS ANY KEY TO CONTINUE Figure 7 2 UPS Control Panel The control panel consists of A liquid crystal display LCD
22. UPM 1 Cable 1G1 amp 1G2 Brown _ Phase B E2A UPM 2 Cable 2G1 amp 2G2 Brown EN O UPM 1 Cable 1G1 amp 162 Orange Phase A E1A UPM 2 Cable 261 amp 262 Orange UPM 3 Cable 3G1 amp 3G2 Orange UPM 1 Cable 1G1 amp 1G2 Yellow UPM 2 Cable 2G1 8 2G2 Yellow Phase C E3A UPM 3 Cable 3G1 amp 3G2 Yellow Phase A E1A AC Input to UPM 4 FI UPM Phase B E2A Plus 1 Model TOUS Phase C E3A AC Input to UPMs NOTE 7wo cable lugs will be connected to each terminal stud When connecting the cable lugs install the first lug on the stud with the raised barrel portion facing the back of the cabinet Install the second lug with the raised barrel portion facing the front of the cabinet NOTE On an UPS without CB1 UPM input wiring terminations are in the same positions on the bus bars installed in the place of CB NOTE On an UPS configured as an Input Output Module IOM UPM input wiring terminations are the same as an ISBM configuration Figure 4 9 ISBM Section Input Power Terminal Detail Common Rectifier Feed 4 12 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION
23. AA Power is present inside the UPS cabinet sections until the upstream input feeder circuit breaker is opened 7 4 11 Using the Remote Emergency Power off Switch A UPS emergency power off is initiated by the REPO pushbutton switch In an emergency you can use this switch to control the UPS output The REPO switch de energizes the critical load and powers down the UPSs immediately without asking for verification The UPS including Bypass remains off until restarted CAUTION All power to the critical load is lost when the REPO switch is activated in the following step You should use this feature only when you want to de energize the critical load NOTE The following instructions are for the Eaton supplied REPO switch If a customer supplied REPO switch is used it may not activate in the same manner refer to the operating instructions provided with the switch To use the REPO switch pan Firmly push the red pushbutton until it locks into place The switch latches into the activated state see Figure 7 7 The input output and bypass backfeed contactors open the battery breaker or disconnect is tripped and the power module is turned off immediately without asking for verification on all UPSs EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 27 UPS OPERATING INSTRUCTIONS CAUTION Do not attempt to restart the system after the REPO until t
24. E T N Powerware Powerware 9395 UPS and Plus 1 UPS 650 825 kVA Installation and Operation Manual IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that you should follow during installation and maintenance of the UPS and batteries Please read all instructions before operating the equipment and save this manual for future reference CONSIGNES DE SECURITE IMPORTANTES CONSERVER CES INSTRUCTIONS Ce manuel comporte des instructions importantes que vous tes invit suivre lors de toute proc dure d installation et de maintenance des batteries et de l onduleur Veuillez consulter enti rement ces instructions avant de faire fonctionner l quipement et conserver ce manuel afin de pouvoir vous y reporter ult rieurement This is a product for restricted sales distribution to informed partners EN IEC 62040 2 Installation restrictions or additional measures may be needed to prevent electromagnetic disturbances Eaton Powerware X Slot LanSafe PowerXpert and Powerware HotSync are registered trademarks and ConnectUPS is a trademark of Eaton Corporation or its subsidiaries and affiliates IBM and AS 400 are registered trademarks of International Business Machines Corporation Modbus is a registered trademark of Schneider Electric National Electrical Code and NEC are registered trademarks of National Fire Protection Association Inc All other trademarks are property of
25. Front View 1 2 Knockout Pattern Typical 5 Sides 95 3 3 57 Square Dimensions are in millimeters inches Figure 3 10 Remote EPO Switch Dimensions EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 7 UPS INSTALLATION PLAN AND UNPACKING 3 2 2 UPS System Power Wiring Preparation Read and understand the following notes while planning and performing the installation Refer to national and local electrical codes for acceptable external wiring practices To allow for future kVA upgrades consider installing a derated UPS using wiring and external overcurrent protection breakers sized for a fully rated UPS For external wiring use 90 C copper or aluminum wire Wire sizes listed in Table 3 4 and Table 3 5 are for copper wiring only If wire is run in an ambient temperature greater than 30 C higher temperature wire and or larger size wire may be necessary Wire sizes are based on using the specified breakers Wire ampacities are chosen from Table 310 16 of the NEC Specification is for copper wire with a 90 C rating Material and labor for external wiring requirements are to be provided by designated personnel If installing a maintenance bypass a minimum of two separate feeds with upstream feeder breakers or a single feed with two upstream feeder breakers must be provided one for the UPS or rectifier input breaker RIB if installed and one f
26. In the ISBM section locate the J39 inverter CAN connector on the PIT interface board and connect the RJ 45 CAN cable connector to the J39 connector see Figure 4 15 and Figure 4 16 on page 4 17 Dress the interface harnesses and secure in place with wire ties as necessary to prevent wire damage When all wiring is complete reinstall the safety shield panels removed in previous steps Reinstall the front wireway panel If installing a Plus 1 model UPS proceed to paragraph 4 5 otherwise proceed to Step 26 If installing a battery system proceed to paragraph 4 6 otherwise proceed to Step 27 If installing a tie cabinet or distribution panel for a distributed bypass system proceed to paragraph 4 7 otherwise proceed to paragraph 4 8 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION
27. See Table 3 13 for conduit requirements Per NEC article 300 3 B 1 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 Conduit is sized to accommodate one neutral conductor the same size as the phase conductor and one ground conductor sized in accordance with NEC Table 250 122 Conduit sizes listed are for copper wiring only Table 3 13 Power Cable Conduit Requirements A Number of Wires Minimum Conduit Number of o Voltage Econ in Conduit Trade Size Conduits AC Input to UPS Rectifier 4 3 4 A B C Ground AC Input to UPS Rectifier Separate Feed 4 2 3 A B C Ground Each UPM 400 Vac AC Input to Bypass and Output Four Wire 4 3 3 A B C Ground AC Input to Bypass and Output Five Wire 5 3 4 A B C Neutral Ground AC Input to UPS Rectifier Powerware 9395 825 650 A B C Ground 4 3 3 AC Input to UPS Rectifier Separate Feed 4 2 2 A B C Ground Each UPM 480 Vac a AC Input to Bypass and Output Four Wire 4 24 2 3 A B C Ground AC Input to Bypass and Output Five Wire 5 3 4 A B C Neutral Ground Battery DC Positive Negative Ground See Note AC Input to UPS Rectifier 4 3 4 A B C Ground AC Input to UPS Rectifier Separate Feed 4 2 3 A B C Ground Each UPM 400 Vac AC Input to Bypass and Output Four Wire 4 3 4 A B C Ground
28. The UPS can automatically use all three modes as required The following paragraphs describe the differences in the three UPS operating modes using block diagrams to show the power flow during each mode of operation Normal Mode Figure 6 2 shows the path of electrical power through the UPS system when the UPS is operating in Normal mode During normal UPS operation power for the system is derived from a utility input source through the rectifier input contactor K1 The front panel displays Normal indicating the incoming power is within voltage and frequency acceptance windows Three phase AC input power is converted to DC using IGBT devices to produce a regulated DC voltage to the inverter When contactor K2 is closed the battery is charged directly from the regulated rectifier output through a buck or boost DC converter depending on the system voltage and the size of the battery string attached to the unit The battery converter derives its input from the regulated DC output of the rectifier and provides either a boosted or bucked regulated DC voltage charge current to the battery The battery is always connected to the UPS and ready to support the inverter should the utility input become unavailable EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Bypass Input UNDERSTANDING UPS OPERATION Bypass Breaker CB4 EN O O Input Br
29. UPS Shutdown Bypass Online Bypass Off On Available Maintenance Bypass Off On Charger Charger Off Charging UPM during startup DC Starting Charger Off DC Starting Close Battery Breaker Inverter Starting Inverter Syncing Ready Online UPM 1 Offline Shutdown Charger Off Ready Ready Charging UPM 2 Online Charger Off Online Charging UPM3 UPM 4 Only Plus 1 model Function Subfunction Operation UPS Control Commands Use the up or down arrow pushbutton to highlight the command function desired then press the SELECT pushbutton to execute the command or proceed to further command screens Go to Normal Starts the UPS in Normal mode or transfers the UPS to Normal mode from Bypass mode Go to Bypass Starts the UPS in Bypass mode or transfers the UPS to Bypass mode from Normal mode Load Off Displays the Load Off screen see paragraph 7 2 8 Bypass Commands Use the up or down arrow pushbutton to highlight the command function desired then press the SELECT pushbutton to execute the command or proceed to further command screens Go to Bypass Starts the UPS in Bypass mode or transfers the UPS to Bypass mode from Normal mode Go to Normal Starts the UPS in Normal mode or transfers the UPS to Normal mode from Bypass mode Load Off Displays the Load Off screen see paragraph 7 2 8 Charger Control Use the up or down arrow pushbutton
30. 164201725 Rev 2 www powerware com 1 7 INTRODUCTION 1 9 Getting Help If help is needed with any of the following e Scheduling initial startup Regional locations and telephone numbers Aquestion about any of the information in this manual e A question this manual does not answer Please call the Eaton Help Desk for Powerware products at United States 1 800 843 9433 or 1 919 870 3028 Canada 1 800 461 9166 ext 260 All other countries Call your local service representative 1 8 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Chapter 2 Safety Warnings IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the UPS and batteries Read all instructions before operating the equipment and save this manual for future reference The UPS is designed for industrial or computer room applications and contains safety shields behind the door and front panels However the UPS is a sophisticated power system and should be handled with appropriate care This UPS contains LETHAL VOLTAGES All repairs and service should be performed by AUTHORIZED SERVICE PERSONNEL ONLY There are NO USER SERVICEABLE PARTS inside the UPS A The UPS is powered by its own energy source batteries The output terminals may carry live voltage even when the UPS is disconnected from an AC
31. 18 19 In the ISBM section see A in Figure 4 14 on page 4 16 locate the coiled wiring harnesses with the J50 J51 J61 and J70 connectors attached Remove the wire ties securing the harnesses and carefully remove the harnesses from the protective cage If necessary loosen the screws securing the protective cage Locate the mating P50 connector in the UPM section wireway see B in Figure 4 14 on page 4 16 and connect the P50 connector to the J50 connector 4 Locate the mating P51 connector in the UPM section wireway see B in Figure 4 14 on page 4 16 and connect the P51 connector to the J51 connector 4 Locate the mating P61 connector in the UPM section wireway see B in Figure 4 14 on page 4 16 and connect the P61 connector to the J61 connector Locate the mating P70 connector in the UPM section wireway see B in Figure 4 14 on page 4 16 and connect the P70 connector to the J70 connector NOTE One intercabinet interface cable is supplied coiled against the left side panel of the UPM section see B in Figure 4 14 on page 4 16 20 21 22 23 24 25 26 27 In the UPM section see B in Figure 4 14 on page 4 16 locate the coiled RJ 45 CAN cable Remove the wire ties securing the cable to the interior left side panel of the UPM section Route this harnesses through the round wiring access in the right side panel of the ISBM section see B in Figure 4 14 on page 4 16
32. 7 E 400 400 Simplified Dual Feed UPS with Maintenance Bypass Figure 6 17 on page 6 20 9395 825 750 480 480 Panel 9395 825 825 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 7 UNDERSTANDING UPS OPERATION AC Input to AC Input to Battery Aux Building Alarms UPS Rectifier Bypass 3 Wire A B C 3 or 4 Wire A B C 48V Battery Alarm Relays Rotation c Potation Bypass Shunt Trip Breaker Slot A B CB4 Remote EPO ERE Interface E1 E2 E3 A E6 E7 OS 68 12 O o Interface Board Single feed Kit Input Breaker 7 O Not supplied Static m CB1 o with the UPS L Switch B optional ruse gt Backfeed Contactor K5 e 0 nput nput Input Contactor Contactor Contactor K1 K1 K1 _ Rectifier Rectifier RE Rectifier Fuse Fuse Fuse e e e Fuse Fuse Fuse Fuse Fuse Fuse Inverter CC Inverter Inverter Jo oe wa Output Output Output Contactor gt Contactor Contactor K3 K3 K3 na pk pi Ka AC
33. Input Output Module Configuration The UPS can be supplied in an Input Output Module IOM configuration without the bypass input connections the static switch the motorized wraparound bypass breaker and the backfeed protection contactor This configuration is primarily used in multiple UPS parallel systems that do not need a bypass for each UPS and use a separate System Bypass Module SBM to provide system bypass capabilities Although not provided with the UPS a battery system is required to provide emergency short term backup power to safeguard operation during brownouts blackouts and other power interruptions The battery system should be equipped with lead acid batteries An external battery disconnect switch must be used The UPMs may be powered with either a common or separate battery system In a common battery system single and multiple UPMs are powered from one common battery source In a separate battery system multiple UPMs are each powered from separate battery sources UPMs in distributed bypass and parallel systems must use a separate battery system A supplemental 48 Vdc shunt trip signal for the battery disconnect device is provided by the UPS but is not required for normal operation EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 1 5 INTRODUCTION 1 4 1 5 1 6 1 6 Basic System Configurations Using This Manual Conventions Used in T
34. On an UPS configured for separate rectifier inputs all sources that feed the separate rectifier inputs must be derived from a common ground point On an UPS configured as an Input Output Module IOM bypass input wiring termination conduit and bypass breaker requirements are not applicable A Field Installed UPM FI UPM is always designated as UPM 4 3 8 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING For external wiring requirements including the minimum AWG size of external wiring see Table 3 4 for installations using a common battery system Table 3 5 for installations using a separate battery system or Table 3 6 for separate rectifier feed installations Wire sizes listed are for copper wiring only Table 3 4 Input Output Ratings and External Wiring Requirements for the Powerware 9395 825 650 9395 825 750 and 9395 825 825 Common Battery Units Rating 50 60 Hz Basic Unit Rating kVA 650 650 750 750 825 825 kW 585 591 675 682 7742 750 Input and Output Voltage Volts 400 400 480 480 400 400 480 480 400 400 480 480 AC Input to UPS Rectifier 0 98 Minimum pF Full load current plus battery recharge current Amps 1079 891 1245 1028 1369 1130 3 Phases 1 Ground A Minimum Conductor Size AWG or kcmil 500 500 500 500 500 500 Number per Phase each 4 3 4 4 5 4 AC Input to UP
35. On the System Status screen select the UPS command Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed On the UPS Control Command screen select GO TO NORMAL Press the SELECT pushbutton on the UPS Command menu bar If Auto Bypass is enabled factory default the critical load is immediately supplied by the bypass source in Bypass mode from all UPSs until the inverter turns on and the UPSs transfer to Normal mode The status indicator on the UPS control panel indicates the UPS is in Bypass mode If Auto Bypass is not enabled the UPS outputs remain off until the UPSs transfer to Normal mode Verify the following messages display sequentially on the UPS status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING ONLINE CHARGING The rectifier and inverter turn on The inverter continues to ramp up to full voltage Once the inverter reaches full voltage all UPS output contactors K3 close and the bypass circuits open Power is now supplied to the critical load in Normal mode from all UPSs It takes approximately one minute for the UPSs to achieve Normal mode The NORMAL status indicator is illuminated The UPS status indicates ONLINE The UPM status indicates ONLINE CHARGING EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS 7 4 2 Starting the Distributed Bypass System in
36. UPM 2 Cable 264 amp 265 Orange 4 Phase A ESA O UPM 3 Cable 3G4 amp 365 Orange 9 lt UPM 1 Cable 164 8 165 Brown AC Output 9 lt UPM 2 Cable 264 amp 265 Brown gr Phase B E10A Somn 9 amp UPM 3 Cable 364 amp 365 Brown 9 lt UPM 1 Cable 164 amp 165 Yellow ie UPM 2 Cable 264 amp 265 Yellow gr Phase C E11A UPM 3 Cable 364 amp 365 Yellow UPM 1 Cable 164 amp 165 Gray Neutral from 9 lt UPM 2 Cable 264 amp 265 Gray UPMS E12A amp UPM 3 Cable 364 amp 365 Gray _J NOTE 7wo cable lugs will be connected to each terminal stud When connecting the cable lugs install the first lug on the stud with the raised barrel portion facing the back of the cabinet Install the second lug with the raised barrel portion facing the front of the cabinet Figure 4 13 ISBM Section Output Power Terminal Detail EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 15 UPS SYSTEM INSTALLATION
37. and also with the purchase of an Eaton PowerTrust Support Agreement after the initial warranty expires eNotify and support agreement availability or specific features may vary by market for more information refer to www powerware com enotify eNotify Service Features The eNotify Service provides proactive monitoring and a monthly report detailing the ongoing health of your Powerware 9395 UPS Proactive monitoring called Anomaly Detection automatically analyzes the status of the Powerware 9395 UPS on a daily basis All data gathered from the unit current and historical is analyzed at the Customer Reliability Center CRC for trending issues A set of factors or rules compared against your UPS s data can indicate a potential impending failure and trigger an appropriate anomaly notification to a CRC Analyst Critical events are checked for additional anomalies Through this service the CRC can take pre emptive corrective action to ensure the highest level of availability of your Powerware 9395 UPS The Customer Monitoring Report delivers information about Eaton s analysis of your Powerware 9395 UPS on a monthly basis Depending on the model the report provides detailed information about voltages loads external factors such as temperature and humidity the attached batteries and system availability All of these factors contribute to the Relative Health Index RHI score that allows you to compare your unit s health relative to E
38. ha tU DNA ENNA MANONG ot ha Ot D REN Lit t mda exei 4 13 Completing the Installation Checklists tet t o YNG Rh Ls ete AG a on UG Ne eet ont ee Installing Options and Accessories sseeuseeeeeenn RR 5 Installing an Optional Powerware Hot Sync CAN Bridge Card 5 2 Installing Distributed Bypass Control Wiring 5 3 Installing an Optional Remote Monitor Panel ll 5 4 Installing an Optional Relay Interface Module ll 5 5 Installing an Optional Supervisory Contact Module Il oona iiis RRRRRRRRRRRRIRRRIR RII bo Accessory Mounting DIMeNnslOns sect Net ehe mese pta sr poet a mr ptm Section Il Operation 6 Understanding UPS Operation IRI III G l UPS Sy Stem OVERVIEW vxo ont n oot ote c Redoute se Re eh e Aum cles tn ce a ice Bon ur 6 2 Single UPS c Ll ec ssmenrbim a e e RE oe Bi a te leet id 6 2 1 Modes Mp uot A A o banal ta bee eH Ne teer Ec bake pan bag 6 2 2 Normal Mode lt 4 6 em uses NA NG doe Me NG Ea uoo NG ede NC Ep NAN MESA NG EO NG RE tren 6 2 3 Bypass MOGB ic ii dd MA 6 2 4 Battery Mode x ber ca laca aa Me e cL AL A A KA Nai A ose rc PE ng ah ed ce 6 3 Single UPS Unit System Oneline Configurations e RRRRRRRRRRRRRIRRRIRRRR ns 64 Multiple UPS Distributed Bypass System RR RR e es 6 4 1 Multiple UPS Parallel System Modes RR RRRRRRRRRRRRRRRRR RR RI e 6 4 2 Normal Mode Distributed Bypass RR RR RI A A I eee 6 4 3 Bypass Mode Distributed B
39. load Output Voltage Adjustment 400 Vac nominal adjustable from 388 Vac to 412 Vac Nominal 3 480 Vac nominal adjustable from 466 Vac to 494 Vac Output Voltage Harmonic Content 1 5 maximum THD linear load 5 maximum THD nonlinear load Output Current See Table 3 4 on page 3 9 or Table 3 5 on page 3 10 Output Voltage Balance 3 for 100 maximum load imbalance linear load Output Voltage Phase 3 for 100 maximum load imbalance linear load Displacement Output Transients 5 10 to 100 load Frequency Regulation 0 1 Hz free running Synchronous to Bypass 10 to 10 3 Frequency Slew Rate 1 Hz per second maximum Load Compatibility 0 9 pF Leading 0 8 pF Lagging Overload Capability 110 for 10 minutes 125 for 30 seconds 150 for 10 seconds 10 2 3 UPS Environmental Operating Temperature 0 to 40 C 32 to 104 F without derating The recommended operating temperature is 25 C 77 F Operating Altitude Maximum 1500m 5000 ft at 40 C without derating Storage Temperature 25 to 60 C excluding batteries prolonged storage above 40 C causes rapid battery self discharge Relative Humidity operating and 5 to 95 maximum noncondensing storage Acoustical Noise 76 dB at a 1m distance A weighted EMI Suppression Meets FCC Regulation 47 Part 15 for class A devices Electrostatic Discharge ESD Meets IEC 801 2 specifications Withstands up to 25 kV pulse Imm
40. supplied key and rotate clockwise until the red pushbutton releases see Figure 7 7 To remove the key rotate the key back to the vertical position 3 Restart the UPS by following the procedure in paragraph 7 3 1 on page 7 11 or 7 3 2 on page 7 12 II HG Power is present inside the UPS cabinet until the upstream input feeder circuit breaker is opened Activated Pushbutton locked into place Deactivated Unlock pushbutton to release Figure 7 7 REPO Operation EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 19 UPS OPERATING INSTRUCTIONS 7 4 7 20 Multiple UPS Distributed Bypass Operation 7 4 1 Starting the Distributed Bypass System in Normal Mode To start the distributed bypass system 1 2 3 4 5 6 10 11 12 13 14 If the UPSs contain input breakers CB1 verify that all input breakers are open Close all Module Output Breakers MOBs Close all UPS input feeder circuit breakers Close all UPS Bypass input feeder circuit breakers Observe the UPS control panel displays becoming active indicating logic power On any UPS press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen verify the UPS status is SHUTDOWN and the UPM status is OFFLINE Close all battery breakers If the UPSs contain input breakers CB1 close all input breakers
41. 1 A horizontal row of pushbutton switches 2 A vertical column of status indicators 3 See paragraph 7 2 1 The following paragraphs describe using the UPS control panel to monitor the UPS See paragraph 7 3 for use of the operational controls When the UPS powers up the screen displays the Eaton Powerware logo as shown in Figure 7 2 To advance to the Main Menu and Mimic screen press any control panel pushbutton once 7 2 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS 7 2 1 Status Indicators The four symbols on the right side of the control panel are status indicators These colored light emitting diode LED lamps work with the alarm horn to let you know the operating status of the UPS Table 7 1 describes the status indicators Table 7 1 Status Indicators Indicator Status Description On The UPS is operating normally The power module is supplying power to the critical load Off The UPS is turned off On The UPS is in Battery mode Because Battery mode is a normal condition of the UPS the Normal indicator also remains illuminated On The UPS is in Bypass mode The critical load is supported by the bypass source The Normal indicator is not illuminated when the system is in Bypass mode On The UPS has an active alarm and requires immediate attention The LCD shows the highest priority active alarms
42. 1 6 6 6 o pla ef EIN E 4 Pac eal C r A e e M I EX ej 5 ELE H B e e glo Lol tail B HU py E nounou ENS 7 elle e Nas e q L ces eo e 89 ela e lolle A SS E mara Ueo p n E E le D D i la al al o o o UPM Wireway Power wiring harnesses are coiled in this area Figure 4 6 ISBM and UPM Sections Joined 10 Reinstall the left top panel see Figure 4 5 and secure using the retained hardware NOTE Three flat cabinet joining brackets are provided in the hardware kit for securing the ISBM and UPM sections at the top front top rear and front base see Steps 11 and 12 11 Locate the hardware kit packed inside a drawstring bag tied to the left middle panel of the UPM section Locate two flat brackets and screws from the hardware kit Align the holes in the flat brackets over holes in the top rear and top front of the ISBM and UPM sections Secure the brackets with the screws from the hardware kit see Figure 4 7 12 Locate one flat bracket and screws from the hardware kit Align the holes in the flat bracket over holes in the front base of the ISBM and UPM sections Secure the bracket with the screws from the hardware kit see Figure 4 7 13 Proceed to paragraph 4 4 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manu
43. 3 or 4 Wire A B C 48V Battery Alarm Relays Rotation c Rotation Bypass Shunt Trip xs Breaker uot A B CB4 Remote EPO Interface E1 E2 EX A E6 E7 CA Na AH E8 E12 O o Interface Board Single feed Kit id Input Breaker 7 O Not supplied Static N CB1 o with the UPS Switch H optional Fuse b Backfeed Contactor K5 e Input Input Input Contactor Contactor Contactor K1 K1 K1 E Rectifier BG Rectifier t Rectifier Fuse Fuse Fuse e 8 e Fuse Fuse Fuse Fuse Fuse Fuse Inverter Inverter Inverter CS TA YIN Output Output Output Contactor Contactor Contactor K3 K3 K3 AC Output to o ers Critical Load Battery Battery Battery E11 E12 D Converter Converter Converter Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPS UPM 1 UPM 2 UPM 3 CABINET E4 E5 E4 E5 E4 E5 CN EN wah KONG la o oh o o o o Battery Breaker BATTERY SYSTEM Not supplied with the UPS Battery Breaker BATTERY SYSTEM Not supplied with the UPS NOTE Callout letters A B C and D map to Table 3 5 on page 3 10 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Battery Breaker BATTERY SYSTEM Not supplie
44. 4 Return Building Alarm 5 Building Alarm 5 Return NOTE Al building alarm inputs require an isolated normally open or normally closed contact or switch rated at 24 Vdc 20 mA minimum connected between the alarm input and common terminal as shown Building alarm inputs can be programmed for use with either normally open or normally closed contacts All control wiring and relay and switch contacts are customer supplied NOTE 7he building alarms can be programmed to display the alarm functional name NOTE A jumper wire must be connected between pins 1 and 2 on TB if the normally closed REPO contact is not used Figure 4 30 Terminal Blocks TB1 TB2 and TB3 Connector Assignments EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 35 UPS SYSTEM INSTALLATION 4 9 2 TB1 Battery Interface Connections To install wiring to connections 1 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS Operating Instructions for shutdown instructions Unfasten the front door latch and swing the door open see Figure 4 1 on page 4 2 Remove the door Remove the retaining screw located inside the door at the bottom hinge pivot point then lift the door off Retain the hardware for later use To gain access to terminal block TB1 and the interface entry conduit landing plate remove the screws securing the top internal safety shield panel
45. 46 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Chapter 5 Installing Options and Accessories 5 1 Installing an Optional Powerware Hot Sync CAN Bridge Card As an option a Powerware Hot Sync Controller Area Network CAN Bridge Card shown in Figure 5 1 can be installed to provide connectivity for operational mode control of a parallel system In addition this card can be used to connect optional system monitoring devices such as a Remote Monitor Panel Il a Relay Interface Module Il or a Supervisory Contact Module Il to the UPS Plug in Terminal Block J3 Figure 5 1 Powerware Hot Sync CAN Bridge Card NOTE Only one Powerware Hot Sync CAN Bridge Card can be installed in the UPS Multiple CAN cards are not supported and will cause system conflicts To install the card 1 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS Operating Instructions for shutdown instructions 2 Unfasten the front door latch and swing the door open see Figure 4 1 on page 4 2 3 Install the Powerware Hot Sync CAN Bridge Card into an open X Slot communication bay on the front of the UPS See Figure 4 27 on page 4 32 and Figure 4 33 on page 4 38 for X Slot communication bay locations EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 5 1 INSTALLING OPTIONS AND ACCESSORIES Re
46. 5 2 and Table 5 1 5 2 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INSTALLING OPTIONS AND ACCESSORIES J3 J NUT om SHIELD O CAN H e Connections for Parallel System Control CAN L e O TX Fs C E Lt KA Connections for RMP II RIM Il or SCM Il TX O NO lo COM O Connections for Bypass Status NC Om ALM RTN N OL ge Alarm ALARM O 4 c YG O ex O uU Figure 5 2 Powerware Hot Sync CAN Bridge Card Connections Table 5 1 Powerware Hot Sync CAN Bridge Card Interface Connections J3 Terminal Name Description 1 Alarm Programmable UPS alarm Activated by a remote dry contact closure 2 Alarm Return 3 Alarm Relay NC Normally closed contact opens when UPS is on bypass 4 Alarm Relay Com Bypass contact return 5 Alarm Relay NO Normally open contact closes when UPS is on bypass 6 TX RMP Il RIM Il and SCM II connections 7 TX 8 CANL 9 Can H CAN input for parallel operation 10 Shield EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 5 3 INSTALLING OPTIONS AND ACCESSORIES 5 2 5 4 Installing Distributed Bypass Control Wiring eD NOTE When installing external wiring to the Powerware Hot Sync CAN Bridge Card conduit must be installed to the UPS cabinet When ins
47. 5 215 9 6 75 8 50 i D Y Knockouts Provided on Five Surfaces e V1 8 47 5 et Flush Mount using 10 Pan Head Screws 7 00 1 87 Mount with vent holes facing up 4 5 a 1 0 48 1 A WARNING 58 7 7 9 thi f ame V J 2 34 0 31 n DO PNG 190 5 A S a 7 50 Surface Mount using 10 Pan A get Rune 88 9 Head Screws for Hanging 2 ity 7BC RAED I 3 50 Mount with vent holes facing up bag lt ESB A ch 6 4 ag f UN b JEAN L 0 25 Na 4 a 455 9 ua aag 785 5 Dimensions are in millimeters inches EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 8 50 Figure 5 12 Remote Monitor Panel Il Dimensions 5 15 INSTALLING OPTIONS AND ACCESSORIES 9 aed 288 8 3 07 11 37 i i nino 8 50 6 75 U AJ Y Knockouts Provided on Five Surfaces Flush Mount using 10 Pan Head Screws 7 00 1 87 Mount with vent holes facing up DE m t i 0 18 1 79 2 V
48. 8 10 97 UPS Maintenance Naam eda ve pt qd as De ota y aed awe Dua nV RR pc 9 1 9 1 Important Safety Instructions IRR y e e 9 1 9 2 Performing Preventive Maintenance z o iia epe te dere tree ANAN a id ha codec den 9 2 9 2 1 BALIYE Maintenances aero ct a a tose tr demus eter uade ce Ste b rete e dte ETE eo tr Oa 9 2 922 MONTHLY Maintenance tacita et de ee calet etn eo qe ecu dci e eva DR c e edes 9 2 9 2 3 PERIODIC Maintenance s snes pg KG A LED AG RA LANANG 9 5 924 ANNUAL Maintenance aeia oi Decet doe el edet bere deinde e Les doce de lege ode Le bee deiade le eta 9 5 925 BATTERY Maintenant sdr wa e o e CPUS EST et ROM Wr II misit IE Durch 9 5 9 3 Installing Batteries a bet e oce een tete e ets eet tu e eu y de aet na LASA 9 5 9 4 Recycling the Used Battery or UPS e e e 9 6 9 5 Maintenance Training La a BNG esee ree dritter tee ka LANG NG islets Hte Pied do 9 6 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com iii TABLE OF CONTENTS 10 Product Specifications NG ka sea ability cabal GD KG a cad ad Ea PR 10 1 10 15 Model NUmD6ers meo t ende e e teer eedem eter tens ip det es Kamang bb Ka a nats eal te ate 10 1 10 2 Specifications tato Dt va Ve Oei o ee sete iate eara ot S eb iet e we Pee AER a ou ee LANE ete fout die re PE UR 10 1 20 230 IBS Input ors da coto oto o lid de ld eii ir ttu basse 10 1 MO Ze 2 PSOE a tot v Na o ra urs he Syk
49. AWG UPS SYSTEM INSTALLATION Battery Disconnect IH 48 Vdc UPS TB1 5 O 6 O 7 O 8 O Figure 4 31 Typical Battery Interface Connection Common Battery System Battery Aux Battery Aux Return 48 Vdc Battery Shunt Trip 4 48 Vdc Battery Shunt Trip UPM 1 UPM 2 UPM 3 UPM 4 Battery Battery Battery Battery UPS Disconnect Disconnect Disconnect Disconnect TB1 o HH O O 48 Vdc O NOTE Battery aux and DC shunt trip wiring should be a minimum of 18 AWG Figure 4 32 Typical Battery Interface Connection Separate Battery System EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 37 UPS SYSTEM INSTALLATION 4 9 3 X Slot Connections o NOTE LAN and telephone drops for use with X Slot cards must be provided by the customer NOTE When installing external wiring to X Slot cards conduit must be installed to the UPS cabinet When installing internal wiring to X Slot terminals route the wiring through the internal opening in the X Slot communication bay For installation and setup of an X Slot card contact an Eaton service representative see page 1 8 To install wiring to connections 1 2 X Slot Communication Bay 1 X Slot Communication Bay 3 If not already installed install the LAN and telephone drops Unfasten the front door latch
50. Bypass remain off until restarted NOTE The UPS Load Off controls each UPS independently and does not shutdown the whole distributed bypass system To immediately shutdown the whole system use the REPO switch see paragraph 7 4 11 To use the LOAD OFF pushbutton 1 Press the LOAD OFF pushbutton on the UPS to shutdown The Load Off screen is displayed providing a choice to proceed or abort the shutdown CAUTION All power to the critical load is lost when the LOAD OFF is selected in the following step You should use this feature only when you want to de energize the critical load N To shut down the UPS press LOAD OFF from the Load Off menu bar and hold for three seconds To abort the shutdown press CANCEL When LOAD OFF is selected and held for three seconds the input output battery and bypass backfeed contactors open and the power module is turned off on the UPSs d If another UPS is to be shutdown proceed to that UPS and repeat Steps 1 and 2 CAUTION Do not attempt to restart the system after Load Off until the cause of the shutdown has been identified and cleared 4 Restart the UPS after pressing the LOAD OFF pushbutton by following the procedure in paragraph 7 4 1 on page 7 20 or 7 4 2 on page 7 21 Power is present inside the UPS cabinet sections until the upstream input feeder circuit breaker is opened gt To use the LOAD OFF command 1 Press the CONTROLS pushbutton on the main
51. Bypass Mode If the inverter output of the distributed bypass system is not available and the critical load needs to be energized In Bypass mode the critical load is not protected from commercial power interruptions and abnormalities o0 7 A w N 10 11 12 If the UPSs contain input breakers CB1 verify that all input breakers are open Close all MOBs Close all UPS input feeder circuit breakers Close all UPS Bypass input feeder circuit breakers Observe the UPS control panel displays becoming active indicating logic power On any UPS press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen verify the UPS status is SHUTDOWN and the UPM status is OFFLINE If the UPSs contain input breakers CB1 close all input breakers On the System Status screen select the BYPASS command Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed On the Bypass Control Command screen select GO TO BYPASS Press the SELECT pushbutton on the Bypass Command menu bar The critical load is immediately supplied by the bypass source in Bypass mode from all UPSs The BYPASS status indicator is illuminated The Bypass status indicates ON The UPM status indicates SHUTDOWN CLOSE BATTERY 7 4 3 Starting the UPSs UPMs To start the power modules without transferring the critical load to Normal mode 1 2 3 4
52. DISPLAY 1 06 TIME 19 17 16 DATE 03 23 2099 03 16 2099 21 25 20 355 S138 CONTROL POWER ON PM1 03 16 2099 21 25 20 515 N011 OUTPUT UNDER OR OVER FREO PM1 03 16 2099 21 25 20 675 S302 EEPS CONFIGURING PM1 03 16 2099 21 25 23 475 N267 POWER MODULE CABLE FAIL 15 PM1 03 16 2099 21 25 25 180 N271 DC HW AMPS LIMIT PM1 03 16 2099 21 25 25 215 N007 INPUT AC UNDER VOLTAGE PM1 03 16 2099 21 25 25 850 N011 OUTPUT UNDER OR OVER FREO OK PM1 03 23 2099 18 59 20 225 A199 BATTERIES DISCONNECTED PM1 ACTIVE ALARMS 11 NOTICE OUTPUT UNDER OR OVER FREO PM1 12 ALARM REMOTE EMERGENCY POWER OFF MCU 102 NOTICE INVERTER L1 CURRENT LIMIT PM1 103 NOTICE INVERTER L2 CURRENT LIMIT PM1 104 NOTICE INVERTER L3 CURRENT LIMIT PM1 Figure 8 2 Sample Event History Log 8 6 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com COMMUNICATION 8 6 Building Alarm Monitoring This standard feature lets you connect the UPS to your building alarms such as smoke detectors or overtemperature alarms The customer interface terminals for external connections are located inside the UPS You should use twisted pair wires for each alarm input and common The building alarms can be programmed to display the alarm functional name 8 7 General Purpose Relay Contact One general purpose relay contact is provided as a standard feature on the UPS The alarm contact is located inside
53. ETE a B d al gh ai ali dm ql q qP q e a P 40 DC Input from Battery E5 UPM 4 FI UPM DC Input from Battery E5 UPM 1 DC Input from Battery E5 UPM 2 1 DC Input from Battery E5 UPM 3 97 9 Section B B Figure 4 26 ISBM Section Power Terminal Detail CC Separate Battery 4 30 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION 49 Installing Interface Connections A 4 9 1 O Hazardous voltages are present near the user interface terminal area if the UPS is not totally disconnected Use the procedures in the following paragraphs to connect the TB1 TB1 Battery TB2 and TB3 interface connections TB1 TB2 and TB3 Connections Other than TB1 Battery Interface Connections NOTE When installing interface wiring for TB1 TB2 and TB3 connections conduit must be installed between each device and the UPS cabinet NOTE Interface wiring must be installed from the top of the UPS cabinet To install wiring to connections 1 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS Operating Instructions for shutdown instructions 2 If not already opened unfasten the front door latch and swing the door open see Figure 4 1 on page 4 2 3 If not already removed remove the door Remove the retaining screw located inside the door at the bottom hinge pivot p
54. Input Remove panel to drill or punch conduit holes TOP VIEW BOTTOM VIEW Bottom Entry Conduit Landing for AC Input and Output and DC Input Remove panel to drill or punch conduit holes gt o HAH Er ELT 5 PEE B IDODOL T T JC T T T J k 4 Front Interface Entry Conduit Landings for TB1 through TB3 Wiring and X Slot Connections Remove panels to drill or punch conduit holes Front sl L AL i X 3 I I of Fo o gt o o o I I Figure 4 18 ISBM Section Conduit and Wire Entry Locations Route the input and output cables through either the top or bottom of the cabinet to the UPS terminals See Figure 4 18 for wiring access information and Figure 4 19 through Figure 4 21 for common rectifier feed terminal locations or Figure 4 19 Figure 4 22 and Figure 4 23 for separate rectifier feed terminal locations Top Access Wiring Remove the top conduit plate from the top of the ISBM section Identify all conduit requirements and mark their location Drill and punch all conduit holes in the top conduit plate prior to mounting on the ISBM section Install the conduit plate and install all conduit runs into the plate Pull wiring through conduit into the ISBM section wiring area Bottom Access Wiring Remove the bottom conduit plate from the inside bottom of the
55. NC UPS 2 CAN Bridge Card J3 2 Alarm Return MOB 2 Aux 1 Com MOB Open Alarm UPS 2 TB2 1 Pull Chain MOB 2 Aux 2 NO Pull Chain UPS 2 TB2 2 Pull Chain Common UPS 3 TB2 2 Pull Chain Common Pull Chain Common UPS 3 CAN Bridge Card J3 1 Alarm MOB 3 Aux 1 NC UPS 3 CAN Bridge Card J3 2 Alarm Return MOB 3 Aux 1 Com MOB Open Alarm UPS 3 TB2 1 Pull Chain MOB 3 Aux 2 NO Pull Chain UPS 3 TB2 2 Pull Chain Common UPS 4 TB2 2 Pull Chain Common Pull Chain Common UPS 4 CAN Bridge Card J3 1 Alarm MOB 4 Aux 1 NC UPS 4 CAN Bridge Card J3 2 Alarm Return MOB 4 Aux 1 Com MOB Open Alarm UPS 4 TB2 1 Pull Chain MOB 4 Aux 2 NO Pull Chain MOB 1 Aux 2 Com MOB 2 Aux 2 Com MOB 2 Aux 2 Com MOB 3 Aux 2 Com Pull Chain MOB Common MOB 3 Aux 2 Com MOB 4 Aux 2 Com 5 8 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INSTALLING OPTIONS AND ACCESSORIES 5 3 Installing an Optional Remote Monitor Panel Il To install RMP Il wiring 1 2 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS Operating Instructions for shutdown instructions Perform the procedure listed in paragraph 5 1 NOTE If mounting to a hollow wall secure the enclosure to a wood or metal stud within the wall Do not use hollow wall anchors 3 Secure
56. Output to Critical Load DC Input from Battery E4 See Figure 4 25 or Figure 4 26 for Detail BB DC Input from Battery E5 See Figure 4 25 or Figure 4 26 for Detail BB Neutral E12 Bag a A ERES ERA a S oc l d q o L Ig Phase C E11 Phase B E10 i ka Phase A E9 TS o 00 Oli ud YY a eds o slo ait o B o o o HD lo Clip C eh oo eqs o ele o U o9 9 kt d N o Ka h I 1 o o i o o o o o o o o lo oj o o o B M A ISBM NOTE AC Input to Bypass terminals are not applicable to an IOM configuration Figure 4 20 ISBM Section Power Terminal Locations Common Rectifier Feed EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 23 UPS SYSTEM INSTALLATION 1 a l O e Wir O Ground Terminals xt 00000000000 Front ooo il
57. Shunt Trip XS A Remote EPO Interface E1 E2 E3 5 Interface Board Input Breaker O CB1 O optional e e nput nput Input Contactor Contactor Contactor K1 K1 K1 EE Rectifier Rectifier RE Rectifier Fuse Fuse Fuse e e e use Fuse Fuse Fuse Fuse Fuse Inverter CC Inverter Inverter Jo oe wa Output Output Output Contactor gt Contactor Contactor K3 K3 K3 AC Output to ad ad ER Critical Load Battery Battery Battery E11 E12 Converter Converter Converter Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPS UPM 1 UPM 2 UPM 3 CABINET e E4 E5 KN o oii Battery Breaker BATTERY SYSTEM Not supplied with the UPS NOTE Callout letters A B C and D map to Table 3 4 on page 3 9 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper 6 12 Service Connector Figure 6 9 UPS System Common Rectifier Feed Common Battery 10M Configuration EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION Building Alarms Battery Aux
58. Table 5 5 for the terminal location and wiring information Terminal TB3 120 Vac Power a m U U TA Ground F Terminal d Terminal TB2 Customer o Supervisory Contact Interface gt WARNING USE NEC CLASS 2 WIRING METERS A Terminal TB1 Signal N um AN WARNING UN Connections from the UPS Bs MU FOR PRESSURE TERMINAL TORQUE VALUES d Hit Figure 5 10 Supervisory Contact Module Il Terminal Location EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 5 13 INSTALLING OPTIONS AND ACCESSORIES NOTE Setup of the Powerware Hot Sync CAN Bridge Card must be performed by an authorized Eaton Customer Service Engineer Contact an Eaton service representative to schedule a date 9 Install wiring between the SCM II terminal block TB2 and the monitoring equipment See Figure 5 10 for terminal block location and Figure 5 11 for terminal assignments 10 Close the front door and secure the latch 11 Restart the UPS See Chapter 7 UPS Operating Instruction
59. UPS 2 Output e UPS 2 E gt Battery oe eo UPS 3 Output e UPS 3 SSD Battery UPS 4 Output UPS 4 55 Battery Breakers V Main Power Fl O Closed Output to ain Power Flow XA Critical Load o Open Figure 6 18 Path of Current through the UPSs in Normal Mode Distributed Bypass 6 22 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Bypass Input 6 4 3 Battery UNDERSTANDING UPS OPERATION If the utility AC power is interrupted or is out of specification the UPSs automatically switch to Battery mode to support the critical load without interruption When utility power returns the UPSs return to Normal mode If the UPSs become overloaded or unavailable the distributed bypass system switches to Bypass mode The distributed bypass system automatically returns to Normal mode when the overload condition is cleared and system operation is restored within specified limits Bypass Mode Distributed Bypass In Bypass mode the output of the system is provided with three phase AC power directly from the bypass input While in this mode the output of the system is not protected from fluctuations spikes or power outages from the source No battery support is available to the output of the system in the Bypass mode of operation The distributed bypass system automatically switches to Bypass mode if it detects a UPS system overload or load fault If one UPS beco
60. UPS OPERATING INSTRUCTIONS Operation Contrast Adjust Select CONTRAST from the System Setup Level 0 menu to display the Contrast Adjust screen Use the left or right arrow pushbutton to adjust the contrast for the LCD When the contrast adjustment is complete press the SAVE pushbutton Once the setting is saved the System Setup screen displays To return to the System Setup screen without saving the setting press the return arrow pushbutton Firmware Versions The Versions screen provides the firmware version numbers installed on the UPS Select VERSIONS from the System Setup Level 0 menu to display the Versions screen To scroll through the firmware types press the up or down arrow pushbutton on the menu bar To return to the System Setup screen press the return arrow pushbutton Identification The Unit Type screen provides the model CTO and serial numbers of the UPS unit Select UNIT TYPE from the System Setup Level 0 menu to display the Unit Type screen To return to the System Setup screen press the return arrow pushbutton System Level 1 Setup Password The System Setup Level 1 screen can be used to set the UPS date and time set the serial ports change the Level 1 password and log out of Level 1 In addition the Level 0 functions are available A password is required to access the Level 1 functions To enter the password select ENTER PASSWORD from the System Setup Level 0 menu to display the Enter Passwo
61. Using the Remote Emergency Power off Switch A UPS emergency power off is initiated by the REPO pushbutton switch In an emergency you can use this switch to control the UPS output The REPO switch de energizes the critical load and powers down the UPS immediately without asking for verification The UPS including Bypass remains off until restarted CAUTION All power to the critical load is lost when the REPO switch is activated in the following step You should use this feature only when you want to de energize the critical load NOTE The following instructions are for the Eaton supplied REPO switch If a customer supplied REPO switch is used it may not activate in the same manner refer to the operating instructions provided with the switch To use the REPO switch 1 Firmly push the red pushbutton until it locks into place The switch latches into the activated state see Figure 7 7 The input output and bypass backfeed contactors open the battery breaker or disconnect is tripped and the power module is turned off immediately without asking for verification 7 18 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS CAUTION Do not attempt to restart the system after the REPO until the cause of the shutdown has been identified and cleared 2 To deactivate the REPO switch in preparation for restarting the UPS insert the
62. and remove the panel Retain the hardware for later use see Figure 4 27 on page 4 32 To locate the appropriate terminals and review the wiring and termination requirements see paragraph 3 2 2 on page 3 8 Table 4 1 on page 4 33 and Figure 4 27 through Figure 4 32 NOTE When installing shunt trip and battery aux interface wiring to the UPS interface terminals conduit must be installed between the UPS and battery system 6 10 11 12 13 Remove the left interface entry conduit landing plate to drill or punch holes see Figure 4 18 on page 4 20 Reinstall the interface entry plate and install the conduit Route the shunt trip optional and battery aux wiring from the battery disconnects to the UPS cabinet See Figure 4 18 and Figure 4 20 for UPS wiring access information and terminal locations Connect the wiring to the TB1 terminals Reinstall the top internal safety shield panel and secure with the retained hardware Reinstall the front door removed in Step 3 and secure with the retained hardware If wiring X Slot connections proceed to paragraph 4 9 3 otherwise proceed to Step 13 Close the door and secure the latch 4 36 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Battery Aux Battery Aux Common 48 Vdc Battery Shunt Trip 4 48 Vdc Battery Shunt Trip NOTE Battery aux and DC shunt trip wiring should be a minimum of 18
63. at the customer interface terminal blocks located inside the UPS A Do not directly connect relay contacts to the mains related circuits Reinforced insulation to the mains is required Read and understand the following notes while planning and performing the installation Use Class 1 wiring methods as defined by the NEC for interface wiring up to 30V The wire should be rated at 24V 1A minimum Use Class 2 wiring methods as defined by the NEC for interface wiring from 30V to 600V The wire should be rated at 600V 1A minimum and 12 AWG maximum Use twisted pair wires for each input and return or common All interface wiring and conduit is to be provided by the customer When installing external interface wiring for example building alarm relay output battery breaker trip and X Slot to the UPS interface terminals conduit must be installed between each device and the UPS cabinet Install the interface wiring in separate conduit from the power wiring When installing internal interface wiring to X Slot terminals route the wiring through the internal opening in the X Slot communication bay All building alarm inputs or remote features require an isolated normally open contact or switch rated at 24 Vdc 20 mA minimum connected between the alarm input and common terminal All control wiring and relay and switch contacts are customer supplied The building alarms can be programmed to display the alarm functional name
64. by a remote dry contact closure Default 10 Building Alarm 5 Return function set for maintenance bypass NOTE Return indicates connection to electronics circuit ground Common indicates connection to common side of isolated relay contact EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 33 UPS SYSTEM INSTALLATION a m m mn om O mg Jo UHR i CI Er AR 9 nI IQ X Slot Communication Bays kag TB1 See Figure 4 30 for terminal assignments Le TB2 T teu cH e N c ES e ijp rmi SS S Figure 4 28 Interface Terminal Detail TB2 O 3 Alarm Relay NG O 4 Alarm Relay Common Alarm Relay Q 5 Alarm Relay NO O 6 Alarm Relay Common NOTE Alarm relay contacts have a maximum current rating of 5A and a switched voltage rating of 30 Vac and 28 Vac NOTE Alarm relay normally open and normally closed return terminals are separated on the terminal board but are electricall
65. e 4 3 Mechanically Joining the Sectlns 2 0 5 5 ica maa mabahala td tpe ie d Lees de tege leet Le di dr iege Ete eps 4 4 Electrically Connecting the Sections e e 45 Field Installed UPM Installation aaa kana tb e Cd e et ee ede ete d nha ak kag get sets 4b Battery System Installation 2 a cca doped e espe NANG GNG E ERE UP RE ER Ups EEEE TAREIS ei cede 47 Distributed Bypass Tie Cabinet Installation ien ehara i a ar E eia RR y es EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 1 34 34 34 3 8 3 19 3 20 3 21 4 1 4 1 4 5 4 8 4 18 4 18 4 18 TABLE OF CONTENTS 48 Installing UPS External and Battery Power Wiring 2 e RRRRRRRRRRRRRRRRRIRR ls 4 8 1 ExtefinaliPower Wiring Installation nauna bas bye Unang gs Dh uti rd Imi euius El siti 4 8 2 Battery Power WIND esr eee Rt e erts ce Need mcer En 4 9 Installing Interface CONNECTIONS ss 2 eh sce RR ERE LR ER ee OI kan RT ERR E EE pu RULES 4 9 1 TB1 TB2 and TB3 Connections Other than TB1 Battery Interface Connections 2 00 sees 4 9 2 TBIBatiery Interface CONNECTIONS ter ad 4 9 3 X Slot CONNECTIONS fats e ote A Een b I ERE E eR No Ue AAO Installirig a BEPO SWIGDy tt ctr ete entro d tee tee o ee e EOD Ne eee S LI Lies 411 Installing Options Accessories and Distributed Bypass Control Wiring RR 412 rtialtart p csse NYE nA OM Set
66. elo O B 9 bs O oo Hito o E i e E5 HIP Olea o IU o OO kt B N o kt f i o o o o o 0 o i o 7 o i o o l o o B A ISBM NOTE AC Input to Bypass terminals are not applicable to an IOM configuration Figure 4 22 ISBM Section Power Terminal Locations Separate Rectifier Feed EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 25 UPS SYSTEM INSTALLATION Cai Ub za Ground Terminals tf 000000000000000 j Front U 4 P o o o o o o o P D E de de da AA UPM Rectifier Input Terminal Block See Figure 4 24 for Detail t 34 AZ 1 el Z CBt6 CBA CB1 2 E Phase A E6 Phase B E7 Ps Phase C E8 n L Section A A NOTE AC Input to Bypass terminals are not applicable to an IOM configuration Figure 4 23 ISBM Section Power Terminal Detail AA Separate Rectifier Feed 4 26 EATON Powerware 93
67. jumpers for each phase and the hardware required for installation Separate Rectifier Input The UPS can be supplied with separate rectifier inputs for each UPM Separate inputs provide increased flexibility and reliability by allowing multiple input sources to supply the UPS Input circuit breaker CB1 is not installed with this configuration AC input control to the UPS and each UPM rectifier is to be provided by the customer Distributed Bypass System There are two types of redundancy UPS based based on the number of UPS units and UPM based based on the number of UPMs Each UPS can contain three to four UPMs A distributed bypass UPS system with two to five UPS units can be installed to provide a capacity and or redundant system This load sharing system provides more capacity than a single UPS and can provide backup depending on the load and configuration In addition when one UPM is taken out of service for maintenance or is not operating properly a redundant UPM continues to supply uninterrupted power to the critical load A Powerware Hot Synce Controller Area Network CAN Bridge Card provides connectivity and operational mode control The distributed bypass system consists of two to five UPS units each with a parallel CAN card and a customer supplied tie cabinet or load distribution panel to act as a tie point The tie cabinet should contain Module Output Breakers MOBs with dual auxiliary contacts for control of the system
68. location Using the Terminal mode the user calls the UPS to perform basic monitoring In the event of a UPS alarm or notice the user is notified at the remote location The UPS calls through the modem to the user s computer or pager and leaves a message Remote Notification is an extension of the Terminal mode with the additional support algorithms necessary to control an external modem Connection to the UPS is made when a user calls the UPS on the phone The user has exactly the same capabilities as if using a terminal connected directly to an RS 232 port EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 8 3 COMMUNICATION 8 5 8 4 Terminal Mode O 8 5 1 Remote Notification differs from the basic Terminal mode with the addition the following functions e Call Answer The Call Answer function allows the user to call into the UPS from a remote location and enter Terminal mode Call Out The Call Out function allows the UPS to be configured to call either a remote computer or numeric paging service over the phone line Call Out allows the UPS to call a remote computer and leave a one line descriptive message of the alarm or notice condition Numeric paging support allows the UPS to call a paging service and send numeric messages Housekeeping The Housekeeping function maintains the link between the UPS and modem In Terminal mode the user can request the fol
69. menu bar of the UPS to be shutdown The System Status screen is displayed 2 On the System Status screen select either the UPS or the BYPASS command 3 Press the CONTROLS pushbutton on the System Status menu bar The UPS or Bypass Control Command screen is displayed 4 On the Control Command screen select LOAD OFF 5 Press the SELECT pushbutton on the Command menu bar The Load Off screen is displayed providing a choice to proceed or abort the shutdown 7 26 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS CAUTION All power to the critical load is lost when the LOAD OFF is selected in the following step You should use this feature only when you want to de energize the critical load 6 To shut down the UPS press LOAD OFF from the Load Off menu bar and hold for three seconds To abort the shutdown press CANCEL When LOAD OFF is selected and held for three seconds the input output battery and bypass backfeed contactors open and the power module is turned off on all UPSs 7 If another UPS is to be shutdown proceed to that UPS and repeat Steps 1 through 6 CAUTION Do not attempt to restart the system after the Load Off until the cause of the shutdown has been identified and cleared 8 Restart the UPS after pressing the LOAD OFF pushbutton by following the procedure in paragraph 7 4 1 on page 7 20 or 7 4 2 on page 7 21
70. o o o o o o Section A A NOTE AC Input to Bypass terminals are not applicable to an IOM configuration 4 24 Phase C E3 AC Input to Phase B E2 put to Phase A E1 UPS Rectifier Phase A E6 Phase B E7 aes Phase C E8 Figure 4 21 ISBM Section Power Terminal Detail AA Common Rectifier Feed EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com AC Input to UPS Rectifier A B C UPS SYSTEM INSTALLATION See Figure 4 23 for Detail AA AC Input to UPS Bypass A B C See Figure 4 23 for Detail AA AC Output to Critical Load DC Input from Battery E4 See Figure 4 25 or Figure 4 26 for Detail BB DC Input from Battery See Figure 4 25 or Figure 4 26 for Detail BB Neutral E12 Bag a A AS 3 x o l d Q Mod oe la Phase C E11 Phase B E10 gt Phase A E9 LB E Y o ore o A Ca lo o D
71. of the log the most recent events is displayed first scroll upward to view older event listings To scroll through the events press the up or down arrow pushbutton on the menu bar To return to the User History screen press the USER pushbutton on the menu bar To return to the Active Events screen press the EVENTS pushbutton on the menu bar Meters UPS Meters UPM The Meter screens show the UPS meter readings for the unit The default voltage displayed on these screens is phase to neutral However an authorized Eaton Customer Service Engineer can change the screens to display the voltage phase to phase A B B C C A Press the METERS pushbutton on the main menu bar to display the Meter screens To scroll through the meter screens press the up or down arrow pushbutton on the menu bar The current UPS readings are displayed in the information area of the screen Output UPS Output UPM 1 2 3 4 The Output screen shows output voltage phase to neutral output current each phase and frequency being supplied by the UPS as well as the kVA kW and power factor measurements Input UPS Input UPM The Input screen shows input voltage phase to neutral input current each phase and frequency of the incoming utility source as well as the kVA kW and power factor measurements Bypass The Bypass screen shows the bypass input voltage phase to neutral input current each phase and frequency of the incoming utility
72. on page 4 18 and secure with the retained hardware 4 28 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION 4 TO DC Input from Battery E4 8 4 duo db due db mall dp de lap qp 1r dh d a Hi Hi Bo Front E 5 E MS po db de 4 ux mb CG Gi Giit Gup Th ib db lap lag Lus DC Input from Battery E5 T Section B B Figure 4 25 ISBM Section Power Terminal Detail BB Common Battery EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 29 UPS SYSTEM INSTALLATION E O DC Input from Battery E4 UPM 3 3 DC Input from Battery E4 UPM 2 DC Input from Battery E4 UPM 1 DC Input from Battery E4 UPM 4 FI UPM 5 a euo auo den cu Lh eye lap lap age a El x zx all Bof Front P 5
73. see the caution statement at the beginning of this procedure raise the cabinet until the cabinet bottom clears the pallet by approximately 3 mm 1 8 5 Pull the pallet from under the cabinet Discard or recycle the pallet and shipping brackets in a responsible manner 6 Carefully lower the cabinet until the cabinet base contacts the floor 7 Repeat Steps 2 through 6 for the remaining cabinet 8 Proceed to paragraph 4 3 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 3 UPS SYSTEM INSTALLATION UPM Removable Front Panels Shipping Bracket Bolts Left Side Shipping Bracket Shipping Bracket Bolts Bracket ipp ion Left Side Sh ing the UPM Sect Remov 4 3 Figure EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 4 UPS SYSTEM INSTALLATION Shipping Bracket Bolts Pallet Right Side Shipping Shipping Bracket Bolts Figure 4 4 Removing the UPM Section Right Side Shipping Bracket NOTE The following procedure permits the UPS sections to be installed in a location where there is limited space to slide the sections together from the sides NOTE for the following step section see Table 3 O Mechanically Join
74. sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING ONLINE CHARGING The rectifier and inverter turn on The inverter continues to ramp up to full voltage Once the inverter reaches full voltage the UPS output contactor K3 closes and the static switch turns off Power is now supplied to the critical load in Normal mode It takes approximately one minute for the UPS to achieve Normal mode The NORMAL status indicator is illuminated The UPS status indicates ONLINE The UPM status indicates ONLINE CHARGING EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 11 UPS OPERATING INSTRUCTIONS 7 12 7 3 2 Starting the UPS in Bypass Mode If the inverter output of the UPS is not available and the critical load needs to be energized In Bypass mode the critical load is not protected from commercial power interruptions and abnormalities 1 If the UPS contains input breaker CB1 verify that input breaker CB1 is open Close the UPS input feeder circuit breaker Close the UPS Bypass input feeder circuit breaker Observe the UPS control panel becoming active indicating logic power a R 9 N Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed 6 On the System Status screen verify the UPS status is SHUTDOWN and the UPM status is OFFLINE 7 f the UPS contains input breaker CB1 close
75. source 1 0 reduce the risk of fire or electric shock install this UPS in a temperature and humidity controlled door environment free of conductive contaminants Ambient temperature must not exceed 40 C 04 F Do not operate near water or excessive humidity 95 maximum The system is not intended for utdoor use nsure all power is disconnected before performing installation or service wm oy atteries can present a risk of electrical shock or burn from high short circuit current The following recautions should be observed 1 Remove watches rings or other metal objects 2 Use tools with sulated handles 3 Do not lay tools or metal parts on top of batteries 4 Wear rubber gloves and boots ELECTRIC ENERGY HAZARD Do not attempt to alter any UPS or battery wiring or connectors Attempting 0 alter wiring can cause injury Do not open or mutilate batteries Released electrolyte is harmful to the skin and eyes It may be toxic su n 3 CAUTION Installation or servicing should be performed by qualified service personnel knowledgeable of UPS and battery systems and required precautions Keep unauthorized personnel away from equipment Consider all warnings cautions and notes before installing or servicing equipment DO NOT DISCONNECT the batteries while the UPS is in Battery mode Replace batteries with the same number and type of batteries as originally installed with the UPS isconnect th
76. static switch The static switch is armed and ready during both types of transfers On an UPS configured as an Input Output Module IOM bypass circuitry is not installed This configuration is primarily used in multiple UPS parallel systems that do not need a bypass for each UPS and use a separate System Bypass Module SBM to provide system bypass capabilities A single UPS operates independently to support an applied load from the inverter providing conditioned and uninterruptible AC power to the critical load from the output of the module During an outage the inverter continues to operate supporting power to the load from the battery supply If the unit requires service applied loads are transferred to the internal bypass continuous duty static switch either automatically or manually With the exception of a battery cabinet no other cabinets or equipment are required for the single UPS to successfully support its applied loads Modes The Powerware 9395 UPS supports a critical load in three different modes of operation n Normal mode 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 n Bypass mode the critical load is directly supported by utility power n Battery mode the battery provides DC power which maintains inverter operation The battery supports the critical load
77. the UPS on the customer interface terminal board You can use a normally closed or normally open contact If the state of the contact changes from the state you specify as normal a signal is issued You can connect this contact to equipment at your facility such as a light or an alarm bell to let you know when an alarm is active on the UPS This feature is useful if the UPS is located in a remote area where the UPS horn may not be heard immediately CAUTION Contacts should not be operated in excess of 30 Vac 5A maximum 8 8 Remote Monitor Panel ll As an option an Remote Monitor Panel II RMP Il can be installed to monitor the operation of the UPS system from virtually any location within the facility up to 150m 500 ft from the UPS The RMP II contains backlit status indicators and a local horn The RMP Il can be flush mounted or surface mounted on a desktop or secured to a wall Figure 8 3 shows an RMP Il front panel UNINTERRUPTIBLE POWER SYSTEM STATUS SYSTEM NORMAL Em CEA m sumo CE Figure 8 3 Remote Monitor Panel Il Front Panel EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 8 7 COMMUNICATION The RMP II contains a local horn and the backlit status indicators listed in Table 8 1 Table 8 1 RMP Il Status Indicators SYSTEM NORMAL The UPS is energized either with utility power or battery backup and is sup
78. the device and the UPS cabinet for wiring the switch NOTE Remove the UPS cabinet interface entry conduit landing plates to drill or punch holes see Figure 4 18 on page 4 20 NOTE The REPO switch must be a normally open or normally closed latching type switch not tied into any other circuits NOTE This procedure is intended to be used for the installation of the Eaton Corporation supplied REPO switch If installing another manufacturer s switch use this procedure only as a guide NOTE The REPO switch wiring must be in accordance with NEC Article 725 Class 2 requirements To Install a REPO switch 1 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS Operating Instructions for shutdown instructions 2 Securely mount the REPO switch Recommended locations include operator s consoles or near exit doors See Figure 3 10 on page 3 7 for enclosure dimensions and wiring knockouts 3 Unfasten the front door latch and swing the door open see Figure 4 1 on page 4 2 4 Remove the door Remove the retaining screw located inside the door at the bottom hinge pivot point then lift the door off Retain the hardware for later use e S EMERGENCY POWER OFF UPS SYSTEM ng 5 5 Zo 18 3 z2 cy Ba mo 22 E o REPO Switch Front View Contact Block Back View Faceplate Removed Figure 4 34 REPO Switch EATON Powerware 9395 UPS 650 825 kVA Installation and Operation
79. to highlight the command function desired then press the Commands SELECT pushbutton to execute the command Charger On Turns the battery charger on Charger Off Turns the battery charger off UPM Control Use the up or down arrow pushbutton to highlight the command function desired then press the Commands CONTROLS pushbutton to execute the command UPM On Turns the UPM on without transferring the load to Normal mode The Load is on bypass UPM Off Transfers the load to bypass and turns the UPM off UPM Go to Normal Turns the UPM on and transfers the load to Normal mode Charger On Turns the battery charger on Charger Off Turns the battery charger off EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 9 UPS OPERATING INSTRUCTIONS 7 2 8 Load Off Screen The Load Off screen Figure 7 6 is displayed when the LOAD OFF pushbutton is selected from the main menu bar the UPS Control Command screen or the Bypass Control Command screen This screen allows the LOAD OFF process to be aborted if the LOAD OFF pushbutton was pressed accidentally For Load Off procedures see paragraph 7 3 10 on page 7 17 HOLD LOAD OFF BUTTON FOR pi SECONDS TO TURN OFF LOAD CANCEL LOAD OFF LAE R Figure 7 6 Load Off Screen 7 10 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware co
80. wire sizes listed in Table 3 4 on page 3 9 or Table 3 5 on page 3 10 the DC terminations listed in Table 3 9 on page 3 13 type of battery installation and requirements from NEC Table 4 Electrical Metallic Tubing EMT External overcurrent protection and disconnect are not provided by this product but are required by codes Refer to Table 3 4 on page 3 9 Table 3 5 on page 3 10 or Table 3 6 on page 3 11 for wiring requirements If an output lockable disconnect is required it is to be supplied by the customer Table 3 14 lists the recommended rating for input circuit breakers Table 3 15 lists the recommended rating for input circuit breakers with separate rectifier inputs UPS A separate breaker is required for each UPM Table 3 14 Recommended Input Circuit Breaker Ratings Input Rating UPS Model Load Rating 400V 480V 80 Rated 1600A 1200A Powerware 9395 825 650 10096 Rated 1200A 1000A 8096 Rated 1600A 1600A Powerware 9395 825 750 10096 Rated 1600A 1200A 8096 Rated 2000A 1600A Powerware 9395 825 825 10096 Rated 1600A 1200A 3 16 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING Table 3 15 Separate Rectifier Input Recommended Input Circuit Breaker Ratings Input Rating for Each UPM UPS Model Load Rating 480V Powerware 9395 825 650 8096 Rated 500A Powerware 9395 825 750 Powerware 9
81. 0 10 O 10 O 10 O 10 O UPS 1 UPS 2 UPS 3 UPS 4 If Installed If Installed NOTE Use twisted pair wiring between the UPS and MOB AUX contacts Figure 5 5 Distributed Bypass Pull Chain Wiring without MOBs Table 5 3 Pull Chain Wiring Terminations From To a uc uS DERE i installed E TB2 1 TB2 1 TB2 1 TB2 1 Pull Chain Pull Chain Pull Chain Pull Chain TB2 2 TB2 2 TB2 2 TB2 2 Pull Chain Common Pull Chain Common Pull Chain Common Pull Chain Common 5 6 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INSTALLING OPTIONS AND ACCESSORIES Shielded Twisted Pair Shielded Twisted Pair Shielded Twisted Pair o Q O ON o e o O o ON O o O O OH RO RO N O N O O o O o O o O la o o 0 o O O O O oO Twisted Pair oO Twisted Pair a O Twisted Pair a O Twisted Pair N Om N OF N OR N OW OH Op Of Op T I I T LLL UPS 1 UPS 2 UPS 3 UPS 4 CAN Bridge Card J3 CAN Bridge Card J3 CAN Bridge Card J3 CAN Bridge Card J3 If Installed If Installed Customer Supplied Tie Cabinet MOB 1 MOB 2 MOB 3 MOB 4 NC NC NC NC COM COM COM COM AUX 1 N09 7 AUX 1 Noo AUX 1 Noo AUX 1 Noo LI 3 3 3 NG bA Nat IU No you M a 1 coy AUX 2 NO o AUX 2 NO AUX 2 NOO AU
82. 0 Configurations Figure 7 1 UPS Controls and Indicators ISBM Section Shown Figure 7 2 UPS Control Panel oooooooooooooo oo Figure 7 3 Parts of the LED o Figure 7 4 Main Menu and Mimic Screen Normal Mode Figure 7 5 Typical System Status Screen o o o oo o o Figure 7 6 Load Off Screen Figure 7 7 REPO Operation liiis lessen vi and Relay Interface Module Il Terminal Locations llis Relay Interface Module Il or Supervisory Contact Module Il Wiring us 1 UPS System Common Rectifier Feed Common Battery IOM Configuration 00 000 cee us 1 UPS System Common Rectifier Feed Separate Battery IOM Configuration 0 00 00 eee PS System Separate Rectifier Feed Separate Battery Dual Feed Configuration ooo ooooo oooo oooo us 1 UPS System Separate Rectifier Feed Separate Battery Dual Feed Configuration o oooo ooooo oooo PS System Separate Rectifier Feed Separate Battery IOM Configuration us 1 UPS System Separate Rectifier Feed Separate Battery IOM Configuration 0 00 00 0 00 ee EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 39 4 40 4 41 4 42 5 1 5 3 5 5 5 5 5 6 5 7 5 10 5 10 5 12 5 13 5 14 5 15 5 16 5 17 6 1 6 4 6 6 6 8 6 9 6 10 6 11 6 12 6 13 6 14 6 15 6 16
83. 2 2G1 2G2 3G1 and 3G2 power wiring harnesses Route these harnesses through the wiring access in the right side panel of the ISBM section to the AC Input to UPMs terminals See Figure 4 8 on page 4 11 for common rectifier feed terminal locations or Figure 4 10 on page 4 13 for separate rectifier feed terminal locations 4 8 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION first lug on the stud with the raised barrel portion facing the back of the cabinet Install the second lug with O NOTE Two cable lugs will be connected to each terminal stud When connecting the cable lugs install the the raised barrel portion facing the front of the cabinet 6 Locate the intercabinet wiring terminal hardware kit packed on the bottom right side of the ISBM section 7 Using hardware from the intercabinet wiring terminal hardware kit see Table 3 8 on page 3 12 connect phase A B and C cable lug connections to the AC Input to UPMs terminals Follow the callout details in Figure 4 9 on page 4 12 for commom rectifier feed or Figure 4 11 on page 4 14 for separate rectifier feed to connect the correct cable lug to the proper terminals See paragraph 3 2 2 on page 3 8 for wiring and termination requirements 8 Locate the 1G3 2G3 and 3G3 power wiring harnesses Route these harnesses through the wiring access in the right side panel of the ISBM section to the DC I
84. 395 825 825 100 Rated 400A CAUTION To reduce the risk of fire connect only to a circuit provided with maximum input circuit breaker current ratings from Table 3 14 in accordance with the NEC ANSI NFPA 70 The line to line unbalanced output capability of the UPS is limited only by the full load per phase current values for AC output to critical load shown in Table 3 4 on page 3 9 or Table 3 5 on page 3 10 The recommended line to line load unbalance is 5096 or less Bypass and output overcurrent protection and bypass and output disconnect switches are to be provided by the customer Module Output Breakers MOBs are to be provided by the customer Table 3 16 lists the recommended rating for bypass output and MOB circuit breakers Table 3 16 Recommended Bypass Output and MOB Circuit Breaker Ratings Output Rating UPS Model Load Rating 400V 480V 8096 Rated 1200A 1000A Powerware 9395 825 650 10096 Rated 1000A 800A 8096 Rated 1600A 1200A Powerware 9395 825 750 10096 Rated 1200A 1000A 8096 Rated 1600A 1600A Powerware 9395 825 825 10096 Rated 1200A 1000A EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 17 UPS INSTALLATION PLAN AND UNPACKING 3 18 There is no manual DC disconnect device within the UPS A battery disconnect switch is required for battery systems and may also be required by NEC or local codes The battery dis
85. 400 cfm 400 400 159 40124 825 kVA 480 480 161 40530 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING BEER i a E 1872 ER 13 1 gt gt E E gt gt Em gt boo th a Ta AT T w ya w N 3515 9 140 8 Figure 3 1 UPS Cabinet Dimensions Front View 830 IF 32 1 Figure 3 2 UPS Cabinet Dimensions Right Side View Dimensions are i Dimensions are n millimeters inches in millimeters inches EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 3 UPS INSTALLATION PLAN AND UNPACKING 1872 73 7 Figure 3 3
86. 5 If the UPSs contain input breakers CB1 verify that all input breakers are open Close all UPS input feeder circuit breakers Close all UPS Bypass input feeder circuit breakers Observe the UPS control panel displays becoming active indicating logic power On any UPS press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen verify the UPS status is SHUTDOWN and the UPM status is OFFLINE If the UPSs contain input breakers CB1 close all input breakers EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 21 UPS OPERATING INSTRUCTIONS 10 11 12 13 14 15 16 17 18 19 On the System Status screen select the UPM command On the UPS Control Command screen select the UPM 1 command Press the CONTROLS pushbutton on the System Status menu bar The UPM 1 Control Command screen is displayed On the UPM 1 Control Command screen select UPM ON Press the SELECT pushbutton on the UPM 1 Command menu bar Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 1 rectifier and inverter turn on If the Inherent Redundancy option is enabled a loss of redundancy alarm will be issued Silence the alarm and continue to Step 14 Repeat Steps 8 through 12 selecting UPM 2 to start UPM 2 Obse
87. 5 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 21 UPS INSTALLATION PLAN AND UNPACKING 3 22 4 Remove the protective covering from the cabinets 5 Remove the packing material and discard or recycle in a responsible manner 6 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 an Eaton service representative immediately to determine the extent of the damage and its impact on further installation NOTE While waiting for installation protect the unpacked cabinets from moisture dust and other harmful contaminants Failure to store and protect the UPS properly may void your warranty eS SSS ize E gt Ez S REEL EL gt gt SS ae ed gt EE SS gt Pa Pr E FIVE Figure 3 11 UPS Cabinet as Shipped on Pallet ISBM Section EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING
88. 6 17 6 18 6 19 6 20 6 22 6 23 6 25 6 27 6 28 6 29 7 1 7 2 7 4 7 5 7 8 7 10 7 19 TABLE OF CONTENTS gure 8 Optional XeSIat Cards ria Le S et e e n es e ee ee ebd d d YD E de ciel rote e den 8 2 gure 8 2 Sampe Event HIST LOG exo eR BN any MARRE AU RETE S Bae UMORE TRIAL Shee EENS 8 6 gure 8 3 Remote Monitor Panel ll Front Panel RR RR RR ls 8 7 gure 8 4 Relay Interface Module Il Customer Interface Connectors J1 through JA ooo 8 9 gure 8 5 Supervisory Contact Module Il Enclosure RR 8 10 gure 9 1 15BM Section Alr Filter Locations s ooo kaba eth n loce kaan qoe Na ete e del ded oe alin gb edo ahaha 9 3 gure 9 2 UPM Section Air Filter Locations iiis RR Y s 9 4 gute 9 3 FI UPM Air Filter Location use ee REC ERO a NOTE AG ees HIER COO a tds 9 5 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com vii TABLE OF CONTENTS This page intentionally left blank viii EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Chapter 1 Introduction Eaton s Powerwaree 9395 uninterruptible power supply UPS is a true online continuous duty transformerless double conversion solid state three phase system providing conditioned and uninterruptible AC power to protect the customer s load from power failures The Powerware 9395 UPS 650 825 kVA contains two sections an integrated sy
89. 64201725 Rev 2 www powerware com 4 21 UPS SYSTEM INSTALLATION UPS 1 by A Bypass Input to UPS Units DV xa 1A aN pn 2A Battery 2A UPS 2 a by ay Battery UPS 3 by KING Output from UPS Units 1B P Battery 2B ZA UPS 4 3B TE NY UN 4B Sak Battery NOTE Required parallel system wiring length must be equal to ensure approximately equal current sharing when in Bypass mode For proper operation the following must be true 1A 2A 3A 4A 1B 2B 3B 4B NOTE Any difference in wire length will result in decreased capacity of the UPS system while on bypass For example a 10 difference between the longest and shortest wire lengths will result in a decrease in bypass capacity of 10 Figure 4 19 Distributed Bypass Wire Length 4 22 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com AC Input to UPS Rectifier A B C UPS SYSTEM INSTALLATION See Figure 4 21 for Detail AA AC Input to UPS Bypass A B C See Figure 4 21 for Detail AA AC
90. 782 1083 902 1191 992 3 Phases 1 Ground D Minimum Conductor Size AWG or kcmil 500 350 500 500 500 500 Number per Phase each 3 3 4 3 4 4 AC Output to Critical Load Five Wire Full Load Current Amps 938 782 1083 902 1191 992 3 Phases 1 Neutral 1 Ground D Minimum Conductor Size AWG or kcmil 400 350 500 500 500 500 Number per Phase each 4 3 5 3 5 4 Neutral Bonding Jumper Four Wire Output Only Minimum Conductor Size AWG or kcmil 4 0 4 0 4 0 4 0 4 0 4 0 Number T each 1 1 1 1 1 1 NOTE Callout letter A maps to Figure 6 6 Figure 6 8 Figure 6 10 or Figure 6 12 starting on page 6 9 Callout letters B C and D map to Figure 6 6 Figure 6 8 Figure 6 10 Figure 6 12 Figure 6 13 Figure 6 14 Figure 6 15 or Figure 6 16 starting on page 6 9 3 10 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING AC input to the UPS with separate rectifier inputs is wired as if each UPM is rated for 275 kVA see Table 3 6 The bypass input battery input and output are wired the same as a separate battery UPS see Table 3 5 Table 3 6 Separate Rectifier Input UPM Ratings and External Wiring Requirements for the Powerware 9395 825 650 9395 825 750 and 9395 825 825 Separate Battery Units Rating 50 60 Hz Basic UPM Rating kVA 215 275 kw 247 5 250 Input Voltage Volts 400 480 AC Input to ea
91. 80500037 100 Conical Washer M12 92 Rectifier Input Bypass Input Battery Input 180500037 120 Output and Neutral Nut M12 92 Rectifier Input Bypass Input Battery Input 180200001 07 Output and Neutral Table 3 11 Recommended Installation Parts and Tools Not Supplied by Eaton Part Size Quantity Manufacturer Part Number Notes 2 0 AWG Thomas amp Betts 54862BE 3 0 AWG Thomas amp Betts 54864BE 4 0 AWG Thomas amp Betts 54866BE 250 MCM Thomas amp Betts 54868BE Long Barrel 2 Hole Lug MEM MCM As required uos RBS 54870BE Copper wire only 350 MCM Thomas amp Betts 54872BE 400 MCM Thomas amp Betts 54874BE 500 MCM Thomas amp Betts 54876BE Manual Hydraulic Crimp Tool 14Ton 1 Thomas amp Betts TBM14M Die Set N A 1 Thomas amp Betts 15506 Table 3 12 Separate Rectifier Input UPM Power Cable Terminations for the Powerware 9395 825 650 9395 825 750 and 9395 825 825 Tightening Torque Terminal Function Terminal Function Size of Pressure Termination Nm Ib ft Type Screw E1 Phase A 2 6 250 kcmil 42 4 375 5 16 Hex AC Input to each UPM Rectifier E2 Phase B 2 6 250 kcmil 42 4 375 5 16 Hex E3 Phase C 2 6 250 kcmil 42 4 375 5 16 Hex 3 14 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING Conduit sizes were chosen from NEC Table 4 Electrical Metallic Tubing EMT
92. 95 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com AC Input to UPM Rectifiers UPS SYSTEM INSTALLATION Phase A E1 Phase B E2 Phase C E3 eLa gue eee um lis oo igo Cb Q um HID DAO IQ UPM 2 i Co Co Co O D DO Cp lt UPM 4 FIUPM Plus 1 Model Only mi jn rT KI aw O O OO Phase A E1A AC Input to Phase B E2A gt UPM 4 FI UPM Plus 1 Model Phase C E3A Figure 4 24 UPM Rectifier Input Power Terminal Block Detail EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 27 UPS SYSTEM INSTALLATION 4 8 2 Battery Power Wiring CAUTION When sizing the battery system do not exceed the internal battery charger capabilities See Chapter 10 Product Specifications for maximum battery charger currents To install wiring to connections NOTE An installed FI UPM is always designated as UPM 4 Route the battery cables between the ISBM section and the battery system or battery disconnect See Fig
93. AC Input to Bypass and Output Five Wire 5 3 5 A B C Neutral Ground AC Input to UPS Rectifier Powerware 9395 825 750 A B C Ground 4 3 4 AC Input to UPS Rectifier Separate Feed 4 2 2 A B C Ground Each UPM 480 Vac AC Input to Bypass and Output Four Wire 4 3 3 A B C Ground AC Input to Bypass and Output Five Wire 5 3 4 A B C Neutral Ground Battery DC Positive Negative Ground See Note EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 15 UPS INSTALLATION PLAN AND UNPACKING Table 3 13 Power Cable Conduit Requirements continued 3 Number of Wires Minimum Conduit Number of Lese Voltage cupis in Conduit Trade Size Conduits AC Input to UPS Rectifier A B C Ground 1 3 5 AC Input to UPS Rectifier Separate Feed 4 2 3 A B C Ground Each UPM 400 Vac AC Input to Bypass and Output Four Wire 4 3 4 A B C Ground AC Input to Bypass and Output Five Wire 5 3 5 A B C Neutral Ground AC Input to UPS Rectifier Powerware 9395 825 825 A B C Ground 4 3 4 AC Input to UPS Rectifier Separate Feed 4 2 2 A B C Ground Each UPM 480 Vac p AC Input to Bypass and Output Four Wire 4 3 4 A B C Ground AC Input to Bypass and Output Five Wire 5 3 5 A B C Neutral Ground DC Battery See Note Positive Negative Ground NOTE Select conduit taking into consideration the DC input
94. AN bus is lost The system is paralleled for redundancy 1 41 in a system where two UPMs are paralleled together and the load is less than the supporting capability of one of the UPMs The system is paralleled for capacity 2 0 if both UPMs in a system are required to support the load A parallel capacity system can also be redundant 2 1 as long as there is always one or more UPMs online than required to support the load Multiple UPS Parallel System Modes Similar to the single UPS system the Powerware 9395 UPS parallel system supports a critical load in three different modes of operation The standard operation modes are n Normal mode the paralleled UPMs supply the critical load with clean filtered power Each UPM battery charger also provides charging current for the battery if needed n Battery mode the battery provides DC power which maintains UPM operation The UPM batteries support the critical load n Bypass mode the critical load is directly supported by utility power through the continuous duty static bypass switch in each UPS EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 21 UNDERSTANDING UPS OPERATION 6 4 2 Bypass Input The UPSs continually monitor themselves and the incoming utility power and automatically switch between these modes as required without operator intervention except when manually switching to Bypass mode The s
95. ATION AC Input to UPS AC Input to Bypass Battery Aux Building Alarms Rectifiers 3 Wire 3 or 4 Wire A B C A B C Rotation Rotation 48V Battery Alarm Relays EN NN NY Bypass Shunt Trip A A A A Breaker X Slot UPM 4 UPM 3 UPM 2 UPM 1 Y B CB4 DERI merate Oo Un El El El El ES E7 Interface Board E2 E2 E2 E2 E8 E12 4 Backfeed E3 E3 E3 E3 Static FORM 5 F Switch al use gt Input Input Input nput Contactor Contactor Contactor Contactor K1 K1 K1 K1 Rectifier Rectifier EE Rectifier Rectifier Fuse Fuse Fuse Fuse e e e e Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Inverter Inverter Inverter Inverter ce ee SN e Output Output Output Output Contactor Contactor Contactor Contactor K3 K3 K3 K3 AC Output e e e e to Critical E9 D Load Battery Battery Battery Battery E10 Converter e Converter Converter Converter 3 Fuse Fus
96. All alarms are accompanied by an audible horn To silence the horn press any control panel pushbutton once The Alarm indicator may be illuminated along with other indicators pag Flashing There is a new UPS alarm condition The indicator flashes until acknowledged by pressing any control panel pushbutton once 7 2 2 System Events When the UPS system is running in Normal mode it continually monitors itself and the incoming utility power In Battery or Bypass modes the UPS may issue alarms to let you know exactly what event caused the change from Normal mode System events on the UPS can be indicated by horns lights messages or all three Select EVENTS from the menu bar on the main menu screen to look at the active events screen This screen shows any currently active alarms notices or commands For more information on using the events screen see paragraph 7 2 6 on page 7 6 System Event Horns The system event horn beeps to alert an operator that an event needing attention is taking place The horn cycles at a half second rate e System Event Indicators The status indicators on the UPS control panel work with the event horn to let the operator know when the is operating in any mode other than normal Only the ON indicator is visible during normal UPS system operation The other indicators illuminate to indicate alarms or events When an alarm occurs first check these indicators to see what type of event has taken place For descripti
97. Contactor Contactor Contactor K1 K1 K1 ei Rectifier B Rectifier E Rectifier Fuse Fuse Fuse e Fuse Fuse Fuse Fuse Fuse C Fuse CC Inverter CC Inverter Inverter ce e kar Output Output Output Contactor gt Contactor Contactor K3 K3 K3 AC Output to a Critical Load E9 E10 D Battery Battery Battery E11 E12 Converter Converter Converter Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPS UPM 1 UPM 2 UPM 3 CABINET E4 E5 E4 E5 E4 E5 KEN NC My CN 4 o oH o oji o oh Battery Breaker BATTERY SYSTEM Not supplied with the UPS Battery Breaker BATTERY SYSTEM Not supplied with the UPS Battery Breaker BATTERY SYSTEM Not supplied with the UPS NOTE Callout letter A maps to Table 3 6 on page 3 11 Callout letters B C and D map to Table 3 5 on page 3 10 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Service Connector Figure 6 13 UPS System Separate Rectifier Feed Separate Battery Dual Feed Configuration 6 16 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPER
98. D OFF procedure in paragraph 7 3 10 The input output battery and bypass backfeed contactors open and the power module is turned off Power is present inside the UPS cabinet sections until the upstream input feeder circuit breaker is opened pene 3 4 If the UPS contains input breaker CB1 open the UPS input breaker CB1 Open the UPS input and bypass feeder circuit breakers 7 3 9 Charger Control To turn the battery charger on 1 4 5 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the CHARGER command Press the CONTROLS pushbutton on the System Status menu bar The Charger Control Command screen is displayed On the Charger Control Command screen select CHARGER ON Press the SELECT pushbutton on the Charger Command menu bar To turn the battery charger off 1 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the CHARGER command Press the CONTROLS pushbutton on the System Status menu bar The Charger Control Command screen is displayed On the Charger Control Command screen select CHARGER OFF Press the SELECT pushbutton on the Charger Command menu bar 7 16 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS 7 3 10 Using the UPS LOAD OFF Pu
99. EEEHHEEH HHHEEHHHEHHHEEHHEHEHHEEH e O sis ssl BHBHEHEHEBREEBHERERERERH BEEEHEHOEBBREEBEREREREEEG o O ssl ll U ssl sl ssl sl ssl sl ssl ssl b B peedanienbeanbc an god EaceeHapapeebe Ego m sla a a a o o o o o o o o gt D D far gt AC Output from UPMs See Figure 4 13 for detail Phase B Ha E y ab c eb e Neutral from UPMs See Figure 4 13 for detail Phase C AC Input to UPMs Phase B See Figure 4 9 for detail Phase A DC Input to UPMs E5 See Figure 4 12 for detail DC Input to UPMs E4 See Figure 4 12 for detail Figure 4 10 ISBM Section Intercabinet Power Terminal Locations Separate Rectifier Feed EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 13 UPS SYSTEM INSTALLATION UPM 1 Cable 161 amp 162 Brown Phase B E2A o OG 98 00 o x UPM 1 Cable 161 amp 162 Orange m UPM 1 Cable 161 amp 1G2 Yellow PEO Y iw Phase A ETA UPM 2 Cable 2G1 amp 262 Orange XO UPM 2 Cable 261 amp 2G2 Yellow gt Phase C E3A iw WZ UPM 3 Cable 361 amp 362 Orange UPM 3 Cable 361 amp 362 Yellow Phase A Phase B Phase A Phase B E2A UPM 3 Cable 3G1 amp 3G2 Brown U
100. ES E4 ES UPS CABINET FN CN CX ug m 0 o 4 i tg o 4ili O o 4ili O o 4ili Battery Battery Battery Battery Breaker Breaker Breaker Breaker BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM Not supplied with the UPS Not supplied with the UPS Not supplied with the UPS Not supplied with the UPS NOTE Callout letters A B C and D map to Table 3 5 on page 3 10 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 8 Plus 1 UPS System Common Rectifier Feed Separate Battery Dual Feed Configuration EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Service Connector 6 11 UNDERSTANDING UPS OPERATION AC Input to Battery Aux Building Alarms UPS Rectifier 3 Wire A B C 48V Battery Alarm Relays Rotation
101. IONS AND ACCESSORIES 5 5 Installing an Optional Supervisory Contact Module II To install SCM Il wiring 1 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS Operating Instructions for shutdown instructions 2 Perform the procedure listed in paragraph 5 1 on page 5 1 NOTE If mounting to a hollow wall secure the enclosure to a wood or metal stud within the wall Do not use hollow wall anchors 3 Securely mount the SCM II at the desired location See Figure 5 14 on page 5 17 for mounting hole locations NOTE When installing signal wiring for CAN card J3 terminals conduit must be installed between the device and the UPS cabinet 4 Remove the ISBM cabinet top right interface conduit landing plate to drill or punch conduit holes see Figure 4 18 on page 4 20 5 Reinstall the conduit landing plate 6 Install conduit between the UPS and SCM ll See Figure 5 14 on page 5 17 for SCM II knockout hole location 7 Install wiring between the UPS and SCM II See Figure 5 2 and Table 5 1 for the Powerware Hot Sync CAN Bridge Card terminal location and wiring information and Figure 5 10 Figure 5 8 and Table 5 5 for the SCM II terminal location and wiring information o NOTE 120 Vac for the SCM Il should be supplied from the critical bus by facility planners or the customer 8 Install 120 Vac power wiring from the critical bus to the SCM II See Figure 5 10 Figure 5 8 and
102. ISBM Section Dimensions Front View Figure 3 4 UPM Section Dimensions Front View 3 4 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING 32 670 5 2 26 4 munnenunnn E H i H E Hi i H H 540 21 3 o Front V 4 Dimensions are in millimeters inches Figure 3 5 ISBM Section Dimensions Top View Front Ng i J j J J 520 que n FL 20 o 650 26 or LIU NO Dimensions are in millimeters inches Figure 3 6 ISBM Section Dimensions Bottom View 415 4 44 514 4 a 158 8 29 9 CUT aka c TE pu ARE Xx an m ER Front Di m
103. ISBM section Identify all conduit requirements and mark their location Drill and punch all conduit holes in the bottom conduit plate prior to mounting on the ISBM section Install the conduit plate and install all conduit runs into the plate Pull wiring through conduit into the ISBM section wiring area 4 20 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION 4 Locate the external wiring terminal hardware kit packed on the bottom left side of the ISBM section 5 If installing an UPS with separate rectifier feeds proceed to Step 6 otherwise proceed to Step 8 NOTE Onan UPS that is configured for separate rectifier inputs all sources that feed the separate rectifier inputs must be derived from a common ground point 6 Connect phase A B and C rectifier input power wiring from the utility source to each UPM rectifier input terminal block in the UPS cabinet See paragraph 3 2 2 on page 3 8 Table 3 6 on page 3 11 and Table 3 12 on page 3 14 for wiring and termination requirements 7 Proceed to Step 9 8 Using hardware from the external wiring terminal hardware kit see Table 3 10 on page 3 14 connect phase A B and C rectifier input power wiring from the utility source to the rectifier input terminals in the ISBM section See paragraph 3 2 2 on page 3 8 for wiring and termination requirements 9 If installing an UPS configured as an Inpu
104. LAN and telephone drops for use with X Slot connectivity cards must be provided by the customer The UPS battery aux signal wiring from the UPS must be connected to the battery disconnect device A supplemental 48 Vdc shunt trip signal for the battery disconnect device is provided but is not required for normal operation Battery aux and 48 Vdc shunt trip wiring should be a minimum of 18 AWG The REPO feature opens all contactors in the UPS cabinet and isolates power from your critical load Local electrical codes may also require tripping upstream protective devices to the UPS The REPO switch must be a latching type switch not tied to any other circuits A jumper wire must be connected between pins 1 and 2 on TB1 if the normally closed REPO contact is not used REPO wiring should be a minimum of 22 AWG and a maximum of 14 AWG EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 19 UPS INSTALLATION PLAN AND UNPACKING 3 20 e The REPO switch wiring must be in accordance with NEC Article 725 Class 2 requirements e The maximum distance between the REPO and the UPS cannot exceed 150 meters 500 feet Alarm relay contacts have a maximum current rating of 5A and a switched voltage rating of 30 Vac and 28 Vdc Alarm relay wiring should be a minimum of 22 AWG 3 24 Distributed Bypass Power Wiring Preparation Read and understand the following notes while plann
105. Manual 164201725 Rev 2 www powerware com 4 39 UPS SYSTEM INSTALLATION 5 To gain access to terminal block TB1 and the interface entry conduit landing plate remove the screws securing the top internal safety shield panel and remove the panel Retain the hardware for later use see Figure 4 27 on page 4 32 6 Remove the left interface entry conduit landing plate to drill or punch holes see Figure 4 18 on page 4 20 7 Reinstall the interface entry plate and install conduit 8 To locate the appropriate terminals and review the wiring and termination requirements see paragraph 3 2 2 on page 3 8 Table 4 1 on page 4 33 and Figure 4 27 through Figure 4 30 starting on page 4 35 9 Route and connect the wiring as shown in Table 4 2 and Figure 4 35 10 If the normally closed REPO TB1 connection in the UPS is not used connect a jumper wire between pins 1 and 2 on TB1 11 If you are installing multiple REPO switches wire additional switches in parallel with the first REPO Table 4 2 REPO Wire Terminations From REPO Station s To Customer Interface Switch Contact Block Terminal Board TB1 in Wire Size Tightening Torque Either Block UPS Cabinet 3NO TB1 3 Twisted Wires 2 Jibi 14 22 AWG e 4 NO TB1 4 0 75 4 0 mm 0 8 Nm LO 1 N0 liso 2 Return UPS TB1 3 ji O 3 NO REPO Switch bus NO ires pi O 4 Return NOTE REPO switch rating is 24 Vdc 1A minimum NOTE
106. OTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com A B O O os El E6 E UPS 1 E E3 Fuse E8 O CBI E12 Co optional KM O CB4 M Rectifier Static Y switch Fuse TI E 9 Fuse e Fuse 7 Inverter JN K3 Battery Converter Fuse K2 C Q E4 E5 Battery Breaker am o E9 TIE E10 BATTERY SYSTEM CABINET E11 Not supplied Optional E12 with the UPS MOB 1 D f X Qo MOB 2 EN 0 0 OS MOB 3 ON o 0B 4 KEN o E Y AC Output to Critical Load Figure 6 23 Typical Distributed Bypass System 341 and 440 Configurations 6 29 UNDERSTANDING UPS OPERATION This page intentionally left blank 6 30 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Chapter 7 UPS Operating Instructions This section describes how to operate the UPS been performed by authorized service personnel The preliminary startup verifies all electrical o NOTE Before starting the UPS ensure all installation tasks are complete and a preliminary startup has interconnections to ensure the installation was
107. Open all of the UPSs input and bypass feeder circuit breakers 7 4 9 Charger Control To turn the battery charger on 1 4 5 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the CHARGER command Press the CONTROLS pushbutton on the System Status menu bar The Charger Control Command screen is displayed On the Charger Control Command screen select CHARGER ON Press the SELECT pushbutton on the Charger Command menu bar To turn the battery charger off 1 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the CHARGER command Press the CONTROLS pushbutton on the System Status menu bar The Charger Control Command screen is displayed On the Charger Control Command screen select CHARGER OFF Press the SELECT pushbutton on the Charger Command menu bar EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 25 UPS OPERATING INSTRUCTIONS 7 4 10 Using the UPS LOAD OFF Pushbutton or Command A UPS Load Off is initiated by the LOAD OFF pushbutton from the main menu bar the Load Off command on the UPS Control Command screen or Load Off command on the Bypass Control Command screen The UPS LOAD OFF controls the UPSs outputs by powering down the UPS and de energizing the critical load The UPSs including
108. Output to E9 E10 Critical Load Battery Battery Battery E11 E12 Converter Converter Converter Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPS UPM 1 UPM 2 UPM 3 CABINET e E4 E5 KS o oii Battery Breaker BATTERY SYSTEM Not supplied with the UPS Service Connector NOTE Callout letters A B C and D map to Table 3 4 on page 3 9 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 5 UPS System Common Rectifier Feed Common Battery Dual Feed Configuration EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION AC Input to AC Input to Battery Aux Building Alarms UPS Rectifier Bypass 3 Wire A B C
109. P Card provides remote monitoring through a Web browser interface e mail and a network management system NMS using SNMP connects to a twisted pair Ethernet 10 100BaseT network It has a built in Switching hub that allows three additional network devices to be connected to the network without the requirement of additional network drops NOTE The Modem Card cannot be installed in X Slot 2 Modem Card provides out of band remote notification and monitoring using modem communication directly to cell phones and pagers Relay Interface Card AS 400 has isolated dry contact Form C relay outputs for UPS status Utility failure Low battery UPS alarm OK or On bypass when interfacing with IBM AS 400 computers other relay connected computers and industrial applications Industrial Relay Card IRC indicates the operating status of the UPS system using the customer s monitoring equipment The IRC uses four isolated normally open or normally closed dry relay contacts to indicate the UPS status Normal Bypass Battery and Alarm modes can be monitored Powerware Hot Sync CAN Bridge Card provides connectivity for operational mode control and metering of a parallel system at any UPM in the system In addition this card can be used to connect optional system monitoring devices such as a Remote Monitor Panel II RMP Il a Relay Interface Module II RIM Il or a Supervisory Contact Module II SCM II to the UPS Power Xpert
110. PM 2 Cable 2G1 amp 2G2 Brown Phase B E2A AC Input to UPMs NOTE 7wo cable lugs will be connected to each terminal stud When connecting the cable lugs install the first lug on the stud with the raised barrel portion facing the back of the cabinet Install the second lug with the raised barrel portion facing the front of the cabinet NOTE On an UPS without CB1 UPM input wiring terminations are in the same positions on the bus bars installed in the place of CB1 NOTE On an UPS configured as an Input Output Module IOM UPM input wiring terminations are the same as an ISBM configuration Figure 4 11 ISBM Section Input Power Terminal Detail Separate Rectifier Feed 4 14 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION Na Cable 163 Red lt Cable 163 B UPM EA o n Q v T UPM 1 1E5A Cable 1G3 Red G Cable 163 Blac e Cable 2G3 Red S Cable 2G3 Blac DC Input to UPMs UPM 2 2E4A UPM 2 2E5A DC Input to UPMs Cable 263 Red Cable 263 Blac Cable 363 Red Cable 363 B upm agen Aa O AN UPM 3 3E5A Cable 363 Red Cable 3G3 Blac a Figure 4 12 ISBM Section Battery Input Power Terminal Detail gt UPM 1 Cable 1G4 8 165 Orange
111. Phase A 3 stud mounting 12 8 3 M8 E10A UPM 1 E10A UPM 2 E10A UPM 3 Phase B 3 stud mounting 12 8 3 M8 AC Output from UPM Section E11A UPM 1 E11A UPM 2 E11A UPM 3 Phase C 3 stud mounting 12 8 3 M8 E12A UPM 1 E12A UPM 2 E12A UPM 3 Neutral 3 stud mounting 12 8 3 M8 1E4A UPM 1 2E4A UPM 2 3E4A UPM 3 Positive 6 stud mounting 2 per UPM 12 8 3 M8 DC Input to UPM Section 1E5A UPM 1 2E5A UPM 2 3E5A UPM 3 Negative 6 stud mounting 2 per UPM 12 8 3 M8 Table 3 8 Supplied Intercabinet Wiring Terminal Hardware Kit Part Size Quantity Terminals Used On Eaton Part Number Flat Washer M8 36 UPM AC Input UPM Battery Input UPM AC 180500036 080 Output and Neutral Conical Washer M8 36 UPM AC Input UPM Battery Input UPM AC 180500037 080 Output and Neutral Nut M8 36 UPM AC Input UPM Battery Input UPM AC 180200001 05 Output and Neutral 3 12 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING For an UPS with common rectifier input terminals ET through E12 are 2 hole bus bar mountings for standard NEMA 2 hole barrel lugs The power wiring connections for this equipment are rated at 90 C See Table 3 9 for external power cable terminations Table 3 10 for supplied external wiring terminal ha
112. Relays Shunt Trip X Slot Remote EPO Interface 1 LU UU El El El EZ EZ EZ Interface Board E3 E3 E3 nput nput Input Contactor Contactor Contactor K1 K1 K1 Rectifier B Rectifier E Rectifier Fuse Fuse Fuse e Fuse Fuse Fuse Fuse Fuse LI Fuse CC Inverter CC Inverter Inverter ce e kar Output Output Output Contactor gt Contactor Contactor K3 K3 K3 AC Output to a Critical Load E9 E10 D Battery Battery Battery E11 E12 Converter Converter Converter Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPS UPM 1 UPM 2 UPM 3 CABINET E4 E5 E4 E5 E4 E5 KEN NC My CN 4 o oH o oji o oh Battery Breaker BATTERY SYSTEM Not supplied with the UPS NOTE Callout letter A maps to Table 3 6 on page 3 11 Callout letters B C and D map to Table 3 5 on page 3 10 Battery Breaker BATTERY SYSTEM Not supplied with the UPS Battery Breaker BATTERY SYSTEM Not supplied with the UPS Service Connector NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bon
113. S Bypass Four Wire Full Load Current Amps 938 782 1083 902 1191 992 3 Phases 1 Ground B Minimum Conductor Size AWG or kcmil 500 350 500 500 500 500 Number per Phase each 3 3 4 3 4 4 AC Input to UPS Bypass Five Wire Full Load Current Amps 938 782 1083 902 1191 992 3 Phases 1 Neutral 1 Ground B Minimum Conductor Size AWG or kcmil 400 500 500 500 500 500 Number per Phase each 4 3 5 4 5 5 DC Input from Battery Di t to UP C input from Battery Disconnect to UPS Total Amps 1280 1280 1502 1502 1600 1600 1 Positive 1 Negative C Minimum Conductor Size AWG or kcmil 350 350 500 500 500 500 Number per Pole each 6 6 6 6 6 6 AC Output to Critical Load Four Wire Full Load Current Amps 938 782 1083 902 1191 992 3 Phases 1 Ground D Minimum Conductor Size AWG or kcmil 500 350 500 500 500 500 Number per Phase each 3 3 4 3 4 4 AC Output to Critical Load Five Wire Full Load Current Amps 938 782 1083 902 1191 992 3 Phases 1 Neutral 1 Ground D Minimum Conductor Size AWG or kcmil 400 500 500 500 500 500 Number per Phase each 4 3 5 4 5 5 Neutral Bonding Jumper Four Wire Output Only Minimum Conductor Size AWG or kcmil 4 0 4 0 4 0 4 0 4 0 4 0 Number each 1 1 1 1 1 1 NOTE Callout letters A B C and D map to Figure 6 5 Figure 6 7 Figure 6 9 or Figure 6 11 starting on page 6 8 EATON Powerware 9395 UPS 650 825 kVA Installation and Oper
114. See Table 3 4 on page 3 9 for neutral bonding jumper wire sizes Bonding jumper must be copper wire Use the procedures in the following paragraphs to connect the external and battery power wiring External Power Wiring Installation To install wiring to connections 1 Remove one top screw and two bottom screws securing each ISBM section left and right front panel see Figure 4 2 on page 4 3 Lift the panels straight up to remove them from the panel hanger brackets at the top of the cabinet 2 Remove the screws securing the top and bottom internal safety shield panels and remove the panels to gain access to the input output and battery terminals Retain the hardware for later use EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION Ventilation Grill Debris Shield Remove shield before operating system ISBM Section Front Ventilation Grill Debris Shields E Remove shields before operating TA UPM Section e A Y Front Figure 4 17 ISBM and UPM Section Debris Shields EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 19 UPS SYSTEM INSTALLATION Top Entry Conduit Landing for AC Input and Output and DC
115. TICAL LOAD Output DISTRIBUTION UNIT from UPS MAINTENANCE BYPASS PANEL Provided by Others Backfeed Contactor Static ON Switch o s M P Output O pg Contactor Ga JN e UPS dn Battery o Breaker Bilar BATTERY SYSTEM RIB Rectifier Input Breaker BIB Bypass Input Breaker MIS Maintenance Isolation Breaker MBP Maintenance Bypass Breaker NOTE f installing a maintenance bypass a minimum of two separate feeds with upstream feeder breakers or a single feed with two upstream feeder breakers must be provided one for the UPS or rectifier input breaker RIB if installed and one for the maintenance bypass input DO NOT use a single feed or a single feeder breaker to supply both the UPS or RIB and the maintenance bypass If a bypass input breaker BIB is installed in the maintenance bypass and a single feed UPS is being installed a single feed to the maintenance bypass is acceptable for supplying both the UPS and the bypass Figure 6 17 Simplified Dual Feed UPS with Maintenance Bypass Panel 6 20 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION 6 4 Multiple UPS Distributed Bypass System 6 4 1 Distributed bypass parallel operation extends the normal operation of Powerware 9395 UPSs by offering increased capacity and or redundant capability The parallel
116. TON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com o INSTALLING OPTIONS AND ACCESSORIES NOTE Setup of the Powerware Hot Sync CAN Bridge Card must be performed by an authorized Eaton Customer Service Engineer Contact an Faton service representative to schedule a date 11 12 To check the operation of the RMP Il ensure that the UPS is supplying the load via inverter or bypass If the indicators on the RMP Il show the appropriate status then it is operating correctly If the communication link between the UPS and the RMP Il is not present the RMP Il performs a self test all indicators flash and the horn beeps at one second intervals If the self test occurs check all harness connectors and the fuse for proper seating If all connections are secure but the RMP II continues to self test replace the fuse with the spare included in the hardware kit If a fuse replacement does not correct the problem contact an Eaton service representative for verification that the RMP II is working correctly To test the indicator lamps press and hold the horn silence pushbutton for three seconds All lamps should illuminate and the horn sounds continuously until you release the pushbutton 5 4 Installing an Optional Relay Interface Module Il O 0 1 To install RIM Il wiring Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS O
117. The REPO switch must be a latching type switch not tied to any other circuits NOTE AREPO normally open and normally closed return terminals are separated on the terminal board but are electrically in common Figure 4 35 Normally Open REPO Switch Wiring 4 40 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION 12 If required install wiring from the REPO switch to the trip circuitry of the upstream protective devices A second contact block is provided on the REPO Switch for this function see Figure 4 34 The REPO switch wiring must be in accordance with NEC Article 725 Class 2 requirements 13 Reinstall the top internal safety shield panel and secure with the retained hardware 14 Reinstall the front door removed in Step 4 and secure with the retained hardware 15 Close the door and secure the latch Figure 4 36 shows the wiring connections if the normally closed REPO contacts are used and Figure 4 37 shows alternative methods of connecting a REPO switch if using another manufacturer s switch 1 O 1 NC REPO Switch Twisted NC Wires bi O 2 Return UPS TB1 O 3 NO O 4 Return NOTE REPO switch rating is 24 Vdc 1A minimum NOTE 7he REPO switch must be a latching type switch not tied to any other circuits NOTE REPO normally open and normally closed return terminals are separated on the terminal board but ar
118. UPS and Critical koad Shutdown 4 tiesit ands edhe I ote eee ete eden ds eer aa ee etate e hak a 7 25 7 4 9 Charger Conto c m de eare ie a E FA E EEN tat Doo a io rete Da NA Ft PANA an Pag GRE N EAE 7 25 7 4 10 Using the UPS LOAD OFF Pushbutton or Command 1 26 7 4 11 Using the Remote Emergency Power off Switch s 7 27 8 COMUNICA ON a PISO dE UP dut qeu ide iur A but 8 1 NA AN 6 4 t 0 AA X Ee EEUU EE 8 1 82 ENON SONCE naaa nana na itio tote c ates eee ades dora ms adsum diente Een ta qe ae ence Ptr eee nua eae 82 82 1 eNotity Semice Feature Sien 4 aot rr rs t t e ER t t Ph cec d AE RU ten S 82 822 Installing eNOtIfViSerVICB e e epe e era etu ee ee de o d han 82 8 3 Powerware LanSafe Power Management Software 8 3 84 Remote Notitication elus ep peste Rec ERREUR EET UE ie ares Aa 8 3 85 Terminal Mode ete t te E eo ab fee e e SR feos E e RO EM UR a e ifa 8 4 8 5 1 DPisplay UPSiGantral Pariglz incisive v e A ALAGA GT eae s oor sesta a Tore 8 4 8 5 2 Event HISTORY HOG AA DU SUN ais OMM uo Rye de cs 8 5 8 6 Buildirig Al rm Monitoring ie RE NAN ERE REOR CRY OU RIEN OR EUNDO A EL e Een es 8 7 87 GeneralP rpose helay DOntabt ster o e FRE a C RR EO Pa RM UR 8 7 88 Remote Monitor Panel ieren e a A pg a e A E E 8 7 8 95 Relay Interface Medulell se er o A Aan tete tM rc ee e eei AE dest di a ir AN a fab mal etes uro Nee quip fea 8 9 8 10 Supervisory Contact Module ll eco pi em AER ED ep SB ERI
119. VA Figure 1 2 shows the Powerware 9395 650 825 kVA UPS with the FI UPM NOTE Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer or the warranty terms specified on page W 1 become void This service is offered as part of the sales contract for the UPS Contact an Eaton service representative in advance usually a two week notice is required to reserve a preferred startup date 1 1 UPS Standard Features 1 1 1 The UPS has many standard features that provide cost effective and consistently reliable power protection The descriptions in this section provide a brief overview of the UPS standard features Installation Features Each UPS section is shipped separately The sections are mechanically and electrically joined at the installation site Sections can be permanently bolted to the floor EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 1 1 INTRODUCTION Power wiring can be routed through the top or bottom of the cabinet with connections made to easily accessible terminals Control wiring is routed through the top of the cabinet and must be installed in accordance with Class 1 wiring methods
120. Vpasss Lect ene eere ep en eese epo t nep oue penus mm 6 4 4 Battery Mode Distributed Bypass isen st eee eet dad RINEK ER ROT ELS EG Wala DALANG i Est E ER 65 Multiple UPS Distributed Bypass System Oneline Configurations ence eee UPS Operating Instructions NAY NAL e bee nei e eg HAC WPS Controls and Indicators x ut nae hin i tpe prc rA AAA au ae AAA A aque 714 GONtrOMPANE A go KO Sle a kA NG Pha ed ate eee bok aaa EGR 7 1 2 Ae A eed d ete et A EET e eut 4 2 CUsimgstheiGontrol Panels wat ees sahara Ja naw ad Maa n eno zo p rte ceo Dore rab ohn tM OS els e E Le gue slo 7 2 1 Status Indicators lt p is A edn AA pn PG oan rude n Aa 7 2 2 NAGLAAN 7 2 3 Usingtthe Dari PUSPDUPOFS 2 lahi Naa must A NG BG Aa aa nan ka NG MG a ceat 7 24 BIBIT METTE AG ae Aaya Ta GAW Kia AI Nan as gg BEN po ak eile NG A i Andon sa a os 7 25 MIMI SChEG totes ica a ti tt atte 7 2 6 Display Men Op ration rasa E dd 7 2 7 System Stat s Screenmand Controls dee od cent de ed Dee Ue ee Md ee ES 728 load Of SEIT otto O en d a NG Bala Mad y oc obo eder BA lu e ote tle oM oe s EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 18 4 18 4 28 4 31 4 31 4 36 4 38 4 39 4 42 4 42 4 42 5 1 5 1 54 5 11 5 13 5 15 6 21 6 21 6 22 6 23 6 24 6 26 TABLE OF CONTENTS 23 SinglesUPS Operation 2 3 23 eas tee te ak A ae ies Ad e UE EAT IMS 7 11 73 1 Starting the UPSu
121. X2 NO o TB1 TB1 TB1 TB1 E Pusa TAS agen en iTO 7 O 7 O 7 O 8 0 MO 8 0 8 0 910 90 310 10 1 O O O 10 O TB2 TB2 TB2 TB2 1 O O 1 O O 210 2 2 ON 210 310 310 310 310 410 410 410 410 510 50 510 510 810 610 6 O 6 O 710 710 ANG 71O 81O 810 810 810 10 31O HILO 0 uO 10 O 10 O 10 UPS 1 UPS 2 UPS 3 UPS 4 If Installed If Installed NOTE NC and NO designations on MOB AUX contacts are defined with breaker in OFF open position NOTE f MOB contacts have pigtail leads use the same wire gauge to connect to UPS and use the correct crimp connections for the wire gauge NOTE External CAN connections between UPS cabinets require shielded twisted pair wire NOTE Use twisted pair wiring between the UPS and MOB AUX contacts NOTE Always confirm contact operation prior to wiring Figure 5 6 Distributed Bypass Pull Chain Wiring with MOBs EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 5 7 INSTALLING OPTIONS AND ACCESSORIES Table 5 4 Pull Chain Wiring Terminations with MOBs From To Function UPS 1 CAN Bridge Card J3 1 Alarm MOB 1 Aux 1 NC UPS 1 CAN Bridge Card J3 2 Alarm Return MOB 1 Aux 1 Com MOB Open Alarm UPS 1 TB2 1 Pull Chain MOB 1 Aux 2 NO Pull Chain UPS 1 TB2 2 Pull Chain Common UPS 2 TB2 2 Pull Chain Common Pull Chain Common UPS 2 CAN Bridge Card J3 1 Alarm MOB 2 Aux 1
122. a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 10 UPS System Common Rectifier Feed Separate Battery IOM Configuration Service Connector 6 13 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION AC Input to Battery Aux Building Alarms UPS Rectifier 3 Wire A B C 48V Battery Alarm Relays Rotation Shunt Trip a A Remote EPO Interface Ak Cd OOOO 1 E1 E2 E3 Interface Board Input Breaker O CB1 O optional 0 e nput nput nput Input Contactor Contactor Contactor Contactor K1 K1 K1 K1 sa Rectifier Ka Rectifier Sa Rectifier Pa Rectifier Fuse Fuse Fuse Fuse 0 e e Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse E Inverter Inverter Inverter CC Inverter YA JN sl Jo Output Output Outp
123. above each cabinet for proper air circulation The clearances required around the UPS cabinet are shown in Table 3 2 Table 3 2 UPS Cabinet Clearances From Top of Cabinet 457 2 mm 18 minimum clearance for ventilation From Front of Cabinet 914 4 mm 36 working space From Back of Cabinet None Required From Right Side of Cabinet 152 4 mm 6 working space From Left Side of Cabinet None Required The basic environmental requirements for operation of the UPS are e Ambient Temperature Range 0 40 C 32 104 F e Recommended Operating Range 20 25 C 68 77 F Maximum Relative Humidity 9596 noncondensing CAUTION If battery systems are located in the same room as the UPS the battery manufacturer s environmental requirements should be followed if they are more stringent than the UPS requirements Operating temperatures above the recommended range will result in decreased battery life and performance and may reduce or void the battery warranty The UPS ventilation requirements are shown in Table 3 3 Table 3 3 Air Conditioning or Ventilation Requirements During Full Load Operation Ratin Input Output Heat Rejection Ventilation Required for 3 Voltage BTU hr x 1000 kg cal hr Cooling Air Exhaust 400 400 125 31613 650 kVA 480 480 127 31933 400 400 145 36476 Approximately 2265 liter sec 4800 cfm GUYA 480 480 146 36845 With Field Installed UPM Approximately 3020 liter sec 6
124. ad and understand the following notes while planning and performing the wiring installation Conduit must be installed between the UPS cabinet and the device for signal wiring Conduit must be installed between the device and the power source for power wiring Install the signal wiring in separate conduit from the power wiring Conduit and wiring between the UPS and the device are to be supplied by the customer Maximum distance between the UPS cabinet and the device is not to exceed 150 meters 500 feet Use Class 1 wiring methods as defined by the NEC for interface and power wiring up to 30V The wire should be rated at 24V 1A minimum Use Class 2 wiring methods as defined by the NEC for interface and power wiring from 30 to 600V Signal wiring should be a minimum of 22 AWG and a maximum of 14 AWG The wire should be twisted pair rated for 5A maximum Power wiring should be a minimum of 22 AWG and a maximum of 14 AWG The wire should be rated for 1A minimum Use only 75 C copper wire 120 Vac for the RMP II RIM Il or SCM Il should be provided from the critical bus by facility planners or the customer Install wiring from the Powerware Hot Sync CAN Bridge Card in accordance with the following instructions Parallel system wiring see paragraph 5 2 RMP II see paragraph 5 3 RIM Il see paragraph 5 4 SCM II see paragraph 5 5 To locate the appropriate terminals on the Powerware Hot Sync CAN Bridge Card see Figure
125. al 164201725 Rev 2 www powerware com 4 7 UPS SYSTEM INSTALLATION Screw from Kit Screw from Kit Screw from Kit Screw from Kit Bracket from Kit Back i ISBM UPM Bracket from Kit d Section Top Section Top ISBM UPM Section Top gt lt Section Top Front Top View Front Bracket Top View Rear Bracket 9 PI o ncn NI Bracket from Kit O UPM Section Base ISBM Section Base O Front View Base Bracket Screw from Kit Screw from Kit Figure 4 7 ISBM Section to UPM Section Joining Brackets 44 Electrically Connecting the Sections 1 Unfasten the front door latch and swing the door open see Figure 4 1 on page 4 2 2 Remove the door Remove the retaining screw located inside the door at the bottom hinge pivot point then lift the door off Retain the hardware for later use 3 Remove the screws securing the ISBM section right bottom internal safety shield panel and remove the panel to gain access to the internal input output and battery terminals Retain the hardware for later use NOTE AC and DC input intercabinet power wiring harnesses are supplied coiled and secured in the UPM wireway on the left side of the UPM section see Figure 4 6 on page 4 7 4 Locate the AC and DC input intercabinet power wiring harnesses long cables labeled xG1 xG2 and xG3 Remove wire ties as necessary and uncoil the cables 5 Locate the 1G1 1G
126. al status and alarm condition of the UPS from virtually any location within the facility Relay Interface Module Il RIM II An optional RIM Il uses relay contact closures to indicate the UPS operating status and alarm condition e Supervisory Contact Module Il SCM Il An optional SCM ll establishes an interface between the UPS system equipment and the customer s monitor X Slot Cards Optional X Slot cards support several protocols such as SNMP HTTP IBMe AS 4009 and Modbuse eNotify Remote Monitoring and Diagnostics Service An optional service that provides 24 7 remote monitoring of 43 alarms temperature humidity and battery charge information daily heartbeat check and monthly report The service also provides customer notification of significant alarms remote diagnostics and dispatch of technicians A ConnectUPS X Web SNMP Card is required in an X Slot communication bay An optional Powerware Environmental Monitoring Probe EMP is required for temperature humidity monitoring See Chapter 8 Communication for additional information on monitoring and communication features 1 4 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 1 3 1 2 5 1 2 6 1 2 7 1 2 8 Battery System INTRODUCTION Single Feed Kit An optional kit is available for converting the dual feed rectifier and bypass inputs to a single feed configuration The kit consists of
127. an internal failure it switches automatically to Bypass mode and remains in that mode until the failure is corrected and the UPS is back in service EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 3 UNDERSTANDING UPS OPERATION Bypass Input Input Breaker Rectifier Input CB1 KN O a Breakers KCN O O 6 2 3 eD Bypass Mode NOTE Bypass mode is not available on an UPS configured as an IOM The UPS automatically switches to Bypass mode if it detects an overload load fault or internal failure The UPS can also be transfered from Normal mode to Bypass mode manually The bypass source supplies the commercial AC power to the load directly Figure 6 3 shows the path of electrical power through the UPS system when operating in Bypass mode Rectifier Bypass Breaker CB4 Static 4 Switch Contactors Closed Open Battery Converter Output Inverter AT K3 X K2 S Battery Breaker I Battery DE Main Power Flow Trickle Current Energized De Energized NOTE On an UPS configured as an IOM the bypass input static switch bypass breaker CB4 and K5 are not present Figure 6 3 Path of Current Through the UPS in Bypass Mode CAUTION The critical
128. and cables are properly routed to the UPS and any ancillary cabinets All power cables are properly sized and terminated Neutral conductors are installed or bonded to ground per requirements Battery cables are terminated on E4 and E5 Battery aux contact signal wiring is connected from the UPS to the battery disconnect Battery shunt trip signal wiring is connected from the UPS to the battery disconnect OPTIONAL LAN and telephone drops are installed All telephone and LAN connections have been completed A ground conductor is properly installed Air conditioning equipment is installed and operating correctly 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 A 120 Vac service outlet is located within 7 5 meters 25 feet of the UPS equipment The REPO device is mounted in its installed location and its wiring is terminated inside the UPS cabinet The normally closed NC Emergency Power off contact pins 1 and 2 on TB1 is jumpered if not used Alarm relays and building alarms are wired appropriately OPTIONAL A remote battery disconnect is mounted in its installed location and its wiring is terminated inside the UPS OPTIONAL Accessories are mounted in installed locations and wiring
129. and swing the door open see Figure 4 1 on page 4 2 Remove the right interface entry conduit landing plate to drill or punch holes see Figure 4 18 on page 4 20 Reinstall the interface entry plate and install the conduit Route and install the LAN telephone and other cables to the appropriate X Slot cards See Figure 4 27 on page 4 32 and Figure 4 33 for X Slot communication bay locations Close the door and secure the latch Refer to the manual supplied with the X Slot card for operator instructions n Es n H H e Sy ER Cl i i a E lt j X Slot Communication Bay 2 pm Oru Ord i O n F NM ud gt ol hk X Slot Communication Bay 4 y Sa LA QU U C p Q Figure 4 33 X Slot Communication Bays 4 38 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION 4 10 Installing a REPO Switch A latching type Remote Emergency Power off REPO switch can be used in an emergency to shut down the UPS and remove power to the critical load from a location away from where the UPS is installed Figure 4 34 shows a REPO switch NOTE Before installing a REPO switch verify that the UPS was installed according to the instructions in paragraphs 4 2 through 4 9 NOTE When installing the REPO switch you must install conduit between
130. apter 3 Prepare your site for the UPS system Chapter 3 Inspect and unpack the UPS sections Chapter 3 Unload and install the UPS sections and wire the system Chapter 4 Install features accessories or options as applicable Chapter 5 Complete the Installation Checklist Chapter 4 SN Do m gt o M Have authorized service personnel perform preliminary operational checks and start up the system NOTE Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer or the warranty terms specified on page W 1 become void This service is offered as part of the sales contract for the UPS Contact an Faton service representative in advance usually a two week notice is required to reserve a preferred startup date Creating an Installation Plan Preparing the Site 3 2 1 Before installing the UPS system read and understand how this manual applies to the system being installed Use the procedures and illustrations in paragraph 3 2 and Chapter 4 to create a logical plan for installing the system For the UPS system to operate at peak efficiency the installation site should meet the environmental parameters outlined in this manual If the UPS is to be operated at an altitude higher than 1500m 5000 ft contact an Eaton service representative for important information about high altitude operation The operating environment must meet the weight clearance and environmental requirement
131. ation Manual 164201725 Rev 2 www powerware com 3 9 UPS INSTALLATION PLAN AND UNPACKING Table 3 5 Input Output Ratings and External Wiring Requirements for the Powerware 9395 825 650 9395 825 750 and 9395 825 825 Separate Battery Units Rating 50 60 Hz Basic Unit Rating kVA 650 650 750 750 825 825 kW 585 591 675 682 742 750 Input and Output Voltage Volts 400 400 480 480 X 400 400 480 480 400 400 480 480 AC Input to UPS Rectifier 0 98 Minimum pF Full load current plus battery recharge current Amps 1079 891 1245 1028 1369 1130 3 Phases 1 Ground A Minimum Conductor Size AWG or kcmil 500 500 500 500 500 500 Number per Phase each 4 3 4 4 5 4 AC Input to UPS Bypass Four Wire Full Load Current Amps 938 782 1083 902 1191 992 3 Phases 1 Ground B Minimum Conductor Size AWG or kcmil 500 350 500 500 500 500 Number per Phase each 3 3 4 3 4 4 AC Input to UPS Bypass Five Wire Full Load Current Amps 938 782 1083 902 1191 992 3 Phases 1 Neutral 1 Ground B Minimum Conductor Size AWG or kcmil 400 500 500 500 500 500 Number per Phase each 4 3 5 4 5 5 DC Input from Each Battery Disconnect to Each UPS UPM Amps per UPM 551 551 551 551 551 551 1 Positive 1 Negative C Minimum Conductor Size AWG or kcmil 250 250 250 250 250 250 Number per Pole each 3 3 3 3 3 3 AC Output to Critical Load Four Wire Full Load Current Amps 938
132. aton s optimum Powerware UPS operating levels Installing eNotify Service A quick start guide and self installation wizard tool are available on both the Software Suite CD included with the Powerware 9395 UPS documentation and on the Web at www powerware com enotify For the latest updates installation tips and information on connecting eNotify visit the eNotify Web page For installation support or questions about the eNotify Service contact crctriagegroup eaton com EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 8 3 8 4 COMMUNICATION The eNotify Service relies on a ConnectUPS X Web SNMP Card or Power Xpert card installed with the UPS sending one way status and event e mails to Powerware Remote Monitoring servers that analyze and store the data Those servers also take the appropriate actions of sending notifications and reports The ConnectUPS Card gathers information from the UPS directly and from any external sensors that are attached The card also records all events that are generated by the UPS This data is stored within the non volatile memory logs on the ConnectUPS Card The eNotify Service runs on common protocols and transport mechanisms making the connectivity between the Powerware 9395 UPS and the Powerware Remote Monitoring servers easy to set up By using common e mail transport mechanism you do not have to open your network to proprietary or potentia
133. atus menu bar The UPM 1 Control Command screen is displayed 11 On the UPM 1 Control Command screen select UPM ON 12 Press the SELECT pushbutton on the UPM 1 Command menu bar 13 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 1 rectifier and inverter turn on If the Inherent Redundancy option is enabled a loss of redundancy alarm will be issued Silence the alarm and continue to Step 14 14 Repeat Steps 8 through 12 selecting UPM 2 to start UPM 2 15 Observe the following messages are displayed sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 2 rectifier and inverter turn on 16 Repeat Steps 8 through 12 selecting UPM 3 to start UPM 3 17 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 3 rectifier and inverter turn on When the inverter reaches full voltage the UPS is ready to transfer to the Normal mode and supply the critical load 18 If the UPS is a Plus 1 model repeat Steps 8 through 12 selecting UPM 4 to start UPM 4 19 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 4 rectifier and inverter turn on When the inverter reaches full
134. bypass system can be transferred from Normal mode to Bypass mode manually However the distributed bypass system automatically switches to Bypass mode whenever the UPSs can no longer supply the critical load If the distributed bypass system transfers to Bypass mode from Normal mode due to an output voltage deviation the distributed bypass system automatically attempts to return to Normal mode up to three times within a 10 minute period After three transfer attempts or an overload the system locks the critical load to the bypass source and requires operator intervention to transfer Bypass mode is a normal operating mode not an alarm condition However if the distributed bypass system is unable to return to Normal mode following an automatic transfer to Bypass mode an alarm condition is recorded Bypass may also be used when the UPSs or UPMs in the system must be shut down to perform routine maintenance or repairs In the Parallel Redundant N 1 arrangement the bypass circuitry in each UPS operates to support the applied loads on bypass If the UPSs are in NORMAL and one UPS trips offline the remaining UPSs do not go to bypass as long as they have the capacity to support the load In the Parallel Capacity N 0 arrangement if one UPS trips offline and goes to bypass the remaining UPSs also go to bypass Battery Mode Distributed Bypass The UPSs transfer to Battery mode automatically if a utility power outage occurs or if the
135. ch UPM Rectifier 0 98 Min pF Full load current plus battery recharge current Amps 456 370 3 Phases 1 Ground A Minimum Conductor Size AWG or kcmil 2 0 4 0 Number per Phase each 3 2 NOTE Callout letter A maps to Figure 6 13 through Figure 6 16 starting on page 6 16 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 11 UPS INSTALLATION PLAN AND UNPACKING Terminals E1A through E5A and E9A through E12A are stud type terminals The intercabinet power wiring connections for this equipment are rated at 90 C See Table 3 7 for intercabinet power cable terminations and Table 3 8 for supplied intercabinet wiring terminal hardware Figure 4 8 through Figure 4 13 starting on page 4 11 show the location of the power cable terminals inside the UPS Table 3 7 UPS Intercabinet Power Cable Terminations for the Powerware 9395 825 650 9395 825 750 and 9395 825 825 Terminal Function Terminal Function Bus Landing Tightening Torque Nm Ib ft Stud E1A UPM 1 E1A UPM 2 E1A UPM 3 E1A UPM 4 Plus 1 Model Phase A 3 stud mounting 12 8 3 M8 E2A UPM 1 E2A UPM 2 E2A UPM 3 E2A UPM 4 Plus 1 Model AC Input to UPM Section Phase B 3 stud mounting 12 8 3 M8 E3A UPM 1 E3A UPM 2 E3A UPM 3 E3A UPM 4 Plus 1 Model Phase C 3 stud mounting 12 8 3 M8 E9A UPM 1 E9A UPM 2 E9A UPM 3
136. connect switch should be installed between the battery and the UPS External DC input overcurrent protection and disconnect switch is to be provided by the customer Table 3 17 and Table 3 18 list the maximum ratings for continuous duty rated circuit breakers satisfying the criteria for both Recommended disconnect size is based on a maximum full load discharge time less than 3 hours For longer discharge times a larger disconnect may be required Table 3 17 Recommended DC Input Battery Disconnect Ratings Common Battery Input Rating UPS Model 400V 480V Powerware 9395 825 650 1600A 1600A Powerware 9395 825 750 2000A 2000A Powerware 9395 825 825 2000A 2000A Table 3 18 Recommended DC Input Battery Disconnect Ratings Separate Battery Input Rating UPS Model esc DENI 400V 480V Powerware 9395 825 650 Powerware 9395 825 750 700A 700A Powerware 9395 825 825 Battery voltage is computed at 2 volts per cell as defined by Article 480 of the NEC Rated battery current is computed at 2 volts per cell The battery wiring used between the battery and the UPS should not allow a voltage drop of more than 196 of nominal DC voltage at rated battery current EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING 3 2 3 UPS System Interface Wiring Preparation Control wiring for features and options should be connected
137. ctifier B AC Input to Bypass C DC Input from Battery D UPS AC Output to Tie Cabinet E Output to Critical Load E Overcurrent Protection provided by customer Y NOTE This oneline does not show each UPM in the UPSs but represents each UPS in the distributed bypass system The internal AN structure of each UPS is shown Figure 6 5 through Figure 6 8 starting on page 6 8 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 22 Typical Distributed Bypass System 2 1 and 3 0 Configurations 6 28 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com A B x JO El E6 E UPS 4 E7 E3 Fuse E8 1 O B1 E12 o optional FK e C84 ha O Rectifier Static Switch Fuse e Fuse Fuse Inverter JN K3 Battery Converter Fuse K2 C E4 E5 Battery Breaker GN O HI A E10 BATTERY SYSTEM E11 Not supplied E12 with the UPS D El E6 E UPS 3 E E3 Fuse E8 O CBI E12 optional KI e e
138. d TB2 X Slot Communication Bays See Figure 4 33 on See Figure 4 28 for detail page 4 38 for detail a og O NM Y TYO wa Lio 3m 9 Dre ict oc c o 0 9 e o DD DD pp o o I ZOO cal 18 oo 90 000 000 o y o y y y T o o op 3 E E o NA a olje ANG o a a a a a y 9 o o y 5 o Dunumnupummpunaenenuennunuenenuenoen ol CASS 0S SSS Sees oo SoS a EEEBHBHEEHEEERHEEREBEEEEREBHEBBEBEREE o a Dd o o Jo o io o o o ti fo o a e e EHBBRHEEREHERBREEBHEEREEHEEEREBEREEEH GOO 000000 000000000000000 000000000000 GOOD 00000 000000000000000 000000000000 I b EHB EHHHEHHEHHHHEEHHHEHHEEEHEEEHEEEH amtmannin ma maalaala tataa a a alata ataa ataata ba ma a m alaaa tataa a a alata ataata aE ba mara maalataan tataa a a alata ataa ataa COS S 00 o o o ba maalaa ataa ataa ETTE COS S00 o o JJ COS S00 o io o ataa aTe E lo ZHHBHHHEHHHEHHBHHEBHHEEEHHHEHHHBHEEEH ol Ie BoBBpBBBBBB p p i 0 0 0 0 0 0 0 0 0 e e e e e LDBBBpBBBBBB B B BIB BpBBDBEOCCCOOOBBOBOBOBOBOBOCEE onnon ononon onn nnno QOO00 0000 1 0 0 0 0 0 0 0 0 e e e e Paa JJ JJ CSS S07 JJ JJ JJ o b E CR SS 0 JJ E cnnennneamamena
139. d UPM Section Debris Shields iiis eee e tenes 4 19 Figure 4 18 ISBM Section Conduit and Wire Entry Locations eee teens 4 20 Figure 4 19 Distributed Bypass Wire Length eet Re ls 4 22 Figure 4 20 ISBM Section Power Terminal Locations Common Rectifier Feed esses 4 23 Figure 4 21 ISBM Section Power Terminal Detail AA Common Rectifier Feed o 4 24 Figure 4 22 ISBM Section Power Terminal Locations Separate Rectifier Feed o 4 25 Figure 4 23 ISBM Section Power Terminal Detail AA Separate Rectifier Feed oo 4 26 Figure 4 24 UPM Rectifier Input Power Terminal Block Detail cilisis RR IR III 4 2 Figure 4 25 ISBM Section Power Terminal Detail BB Common Battery lille 4 29 Figure 4 26 ISBM Section Power Terminal Detail CC Separate Battery o oo nnana teens 4 30 Figure 4 27 ISBM Section Interface Terminal Locations ooo 4 32 Figure 4 28 Intertac Terminal Detalle tattoo baat Me Se ina ka AULD paa trar o Baad Kesha debas 4 34 Figure 4 29 Typical Alarm Relay Connection erbe A a A NG nG RD ER kn 4 34 Figure 4 30 Terminal Blocks TB1 TB2 and TB3 Connector Assignments ooo 4 35 Figure 4 31 Typical Battery Interface Connection Common Battery System esee 4 37 Figure 4 32 Typical Battery Interface Connection Separate Battery System liliis 4 37 Figure 4 33 X Slot Communication Bays RR es 4 38 EATON Po
140. d with the UPS gt gt Service Connector Figure 6 6 UPS System Common Rectifier Feed Separate Battery Dual Feed Configuration EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 9 UNDERSTANDING UPS OPERATION AC Input to AC Input to Battery Aux Building Alarms UPS Rectifier Bypass 3 Wire A B C 3 or 4 Wire A B C 48V Battery Alarm Relays Rotation Rotation Bypass Shunt Trip ig A B Breaker Remote EPO eee CB4 A zi 00 000 E1 E2 E3 E6 E7 OS Qe LA E8 E12 OO Interface Board Single feed Kit 4 Input Breaker 7 Not supplied Static m CB1 O with the UPS E Switch iT optional RUSE Backfeed Contactor K5 nput nput nput Input Contactor Contactor Contactor Contactor K1 K1 K1 K1 sa Rectifier Ka Rectifier Sa Rectifier Pa Rectifier Fuse Fuse Fuse Fuse 0 e e Fuse Fuse Fuse Fuse Fuse F
141. ding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 15 UPS System Separate Rectifier Feed Separate Battery IOM Configuration 6 18 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION AC Input to UPS Battery Aux Building Alarms Rectifiers 3 Wire A B C Rotation 48V Battery Alarm Relays ES Shunt Trip A A A A X Slot Remote EPO Interface UPM 4 UPM 3 UPM 2 UPM 1 O El El El El EZ EZ E EZ Interface Board E3 E3 E3 E3 Input Input Input nput Contactor Contactor Contactor Contactor K1 K1 K1 K1 Rectifier Rectifier EE Rectifier Rectifier Fuse Fuse Fuse Fuse e e e e Fuse Fuse Fuse Fuse Fuse Fuse Fuse Fuse Inverter Inverter Inverter Inverter ce ee SN e Output Output Output Output Contactor Contactor Contactor Contactor K3 K3 K3 K3 AC Ou
142. e flush mounted or surface mounted on a desktop or secured to a wall Figure 8 5 shows the SCM II Figure 8 5 Supervisory Contact Module II Enclosure The SCM II provides signals for the indications shown in Table 8 3 Table 8 3 SCM Il Status Indicators and Connections Indication TB2 Connections SYSTEM NORMAL TB2 1 through TB2 3 NO REDUNDANCY TB2 4 through TB2 6 ON GENERATOR TB2 7 through TB2 9 BYPASS NOT AVAILABLE TB2 10 through TB2 12 ON BATTERY TB2 13 through TB2 15 UPS ALARM TB2 16 through TB2 18 ON BYPASS TB2 19 through TB2 21 SHUTDOWN IMMINENT TB2 22 through TB2 24 8 10 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Chapter 9 UPS Maintenance The components inside the UPS cabinet are secured to a sturdy metal frame All repairable parts and assemblies are located for easy removal with very little disassembly This design allows authorized service personnel to perform routine maintenance and servicing quickly You must schedule periodic performance checks of your UPS system to keep it running properly Regular routine checks of operation and system parameters enable your system to function efficiently for many trouble free years 9 1 Important Safety Instructions Remember that your UPS system is designed to supply power EVEN WHEN DISCONNECTED FROM THE UTILITY POWER The UPS module interiors are unsafe until the DC power so
143. e Be Met dr ca Mor ee Lr ot oe ne eio e 10 2 1023 e URS Environmental c cto ct etcetera potere ale uera Vom etd atu in basin Loch Lent atem lar oh 10 2 Warranty oc lw Ix ob Rx y Re ee Pe ed KINANG CEDAR Y XE RE W 1 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com TABLE OF CONTENTS List of Figures Figure 1 1 Powerware 9395 UPS 650 825 KVA Ar air ter a 1 2 Figure 1 2 Powerware 9395 UPS 650 825 kVA with the Field Installed UPM RR 1 3 Figure 3 1 UPS Cabinet Dimensions Front View n e RRRRRRRRRRRRRRRRRRRIR E I e 3 3 Figure 3 2 UPS Cabinet Dimensions Right Side View RR e teens 3 3 Figure 3 3 ISBM Section Dimensions Front View o n e RRRRRRRRRRRRRRRI Ie 3 4 Figure 3 4 UPM Section Dimensions Front View eR RRRRRRRRIRRR RR RI ees 3 4 Figure 3 5 ISBM Section Dimensions TOPVIEW neseg IRR e 3 5 Figure 3 6 ISBM Section Dimensions Bottom View 3 5 Figure 3 7 UPM Section Dimensions Top View RR e 3 5 Figure 3 8 4S BM Section Comer ol Gra saeia HALANG pe ht detener ace Naay Dal aa Kainan hides 3 6 Fig re 3 9 UPM Section Center oF Gravity ee e a cts eg cube P ret tede bs D E n 3 6 Figure 3 10 Remote EPO S witch DIMENSIONS sue ena sou REDE oe Re eae ER RET EUR d RE RED E RE RE EE te 3 7 Figure 3 11 UPS Cabinet as Shipped on Pallet ISBM Section RR 3 22 Figure 3 12 UPS Cabinet a
144. e Configuration 5 9 254 ET In erat rec Rea Rer dac hat Batten System veau TRA eU NABAL LSU AS RS INS AA SAN IS PA a eo UNI LA UL ENS le DM dr St a Basic System CoffIgutatlOtis x cotone tee p vt ge eoe v pup end cet he ear ger eere tet ere e Usingst his Manual 2 et os ume rto e o Ee e RS e e fab pA A Conventions Usedin This Manual 4 ees eot a PAGONG a ett Symbols Controls ONIS La etel S Ce t alla aa AG E te db eut vote eo Io EE For More Informiatlofz ope a EE ER WR REPRE RR AE REESE Heb EDS Getting El Dis aang aka Aa Kna to Ee odes Re ede i a a ta Ia um de tur oat ty Warnings steric EIDEM A ADU ER eee a Section I Installation 3 UPS Installation Plan and Unpacking RR 34 Creating an installation Plant ier A ERA NG ANNA LA BA al 3 2 Preparitig thB S Ite cu ai eee Re t RC D e o a d t et 32 1 Environmental and Installation Considerations eiiis II e 322 UPS System Power Wiring Preparation eto ter reprher pnr RE HS 3 2 3 UPS System Interface Wiring Preparation e 3 24 Distributed Bypass Power Wiring Preparation RR RR e 3 3 Inspecting and Wnpacking the URS Cabinets s sca cs RC RC eR LO RERO CERRO EE Oy OCC AERE 4 UPS System Installation 2 3 0 5054 KAKA wk eie wp x3 EYE LAT KG NAKA KAN BLK NAG 4 1 Preliminary Installation Information e siae eae ete tecti p aaa Lala eee aie 4 2 Unloading the UPS Sections from the Pallet I
145. e Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPM 4 UPM 1 UPM 2 UPM 3 FI UPM CABINET gt E4 E5 E4 E5 E4 E5 UPS CABINET CON a Na ae mE o o o oji o o o o Battery Battery Battery Battery Breaker Breaker Breaker Breaker BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM Not supplied with the UPS Not supplied with the UPS Not supplied with the UPS Not supplied with the UPS NOTE Callout letter A maps to Table 3 6 on page 3 11 Callout letters B C and D map to Table 3 5 on page 3 10 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 14 Plus 1 UPS System Separate Rectifier Feed Separate Battery Dual Feed Configuration EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Service Connector 6 17 UNDERSTANDING UPS OPERATION AC Input to UPS Rectifiers 3 Wire A B C Rotation A A A UPM 3 UPM 2 UPM 1 O Battery Aux Building Alarms 48V Battery Alarm
146. e Gateway Card provides a data gateway from the UPS to the Power Xpert software provides remote monitoring through a Web browser interface e mail and a network management system using SNMP connects to a twisted pair Ethernet 10 100BaseT network Modbus TCP support provides direct integration of the PDU s parameters to a Building Management System BMS It has a built in switching hub that allows one additional network device to be connected to the network without the requirement of an additional network drop EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 8 1 COMMUNICATION 8 2 eNotify Service 8 2 1 8 2 2 LAN and telephone drops for use with X Slot connectivity cards must be provided by facility planners or the customer For installation and setup of an X Slot card contact an Eaton service representative see page 1 8 Refer to the manual supplied with the X Slot card for user instructions KILL ConnectUPS X Web SNMP Card ba WU Mien Modem Card Modbus Card P Eme pg MAN GN Relay Interface Card mp O 4 a O ss d Industrial Relay Card Power Xpert Gateway Card i gy Figure 8 1 Optional X Slot Cards The Powerware 9395 UPS supports Eaton s eNotify Service eNotify Service is included at no charge during the first year of operation warranty period
147. e UPS battery supply and basic maintenance bypass in a multiple UPS configuration These onelines do not show each UPM in the UPSs but represent each UPS in the distributed bypass system The internal structure of each UPS is shown in Figure 6 5 through Figure 6 8 starting on page 6 8 Voltage Oneline Drawing UPS Model System Type Input Output 9395 825 650 Figure 6 21 on page 6 27 9395 825 750 480 480 9395 825 825 9395 825 650 Figure 6 22 on page 6 28 9395 825 750 480 480 9395 825 825 9395 825 650 Figure 6 23 on page 6 29 9395 825 750 480 480 9395 825 825 Multiple UPS Distributed Bypass 1 1 and 2 0 Configurations Multiple UPS Distributed Bypass 241 and 340 Configurations Multiple UPS Distributed Bypass 3 1 and 4 0 Configurations 6 26 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION A B A B O O O O P C C ga El E6 El E6 E2 Urs E7 E2 MEN E7 E3 Fuse E8 E3 Fuse E8 O B1 E12 O CBI E12 optional C optional bi i e F KM pa Ki CB4 CB4 SA ERA O A o Rectif
148. e UPS is in Normal mode Normal status indicator is illuminated If an alarm lamp is illuminated or the Normal status indicator is not illuminated contact an Eaton service representative MONTHLY Maintenance Perform the following steps monthly 1 Monitor system parameters as described in paragraph 7 2 Using the Control Panel on page 3 1 Check the UPS air filters located behind the front panels and wash or replace as necessary See Figure 9 1 and Figure 9 2 for filter locations The ISBM section filter sizes are 12 x 20 x 0 25 and the UPM section filter sizes are 20 x 44 x 0 25 Contact an Eaton service representative for replacement filters To remove the filters a Remove one top screw and two bottom screws securing each UPM section front panel see Figure 4 3 on page 4 4 Lift the panel straight up to remove it from the panel hanger bracket at the top of the cabinet b Remove one top screw and two bottom screws securing each ISBM section front panel see Figure 4 2 on page 4 3 Lift the panel straight up to remove it from the panel hanger bracket at the top of the cabinet c Pull the foam filters over the screw heads on the cabinet mounted studs and remove the filters from the cabinet EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS MAINTENANCE
149. e charging source prior to connecting or disconnecting terminals D Determine if the battery is inadvertently grounded If it is remove the source of the ground Contacting any part of a grounded battery can cause a risk of electric shock An electric shock is less likely if you disconnect the grounding connection before you work on the batteries P D K roper disposal of batteries is required Refer to local codes for disposal requirements 0 not dispose of batteries in a fire Batteries may explode when exposed to flame eep the UPS door closed and front panels installed to ensure proper cooling airflow and to protect ersonnel from dangerous voltages inside the unit p Do not install or operate the UPS system close to gas or electric heat sources EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 2 1 SAFETY WARNINGS The operating environment should be maintained within the parameters stated in this manual e Keep surroundings uncluttered clean and free from excess moisture Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of the equipment CAUTION To prevent damage to the wiring channel and wiring in the UPS cabinet base when lifting or moving the cabinet e Lift and move the cabinet using only the front or rear forklift slots e Verify that the forklift forks are in a horizontal position before inserting them into th
150. e electrically in common Figure 4 36 Normally Closed REPO Switch Wiring EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 41 UPS SYSTEM INSTALLATION T O 1 NC REPO Wires NO I 4 Return NOTE REPO switch rating is 24 Vdc 1A minimum NOTE The REPO switch must be a latching type switch not tied to any other circuits NOTE AREPO normally open and normally closed return terminals are separated on the terminal board but are electrically in common Switch _ NC O 2 Return UPS TB1 T O 3 NO REPO Switch Twisted Figure 4 37 Normally Closed and Normally Open REPO Switch Wiring 4 11 Installing Options Accessories and Distributed Bypass Control Wiring To install options accessories and distributed bypass control wiring see Chapter 5 Installing Options and Accessories 4 12 Initial Startup Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer or the warranty terms specified on page W 1 become void This service is offered as part of the sales contract for the UPS Contact an Eaton service representative in advance usually a two week notice is required to reserve a preferred startup date 413 Completing the Installation Checklist The final step in installing the UPS system is completing the following Installation Checklist This checklist ensures that y
151. e forklift slots DO NOT angle fork tips upward e Insert the forks all the way through the base DO NOT insert forks partially into the base to move the cabinet Forks may be partially inserted into the front or rear forklift slots for minor positioning if the forks are kept in a horizontal position with no upward angling e DO NOT use the forklift slots on the end of the cabinet to move the cabinet End forklift slots may be used for minor positioning if the forks are kept in a horizontal position with no upward angling If these instructions are not followed damage to the wiring channel and wiring will occur AVERTISSEMENT e es batteries peuvent pr senter un risque de d charge lectrique ou de br lure par des courts circuits de haute intensit Prendre les pr cautions n cessaires Pour le replacement utiliser le m me nombre et mod le des batteries ATTENTION e Une mise au rebut r glementaire des batteries est obligatoire Consulter les r glements en vigueur dans votre localit Ne jamais jeter les batteries au feu L exposition aux flammes risque de les faire exploser 2 2 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Section Installation Chapter 3 3 1 3 2 0 UPS Installation Plan and Unpacking Use the following basic sequence of steps to install the UPS 1 Create an installation plan for the UPS system Ch
152. eaker Rectifier CB1 Input mama Oma Breakers o a O O Con actors Closed Open Rectifier Switch Inverter Battery Converter E Main Power Flow K2 Trickle Current di Battery Battery Mo Breaker Breaker Energized De Energized Battery NOTE On an UPS configured as an IOM the bypass input static switch bypass breaker CB4 and K5 are not present Figure 6 2 Path of Current Through the UPS in Normal Mode The inverter produces a three phase AC output to a customer s load without the use of a transformer The inverter derives regulated DC from the rectifier and uses IGBT devices and pulse width modulation PWM to produce a regulated and filtered AC output The AC output of the inverter is delivered to the system output through the output contactor K3 If the utility AC power is interrupted or is out of specification the UPS automatically switches to Battery mode to support the critical load without interruption When utility power returns the UPS returns to Normal mode NOTE Bypass mode is not available on an UPS configured as an IOM 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 suffers
153. ensions are in millim D ers inches Figure 3 7 UPM Section Dimensions Top View EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 5 UPS INSTALLATION PLAN AND UNPACKING pa T f 7 7 7 O 5 B 5 5 E i 3 E 1872 1872 L CG 73 7 CG E 73 71 i i E 86 86 33 9 33 9 Hd 5 A liha o E A a 438 11 2 830 Figure 3 8 ISBM Section Center of Gravity 32 1 Dimensions are in millimeters inches 1872 1872 13 1 CG 13 1 1 874 814 34 34 4 E s la L396 830 15 6 g 32 1 Dimensions are in millimeters inches Figure 3 9 UPM Section Center of Gravity 3 6 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING 0 87 115 8 lt 4 56 j 0 22 A 1143 4 50 1 57 0 40 Y Needed to remove key
154. er Inverter Power Module Output Contactor K3 H Protection Contactor Static Ka AC Input to Bypass Switch Digital Metering Backfeed Bypass Breaker CB4 DN oo UPS Cabinet NOTE On an UPS configured as an Input Output Module IOM the bypass input static switch bypass breaker CB4 and backfeed protection contactor K5 are not present Figure 6 1 Main Elements of the UPS System AC Output to Critical Load If utility power is interrupted or falls outside the parameters specified in Chapter 10 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 allows you to either transfer to an alternative power system such as a generator or shut down your critical load in an orderly manner EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 1 UNDERSTANDING UPS OPERATION 6 2 6 2 Single UPS 6 2 1 6 2 2 The emergency bypass consists of a momentary duty static switch a wraparound bypass breaker and a backfeed protection contactor K5 The bypass breaker is located in parallel with the static switch The backfeed protection contactor is located in series with the static switch Bypass breaker CB4 is used for manual transfers to bypass without using the
155. ery breaker Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the UPS command Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed On the UPS Control Command screen select GO TO NORMAL Press the SELECT pushbutton on the UPS Command menu bar The UPS transfers to Normal mode If the power module is not available the system remains on bypass and an alarm sounds The NORMAL status indicator is illuminated The UPS status indicates ONLINE The UPM status indicates ONLINE 7 14 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS 7 3 6 Transfer from Normal to Bypass Mode and Shut Down UPS To transfer the critical load to Bypass mode and shut down the UPS 1 10 Transfer the critical load to bypass by performing the procedure in paragraph 7 3 4 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the UPM command On the UPS Control Command screen select the UPM 1 command Press the CONTROLS pushbutton on the System Status menu bar The UPM 1 Control Command screen is displayed On the UPM 1 Control Command screen select UPM OFF Press the SELECT pushbutton on the UPM 1 Command menu bar The UPM status indicates SHUTDOWN The in
156. es is required Refer to your local codes for disposal requirements e Do not open or mutilate the battery or batteries Released electrolyte is harmful to the skin and eyes It may be toxic A battery can cause electrical shock burn from high short circuit current or fire Observe proper precautions ATTENTION e Une batterie peut pr senter un risque de choc lectrique de brulure ou d incendie Suivre les pr cautions qui s imposent e Pour le remplacement utiliser le m me nombre et mod le des batteries e limination des batteries est r glement e Consulter les codes locaux cet effet CAUTION ja Do not discard the UPS or the UPS batteries in the trash This product contains sealed lead acid batteries IN and must be disposed of properly For more information contact your local recycling reuse or hazardous Ue Pb waste center CAUTION Do not discard waste electrical or electronic equipment WEEE in the trash For proper disposal contact your local recycling reuse or hazardous waste center 95 Maintenance Training A basic training course available from Eaton Corporation gives you a competent working knowledge of the UPS system operation and teaches you how to perform first level corrective maintenance For more information about training and other services contact the Eaton Help Desk for Powerware products see page 1 8 9 6 EATON Powerware 9395 UPS 650 825 kVA Installation and O
157. figuration 9395 825 650 Figure 6 9 on page 6 12 9395 825 750 ps pa Il is p ranster a ds n pus xi om 9395 825 825 ectifier Feed Common Battery onfiguration 9395 825 650 3 400 400 Single Reverse Transfer UPS Three UPM Common Figure 6 10 on page 6 13 9395 825 750 n 9395 825 825 480 480 Rectifier Feed Separate Battery IOM Configuration 9395 825 650 Figure 6 11 on page 6 14 9395 825 750 pe m RA D e de ees H ce ma 9395 825 825 ectifier Feed Common Battery onfiguration 9395 825 650 a 400 400 Single Reverse Transfer UPS Four UPM Common Figure 6 12 on page 6 15 9395 825 750 gi i 9395 825 825 480 480 Rectifier Feed Separate Battery IOM Configuration 9395 825 650 400 400 Single Reverse Transfer UPS Three UPM Separate Figure 6 13 on page 6 16 9395 825 750 480 480 Rectifier Feed Separate Battery Dual Feed 9395 825 825 Configuration 9395 825 650 400 400 Single Reverse Transfer UPS Four UPM Separate Figure 6 14 on page 6 17 9395 825 750 480 480 Rectifier Feed Separate Battery Dual Feed 9395 825 825 Configuration 9395 825 650 400 400 Single Reverse Transfer UPS Three UPM Separate Figure 6 15 on page 6 18 9395 825 750 ps 3 9395 825 825 480 480 Rectifier Feed Separate Battery IOM Configuration 9395 825 650 i 400 400 Single Reverse Transfer UPS Four UPM Separate Figure 6 16 on page 6 19 9395 825 750 ng 9395 825 825 480 480 Rectifier Feed Separate Battery IOM Configuration 9395 825 650 eT F
158. ft or pallet jack forks from the right side of the pallet facing the cabinet between the supports on the bottom of the pallet see Figure 3 8 and Figure 3 9 on page 3 6 for the ISBM and UPM section center of gravity measurements If the sections must be moved using the cabinet front or rear fork lift slots see the caution statements at the beginning of this procedure 2 Remove the three bolts securing the left side shipping bracket to the cabinet and three bolts securing the bracket to the pallet see Figure 4 1 or Figure 4 3 Remove the left side shipping bracket 3 Remove the three bolts securing the right side shipping bracket to the cabinet and three bolts securing the bracket to the pallet see Figure 4 2 or Figure 4 4 Remove the right side shipping bracket Front Door Pallet Shipping Bracket Bolts Shipping Bracket Left Side Shipping Bolts Bracket Figure 4 1 Removing the ISBM Section Left Side Shipping Bracket 4 2 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION ISBM Removable Front Panels CEA DA CO Pallet Es Shipping Bracket Bolts Right Side Shipping Bracket Shipping Bracket Bolts Figure 4 2 Removing the ISBM Section Right Side Shipping Bracket 4 Using a forklift
159. harnesses attached to the left side UPM section from damage NOTE Clearance between the ISBM and the UPM sections must be less than 1 2 so that joining brackets can be installed Using a forklift with the forks in the front forklift slots position the ISBM section adjacent to the left side of the previously installed UPM section Verify that the ISBM section right side is against the UPM section left side and the front of the cabinet bases are flush with each other see Figure 4 6 Reinstall the corner channel see Figure 4 5 and secure using the retained hardware Reinstall the left middle panel see Figure 4 5 and secure using the retained hardware 4 6 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION T 5 s MEN H Hm i loo i amp Jo o e gt O H a B ej ET a m o O 0 O To el a 6 0 0 0 o e e
160. he cause of the shutdown has been identified and cleared 2 To deactivate the REPO switch in preparation for restarting the UPS insert the supplied key and rotate clockwise until the red pushbutton releases see Figure 7 7 To remove the key rotate the key back to the vertical position 3 Restart the UPSs by following the procedure in paragraph 7 4 1 on page 7 20 or 7 4 2 on page 7 21 NTG Power is present inside the UPS cabinet until the upstream input feeder circuit breaker is opened 7 28 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Chapter 8 8 1 X Slot Cards Communication This chapter describes the communication features of the Powerware 9395 650 825 kVA UPS and provides information about connecting hardware and using Terminal mode For terminal wiring information see paragraph 3 2 3 on page 3 19 and paragraph 4 9 on page 4 31 For location of the customer interface panels and terminals see Figure 4 18 on page 4 20 and Figure 4 27 through Figure 4 30 starting on page 4 32 The Powerware 9395 UPS has four standard factory installed X Slot communication bays See Figure 4 27 on page 4 32 for bay locations The UPS is compatible with the following X Slot cards see Figure 8 1 Modbus Card provides direct integration of UPS information meters and status to a Building Management System BMS using the Modbus RTU protocol ConnectUPS X Web SNM
161. he following basic UPS system configurations are possible e Single UPS with three common battery UPMs and a standalone common battery system with a battery disconnect e Single UPS with three common battery UPMs a common battery FI UPM and a standalone common battery system with a battery disconnect e Single UPS with three separate battery UPMs and a standalone separate battery system with a battery disconnect for each UPM e Single UPS with three separate battery UPMs a separate battery FI UPM and a standalone separate battery system with a battery disconnect for each UPM Distributed bypass system with two to five UPSs and a customer supplied tie cabinet The UPS system configuration can be enhanced by adding optional accessories such as a Remote Emergency Power off REPO control RMP Il or X Slot communication cards This manual describes how to install and operate the Powerware 9395 650 825 kVA UPS Read and understand the procedures described in this manual to ensure trouble free installation and operation In particular be thoroughly familiar with the REPO procedure see paragraph 7 3 11 on page 7 18 The information in this manual is divided into sections and chapters The system options and accessories being installed dictate which parts of this manual should be read At a minimum Chapters 1 through 4 and Chapter 7 should be examined Read through each procedure before beginning the procedure Perform only those pr
162. he main menu bar The System Status screen is displayed 2 On the System Status screen select either the UPS or the BYPASS command 3 Press the CONTROLS pushbutton on the System Status menu bar The UPS or Bypass Control Command screen is displayed 4 On the Control Command screen select LOAD OFF 5 Press the SELECT pushbutton on the Command menu bar The Load Off screen is displayed providing a choice to proceed or abort the shutdown EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 17 UPS OPERATING INSTRUCTIONS CAUTION All power to the critical load is lost when the LOAD OFF is selected in the following step You should use this feature only when you want to de energize the critical load 6 To shut down the UPS press LOAD OFF from the Load Off menu bar and hold for three seconds To abort the shutdown press CANCEL When LOAD OFF is selected and held for three seconds the input output battery and bypass backfeed contactors open and the power module is turned off CAUTION Do not attempt to restart the system after the Load Off until the cause of the shutdown has been identified and cleared 7 Torestart the UPS after pressing the LOAD OFF pushbutton follow the procedure paragraph 7 3 1 on page 7 11 or 7 3 2 on page 7 12 A Power is present inside the UPS cabinet sections until the upstream input feeder circuit breaker is opened 7 3 11
163. her month day year or day month year formats for display on the screen and for logging events in the Event and History Logs Select DATE AND TIME from the System Setup Level 1 menu to display the Time Format Setup screen Use the up or down arrow pushbutton to highlight the desired format then press the SELECT pushbutton to display the Set Date and Time screen To return to the System Setup screen press the return arrow pushbutton Set Date and Time MM DD YYYY The Set Date and Time MM DD YYYY screen allows the internal date and time of the UPS to be set in the month day year format The date and time information is used for display on the screen and for logging events in the Event and History Logs Use the left or right arrow pushbutton to highlight the setting to be changed Use the up or down arrow pushbutton to make the change When finished making changes use the left or right arrow pushbutton to highlight SAVE and the up or down arrow pushbutton to select YES To complete the save function and return to the System Setup screen select the return arrow pushbutton Set Date and Time DD MM YYYY The Set Date and Time DD MM YYYY screen allows the internal date and time of the UPS to be set in the day month year format The date and time information is used for display on the screen and for logging events in the Event and History Logs Use the left or right arrow pushbutton to highlight the setting to be changed Use the up or down arrow pu
164. ier Rectifier Static Static Y switch Y switch Fuse Fuse erem K5 9 9 ruse ruse e e Fuse Fuse T Inverter F Inverter SR A K3 K3 e e Battery Battery Converter Converter Fuse Fuse NING K2 LAS K2 C E4 E5 C E4 E5 Battery Breaker Battery Breaker N ON 0 oH HI O oH Hl E9 E9 TIE E10 BATTERY SYSTEM 10 BATTERY SYSTEM CABINET E11 Not supplied E11 Not supplied Optional E12 with the UPS E12 with the UPS MOB 1 D D ON MOB 2 a O 0 A AC Input to UPS Rectifier B AC Input to Bypass C DC Input from Battery D UPS AC Output to Tie Cabinet E Output to Critical Load E Overcurrent Protection provided by customer Y NOTE This oneline does not show each UPM in the UPSs but represents each UPS in the distributed bypass system The internal BA be structure of each UPS is shown Figure 6 5 through Figure 6 8 starting on page 6 8 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 21 Typical Distributed Bypass System 1 1 and 2 0 Configurations EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 27 UNDERSTANDING UPS OPERATION
165. ift the cabinets only with a forklift or damage may occur nt damage to the wiring channel and wiring in the UPM section base when lifting or moving the nd move the UPM section using only the front or rear forklift slots Verify that the forklift forks are in a horizontal position before inserting them into the forklift slots DO NOT angle fork tips upward the forks all the way through the base DO NOT insert forks partially into the base to move the et may be partially inserted into the front or rear forklift slots for minor positioning if the forks are n a horizontal position with no upward angling OT use the forklift slots on the end of the cabinet to move the cabinet orklift slots may be used for minor positioning if the forks are kept in a horizontal position with no upward angling If these instructions are not followed damage to the wiring channel and wiring will occur EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 1 UPS SYSTEM INSTALLATION NOTE for the following steps verify that the forklift or pallet jack is rated to handle the weight of the cabinet see Table 3 1 on page 3 2 for cabinet weight 1 If not already accomplished use a forklift or pallet jack to move the ISBM and UPM sections to the installation area or as close as possible before unloading from the pallets If possible move each section using the pallet Insert the forkli
166. ing and performing the installation e All distributed bypass UPS rectifier inputs must come from one source and all bypass input feeds must come from one source Distributed bypass UPS input wiring size requirements and output wiring size requirements from the UPSs to the tie cabinet or distribution panel are the same as listed in Table 3 4 on page 3 9 and Table 3 5 on page 3 10 e fthe load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed Install neutral conductors from the UPSs to the common point of connection tie cabinet and then install a system neutral to ground bonding jumper The bonding jumper must be copper wire DO NOT install both a source neutral and a bonding jumper If the recommended system neutral bonding jumper installation method cannot be accomplished each UPS should have a separate neutral to ground bonding jumper installed See Table 3 4 or Table 3 5 for UPS neutral bonding jumper wire sizes The bonding jumper must be copper wire DO NOT install both a source neutral and a bonding jumper The UPS cannot be installed in a high resistance ground application e MOBs with dual auxiliary contacts are to be provided by the customer Table 3 16 on page 3 17 lists the recommended rating for the MOBs EATON Powerware 9395 UPS 650 825 kVA Instal
167. ing the Sections 4 3 s verify that the forklift or pallet jack is rated to handle the weight of the 3 2 for cabinet weight 1 on page Using a forklift move the UPM section to the final installed location 1 2 Remove one top screw and two bottom screws securing the UPM section Lift the panel straight up to remove it from the panel hanger brackets at the top of the cabinet 5 wireway panel see Figure 4 3 Remove the screws securing the top and bottom internal safety shield panels and remove the panels Retain the hardware for later use 4 Remove the screws securing the corner channel and remove the channel see Figure 4 5 Retain the hardware for later use 4 5 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION Left Top Panel Left Middle Panel Interior Left Side Panel Corner Channel UPM Section Wireway Panel Figure 4 5 Section Joining Remove the screws securing the left top panel and remove the panel see Figure 4 5 Retain the hardware for later use Remove the screws securing the left middle panel and remove the panel see Figure 4 5 Retain the hardware for later use CAUTION Use care during installation to protect components mounted on the right side of the ISBM section and the intercabinet wiring
168. input breaker CB1 8 On the System Status screen select the BYPASS command 9 Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed 10 On the Bypass Control Command screen select G0 TO BYPASS 11 Press the SELECT pushbutton on the Bypass Command menu bar The critical load is immediately supplied by the bypass source in Bypass mode The BYPASS status indicator is illuminated The Bypass status indicates ON The UPM status indicates SHUTDOWN CLOSE BATTERY 7 3 3 Starting the UPMs To start the power module without transferring the critical load to Normal mode 1 If the UPS contains input breaker CB1 verify that input breaker CB1 is open 2 Close the UPS input feeder circuit breaker 3 Close the UPS Bypass input feeder circuit breaker 4 Observe the UPS control panel becoming active indicating logic power 5 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed 6 On the System Status screen verify the UPS status is SHUTDOWN and the UPM status is OFFLINE 7 Ifthe UPS contains input breaker CB1 close input breaker CB1 8 On the System Status screen select the UPM command 9 On the UPS Control Command screen select the UPM 1 command EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS 10 Press the CONTROLS pushbutton on the System St
169. input source If the input power fails to return or is not within the acceptance windows required for normal operation the battery continues discharging until a DC voltage level is reached where the inverter output can no longer support the connected loads When this event occurs the UPS issues another set of audible and visual alarms indicating SHUTDOWN IMMINENT Unless the rectifier has a valid AC input soon the output can be supported for only two minutes before the output of the system shuts down If the bypass source is available the UPS transfers to bypass instead of shutting down If at any time during the battery discharge the input power becomes available again contactors K1 and K5 close and the rectifier begins to supply DC current to the converter and inverter At this point the unit returns to Normal mode Depending on the total load and the duration of the battery discharge battery current limit alarms may be seen for a short time due to the current required to recharge the battery EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 5 UNDERSTANDING UPS OPERATION Bypass Breaker CB4 KIN O Static Bypass Input J lt gt K5 Input Switch Breaker Rectifier CB1 Input we p O Rectifier Output Inverter Battery Converter paaa Main Power Flow K2
170. inside the UPS cabinet sections 7 4 7 Single UPM Shutdown To shutdown a single UPM 1 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the the UPM Command The UPS Control Command screen is displayed On the UPS Control Command screen select the the UPM to shutdown Press the CONTROLS pushbutton on the System Status menu bar The UPM Control Command screen is displayed On the UPM Control Command screen select UPM OFF Press the SELECT pushbutton on the UPM Command menu bar The UPM status indicates SHUTDOWN The input output and battery contactors open and the power module is turned off The remaining UPMs supply the critical load EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS 7 4 8 UPS and Critical Load Shutdown To perform maintenance or service on the critical load shut down power to the load 1 2 Turn off all equipment that is being powered by the distributed bypass system Perform the LOAD OFF procedure in paragraph 7 4 10 The input output battery and bypass backfeed contactors open and the power module is turned off Power is present inside the UPS cabinet sections until the upstream input feeder circuit breaker is opened pere UTE 3 4 If the UPSs contain input breakers CB1 open all UPS input breakers
171. ions and abnormalities On any UPS press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the BYPASS command Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed On the Bypass Control Command screen select GO TO BYPASS Press the SELECT pushbutton on the Bypass Command menu bar All of the UPSs transfer to Bypass mode and the critical load is immediately supplied by the bypass source from all UPSs If the bypass source is not available the power module remains on and an alarm sounds The BYPASS status indicator is illuminated The Bypass status indicates ON The UPM status indicates READY The power module remains on XS eee Power is present inside the UPS cabinet sections 7 45 Transfer from Bypass to Normal Mode To transfer the critical load to Normal mode 1 2 If not already closed close the battery breaker On any UPS press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the UPS command Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed On the UPS Control Command screen select GO TO NORMAL Press the SELECT pushbutton on the UPS Command menu bar All of the UPSs transfer to Normal mode If the power module is not available the system
172. is terminated inside the UPS cabinet OPTIONAL The debris shields covering the UPS cabinet ventilation grills are removed Startup and operational checks are performed by an authorized Eaton Customer Service Engineer EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 43 UPS SYSTEM INSTALLATION Distributed Bypass Installation Checklist O D DL D DL D D D D 4 44 Each cabinet in the distributed bypass system is placed in its installed location All conduits and cables are properly routed to the UPS cabinets and to the tie cabinet or distribution panel All power cables are properly sized and terminated Neutral conductors are installed or bonded to ground as per requirements A ground conductor is properly installed Controller Area Network CAN wiring between the UPS cabinets is properly installed Pull chain wiring between the UPS cabinets is properly installed Adequate workspace exists around the UPS cabinets the tie cabinet and other cabinets Startup and operational checks are performed by an authorized Eaton Customer Service Engineer EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION Notes EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 45 UPS SYSTEM INSTALLATION This page intentionally left blank 4
173. lation and Operation Manual 164201725 Rev 2 www powerware com UPS INSTALLATION PLAN AND UNPACKING 3 3 Inspecting and Unpacking the UPS Cabinets By O O The UPS cabinet is divided into two sections palleted separately for shipping The sections are shipped bolted to wooden pallets see Figure 3 11 and Figure 3 12 and protected with outer protective packaging material The UPS sections are heavy see Table 3 1 on page 3 2 If unpacking and unloading instructions are not closely followed the cabinets may tip and cause serious injury CAUTION To prevent damage to the wiring channel and wiring in the UPM section base when lifting or moving the cabinet Lift and move the UPM section using only the front or rear forklift slots Verify that the forklift forks are in a horizontal position before inserting them into the forklift slots DO NOT angle fork tips upward e Insert the forks all the way through the base DO NOT insert forks partially into the base to move the cabinet Forks may be partially inserted into the front or rear forklift slots for minor positioning if the forks are kept in a horizontal position with no upward angling e DO NOT use the forklift slots on the end of the cabinet to move the cabinet End forklift slots may be used for minor positioning if the forks are kept in a horizontal position with no upward angling If these instructions are not followed damage to the wiring channel and wi
174. lly unsecure protocols and transports Powerware LanSafe Power Management Software Remote Notification Each Powerware 9395 UPS ships with LanSafe Power Management Software To install the Powerware LanSafe software see the instructions accompanying the Software Suite CD Powerware LanSafe software uses an RS 232 serial link to communicate with the UPS The software provides up to date graphics of UPS power and system data and power flow a complete record of critical power events and notification of important UPS or power information With custom views for monitoring status and metering information various user groups can select the most useful view for their specific needs For connection and setup of a modem or to enable Remote Notify and Call Home features within the UPS contact an Eaton service representative see page 1 8 Remote Notification allows the UPS to use a standard off the shelf PC modem as a telephone interface The features provided by this option are Call to a remote terminal or pager based on programmable events and alarms Four separate programmable notification groups phone numbers Automatic answering user configurable for access to the Terminal mode of the UPS Remote and local ability to clear Call Out alarms and events Error detection and correction for misconfigured and disconnected modems Remote Notification provides the user with the option of receiving alarms and notices at a remote
175. load is not protected while the UPS is in Bypass mode In Bypass mode the output of the system is provided with three phase AC power directly from the system 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 but no active power conditioning or battery support is available to the output of the system in the Bypass mode of operation EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION The internal bypass is comprised of a solid state silicon controlled rectifier SCR static switch SSW a motorized wraparound bypass breaker CB4 and a backfeed protection contactor K5 The static switch is rated as a momentary duty device that is used instantaneously anytime the inverter is unable to support the applied load The static switch is wired in series with the backfeed protection contactor and CB4 is wired in parallel with this combination Together they are wired in parallel with the rectifier and inverter The static switch being an electronically controlled device can be turned on immediately to pick up the load from the inverter while bypass breaker CB4 closes and inverter output contactor K3 opens to isolate the inverter When breaker CB4 closes the static switch stops conducting The backfeed pr
176. lowing functions NOTE The brackets in the following bullets indicate standard keyboard characters To use a key combination hold down the Escape key and press the indicated letter key ESC A displays the Active Alarms ESC H displays the Event History ESC N displays the Node Bits Setup ESC O Quit Display UPS Control Panel When this function is invoked a facsimile of the UPS control panel is displayed on the terminal screen All controls are functional and can control the UPS remotely The only exception is the Load Off control which requires the operator to press and hold the local control for two seconds to shut down the UPS To remotely control the UPS or view UPS information use the Escape key legend to control the function normally controlled by the control panel softkeys See paragraph 7 2 on page 7 2 Using the Control Panel for instructions on navigating the control panel EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com COMMUNICATION 8 5 2 Event History Log This key sequence prints the entire Event History Log of the UPS at the time the data is requested The printout begins with the oldest alarm entry in the queue and ends with the most recent Any alarms that occur while the Event History Log is printing are included in chronological order The Event History Log lists up to 500 system events in chronological order with the mo
177. ly mount the RMP II at the desired location See Figure 5 12 on page 5 15 for mounting hole locations NOTE When installing signal wiring for CAN card J3 terminals conduit must be installed between the device and the UPS cabinet Remove the ISBM cabinet top right interface conduit landing plate to drill or punch conduit holes see Figure 4 18 on page 4 20 Reinstall the conduit landing plate Install conduit between the UPS and RMP II See Figure 5 12 on page 5 15 for RMP II knockout hole location Install wiring between the UPS and RMP II See Figure 5 2 and Table 5 1 for the Powerware Hot Sync CAN Bridge Card terminal location and wiring information and Figure 5 7 Figure 5 8 and Table 5 5 for the RMP Il terminal location and wiring information NOTE 120 Vac for the RMP Il should be supplied from the critical bus by facility planners or the customer 10 Install 120 Vac power wiring from the critical bus to the RMP Il See Figure 5 7 Figure 5 8 and Table 5 5 for the terminal location and wiring information Close the front door and secure the latch Restart the UPS See Chapter 7 UPS Operating Instructions for startup instructions EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 5 9 INSTALLING OPTIONS AND ACCESSORIES
178. m 7 3 Single UPS Operation UPS OPERATING INSTRUCTIONS o NOTE A Field Installed UPM FI UPM is always designated as UPM 4 7 3 1 Starting the UPS in Normal Mode To start the UPS system 1 2 3 4 5 10 11 12 13 If the UPS contains input breaker CB1 verify that input breaker CB1 is open Close the UPS input feeder circuit breaker Close the UPS Bypass input feeder circuit breaker Observe the UPS control panel display becoming active indicating logic power Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen verify the UPS status is SHUTDOWN and the UPM status is OFFLINE Close the battery breaker If the UPS contains input breaker CB1 close input breaker CB1 On the System Status screen select the UPS command Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed On the UPS Control Command screen select GO TO NORMAL Press the SELECT pushbutton on the UPS Command menu bar If Auto Bypass is enabled factory default the critical load is immediately supplied by the bypass source in Bypass mode until the inverter turns on and the UPS transfers to Normal mode The status indicator on the UPS control panel indicates the UPS is in Bypass mode If Auto Bypass is not enabled the UPS output remains off until the UPS transfers to Normal mode Verify the following messages display
179. m Status screen SETUP Allows you to set the display contrast set the date and time for the time stamp configure the UPS serial communication ports and view the firmware version numbers LOAD OFF De energizes the critical load and powers down the UPS ESC Returns to Main Menu and Mimic screen from the Events Meters Controls or Setup screens Returns to the main System Setup Level screen from a setup submenu Pm Return arrow acknowledges or executes a command or saves a setting t4 Up and down arrows scroll through screens and lists or highlight settings a 2 Left and right arrows select or adjust settings displayed on the screen 7 2 5 Mimic Screen Figure 7 4 shows the Main Menu and Mimic screen To select the Mimic screen from the Events Meters Controls or Setup screens press the ESC pushbutton on the current menu bar The Mimic screen shows the internal components of the UPS cabinet and a real time graphical representation of the operating status of the system TIME 11 35 43 DATE 06 25 2008 INPUT BATT STSW OUTPUT BYPASS EVENIS METERS CONTROLS SETUP LOAD OFF Figure 7 4 Main Menu and Mimic Screen Normal Mode EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 5 UPS OPERATING INSTRUCTIONS 7 2 6 Display Menu Operation Table 7 3 describes
180. mes unavailable the distributed bypass system dynamically updates the redundancy calculation to determine if the remaining UPSs can support the load If the load can be supported the system does not switch to bypass Figure 6 19 shows the path of electrical power through the parallel system when operating in Bypass mode UPS Input Tie Cabinet UPS 1 Output UPS 1 SSD Battery UPS 2 Output UPS 2 SSD Battery UPS 3 Output UPS 3 SSB Battery UPS 4 Output UPS 4 SD Main Power Flow Breakers e 7 Closed Output to ZA Critical Load O O Open Figure 6 19 Path of Current through the UPSs in Bypass Mode Distributed Bypass EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 23 UNDERSTANDING UPS OPERATION 6 4 4 In a distributed bypass system each UPS operates similar to a single UPS but in parallel with each other The bypass source for the load is derived from the bypass input of one two three or four UPSs depending on the system configuration through the internal static switches If a module is taken offline the other modules remain online to support the load If more modules than can support the load must be taken offline the load must be transferred to maintenance bypass or shut down The distributed
181. ms and notices see paragraph 7 2 2 B The information area contains data about UPS status and operations C The menu bar lists the titles of the available screens To select a screen press the pushbutton underneath the desired screen D Each navigation pushbutton function depends on the screen displayed Use the pushbuttons to select menu screens or scroll through available screens The LCD options above the pushbuttons indicate each pushbutton s function You can use the LCD and the pushbuttons to e Look at a log of UPS events alarms notices and commands see paragraph 7 2 6 Monitor UPS operation see paragraph 7 2 6 e Set UPS parameters see paragraph 7 2 6 e Control UPS operation see paragraphs 7 2 7 and 7 2 8 After approximately 30 minutes the display screen darkens To restore the screen press any pushbutton once 7 4 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS 7 2 4 Using the Menu The UPS menu bar allows you to display data in the information area to help you monitor and control UPS operation Table 7 2 shows the basic menu structure Table 7 2 Display Function Menu Map Menu Option Description EVENTS Displays the list of Active System Events and a historical log of system events METERS Displays performance meters for the system or critical load CONTROLS Displays the Syste
182. n Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION Bypass Input Y UPS Input Tie Cabinet q UPS 1 Output UPS 1 SG Battery e UPS 2 Output UPS 2 Sd e Battery e O UPS 3 Output e UPS 3 SSB Battery UPS 4 Output UPS 4 SY Battery Breakers M 6d Closed Main Power Flow a erie O Open ritical Loa Figure 6 20 Path of Current through the UPSs in Battery Mode Distributed Bypass If at any time during the battery discharge the input power becomes available again the rectifier begins to supply DC current to the inverter At this point the UPS returns to Normal mode If at any time during the battery discharge the AC input power becomes available again each rectifier turns on assumes the inverter load from the batteries and begins recharging the batteries Depending on the total load and the duration of the battery discharge battery and rectifier input current limit alarms may be seen for a short time due to the current required to recharge the batteries EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 25 UNDERSTANDING UPS OPERATION 65 Multiple UPS Distributed Bypass System Oneline Configurations The distributed bypass system oneline drawings in this section show the simplified internal structure of th
183. n Normal Mode seden al LAN dts denials ang shade DARLA a ota Ka ERU eta oats 7 11 7 3 2 Starting the UPS in Bypass Modes eien shai eee eec educta rea ua ets ea ete opes 7 12 7 33 AA A A O AN E RA NR 7 12 7 3 4 Transterirom Normal to Bypass MOS roots seai a AA GNG A A GA 7 14 7 3 5 Transfer from Bypass to Normal Mode RR RR RR RR e ene eens 7 14 73 6 Transfer from Normal to Bypass Mode and Shut Down UPS 0 20 00 ee 7 15 7134 SINGIEUPMESHUTAOWN esos nt A FARE MR ML e ata WA ead e Ca Ba 7 15 7 38 UPS and Griticalboad Shutdown 5 3 ttt ge tere Dee rette eter cw a e bend Eoo Een eT Ea 7 16 73 9 Charger Control massana uct a KAN Laga EOD E ng pm E te ett ig e E ECL aaa 7 16 7 3 10 Using the UPS LOAD OFF Pushbutton or Command sse erea e rs 7 17 7 3 11 Using the Remote Emergency Power off Switch 0 ooo 7 18 74 Multiple UPS Distributed Bypass Operation 0 2 eee e 7 20 744 Starting the Distributed Bypass System in Normal Mode Ie 7 20 742 Starting the Distributed Bypass System in Bypass Mode 7 2 743 Starina the UPS UPS we one atten Naa Mita AN kaaa a te eter toa Nan ketenes sake nt Na aa 7 21 744 Transter trom Normalto Bypass Mode etica e a SG got os ey DS ED DR Med ee 7 23 74 5 Transfer from Bypass to Normal Mode 7 23 746 Transfer from Normal to Bypass Mode and Shut Down all UPSs 0 0 eee 7 24 747 single UBMESHUtdOWnE d es ya baran nan pt NAA dna ac E e Eb he E e a oka e Ihe nG AG BAHANG cat NG 7 24 748
184. nennaeemnaannnannoonn CRISS 0 03S o o o ataa aTa p p ecododonedodododedodondnadodonananado e o QO 0 0 o o o 1 0 0 0 0 0 0 0 0 0 0 e e e e e O00000O0ODODDDODODODDODODODODODODODO a SSeS nnn QOD 000000 000000000000000 000000000000 EHB EHHEEHHEHHHHEEHHHEEHHEEEHEEEHEHEH lo amtmann miar m alaaa tataa a aala ataa ataa aE CSS S00 SSS Coes oO SSeS Seer alaa ataa ataa aTe E CHBHBHHBHHEHEHBHHEBHHHEEHHHBBHEBHHEEEE 9 CSCS 0 03S o JJ a In ba o o JJ JJ EHEBHHEEREHERBREEBHEEEEREEBEREBERECER QOD 08 0 0 0 0 BB D B 000 00 0 0 0 0 0 0 0 000000000000 JJ JJ JJ JJ lol ERBEEHBEEHHEEERHEEHHEEHRHEEHRHEEREEEH Fo o 0 0 0 0 o o o 000000000000000 000000000000 oppor ononon onn nnn nnn CSS S07 JJ JJ bn JJ a a alaa ataa ataa aTa eEHEBHBEEHEEERHEEREEEBEEEREBHEEBEBECEE e EnBeBnBEHBEHERBREERBHEHEEREBEREBEREEER o EEBeenpBEREEERBBERBRERREREEBREEBBEEER f o a a JI a a a a a F Figure 4 27 ISBM Section Interface Terminal Locations EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 32 Table 4 1 TB1 TB2 and TB3 Interface Connections UPS SYSTEM INSTALLATION Terminal TB1 Name Description 1 REPO NC Input Normally closed dry contact used to activate UPS EPO from a remote switch 2 REPO Return 3 REPO NO Input Normally open dry contact used to activate UPS EPO from a remote switch 4 REPO Return 5 Battery Aux i E 3 I
185. nput Normally open contact used to indicate when UPS battery breaker is open or 6 Battery Aux Common closed 7 48 Vdc Battery Shunt Trip 3 Output Contacts used to open battery breaker or disconnect 8 48 Vdc Battery Shunt Trip 9 Output Contactor K3 NC Aux 10 Output Contactor K3 NC Aux Output Normally closed contact opens when output contactor closes Common Terminal TB2 Name Description 1 Pull Chain E Output Backup control for parallel operation 2 Pull Chain Common 3 Alarm Relay NC Output General purpose normally closed NC relay contact 4 Alarm Relay Common 5 Alarm Relay NO Output General purpose normally open NO relay contact 6 Alarm Relay Common 7 Not Used 8 Not Used 9 Not Used 10 Not Used Terminal TB3 Name Description 1 Building Alarm 1 S Input Programmable UPS alarm activated by a remote dry contact closure 2 Building Alarm 1 Return 3 Building Alarm 2 eS Input Programmable UPS alarm activated by a remote dry contact closure 4 Building Alarm 2 Return 5 Building Alarm 3 Default Charger Off 6 Building Alarm 3 Return Input Programmable UPS alarm activated by a remote dry contact closure Default function set for charger off Building Alarm 4 f Default On Generator Input Programmable UPS alarm activated by a remote dry contact closure Default 8 Building Alarm 4 Return function set for on generator 9 Building Alarm 5 Default Maintenance Bypass Input Programmable UPS alarm activated
186. nput to UPMs terminals See Figure 4 8 on page 4 11 for common rectifier feed terminal locations or Figure 4 10 on page 4 13 for separate rectifier feed terminal locations o NOTE When connecting the UPM battery cables verify the cables are connected to the correct terminals 9 Using hardware from the intercabinet wiring terminal hardware kit see Table 3 8 connect the positive and negative cable lug connections to the DC Input to UPMs terminals Follow the callout details in Figure 4 12 on page 4 15 to connect the correct cable lug to the proper terminals See paragraph 3 2 2 on page 3 8 for wiring and termination requirements NOTE AC output intercabinet power wiring harnesses are supplied attached to the interior left side panel of the UPM section see Figure 4 5 on page 4 6 10 Locate the 1G4 1Gb 2G4 2G5 3G4 and 3G5 power wiring harnesses Remove the front two columns of wire ties securing the cables to facilitate routing cables to the AC Output from UPMs terminals See Figure 4 8 on page 4 11 for common rectifier feed terminal locations or Figure 4 10 on page 4 13 for separate rectifier feed terminal locations first lug on the stud with the raised barrel portion facing the back of the cabinet Install the second lug with o NOTE Two cable lugs will be connected to each terminal stud When connecting the cable lugs install the the raised barrel portion facing the front of the cabinet 11 Using hardware from
187. ocedures that apply to the UPS system being installed or operated This Manual This manual uses these type conventions Boldtype highlights important concepts in discussions key terms in procedures and menu options or represents a command or option that you type or enter at a prompt e Italic type highlights notes and new terms where they are defined Screen type represents information that appears on the screen or LCD Icon Description o Information notes call attention to important features or instructions Keys Brackets are used when referring to a specific key such as Enter or Ctrl 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 system the UPS cabinet the battery system and options or accessories installed EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INTRODUCTION 1 7 Symbols Controls and Indicators The following are examples of symbols used on the UPS or accessories to alert you to important information Pb K 1 8 For More Information RISK OF ELECTRIC SHOCK Observe the warning associated with the risk of electric shock symbol CAUTION REFER TO OPERATOR S MANUAL Refer to your operator s manual for additional information such as important operating and maintenance instructions This symbol indicates that you sho
188. of action however denominated Eaton shall not be responsible for failure to provide service or parts due to causes beyond Eaton s reasonable control In no case will Eaton s liability under this Warranty exceed the replacement value of the Warranted Items END USER S OBLIGATIONS In order to receive the benefits of this Warranty the End User must use the Product in a normal way follow the Product s installation operation and maintenance manual and protect against further damage to the Product if there is a covered defect OTHER LIMITATIONS Eaton s obligations under this Warranty are expressly conditioned upon receipt by Eaton of all payments due to it including interest charges if any During such time as Eaton has not received payment of any amount due to it for the Product in accordance with the contract terms under which the Product is sold Eaton shall have no obligation under this Warranty Also during such time the period of this Warranty shall continue to run and the expiration of this Warranty shall not be extended upon payment of any overdue or unpaid amounts COSTS NOT RELATED TO WARRANTY The End User shall be invoiced for and shall pay for all services not expressly provided for by the terms of this Warranty including without limitation site calls involving an inspection that determines no corrective maintenance is required Any costs for replacement equipment installation materials freight charges travel expenses or labor of Ea
189. oint then lift the door off Retain the hardware for later use 4 Terminal block TB3 is accessible on the left side of the X Slot communication bay To gain access to terminal block TB1 TB2 and the left interface entry conduit landing plates remove the screws securing the top internal safety shield panel and remove the panel Retain the hardware for later use see Figure 4 27 on page 4 32 5 Remove the interface entry conduit landing plates to drill or punch holes see Figure 4 18 on page 4 20 6 Reinstall the interface entry plates and install the conduit Do not directly connect relay contacts to the mains related circuits Reinforced insulation to the mains is required 7 Tolocate the appropriate terminals and review the wiring and termination requirements see paragraph 3 2 3 on page 3 19 Table 4 1 on page 4 33 and Figure 4 27 through Figure 4 30 8 Route and connect the wiring 9 If wiring TB1 battery interface connections proceed to paragraph 4 9 2 if wiring the X Slot connections only proceed to paragraph 4 9 3 otherwise proceed to Step 10 10 Reinstall the top internal safety shield panel and secure with the retained hardware EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 31 UPS SYSTEM INSTALLATION 11 Reinstall the front door removed in Step 3 and secure with the retained hardware 12 Close the door and secure the latch TB1 an
190. on personnel or performed by an authorized Eaton Customer Service Engineer or Agent This Warranty is not valid a unless an authorized Eaton Customer Service Engineer in the USA or Agent outside of the USA performs startup and commissioning of the Product b if the Product is moved to a new location by someone other than an authorized Eaton Customer Service Engineer in the USA or Agent outside of the USA or c if the Product s serial numbers have been removed or are illegible Any Warranted Items repaired or replaced pursuant to this Warranty will be warranted for the remaining portion of the original Warranty subject to all the terms thereof Labor warranty is not provided for Product located outside of the fifty 50 United States or the District of Columbia Any equipment parts or materials included in the Product and not manufactured by Eaton are warranted solely by the manufacturer of such equipment parts or materials and are not included as part of this Warranty Batteries are not warranted by Eaton THIS WARRANTY IS THE END USER S SOLE REMEDY AND IS EXPRESSLY IN LIEU OF AND THERE ARE NO OTHER EXPRESSED OR IMPLIED GUARANTEES OR WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PURPOSE WHICH ARE EXPRESSLY DISCLAIMED LIMITATION OF LIABILITY In no event shall Eaton be liable for any indirect incidental special or consequential damages of any kind or type whatsoever or based on any claim or cause
191. onnnnnnnnnnnnnnnnnnnnnn jaan ml do o HEEEEHEEHEEHEEEECEEHEEHH EEEHEEHEEHEEHECEEHEEHEEH DOOOOSCGOGS000o0000000909 O00000000000000000009009 Ol O YY ollollo SSH He See See SHEER SERS SEES ee Seed sl las 0 0 EHBBEBBBBEBBBEEIERHEBOBEH CHBBBBBBEBBEBEEDBREBEBBES il las EERE EREEREER OS SSH SEES ee TaTa aTe SEES EES See SS 6 6 BSE EE See sil SEBS eee ee n n DODODDOODDODDDODODDDODOD GOODDODDDODDDODODDODDDDDO O O DODODDOODDODDDODOD0DOD0D 400000 0 000 0000 0 0 0 0 0 0 0 0 0 0 0 0 0 M DODODDOODDODDDODOD0DOD0D 400000 0 0000 000 0 0 0 0 0 0 0 0 0 0 0 0 0 A A BBB SEES See EEEHEEHEEHEEHECEEHEEHEEH la lala lll SSH dodo dedos SS SEES SEES SHES SSS SEES EE EEE ESE Se SEBEEEEEEEEEEEEEEEEEEEE do 7 gt a a a a o o o o o o o o o Phase C AC Input to UPMs Phase B See Figure 4 9 for detail hase A DC Input to UPMs E5 See Figure 4 12 for detail DC Input to UPMs E4 See Figure 4 12 for detail Figure 4 8 ISBM Section Intercabinet Power Terminal Locations Common Rectifier Feed EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 11 UPS SYSTEM INSTALLATION 000 000 000 o O Y Oo MER O _ O lt AC Input Breaker CB1 Im O Phase B E2A UPM 3 Cable 3G1 amp 3G2 Brown
192. ons of the status indicators see paragraph 7 2 1 System Event Messages When a system event occurs a message appears on the LCD in the UPS status area This message is also written to the Active Events Log and may be added to the History Log The messages are divided into four categories alarms notices status and commands EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 3 UPS OPERATING INSTRUCTIONS 7 2 3 Using the LCD and Pushbuttons The LCD on the control panel provides an operator interface with the UPS system Figure 7 3 identifies the display areas discussed in the following sections A 7 ALARM INPUT AC UNDER VOLTAGE INPUT UPS B BATT STSW OUTPUT BYPASS C EVENTS METERS CONTROLS SETUP LOAD OFF i AN 7 Jh Rem i C X Y NAA ED RS AN Figure 7 3 Parts of the LCD A The UPS status area automatically scrolls between the Powerware model number current date and time active alarms active notices and load percent and battery runtime for the UPS The top line of display blinks while scrolling when the system needs attention Some notices and alarms may be accompanied by an audible horn To silence the horn press any control panel pushbutton once Shown is a typical alarm message For more information about alar
193. ophisticated detection and switching logic inside the UPSs ensures that operating mode changes are automatic and transparent to the critical load while internal monitoring systems indicate the current mode of operation The UPSs switch operating modes in response to these system events A command is an intervention that is externally initiated by an operator or by some site action A command causes the UPSs to switch operating modes it usually does not require any further action e A notice is a minor system event that may or may not require attention An alarm is a system event that requires immediate intervention The following paragraphs describe the differences in the three parallel system operating modes using block diagrams to show the power flow during each mode of operation Normal Mode Distributed Bypass In Normal mode utility AC power is supplied to the UPSs Each UPS then conditions the incoming AC power and provides clean regulated AC power to tie cabinet or distribution panel for parallel systems up to four modules The applied load is shared equally among the available UPMs in the system Figure 6 18 shows the path of electrical power through the parallel system when operating in Normal mode UPS Input Tie Cabinet UPS 1 Output UPS 1 SYO e Battery 48 4
194. or the maintenance bypass input DO NOT use a single feed or a single feeder breaker to supply both the UPS or RIB and the maintenance bypass If a bypass input breaker BIB is installed in the maintenance bypass and a single feed UPS is being installed a single feed to the maintenance bypass is acceptable for supplying both the UPS and the bypass The bypass feed into this equipment uses three or four wires The rectifier feed into this equipment uses three wires The phases must be symmetrical about ground from a Wye source for proper equipment operation If the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper See Table 3 4 or Table 3 5 for neutral bonding jumper wire sizes The bonding jumper must be copper wire The ISBM and UPM sections are shipped with debris shields covering the ventilation grills on top of the sections Do not remove the debris shields until installation is complete However remove the shields before operating the UPS Once the debris shields are removed do not place objects on the ventilation grills In a common battery system single and multiple UPMs are powered from one common battery source In a separate battery system multiple UPMs are each powered from separate battery sources
195. otection contactor is normally always closed ready to support the static switch unless the bypass input source becomes unavailable If the UPS transfers to Bypass mode from Normal mode due to any reason other than operator intervention the UPS automatically attempts to transfer back to Normal mode up to three times within a ten minute period The fourth transfer locks the critical load to the bypass source and requires operator intervention to transfer 6 2 4 Battery Mode The UPS automatically transfers to Battery mode 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 6 4 shows the path of electrical power through the UPS system when operating in Battery mode 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 inverter The input contactor K1 opens and the battery instantaneously supplies energy to the battery converter The converter either bucks or boosts the voltage so that the inverter can support the customer s load without interruption If bypass is common with the rectifier input the backfeed protection contactor K5 also opens The opening of contactors K1 and K5 prevent system voltages from bleeding backwards through the static switch and rectifier snubber components and re entering the
196. ou have completely installed all hardware cables and other equipment Complete all items listed on the checklist to ensure a smooth installation Make a copy of the Installation Checklist before filling it out and retain the original After the installation is complete an Eaton Customer Service Engineer must verify the operation of the UPS system and commission it to support the 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 verify all applicable equipment installations have been completed O NOTE The Installation Checklist MUST be completed prior to starting the UPS system for the first time 4 42 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS SYSTEM INSTALLATION Installation Checklist a PAHABA quao um c pd DO DL D D D D D o D O All packing materials and restraints have been removed from each cabinet Each cabinet in the UPS system is placed in its installed location Joining brackets are installed between the ISBM and UPM sections Intercabinet power wiring is installed between the ISBM and UPM sections Intercabinet interface wiring is installed between the ISBM and UPM sections A cabinet grounding mounting kit is installed between the ISBM and UPM sections All conduits
197. pass Mode Figure 6 4 Path of Current Through the UPS in Battery Mode Figure 6 5 UPS System Common Rectifier Feed Common Battery Dual Feed Configuration oooooooooooooooooo Figure 6 6 UPS System Common Rectifier Feed Separate Battery Dual Feed Configuration 0 0 0 0 cee eee ees Figure 6 7 Plus 1 UPS System Common Rectifier Feed Common Battery Dual Feed Configuration 0 0005 Figure 6 8 Plus 1 UPS System Common Rectifier Feed Separate Battery Dual Feed Configuration 00 0005 Figure 6 9 UPS System Common Rectifier Feed Common Battery IOM Configuration Figure 6 10 UPS System Common Rectifier Feed Separate Battery IOM Configuration 0 0 0 0 Figure 6 11 P Figure 6 12 P Figure 6 13 U Figure 6 14 P Figure 6 15 U Figure 6 16 P Figure 6 17 Simplified Dual Feed UPS with Maintenance Bypass Panel Figure 6 18 Path of Current through the UPSs in Normal Mode Distributed Bypass 2 0 sese Figure 6 19 Path of Current through the UPSs in Bypass Mode Distributed Bypass liiis Figure 6 20 Path of Current through the UPSs in Battery Mode Distributed Bypass 2 0 sees Figure 6 21 Typical Distributed Bypass System 141 and 2 0 Configurations ees Figure 6 22 Typical Distributed Bypass System 241 and 3 0 Configurations iilis Figure 6 23 Typical Distributed Bypass System 341 and 4
198. perating Instructions for shutdown instructions 2 Perform the procedure listed in paragraph 5 1 on page 5 1 NOTE If mounting to a hollow wall secure the enclosure to a wood or metal stud within the wall Do not use hollow wall anchors 3 Securely mount the RIM Il at the desired location See Figure 5 13 on page 5 16 for mounting hole locations NOTE When installing signal wiring for CAN card J3 terminals conduit must be installed between the device and the UPS cabinet Remove the ISBM cabinet top right interface conduit landing plate to drill or punch conduit holes see Figure 4 18 on page 4 20 Reinstall the conduit landing plate Install conduit between the UPS and RIM Il See Figure 5 13 on page 5 16 for RIM II knockout hole location Install wiring between the UPS and RIM Il See Figure 5 2 and Table 5 1 for the Powerware Hot Sync CAN Bridge Card terminal location and wiring information and Figure 5 7 Figure 5 8 and Table 5 5 for the RIM II terminal location and wiring information NOTE 120 Vac for the RIM Il should be supplied from the critical bus by facility planners or the customer 8 Install 120 Vac power wiring from the critical bus to the RIM Il See Figure 5 7 Figure 5 8 and Table 5 5 for the terminal location and wiring information 9 Close the front door and secure the latch EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerwa
199. peration Manual 164201725 Rev 2 www powerware com Chapter 10 10 1 Model Numbers 10 2 Specifications 10 2 1 Product Specifications The UPS is housed in a free standing cabinet divided into two sections with safety shields behind the door and front panels The UPS is available in 50 or 60 Hz with various output power ratings Models Power Rating Frequency Powerware 9395 825 650 650 kVA 50 60 Hz Powerware 9395 825 750 750 kVA 50 60 Hz Powerware 9395 825 825 825 kVA 50 60 Hz The following sections detail the input output environmental and battery specifications for the UPS UPS Input Operating Input Voltage 400 Vac 480 Vac Operating Input Frequency Range 50 60 Hz Operating Input Current See Table 3 4 on page 3 9 Table 3 5 on page 3 10 or Table 3 6 on page 3 11 Reduced for Generator Adjustable Input Current Harmonic Content 5 THD at full load Power Factor Minimum 0 99 Line Surges 6 kV OC 3 kA SC per ANSI 62 41 and IEC 801 4 Battery Voltage 480 Vdc Battery Charging Capacity Configurable per UPM at nominal line voltage Up to 120A with less than 85 load Up to 80A with 100 load Battery Shunt Trip 48 Vdc EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 10 1 PRODUCT SPECIFICATIONS 10 2 2 UPS Output UPS Output Capacity 10096 rated current Output Voltage Regulation 196 10 to 100
200. plying conditioned power to the critical load NO REDUNDANCY This indicator applies only to parallel systems when one cabinet is not SYSTEM functioning ON GENERATOR NORMAL The UPS input and bypass are being supplied by the power from the generator instead of from the utility power ON BYPASS The bypass source is supplying the critical load Usually this means that the UPS is not energized The load is not protected in Bypass mode and a horn sounds after 30 seconds REDUNDANCY BATTERY UPS ALARM The UPS system is issuing an alarm Conditions that affect the current UPS mode are indicated by the indicators and horn on the UPS BYPASS ON BATTERY The UPS battery backup is supplying the critical load The utility power is GENERATOR UNAVAILABLE either interrupted or out of specification The SYSTEM NORMAL indicator is also illuminated BYPASS UNAVAILABLE SHUTDOWN The UPS system is in Normal mode but a bypass source is not within specification A horn sounds after 30 seconds BYPASS IMMINENT SHUTDOWN IMMINENT The UPS is preparing to shut down because the UPS is in Battery mode and the DC voltage is approaching its low limit This indicator is accompanied by a horn 8 8 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com COMMUNICATION 8 9 Relay Interface Module ll An optional Relay Interface Module II RIM Il uses relay contact clos
201. put output and battery contactors open and the power module is turned off The bypass source supplies the critical load Repeat Steps 2 through 7 selecting UPM 2 to shut down UPM 2 Repeat Steps 2 through 7 selecting UPM 3 to shut down UPM 3 If the UPS is a Plus 1 model repeat Steps 2 through 7 selecting UPM 4 to shut down UPM 4 Aa E Power is present inside the UPS cabinet sections 7 3 7 Single UPM Shutdown To shutdown a single UPM 1 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the the UPM Command The UPS Control Command screen is displayed On the UPS Control Command screen select the the UPM to shutdown Press the CONTROLS pushbutton on the System Status menu bar The UPM Control Command screen is displayed On the UPM Control Command screen select UPM OFF Press the SELECT pushbutton on the UPM Command menu bar The UPM status indicates SHUTDOWN The input output and battery contactors open and the power module is turned off The remaining UPMs supply the critical load EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 15 UPS OPERATING INSTRUCTIONS 7 3 8 UPS and Critical Load Shutdown To perform maintenance or service on the critical load shut down power to the load 1 2 Turn off all equipment that is being powered by the UPS Perform the LOA
202. rd screen Use the left or right arrow pushbutton to select the password character position Use the up or down arrow pushbutton to change the password character Once the password is entered press the DONE pushbutton The System Setup Level 1 menu screen is displayed The default password is L1 Function Selection Use the up or down arrow pushbutton to highlight the setup function screen desired then press the SELECT pushbutton to display the function screen The Level 1 screen times out after 60 minutes or can be logged out at any time by selecting the LOG OUT function from the menu screen Change Password The Change Password screen allows the System Setup Level 1 password to be changed Select CHANGE PASSWORD from the System Setup Level 1 menu to display the Change Password screen Use the left or right arrow pushbutton to select the password character position Use the up or down arrow pushbutton to change the password character Once the new password is entered press the DONE pushbutton The Change Password Save screen is displayed Change Password Save The Change Password Save screen lets you save the new password retry another password or abort the password change Press SAVE RETRY or ABORT If SAVE or ABORT is pressed the action is completed and the System Setup screen displays If RETRY is pressed the Change Password screen is redisplayed Time Format The Time Format Setup screen allows the selection of eit
203. rdware and Table 3 11 for recommended installation parts and tools not supplied by Eaton Corporation For an UPS with separate rectifier input terminals for the UPMs E1 through E3 are pressure terminations UL and CSA rated at 90 C See Table 3 12 on page 3 14 for these power cable terminations Figure 4 20 through Figure 4 26 starting on page 4 24 show the location of the power cable terminals inside the UPS Table 3 9 UPS External Power Cable Terminations for the Powerware 9395 825 650 9395 825 750 and 9395 825 825 Bus Landings Tightening Torque Terminal Function Terminal Function using both sides of bus Nm Ib ft Bolt Size E1 Phase A 4 2 bolt mounting 76 56 M12 AC Input to UPS Rectifier E2 Phase B 4 2 bolt mounting 76 56 M12 E3 Phase C 4 2 bolt mounting 76 56 M12 E6 Phase A 6 2 bolt mounting 76 56 M12 AC Input to Bypass E7 Phase B 6 2 bolt mounting 76 56 M12 E8 Phase C 6 2 bolt mounting 76 56 M12 E9 Phase A 6 2 bolt mounting 76 56 M12 AC Output to Critical Load E10 Phase B 6 2 bolt mounting 76 56 M12 E11 Phase C 6 2 bolt mounting 76 56 M12 DC Input from Battery or Battery E4 Battery 4 12 2 bolt mounting 76 56 M12 Disconnect to UPS Common Battery E5 Battery 12 2 bolt mounting 76 56 M12 DC Input from Battery or Battery E4 Battery 4 4 2 bolt mounting 76 56 M12 Disconnect to UPS Separate Batte
204. re com 5 11 INSTALLING OPTIONS AND ACCESSORIES 5 12 10 Restart the UPS See Chapter 7 UPS Operating Instructions for startup instructions NOTE Setup of the Powerware Hot Sync CAN Bridge Card must be performed by an authorized Eaton Customer Service Engineer Contact an Eaton service representative to schedule a date 11 Contact an Eaton service representative for verification and testing of the RIM II and its connections prior to making connections with J1 through J4 see Table 5 6 and Figure 5 9 You can order interface cables separately for connecting to the 15 Pin D Sub Connectors Table 5 6 J1 through J4 Interface Connectors Status J1 through J4 Description UPS AVAILABLE Pins 1 and 12 Contacts are closed when the UPS is operating in Normal mode or ready to supply the load UPS OFFLINE Pins 3 and 13 Contacts are open when the UPS is offline Contacts are closed when the UPS is operating in Normal mode BATTERY WEAK Pins 5 and 14 Contacts are closed when approximately two minutes of battery time remains before the critical load is lost UTILITY FAILURE Pins 6 and 15 Contacts are closed when Utility Failure is detected 15 Pin D Sub Connectors a BD Go Figure 5 9 J1 J2 J3 and J4 15 Pin D Sub Connectors EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INSTALLING OPT
205. remains on bypass and an alarm sounds The NORMAL status indicator is illuminated The UPS status indicates ONLINE The UPM status indicates ONLINE EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 23 UPS OPERATING INSTRUCTIONS 7 24 7 4 6 Transfer from Normal to Bypass Mode and Shut Down all UPSs To transfer the critical load to Bypass mode and shut down all UPSs 1 10 11 Transfer the critical load to bypass by performing the procedure in paragraph 7 4 4 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the UPM command On the UPS Control Command screen select the UPM 1 command Press the CONTROLS pushbutton on the System Status menu bar The UPM 1 Control Command screen is displayed On the UPM 1 Control Command screen select UPM OFF Press the SELECT pushbutton on the UPM 1 Command menu bar The UPM status indicates SHUTDOWN The input output and battery contactors open and the power module is turned off The bypass source supplies the critical load Repeat Steps 2 through 7 selecting UPM 2 to shut down UPM 2 Repeat Steps 2 through 7 selecting UPM 3 to shut down UPM 3 If the UPS is a Plus 1 model repeat Steps 2 through 7 selecting UPM 4 to shut down UPM 4 Repeat Steps 2 through 10 for each UPS in the distributed bypass system TI RR ERR Power is present
206. ring will occur 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 an Eaton service representative immediately NOTE For the following step verify that the forklift or pallet jack is rated to handle the weight of the cabinet see Table 3 1 on page 3 2 for cabinet weight 2 Usea forklift or pallet jack to move the packaged cabinets to the installation site or as close as possible before unpacking If possible move the cabinets using the pallet Insert the forklift or pallet jack forks from the right side of the pallet facing the cabinet between the supports on the bottom of the pallet see Figure 3 8 and Figure 3 9 on page 3 6 for the UPS cabinet center of gravity measurements If the cabinets must be moved using the cabinet front or rear fork lift slots see the caution statement at the beginning of this procedure CAUTION Do not tilt the UPS cabinets more than 10 from vertical or the cabinets may tip over 3 Set the pallet on a firm level surface allowing a minimum clearance of 3m 10 ft on each side for removing the cabinet from the pallet NOTE The ISBM and UPM sections are shipped with debris shields covering the ventilation grills on top of the sections see Figure 4 17 on page 4 19 Do not remove the debris shields until installation is complete EATON Powerware 9395 UPS 650 82
207. rve the following messages are displayed sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 2 rectifier and inverter turn on Repeat Steps 8 through 12 selecting UPM 3 to start UPM 3 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 3 rectifier and inverter turn on When the inverter reaches full voltage the UPS is ready to transfer to the Normal mode and supply the critical load If the UPS is a Plus 1 model repeat Steps 8 through 12 selecting UPM 4 to start UPM 4 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 4 rectifier and inverter turn on When the inverter reaches full voltage the UPS is ready to transfer to the Normal mode and supply the critical load 7 22 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS OPERATING INSTRUCTIONS 20 Repeat Steps 8 through 19 for each UPS in the distributed bypass system o NOTE To transfer to Normal mode after starting individual UPMs follow the procedure in paragraph 7 4 5 7 4 4 Transfer from Normal to Bypass Mode To transfer the critical load to Bypass mode In Bypass mode the critical load is not protected from commercial power interrupt
208. ry UPM 1 E5 Battery 4 2 bolt mounting 76 56 M12 DC Input from Battery or Battery E4 Battery 4 4 2 bolt mounting 76 56 M12 Disconnect to UPS Separate Battery UPM 2 E5 Battery 4 2 bolt mounting 76 56 M12 DC Input from Battery or Battery E4 Battery 4 4 2 bolt mounting 76 56 M12 Disconnect to UPS Separate Battery UPM 3 E5 Battery 4 2 bolt mounting 76 56 M12 DC Input from Battery or Battery E4 Battery 4 4 2 bolt mounting 76 56 M12 Disconnect to UPS Separate Battery UPM 4 FI UPM E5 Battery 4 2 bolt mounting 76 56 M12 Input and Output Neutral E12 Neutral 12 72 bolt mounting 22 16 M10 Customer Ground Ground Ground 15 1 bolt mounting 22 16 M10 NOTE Customer ground sized in accordance with NEC Table 250 122 can be run in any conduit listed in Table 3 13 on page 3 15 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 13 UPS INSTALLATION PLAN AND UNPACKING Table 3 10 Supplied External Wiring Terminal Hardware Kit Part Size Quantity Terminals Used On Eaton Part Number Bolt Grade 5 M10 x 25 mm 15 Ground 180190078 087 Bolt Grade 5 M12x 45 mm 92 Rectifier Input Bypass Input Battery Input 180190078 113 Output and Neutral Flat Washer M10 15 Ground 180500036 100 Flat Washer M12 184 Rectifier Input Bypass Input Battery Input 180500036 120 Output and Neutral Conical Washer M10 15 Ground 1
209. s for startup instructions System Normal No Redundancy On Generator ah O Bypass Not Available h k 1 LOT NN NH NM E la E 0 On Battery Ci UPS Alarm N CO On Bypass N NO O NO AJ O 00 O N N Shutdown Imminent Figure 5 11 Supervisory Contact Module II TB2 O NOTE Supervisory contacts are rated at 2 04 at 28 Vdc or 120 Vac and 0 154 at 115 Vdc NOTE Supervisory contacts require an external power supply Internal 24 Vdc is not capable of supplying contact current 5 14 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INSTALLING OPTIONS AND ACCESSORIES 5 6 Accessory Mounting Dimensions Figure 5 12 through Figure 5 14 show the dimensions of the RMP Il the RIM Il and the SCM Il 25 1 1 00 a JF 0 ww a 88 8 3 07 11 37 A i 4 K 111
210. s including the National Electrical Code NEC Article 480 After the battery system is installed proceed to paragraph 4 7 if installing a distributed bypass tie cabinet otherwise proceed to paragraph 4 8 Distributed Bypass Tie Cabinet Installation If installing a distributed bypass system install the customer supplied tie cabinet or distribution panel according to the tie cabinet or distribution panel manufacturer s instructions and all applicable codes and regulations including the National Electrical Code NEC Article 480 After the tie cabinet is installed proceed to paragraph 4 8 to complete the wiring of the UPS Installing UPS External and Battery Power Wiring 0 4 8 1 NOTE The ISBM and UPM sections are shipped with debris shields covering the ventilation grills on top of the sections see Figure 4 17 Do not remove the debris shields until installation is complete However remove the shields before operating the UPS Once the debris shields are removed do not place objects on the ventilation grills NOTE Remove the ISBM section top or bottom conduit landing plate to drill or punch conduit holes see Figure 4 18 on page 4 20 NOTE If the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper
211. s Shipped on Pallet UPM Section RR 3 23 Figure 4 1 Removing the ISBM Section Left Side Shipping Bracket eee eens 4 2 Figure 4 2 Removing the ISBM Section Right Side Shipping Bracket oooooooooooooooo 4 3 Figure 4 3 Removing the UPM Section Left Side Shipping Bracket iilis 4 4 Figure 4 4 Removing the UPM Section Right Side Shipping Bracket 4 5 Fig re 4 5 SECOND otto A e pec tis beg E E E stb te t edet eot cen 4 6 Figure 4 6 ISBM and UPM Sections Joined I s 4 7 Figure 4 7 ISBM Section to UPM Section Joining Brackets anaana 4 8 Figure 4 8 ISBM Section Intercabinet Power Terminal Locations Common Rectifier Feed 2 000 eee 4 11 Figure 4 9 ISBM Section Input Power Terminal Detail Common Rectifier Feed iiis see 4 12 Figure 4 10 ISBM Section Intercabinet Power Terminal Locations Separate Rectifier Feed AA 4 13 Figure 4 11 ISBM Section Input Power Terminal Detail Separate Rectifier Feed leise 4 14 Figure 4 12 ISBM Section Battery Input Power Terminal Detail leise RR 4 15 Figure 4 13 ISBM Section Output Power Terminal Detail RR 4 15 Figure 4 14 UPS Intercabinet Interface Harness Locations isse e 4 16 Figure 4 15 PIT Interface Board Location ess se cetero Npa deter a soos edet dep GP LAN tec ed ox didus 4 17 Figure 4 16 J39 Location on PI1 Interface Board 2 0 ee 4 17 Figure 4 17 ISBM an
212. s are needed for redundancy Operation remains the same as the original UPS Inherent Redundancy To deliver greater reliability the Powerware 9395 UPS can be configured by an authorized Eaton Customer Service Engineer for inherent redundancy When configured the UPS automatically becomes redundant if the load is at or below the capacity of the UPMs minus the capacity of one UPM Under normal conditions the UPMs in the UPS share the load equally If one or more UPMs becomes unavailable and the load is at or below the capacity of remaining UPMs the remaining UPMs supply the load instead of transferring to bypass If the capacity of the UPMs falls below the redundancy level or the load increases above redundancy level but is still able to maintain the load a loss of redundancy alarm is sounded If the load exceeds the capacity of remaining UPMs the UPS transfers to bypass Sync Control An optional Powerware 9395 Sync Control maintains the critical load outputs of two separate single module Powerware 9395 UPS systems in synchronization This option facilitates the uninterrupted transfer of the load from one load bus to another by means of transfer switches The Sync Control is housed in a wall mounted panel that can be located between the UPS units for easy wiring Monitoring and Communication e Remote Monitor Panel II RMP II An optional RMP Il contains backlit status indicators and a local horn allowing monitoring of the operation
213. s specified Environmental and Installation Considerations The UPS system installation must meet the following guidelines The system must be installed on a level floor suitable for computer or electronic equipment The system must be installed in a temperature and humidity controlled indoor area free of conductive contaminants Failure to follow guidelines may void your warranty The UPS equipment operating environment must meet the weight requirements shown in Table 3 1 and the size requirements shown in Figure 3 1 through Figure 3 10 Dimensions are in millimeters inches For Field Installed UPM FI UPM weights and dimensions refer to the Powerware 9395 Field Installed UPM Mechanical Installation Manual listed in paragraph 1 8 on page 1 7 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 3 1 UPS INSTALLATION PLAN AND UNPACKING Table 3 1 UPS Cabinet Weights Weight Model Section kg 1b Shipping Installed ISBM 1498 3302 1390 3064 Powerware 9395 825 650 UPM 1590 3505 1482 3267 ISBM 1498 3302 1390 3064 Powerware 9395 825 750 UPM 1590 3505 1482 3267 ISBM 1498 3302 1390 3064 Powerware 9395 825 825 UPM 1590 3505 1482 3267 The UPS cabinet uses forced air cooling to regulate internal component temperature Air inlets are in the front of the cabinet and outlets are in the top Allow clearance in front of and
214. shbutton or Command A UPS Load Off is initiated by the LOAD OFF pushbutton from the main menu bar the Load Off command on the UPS Control Command screen or Load Off command on the Bypass Control Command screen The UPS LOAD OFF controls the UPS output by powering down the UPS and de energizing the critical load The UPS including Bypass remains off until restarted To use the LOAD OFF pushbutton 1 Press the LOAD OFF pushbutton The Load Off screen is displayed providing a choice to proceed or abort the shutdown CAUTION All power to the critical load is lost when the LOAD OFF is selected in the following step You should use this feature only when you want to de energize the critical load N To shut down the UPS press LOAD OFF from the Load Off menu bar and hold for three seconds To abort the shutdown press CANCEL When LOAD OFF is selected and held for three seconds the input output battery and bypass backfeed contactors open and the power module is turned off CAUTION Do not attempt to restart the system after Load Off until the cause of the shutdown has been identified and cleared 3 Torestart the UPS after pressing the LOAD OFF pushbutton follow the procedure in paragraph 7 3 1 on page 7 11 or 7 3 2 on page 7 12 gt Power is present inside the UPS cabinet sections until the upstream input feeder circuit breaker is opened To use the LOAD OFF command 1 Press the CONTROLS pushbutton on t
215. shbutton to make the change When finished making changes use the left or right arrow pushbutton to highlight SAVE and the up or down arrow pushbutton to select YES To complete the save function and return to the System Setup screen select the return arrow pushbutton EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 7 UPS OPERATING INSTRUCTIONS Table 7 3 Display Menu Operation continued Function Subfunction Operation Com Port Selection The Com Port Setup screen allows selection of the serial COM port to set up Select COM PORT SETUP from the System Setup Level 1 menu to display the COM Port Setup screen Use the up or down arrow pushbutton to highlight the the COM port to be set up then press the SELECT pushbutton To return to the System Setup screen press the return arrow pushbutton Com Port Setup The COM Setup screen is used to change and save the settings for the selected serial communication port The COM port number selected from the COM Port Setup screen displays If the changes are not wanted use the ABORT pushbutton to return to the COM Port Setup screen Use the up or down arrow pushbutton to highlight the setting to be changed Use the return arrow pushbutton to toggle through the values for the setting to make the change Press SAVE or ABORT Once the action is completed the COM Port Setup screen is displayed Control See paragraph 7 2 7 for de
216. source as well as the kVA kW and power factor measurements Battery UPS Battery UPM The Battery screen displays the battery voltage Vdc the battery current Idc the minutes of battery time remaining and battery temperature Battery temperature must be set up by an authorized Eaton Customer Service Engineer When battery life decreases to less than 2096 Check Battery is displayed Statistics The Statistics screen displays the hours on line and the total kW hours used Output Current UPS Output Current UPM The Output Current screen displays a real time bar graph of the output current of the UPS The graph shows the current for each phase Output Power UPM The Output Power screen displays the power in kW and kVA for each UPM System Level 0 Setup Function Selection This screen can be used to set the screen contrast show the firmware versions installed identify the unit type and enter a password to access Level 1 functions Press the SETUP pushbutton on the main menu bar to display the System Setup Level 0 Screen No password is necessary to access Level 0 functions Use the up or down arrow pushbutton to highlight the setup function screen desired then press the SELECT pushbutton to display the function screen 7 6 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Table 7 3 Display Menu Operation continued Function Subfunction
217. st recent event listed last Figure 8 2 shows a sample Event History Log printout In this mode system events are continually logged through the serial port to the device connected to the port The printed log entries contain a time and date stamp and the alarm text message Terminal mode uses this format for printing alarm entries MM DD YYYY HH MM SS hh KYWD MESSAGE CR LF Where Equals MM Month 2 digits DD Day 2 digits YYYY Year 4 digits HH Hour 2 digits MM Minute 2 digits SS Second 2 digits hh Hundredths of Second 3 digits KYWD Keyword ALARM NOTICE COMMAND or STATUS Message System Diagnostic Information CR Carriage Return Character ASCII 13 AB Line Feed ASCII 10 An alarm message is prefixed by the word CLEAR whenever an alarm is entered into the Event History Log with a cleared status If a port is operating in Terminal mode and is connected to a computer you can press Esc H to print the entire log with a firmware version header The log in Terminal mode is always in English EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 8 5 COMMUNICATION MODEL POWERWARE 9395 CTO TF12710000000 SERIAL MCU DSP 70 81 14 MCU BOOTLOADER 80 40 MCU PLD 1 00 PMF 1 DSP 80 81 14 PMF 1 BOOTLOADER 80 40 PMF 1 PLD 1 00 XSLOT CAN BRIDGE 0 00 CSB DSP 70 81 14 CSB BOOTLOADER 1 12
218. stem bypass module ISBM or an Input Output Module IOM rated for a maximum of 825 kVA and an Uninterruptible Power Module UPM section containing three UPMs Each UPM is rated for a maximum of 275 kVA for a total maximum of 825 kVA The UPS is available as a single unit or an optional multiple unit distributed bypass System see paragraph 1 2 7 The UPS Plus 1 model using the Field Installed UPM FI UPM provides N 1 redundancy for the system see paragraph 1 2 1 The Powerware 9395 online power protection system is used to prevent loss of valuable electronic information minimize equipment downtime and minimize the adverse effect on production equipment due to unexpected power problems The Powerware 9395 UPS continually monitors incoming electrical power and removes the surges spikes sags and other irregularities that are inherent in commercial utility power Working with a building s electrical system the UPS system supplies clean consistent power that sensitive electronic equipment requires for reliable operation During brownouts blackouts and other power interruptions batteries provide emergency power to safeguard operation The UPS is housed in a free standing cabinet divided into two sections to facilitate shipping The sections match in style and color and have safety shields behind the doors for hazardous voltage protection The FI UPM matches the UPS in style and color Figure 1 1 shows the Powerware 9395 UPS 650 825 k
219. successful and the system operates properly NOTE Read this section of the manual and have thorough knowledge of UPS operation before attempting to operate any of the controls NOTE The UPS displays two minutes of battery runtime at the initial startup After a 24 hour charging period the UPS automatically runs a battery test and the correct battery runtime displays 7 1 UPS Controls and Indicators The controls and indicators identified and described in this section are used to control and monitor UPS operation Figure 7 1 shows the UPS controls and indicators U a La b e i 3 j b A bt past E B Control Panel 8 El ls la b a h O a a a a jJ 1e v v v v O b 4 1e e O e P a re s e e AC Input Breaker CB1 Le optional gt SS gt _ a ea a S555 LA A A r o o e gt pS gt SSS yA gt gt E gt p A SS A RO 1 S A ee REEL AAA A ee A a r y AAA ee SS Sj a o _ gt n A SS E 2 Ca Ss ae gt a p a So O ELE a er Sess ES t2 E gt A gt So AA EE a SS E SS Er A gt SS aoee aa ai Gee
220. system continues to maintain power to the critical loads during commercial electrical power brownout blackout overvoltage undervoltage and out of tolerance frequency conditions The output of the system is normally supplied by several Uninterruptible Power Modules UPMs contained in each UPS Multiple UPMs are connected with their outputs in parallel tied together to provide a load level greater than the rating of one UPM and or for redundancy The paralleled UPMs supply the output load with protected power as long as the load does not exceed the combined rating of the paralleled UPMs The power system is redundant as long as one of the UPMs can be disconnected from the output bus and the remaining UPMs can continue to supply power to the load without exceeding their ratings When the load is being supplied by the UPMs the system output bus is continuously monitored for an overvoltage or undervoltage condition If an out of limits condition is detected the paralleled UPMs transfer the load to bypass using the UPS static switches Communication is required between the UPSs for system metering and mode control System level communication and control are accomplished using a Controller Area Network CAN A single building alarm in each UPS connected to the other UPSs in parallel and tied to the bypass contactor auxiliary contacts in each UPS are used for a secondary communication path This arrangement ensures bypass control even if the C
221. t Output Module IOM proceed to Step 11 otherwise proceed to Step 10 10 Using hardware from the external wiring terminal hardware kit see Table 3 10 on page 3 14 connect phase A B and C and Neutral if required bypass input power wiring from the utility source to the bypass input terminals and neutral terminals in the ISBM section See paragraph 3 2 2 on page 3 8 for wiring and termination requirements 11 If wiring a distributed bypass system proceed to Step 12 otherwise proceed to Step 14 CAUTION Distributed bypass system wiring length should be in accordance with Figure 4 19 to ensure approximately equal current sharing when in Bypass mode 12 Using hardware from the external wiring terminal hardware kit see Table 3 10 on page 3 14 connect phase A B and C and Neutral power wiring from the output and neutral terminals of each UPS unit to the customer supplied tie cabinet or load distribution panel See paragraph 3 2 2 on page 3 8 for wiring and termination requirements 13 Proceed to paragraph 4 8 2 14 Using hardware from the external wiring terminal hardware kit see Table 3 10 on page 3 14 connect phase A B and C and Neutral if required power wiring from output terminals and neutral terminals to the critical load See paragraph 3 2 2 on page 3 8 for wiring and termination requirements 15 Proceed to paragraph 4 8 2 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 1
222. tails 7 2 7 System Status Screen and Controls Press the CONTROLS pushbutton on the main menu bar to display the System Status screen Normal operation transfer to bypass charger control UPM startup and shutdown and LOAD OFF commands are controlled through this screen In addition the screen displays the current status of the UPS and indicates whether the UPS is in Maintenance Bypass or Bypass and the state of the UPM and battery charger Figure 7 5 shows the System Status screen Use the T or Y pushbutton on the System Status menu bar to highlight the command screen desired then press the CONTROLS pushbutton to display the command menu screen Table 7 4 lists the typical System Status Screen Messages that are displayed during UPS operation Table 7 5 describes the control functions and provides instructions to access and use the command menu screens For detailed information about using the System Controls see paragraph 7 3 SYSTEM STATUS UPS SHUTDOWN BYPASS AVAILABLE MAINTENANCE BYPASS OFF CHARGER OFF UPM OFFLINE panig CONTROLS ESC EN EN FO ae e o D BENE dedico cuo aaa Figure 7 5 Typical System Status Screen 7 8 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Table 7 5 Command Menu Operation UPS OPERATING INSTRUCTIONS Table 7 4 Typical System Status Messages Function Message
223. talling internal wiring to the Powerware Hot Sync CAN Bridge Card terminals route the wiring through the internal opening in the X Slot communication bay NOTE When installing interface wiring for the parallel system pull chain conduit must be installed between UPSs To install distributed bypass control wiring 1 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS Operating Instructions for shutdown instructions 2 Perform the procedure listed in paragraph 5 1 3 Terminal block TB3 is accessible on the left side of the X Slot communication bay see Figure 4 27 on page 4 32 To gain access to terminal block TB1 TB2 and the left interface entry conduit landing plates remove the screws securing the top internal safety shield panel and remove the panel Retain the hardware for later use 4 Remove the interface entry conduit landing plates to drill or punch holes see Figure 4 18 on page 4 20 b Reinstall the interface entry plates and install the conduit 6 Tolocate the appropriate terminals and review the wiring and termination requirements see paragraph 3 2 3 on page 3 19 Table 4 1 on page 4 33 and Figure 4 27 through Figure 4 30 7 Route and install CAN wiring between the UPS cabinets See Figure 5 2 and Table 5 1 for the Powerware Hot Sync CAN Bridge Card terminal location and Figure 5 3 Figure 5 4 and Table 5 2 for wiring information 8 If a tie cabinet with Module Outp
224. that the Powerware three phase UPS electronics Eaton built accessories and Powerware built battery cabinets individually and collectively the Warranted Items are free from defects in material and workmanship If in the opinion of Eaton a Warranted Item is defective and the defect is within the terms of this Warranty Eaton s sole obligation will be to repair or replace such defective item including by providing service parts and labor as applicable at the option of Eaton The Warranted Item will be repaired or replaced onsite at the End User s location or such other location as determined by Eaton Any parts that are replaced may be new or reconditioned All parts replaced by Eaton shall become the property of Eaton WHAT THIS LIMITED WARRANTY DOES NOT COVER This Warranty does not cover any defects or damages caused by a failure to properly store the Product before installation including the trickle charge of batteries no later than the date indicated on the packaging b shipping and delivery of the Product if shipping is FOB Factory c neglect accident fire flood lightning vandalism acts of God Customer s neglect abuse misuse misapplication incorrect installation d repair or alteration not authorized in writing by Eaton personnel or performed by an authorized Eaton Customer Service Engineer or Agent or e improper testing operation maintenance adjustment or any modification of any kind not authorized in writing by Eat
225. the intercabinet wiring terminal hardware kit see Table 3 8 connect phase A B and C and Neutral cable lug connections to the AC Output from UPMs terminals Follow the callout details in Figure 4 13 on page 4 15 to connect the correct cable lug to the proper terminals See paragraph 3 2 2 on page 3 8 for wiring and termination requirements 12 Install the remaining hardware three washers conical washers and nuts onto the AC Input to UPMs terminals designated for the Plus 1 model and secure the hardware see Figure 4 9 on page 4 12 for common rectifier feed or Figure 4 23 on page 4 26 for separate rectifier feed This hardware is for future use if a Field Installed UPM FI UPM is installed to upgrade the UPS to a Plus 1 model EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 4 9 UPS SYSTEM INSTALLATION 4 10 13 14 Locate the ground braid in the bottom left front corner of the UPM section The ground braid is secured at the factory to the UPM section ground bolt Route the ground braid through the wiring access in the right side panel of the ISBM section to the ground bolt in the ISBM section Connect the ground braid to the ISBM section ground bolt and secure right side panel of the ISBM section see A in Figure 4 14 on page 4 16 o NOTE Four intercabinet interface wiring harnesses are supplied coiled inside the protective cage on the 15 16 17
226. the menu functions and and how to use them Table 7 3 Display Menu Operation Function Subfunction Operation Events Press the EVENTS pushbutton on the main menu bar or History menu bar to display a listing of all system events that are currently active The most recent event is listed first As events clear they are removed from the Active System Events listing To scroll through the events press the up or down arrow pushbutton on the menu bar User History Press the HISTORY pushbutton on the Active Events menu bar to display the User History Log The User History Log lists up to 2048 events in chronological order with the most recent event listed last once 2048 is reached the earliest event is overwritten The end of the log the most recent events is displayed first scroll upward to view older event listings To scroll through the events press the up or down arrow pushbutton on the menu bar To return to the Active Events screen press the EVENTS pushbutton on the menu bar Service History The Service History Log is for service personnel and is password protected If the customer needs access to the log contact an Eaton service representative Press the SERVICE pushbutton on the User History menu bar to display the Service History Log The Service History Log lists up to 2048 events in chronological order with the most recent event listed last once 2048 is reached the earliest event is overwritten The end
227. their respective companies Copyright 2008 Eaton Corporation Raleigh NC USA All rights reserved No part of this document may be reproduced in any way without the express written approval of Eaton Corporation Table of Contents T O UCION ia A A tas fee areata e e at dag RICE e YES ec d arate EAS UPS Standard Features stas uox Bs Mana DIO DU A eA UE Pine dors B O ERE UNE o 1 1 co gy D a B w 1 9 2 Safe 1 1 AZ 13 44 1 1 5 1 2 1 122 1 2 3 24 1 2 5 2 6 1 27 1 2 8 ristallatiotiFeat f8s om i oo ee aka ble ab dene aly ah Ma NG a NAG ah LAB bab la A aag COntt bPallele ee RU ie tot hats an au A oce US Pana O Er mucus e ne ius AG Er E ca Customer Intelface i tenen a esee tts yet tese ec de te b et tette Advanced Battery Management e e Power Management SoftWare zi bree kae ta eet iver et eade ede Lue espe de leti eee Ul dee dela eee oe Ies Options and ACCESSOMES a eet eR aO Res e Rees BNG SURE UP d E Ser Be Ya et DRE IPS ER Fieldilnstalled URM 3 2 rtt leote nde e e Sete e ed edet s Sede ue Se etes em ares Mherent Redundancy omes door ob lhe Ets RU Seti dA tete t ANE Ese ut S ER I LAUNE E E es Sync CONTO ss cederet VE pakay eret Ue epe deis dee dei deed etes e Ha ated Monitoring and Communication s y rs Single Eead KIES at ote bee ned ence etn i ec ate ee ca io oe cee test t e Dh e i eet Separate Rectifier Input eee Distributed Bypass Syste AA Input Output Modul
228. tion for additional information FI UPM ISBM SECTION UPM SECTION Figure 1 2 Powerware 9395 UPS 650 825 kVA with the Field Installed UPM 1 1 4 1 1 5 Advanced Battery Management A three stage charging system increases battery service life by optimizing recharge time and protects batteries from damage due to high current charging and inverter ripple currents Charging at high currents can overheat and damage batteries Power Management Software Powerware LanSafee Power Management Software is bundled as part of the Software Suite CD shipped with the UPS See Chapter 8 Communication for additional information EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 1 3 INTRODUCTION 1 2 Options and Accessories 1 2 1 1 2 2 1 2 3 1 2 4 Contact an Eaton sales representative for information about the following options Field Installed UPM A Field Installed UPM FI UPM provides N 1 redundancy for the UPS system The FI UPM may be installed at any time in the future when power needs change The module cabinet is installed on the left side of the ISBM section and is wired directly to the UPS No input or output wiring change
229. ton representatives outside the terms of this Warranty will be borne by the End User OBTAINING WARRANTY SERVICE In the USA call the Eaton Customer Reliability Center 7x24 at 800 843 9433 Outside of the USA call your local Eaton sales or service representative or call the Eaton Customer Reliability Center in the USA at 919 870 3028 For comments or questions about this Limited Factory Warranty write to the Customer Quality Representative 3301 Spring Forest Road Raleigh North Carolina 27616 USA EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com W 1 WARRANTY This page intentionally left blank W 2 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 164201725 2
230. tput e e e to Critical E9 D Load Battery Battery Battery Battery E10 Converter e Converter Converter Converter 3 Fuse Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPM 4 UPM 1 UPM 2 UPM 3 FI UPM CABINET gt E4 E5 E4 E5 E4 ES UPS CABINET EN CN 4 CX ug m 0 o 11 o 4ili O o 4ili O o 4ili Battery Battery Battery Battery Breaker Breaker Breaker Breaker BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM BATTERY SYSTEM Not supplied with the UPS Not supplied with the UPS Not supplied with the UPS Not supplied with the UPS NOTE Callout letter A maps to Table 3 6 on page 3 11 Callout letters B C and D map to Table 3 5 on page 3 10 service Connector NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 16 Plus 1 UPS System Separate Rectifier Feed Separate Battery IOM Configuration EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 6 19 UNDERSTANDING UPS OPERATION To UPS To UPS AC Input AC Input Rectifier Bypass Input Input RIB MBP oN CN O eo BIB iN MIS CA CRI
231. uld not discard the UPS or the UPS batteries in the trash This product contains sealed lead acid batteries and must be disposed of properly For more information contact your local recycling reuse or hazardous waste center This symbol indicates that you should not discard waste electrical or electronic equipment WEEE in the trash For proper disposal contact your local recycling reuse or hazardous waste center Refer to the Powerware 9390 and 9395 Sync Control Installation and Operation Manual for the following additional information e Installation instructions including site preparation planning for installation and wiring and safety information Detailed illustrations of the cabinet with dimensional and connection point drawings are provided Operation including controls functions of the standard and optional features procedures for using with the UPS and information about maintenance Refer to the Powerware 9395 Field Installed UPM Mechanical Installation Manual for the following additional information Mechanical installation instructions including site preparation planning for mechanical installation and safety information Detailed illustrations of the cabinet including dimension and pallet removal drawings Visit www powerware com or contact an Eaton service representative for information on how to obtain copies of these manuals EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual
232. unity without damage and with no disturbance or adverse effect to the critical load 10 2 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Warranty LIMITED FACTORY WARRANTY FOR THREE PHASE POWERWAREe UPS PRODUCTS WARRANTOR The warrantor for the limited warranties set forth herein is Eaton Corporation a Delaware Corporation Eaton LIMITED WARRANTY This limited warranty this Warranty applies only to the original end user the End User of the Powerware Three Phase UPS Products the Product and cannot be transferred This Warranty applies even in the event that the Product is initially sold by Eaton for resale to an End User LIMITED WARRANTY PERIOD The period covered by this Warranty for Product installed and currently located in the fifty 50 United States and the District of Columbia is twelve 12 months from the date of Product start up or eighteen 18 months from the date of Product shipment whichever occurs first for parts coverage and 90 days from the date of Product start up for labor coverage The period covered by this Warranty for Product installed and currently located outside of the fifty 50 United States and the District of Columbia is twelve 12 months from the date of Product start up or eighteen 18 months from the date of Product shipment whichever occurs first for parts coverage WHAT THIS LIMITED WARRANTY COVERS The warrantor warrants
233. urce is disconnected and the electrolytic capacitors are discharged After disconnecting the utility power and the DC power authorized service personnel should wait at least five minutes for capacitor bleedoff before attempting internal access to the UPS module e Servicing and maintenance should be performed by qualified service personnel only e 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 Because 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 contact an Eaton service representative If the string requires service refer to the battery manufacturer s operating manual for instructions on battery maintenance or contact an Eaton service representative Observe these precautions when working on or around batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots e Do not lay tools or metal parts on top of batteries Disconnect the charging source prior to connecting or disconnecting terminals Determine if the battery is inadvertentl
234. ure 4 18 Figure 4 20 Figure 4 25 and Figure 4 26 for wiring access information and terminal locations If wiring the UPS for a common battery proceed to Step 3 if wiring for a separate battery proceed to Step 5 Using hardware from the external wiring terminal hardware kit see Table 3 10 on page 3 14 connect the positive negative and ground DC power wiring from the battery system or disconnect to the ISBM section battery and ground terminals Use both sets of terminals shown in Figure 4 25 as needed See paragraph 3 2 2 on page 3 8 for wiring and termination requirements Proceed to Step 6 Using hardware from the external wiring terminal hardware kit see Table 3 10 on page 3 14 connect the positive negative and ground DC power wiring from the battery systems or disconnects to the ISBM section battery and ground terminals Use one set of terminals for each UPM as shown in Figure 4 26 See paragraph 3 2 2 on page 3 8 for wiring and termination requirements After wiring the UPS system to the facility power and critical load be sure to ground the system according to local and or national electrical wiring codes If wiring interface connections proceed to paragraph 4 9 otherwise proceed to Step 8 When all wiring is complete reinstall the top and bottom safety shield panels removed in paragraph 4 8 1 Step 2 on page 4 18 Secure with the retained hardware Reinstall the left front panel removed in paragraph 4 8 1 Step 1
235. ures to indicate the operating status and alarm condition of the UPS system The module uses a serial interface line and may support up to eight critical loads The RIM Il can be flush mounted or surface mounted on a desktop or secured to a wall Figure 8 4 shows the RIM Il with its four 15 pin connectors labeled J1 through J4 Figure 8 4 Relay Interface Module Il Customer Interface Connectors J1 through J4 The RIM Il can provide the status and alarm signals shown in Table 8 2 Table 8 2 Customer Interface Connectors Status J1 through J4 Description UPS AVAILABLE Pins 1 and 12 Contacts are closed when the UPS is operating in Normal mode or ready to supply the load UPS OFFLINE Pins 3 and 13 Contacts are open when the UPS is offline Contacts are closed when the UPS is operating in Normal mode BATTERY WEAK Pins 5 and 14 Contacts are closed when approximately two minutes of battery time is remaining before the critical load is lost UTILITY FAILURE Pins 6 and 15 Contacts are closed when Utility Failure is detected EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 8 9 COMMUNICATION 8 10 Supervisory Contact Module Il An optional Supervisory Contact Module Il SCM Il establishes an interface between the UPS system and the customer s monitor This interface allows the customer to monitor operational status of the UPS system equipment The SCM Il can b
236. use Fuse Fuse E Inverter Inverter Inverter Inverter YA JN sl Jo Output Output Output Output gt Contactor Contactor gt Contactor Contactor K3 K3 K3 K3 AC Output e e e e to Critical E9 D Load Battery Battery Battery Battery E10 Converter Converter Converter Converter 2 Fuse Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPM 4 UPM 1 UPM 2 UPM 3 e e FI UPM CABINET E4 E5 UPS CABINET 7 o oH NOTE Callout letters A B C and D map to Table 3 4 on page 3 9 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Battery Breaker BATTERY SYSTEM Not supplied with the UPS Service Connector Figure 6 7 Plus 1 UPS System Common Rectifier Feed Common Battery Dual Feed Configuration 6 10 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION
237. ut Breakers MOBs is being wired proceed to Step 11 otherwise proceed to Step 9 9 Route and install distributed bypass system pull chain wiring between the UPS cabinets See Figure 5 5 and Table 5 3 on page 5 6 for wiring information 10 Proceed to Step 12 11 Route and install distributed bypass system pull chain wiring between the UPS cabinets and tie cabinet MOBs See Figure 5 6 on page 5 7 and Table 5 4 on page 5 8 for wiring information NOTE Setup of the Powerware Hot Sync CAN Bridge Card for parallel operation must be performed by an authorized Eaton Customer Service Engineer Contact an Eaton service representative to schedule a date 12 Reinstall the top internal safety shield panel and secure with the retained hardware 13 Close the door and secure the latch EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com INSTALLING OPTIONS AND ACCESSORIES CAN Pull Chain UPS 1 UPS 2 UPS 3 UPS 4 If Installed If Installed NOTE This drawing is for distributed bypass wiring purposes and is not a floor layout plan UPSs can be placed in any physical order Figure 5 3 Distributed Bypass System Can and Pull Chain Simplified Interface Wiring Shielded Twisted Pair Shielded Twisted Pair Shielded Twisted Pair
238. ut Output gt Contactor Contactor gt Contactor Contactor K3 K3 K3 K3 AC Output e e e to Critical E9 D Load Battery Battery Battery Battery E10 Converter Converter Converter Converter 2 Fuse Fuse Fuse Fuse Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 Battery Contactor K2 UPM 4 UPM 1 UPM 2 UPM 3 e e FI UPM CABINET E4 E5 UPS CABINET CO o oH Battery Breaker BATTERY SYSTEM Not supplied with the UPS NOTE Callout letters A B C and D map to Table 3 4 on page 3 9 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 11 Plus 1 UPS System Common Rectifier Feed Common Battery IOM Configuration 6 14 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com Service Connector UNDERSTANDING UPS OPERATION
239. 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 6 20 shows the path of electrical power through the distributed bypass system when operating in Battery mode While in Battery mode the UPSs sound an audible horn illuminate a visual indicator lamp on the front panel System Normal On Battery and create an entry into the alarm event history As the battery discharges the boost converter and inverter constantly make minute adjustments maintaining a steady output The UPSs remain in this operating mode until the input power to the rectifier is again within the specified voltage or frequency acceptance windows If the input power fails to return or is not within the acceptance windows required for normal operation the battery continues discharging until a DC voltage level is reached where the inverter output can no longer support the shared loads When this event occurs each UPS issues another set of audible and visual alarms that indicate a two minute SHUTDOWN IMMINENT warning Unless the system has a valid AC input soon redundant UPMs begin shutting down until there are no longer enough UPMs online to support the connected load When this event occurs the system shuts down If the bypass source is available the system transfers to bypass instead of shutting down 6 24 EATON Powerware 9395 UPS 650 825 kVA Installation and Operatio
240. voltage the UPS is ready to transfer to the Normal mode and supply the critical load o NOTE To transfer to Normal mode after starting individual UPMs follow the procedure in paragraph 7 3 5 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 7 13 UPS OPERATING INSTRUCTIONS 7 3 4 Transfer from Normal to Bypass Mode To transfer the critical load to Bypass mode In Bypass mode the critical load is not protected from commercial power interruptions and abnormalities Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed On the System Status screen select the BYPASS command Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed On the Bypass Control Command screen select GO TO BYPASS Press the SELECT pushbutton on the Bypass Command menu bar The UPS transfers to Bypass mode and the critical load is immediately supplied by the bypass source If the bypass source is not available the power module remains on and an alarm sounds The BYPASS status indicator is illuminated The Bypass status indicates ON The UPM status indicates READY The power module remains on Power is present inside the UPS cabinet sections P nere AA 7 3 5 Transfer from Bypass to Normal Mode To transfer the critical load to Normal mode 1 2 If not already closed close the batt
241. werware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com v TABLE OF CONTENTS Figure AoA REPO Switch itat tt he t LL Figure 4 35 Normally Open REPO Switch Wiring Figure 4 36 Normally Closed REPO Switch Wiring Figure 4 37 Normally Closed and Normally Open REPO Switch Wiring Figure 5 1 Powerware Hot Sync CAN Bridge Card Figure 5 2 Powerware Hot Sync CAN Bridge Card Connections stributed Bypass System Can and Pull Chain Simplified Interface Wiring siiis Figure 5 3 Di istributed Bypass System UPS CAN Wiring without MOBs Figure 5 5 Di Figure 5 8 Di Figure 5 7 Remote Monitor Panel Figure 5 8 Remote Monitor Panel Figure 5 9 J1 Figure 5 4 D stributed Bypass Pull Chain Wiring without MOBs stributed Bypass Pull Chain Wiring with MOBs J2 J3 and J4 15 Pin D Sub Connectors Figure 5 10 Supervisory Contact Module Il Terminal Location Figure 5 11 Supervisory Contact Module ll TB2 Figure 5 1 1 Figure 5 1 1 2 Remote Monitor Panel ll Dimensions 3 Relay Interface Module ll Dimensions Figure 5 14 Supervisory Contact Module Il Dimensions Figure 6 1 Main Elements of the UPS SysteM Figure 6 2 Path of Current Through the UPS in Normal Mode Figure 6 3 Path of Current Through the UPS in By
242. with the UPS NOTE Callout letters A B C and D map to Table 3 5 on page 3 10 NOTE f the load requires a neutral a bypass source neutral must be provided If the load does not require a neutral and there is no neutral conductor connected at the bypass input a neutral to ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper Figure 6 12 Plus 1 UPS System Common Rectifier Feed Separate Battery IOM Configuration Service Connector 6 15 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UNDERSTANDING UPS OPERATION AC Input to UPS AC Input to Bypass Battery Aux Building Alarms Rectifiers 3 Wire 3 or 4 Wire A B C A B C Rotation Rotation 48V Battery Alarm Relays A A A Bypass Shunt Trip XS Breaker 20 UPM 3 UPM 2 UPM 1 B CB4 Remote EPO Interface O O OO O Et Et El E6 E7 an EZ EZ EZ ES E12 E O TEN Interface Board E3 E3 E3 Static Contactor K5 F Switch E use gt nput nput Input
243. y grounded If it is remove the source of the ground Contact with any part of a grounded battery can result in electrical shock The likelihood of such shock is reduced if such grounds are removed during installation and maintenance When replacing batteries use the same number of sealed lead acid batteries EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com 9 1 UPS MAINTENANCE 9 2 Proper disposal of batteries is required Refer to your local codes for disposal requirements Do not dispose of batteries in a fire Batteries may explode when exposed to flame Do not open or mutilate batteries Released electrolyte is harmful to the skin and eyes It may be toxic Performing Preventive Maintenance 9 2 1 9 2 2 The UPS system requires very little preventive maintenance However the system should be inspected periodically to verify that the units are operating normally and that the batteries are in good condition DAILY Maintenance Perform the following steps daily 1 Check the area surrounding the UPS system Ensure the area is not cluttered allowing free access to the unit Ensure the air intakes vents on the front door or panels and the exhaust openings on top of the UPM section are not blocked Ensure the operating environment is within the parameters specified in paragraph 3 2 1 on page 3 1 and Chapter 10 Product Specifications Ensure th
244. y in common NOTE Do not directly connect relay contacts to the mains related circuits Reinforced insulation to the mains is required NOTE Alarm relay wiring should be a minimum of 22 AWG Figure 4 29 Typical Alarm Relay Connection 4 34 EATON Powerware 9395 UPS 650 825 kVA Installation and Operation Manual 164201725 Rev 2 www powerware com UPS 1 e St ee E Eee S e Sf TBI amp Se A e Sa amp E e E St 10019 SH ei 10976 SI JE ma he eee e ES TB2 FS cq ee rc ee S Sf pur Sf 10110 SI UPS 1He SAI AO e SHE RARA e SH TB3 E 8 gt H H sE eh e SHO Tm SIS cM sa UPS SYSTEM INSTALLATION REPO NC REPO Return REPO NO REPO Return Battery Aux Battery Aux Common Battery Shunt Trip Battery Shunt Trip Output Contactor K3 NC Aux Output Contactor K3 NC Aux Common Pull Chain Pull Chain Common Alarm Relay NC Alarm Relay Common A A arm Relay NO arm Relay Common Building Alarm 1 Building Alarm 1 Return Building Alarm 2 Building Alarm 2 Return Building Alarm 3 Building Alarm 3 Return Building Alarm 4 Building Alarm

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