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Eaton Electrical UPS 225275 kVA Powerware 9395 User's Manual

1. Figure 2 3 UPS cabinet dimensions top view Front 1818 R 28ra 14 3 tr x aC c 6 pes i y i i i 9 co o f a 2 rp ae ath a ge tek ae w Ms R i m ea we a 3 A o i N O 38 356 to A Figure 2 4 UPS cabinet dimensions bottom view 1027574 UPS 450 550 kVA 2x225 2x275 kVA 13 Revision B User s and Installation Guide CG a 412 mm 1057 830 mm R Figure 2 5 UPS cabinet center of
2. Figure 5 1 Powerware 9395 450 550 kVA UPS controls and indicators 5 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 5 2 5 1 2 Circuit breakers Circuit breaker CB1 is used to control the AC input to the UPS rectifier 1027574 UPS 450 550 kVA 2x225 2x275 kVA 49 Revision B User s and Installation Guide 5 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 5 2 is located on the front door of the UPS Figure 5 2 UPS control panel The control panel consists of the following e A liquid crystal display LCD 1 e A horizontal row of pushbutton switches 2 e A vertical column of status indicators 3 See paragraph 5 2 1 The following paragraphs describe using the UPS control panel to monitor the UPS See paragraph 6 3 for use of the operational controls When the unit powers up the screen displays the Eaton Powerware logo as shown in Figure 5 2 To advance to the main menu and mimic screen press any control panel pushbutton once 5 2 1 Status indicators The four symbols on the right side of the control panel are status indicators They are colored
3. y o 193 250 62 T 417 o Q D g Figure 3 5 b side view UPS power terminal locations MBS version 28 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 3 4 2 Battery 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 1 If using a Powerware battery cabinet proceed to Step 2 otherwise proceed to Step 5 2 Route and connect the battery cables between the UPS and battery cabinets in accordance with the instructions in the Powerware 9395 Integrated Battery Cabinet Model IBC L installation manual See Figure 3 3 through Figure 3 5 for wiring access information and terminal locations 3 Connect the positive negative and ground DC power wiring from the battery cabinet to the UPS cabinet battery and ground terminals See paragraph 2 2 2 on page 14 for wiring and termination requirements 4 Proceed to Step 7 5 Route and connect the battery cables between the UPS and the battery system See Figure 3 3 through Figure 3 5 for wiring access information and terminal locations 6 Connect the positive negative and ground DC power wiring from the battery system to the UPS cabinet battery and ground terminals See paragraph 2 2 2 on page 14 for wiring and termination requirements 7 After wiring t
4. O O 0 0 0 0O E1 E2 E3 E6 E7 E8 E12 aes Beard Input contactor K1 Rectifier Static switch Backfeed contactor K5 AC output to critical load Battery Output lo converter contactor nd K3 l l lo i Inverter Fuse Battery l cabinet Optional UPS cabinet l L 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 Figure 4 5 Powerware 9395 450 550 kVA UPS system 400 V input and 400 V output dual feed 46 1027574 Revision B UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide AC input Critical load distribution unit Output from UPS Maintenance i bypass panel i Provided by others Static switch Backfeed i i MIB Maintenance isolation breaker MBP Maintenance bypass breaker NOTE If installing as part of the UPS system a maintenance bypass without a rectifier input breaker a minimum of two separate feeds with upstream feeder breakers or one feed with two upstream feeder breakers must be provided one for the UPS and one for the maintenance bypass input DO NOT use one feed or a single feeder breaker to supply both the UP
5. AN WARNING Power is present inside the UPS cabinets 5 3 7 UPS and critical load shutdown To perform maintenance or service on the critical load shut down power to the load by performing the following procedure 1 Turn off all equipment that is being powered by the UPS 2 Perform the LOAD OFF procedure in paragraph 5 3 9 The input output and bypass backfeed contactors open the battery breaker or disconnect is tripped and the power module is turned off N warning Power is present inside the UPS cabinet until the upstream input feeder circuit breaker is opened 3 Ifthe UPS contains input breaker CB1 open the UPS input breaker CB1 4 Open the UPS input and bypass feeder circuit breakers 61 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 5 3 8 Charger control To turn the battery charger on or off perform the following procedure 1 Press the CONTROLS pushbutton on the main menu bar The System Control screen appears 2 Press the pushbutton to display System Controls Screen 2 3 Press the CHGR ON or CHGR OFF pushbutton on the System Controls menu bar to toggle the charger on or off 5 3 9 Using the UPS LOAD OFF pushbutton A UPS Load Off is initiated by the LOAD OFF pushbutton from the main menu bar or the System Controls menu bar This pushbutton can be pressed to control the UPS output The UPS LOAD OFF pushbutton de energizes the critical load and powers down the
6. Operating Temperature 0 to 40 C without derating The recommended operating temperature is 25 C Operating Altitude Maximum 1500m 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 storage 5 to 95 maximum noncondensing Acoustical Noise 75 dB at a 1m distance c weighted EMI Suppression Meets EMC EN 62040 2 2006 specification Electrostatic Discharge ESD Immunity Meets IEC 61000 4 2 specification 11 Warranty The product is warranted against defects in design materials and workmanship for a period of twelve 12 months from its original date of purchase The local office or distributor may grant a warranty period different to the above and refer to local terms of liability as defined in the supply contract The UPS manufacturer is not responsible for e Any costs resulting from a failure if the installation commissioning repair alternation or ambient conditions of the equipment do not fulfil the requirements specified in the documentation delivered with the unit and other relevant documentation e Equipment subjected to misuse negligence or accident e Equipment comprised of materials provided or designs stipulated by the purchaser Under no circumstances shall themanufacturer its suppliers or subcontractors be liable for special indirect inci
7. 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 three 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 5 2 on page 49 Using the control panel for instructions on navigating the control panel 7 3 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 most recent event listed last Figure 7 3 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 1027574 UPS 450 550 kVA 2x225 2x275 kVA 68 Revision B User s and Installation Guide MM DD YYYY HH MM SS hh KYWD MESSAGE lt CR gt lt
8. Figure 5 3 identifies the display areas discussed in the following sections Figure 5 3 Parts of the LCD A The UPS status area automatically scrolls between the Eaton Corporation 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 alarms and notices see Chapter 6 Responding to system events 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 The navigation pushbuttons function depending 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 5 2 5 e Monitor UPS operation see paragraph 5 2 5 e Set UPS parameters see paragraph 5 2 5 e Control UPS operation see paragraphs 5 2 6 and 5 2 7 After approximately 30 minutes the display screen darkens To restore the screen press any pushbutton once 1
9. ion tallat refer to the Powerware 9395 Integrated Battery Cabinet Model IBC L installation manual After the battery cabinet is installed return to paragraph 3 4 to wire the UPS and battery cabinet INS 3 3 Battery cabinet To install the battery cabinet 1027574 Revision B UPS 450 550 kVA 2x225 2x275 kVA 24 User s and Installation Guide 3 4 Installing UPS external and battery power wiring AN NOTE The UPS cabinet is shipped with a debris shield covering the ventilation grill on top of the unit Do not remove the debris shield until installation is complete However remove the shield before operating the UPS Once the debris shield is removed do not place objects on the ventilation grill NOTE Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes see Figure 3 3 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 See Table 2 4 on page 15 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 3 4 1 External power wiring installation To install wiring to connections 1 Remove one top screw a
10. kW Demand Log Summary The kW demand log collects information on events where the unit load exceeds a user defined kW limit within a user defined time interval The user can choose a time period up to 9999 minutes and a load limit up to 9999 kW If the limit is exceeded within a given time period a log event is created The kW Demand Log Summary screen displays the number of total times the limit has been exceeded since the last log reset the date of the last log reset the maximum kW reading and the total time over the limit It also displays the average kW over the limit and an estimated number of kWh used over the limit Both of these values are calculated using the difference between the actual measurement reading and the user defined limit level For example during a 60 minute interval if the limit is set at 10 kW and the measurement is a constant 15 kW for the entire period the average kW over would be 5 kW and the total kWh used over the limit would be 5 kWh Press the METERS pushbutton on the main menu bar to display the Unit Meter screens Scroll through the meter screens using the up or down ar row pushbuttons on the menu bar until the kWDemand Log Summary screen is displayed 1027574 Revision B UPS 450 550 kVA 2x225 2x275 kVA 53 User s and Installation Guide Function Subfunction Operation kW Demand Log The kW Demand Log screen displays the individual log entries including the interval date and
11. contained in paragraph 5 3 2 Turn S10 switch from bypass position to UPS position to connect UPS output to load ao a F WY N Perform transfer from bypass to normal mode as described in paragraph 5 3 5 Remember to verify the transfer before proceeding the next step 7 UPS is now in Normal mode see below Maintenance bypass Maintenance switch S10 bypass input Static bypass input Rectifier input 65 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 6 Responding to system events 6 1 General 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 System Events screen This screen shows any currently active alarms notices or commands For more information on using the Events screen see paragraph 5 2 5 Display menu operation on page 51 6 2 System event horns The system event horn beeps to alert an operator that an event needing attention is taking place Horn 1 cycles at a one second rate 6 3 System event indicators The status indicators on the UPS control panel and the event horn let you know when the UPS system is operating in any
12. is jumpered if not used Alarm relays and building alarms are wired appropriately OPTIONAL A remote battery disconnect control is mounted in its installed location and its wiring is terminated inside the UPS and battery cabinet OPTIONAL Accessories are mounted in installed locations and wiring is terminated inside the UPS cabinet OPTIONAL The debris shield covering the UPS cabinet ventilation grill is removed Startup and operational checks are performed by an authorized Eaton Customer Service Engineer UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 4 Understanding UPS operation 4 1 Looking inside the UPS system The Powerware 9395 UPS is a continuous duty solid state transformerless at 400 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 Battery Fill Battery breaker lt 9 Battery converter Input Output contactor contactor K1 K3 AC input to rectifier charger Rectifier Inverter Power module Digital metering AC input AC output ta to bypass critical load Backfeed protection contactor K5 UPS cabinet Figure 4 1 Main elements of the UPS system If utility power is interrupted or falls outside the parameters specif
13. 7 in accordance with the National Electrical Code ANSI NFPA 70 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1027574 Revision B 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 2 4 The recommended line to line load unbalance is 50 or less Source protection for the AC input to bypass should be treated as if supplying a 550 kVA three phase transformer to allow for inrush current Bypass input wiring and bypass input breaker rating should be treated as if supplying a 550 kVA load regardless of the rating of the UPS Bypass and output overcurrent protection and bypass and output disconnect switches are to be provided by the user Table 2 8 lists the recommended rating for bypass and output circuit breakers satisfying the criteria for both Circuit breaker rating UPS model 400 V Load rating Bypass Output 9395 2 225 100 rated 800 A 160 A B type breaker 9395 450 100 rated 800A 160 A B type breaker 9395 2 275 100 rated 1000 A 200 A B type breaker 9395 550 100 rated 1000 A 200 A B type breaker Table 2 8 Recommended bypass and output circuit breaker ratings There is no DC disconnect device within the UPS A battery disconnect switch is recommended and may be required by local codes when batteries are remotely located The battery disconnect switch should be ins
14. METERS pushbutton on the main menu bar to display the Unit Meter screens Scroll through the meter screens using the up or down arrow pushbuttons on the menu bar until the Maximum Current Log Summary screen is displayed 54 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1027574 Revision B Function Subfunction Operation Maximum Current Log The Maximum Current Log screen displays the individual log entries including the interval date and time frame the maximum percent of full load during the interval the total time over limit during the interval and the number of times over during the interval If the individual phase option is selected the phases that exceeded the limit will also be displayed If no events have occurred the screen will display LOG EMPTY Press the LOG pushbutton on the Maximum Current Log Summary menu bar to display the Maximum Current Log screen To scroll through the individual events press the up or down arrow pushbuttons on the menu bar To return to the Maximum Current Log Summary screen press the SUMMARY pushbutton on the menu bar To clear the Maximum Current Log press the RESET pushbutton on the menu bar Maximum Current Log Setup Screen 1 The Maximum Current Log Setup screen 1 displays the current user defined log settings If no log settings are configured the screen will display MAXIMUM CURRENT LOG DISABLED Press the SETUP pushbutton on theMaximum Curr
15. Output Current Screen displays a real time bar graph of the output current of the UPS The graph shows the current for each phase Battery Discharge Log Summary The Battery Discharge Log Summary collects information when the unit is on battery The screen displays the total number of times since the last log reset that the unit has transferred to battery It also displays the date of the last log reset the average time spent on battery per event and the total time on battery since the last reset Press the METERS pushbutton on the main menu bar to display the Unit Meter screens Scroll through the meter screens using the up or down arrow pushbuttons on the menu bar until the Battery Discharge Log Sum mary screen is displayed Battery Discharge Log The Battery Discharge Log screen displays the individual log entries including the date and time of the event how long it was on battery the unit load when the event occurred and the end voltage of the battery for that discharge period If no events have occurred the screen will display LOG EMPTY Press the LOG pushbutton on the Battery Discharge Log Summary menu bar to display the Bat tery Discharge Log screen To scroll through the individual events press the up or down arrow pushbuttons on the menu bar To return to the Battery Discharge Log Summary screen press the SUMMARY pushbutton on the menu bar To clear the Battery Discharge Log press the RESET pushbutton on the menu bar
16. SSS SS SSS SS Sa n aE aE n EA aG aG a EHA EH _ SSS a lt z z z a ee z aee SSS o z n SSS SSS a e 2 eee eeel o E SSS SSS Ss SSS og a pF Figure 3 7 Interface terminal locations 1027574 UPS 450 550 kVA 2x225 2x275 kVA Revision B User s and Installation Guide Terminal TB1 Descrition 1 Remote EPO NC ne iO Dry contact used to active remote EPO of UPS 4 Remote EPO return 5 Battery aux 6 Battery aux return 7 48 Vdc battery shunt trip 8 48 Vdc battery shunt trip 9 Not used 10 Not used Terminal TB2 Name Descrition chan eium Back control for parallel operation 3 Alarm relay NC 4 Alarm relay return General purpose normally open NO and normally closed 5 Alarm relay NO NC relay contacts 6 Alarm relay return 7 Not used 8 Not used 9 Not used 10 Not used Terminal TB3 Name Descrition 1 Building alarm 1 Programmable UPS alarm Activated by a remote dry contact 2 Building alarm 1 return closure 3 Building alarm 2 Programmable UPS alarm Activated by a remote dry contact 4 Building alarm 2 return closure 5 Building alarm 3 Programmable UPS alarm Activated by a remote dry contact 6 Building ala
17. The Meter screens show the UPS meter readings for the unit The default volt age 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 Unit Meter screens To scroll through the meter screens press the up or down arrow pushbuttons on the menu bar The current UPS readings are displayed in the information area of the screen Output 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 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 cur rent each phase and frequency of the incoming utility source as well as the kVA kW and power factor measurements Battery 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 20 Check Battery is displayed Output Current The
18. 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 informa tion is used for display on the screen and for logging events in the Event and History Logs Use the left or right arrow pushbuttons to highlight the setting to be changed Use the up or down arrow pushbuttons to make the change When fin ished making changes use the left or right arrow pushbuttons to highlight SAVE and the up or down arrow pushbuttons to select YES To complete the save func tion and return to the System Setup screen select the return arrow pushbutton 56 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1027574 Revision B Function Subfunction Operation 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 informa tion is used for display on the screen and for logging events in the Event and History Logs Use the left or right arrow pushbuttons to highlight the setting to be changed Use the up or down arrow pushbuttons to make the change When fin ished making changes use the left or right arrow pushbuttons to highlight SAVE and the up or down arrow pushbuttons to select YES To complete the save func tion and return to the System Setup screen select the return arrow pushbutton Com Port Selection The Com Port Setup screen a
19. UPS The UPS including Bypass remains off until restarted To use the LOAD OFF pushbutton 1 Press the LOAD OFF pushbutton The Load Off screen appears providing a choice to proceed or abort the shutdown A N 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 2 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 and bypass backfeed contactors open the battery breaker or disconnect is tripped and the power module is turned off N CAUTION Do not attempt to restart the system after Load Off until the cause of the shutdown has been identified and cleared 3 To restart the UPS after pressing the LOAD OFF pushbutton follow the procedure in paragraph 5 3 1 or 5 3 2 1027574 UPS 450 550 KVA 2x225 2x275 kVA 62 Revision B User s and Installation Guide 5 3 10 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 AN CAUTION All power to the criti
20. X Slot communication bays see Figure 3 7 on page 30 for The UPS is compatible with the following X Slot cards see Figure 7 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 SNMP 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 This card is provided as standard equipment with the UPS N 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 ConnectU
21. and a real time graphical representation of the operating status of the system TIME 11 35 43 DATE 02 25 2004 OUTPUT EVENTS METERS CONTROLS SETUP LOAD OFF Figure 5 4 Main menu and Mimic screen normal mode 5 2 5 Display menu operation Table 5 3 describes the menu functions and provides instructions to access and use the menu screens 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 pushbut tons on the menu bar 52 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B Function Subfunction Operation History Press the HISTORY pushbutton on the Active Events menu bar to display the His tory Log The History Log lists up to the 500 system events in chronological order with the most recent event listed last once 500 is reached the earliest event is overwritten The end of the log the most recent events appears when you display the screen scroll upward to view older event listings To scroll through the events press the up or down arrow pushbuttons on the menu bar To return to the Active Events screen press the EVENTS pushbutton on the menu bar Meters
22. between pins 1 and 2 on TB1 if the normally closed Remote EPO contact is not used Remote EPO wiring should be a minimum of 0 75 mm and a maximum of 2 5 mm The maximum distance between the Remote EPO and the UPS cannot exceed 150 meters 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 0 75 mm UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 2 3 Inspecting and unpacking the UPS cabinet The UPS cabinet is palleted separately for shipping The cabinet is shipped bolted to a wooden pallet and protected with outer protective packaging material see Figure 3 8 CAUTION The UPS cabinet is heavy see Table 2 1 on page 11 If unpacking instructions are not closely followed the cabinet may tip and cause serious injury 1 Carefully inspect the outer packaging for evidence of damage during transit CAUTION Do not install a damaged cabinet Report any damage to the carrier and contact your service representative immediately AN NOTE For the following step verify that the forklift or pallet jack is rated to handle the weight of the cabinet see Table 2 1 on page 11 for cabinet weight 2 Use a forklift or pallet jack to move the packaged cabinet to the installation site or as close as possible before unpacking Insert the forklift or pallet jack forks from the right side of the c
23. control panel display becoming active indicating logic power 5 Press the CONTROLS pushbutton on the main menu bar The system controls screen appears 58 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 10 11 On the System Controls screen the power module PM status should indicate SHUTDOWN Close the battery breaker If the UPS contains input breaker CB1 close input breaker CB1 Press the NORMAL pushbutton on the system controls 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 Observe the following messages appear sequentially on the power module PM status line DC STARTING INVERTER STARTING INVERTER SYNCING READY ONLINE The rectifier and inverter turn on The inverter continues to ramp up to full voltage Once the inverter reaches full voltage and the battery breaker is closed 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 1 minute for the UPS to achieve Normal mode The UPS is now operating in Normal mode and the NORMAL status indicator is i
24. gravity 116 mm r 90 mm i D ae E lt q E Lo oOo 2E 1 2 in Knockout Pattern typ 5 sides Figure 2 6 Remote EPO switch dimensions 2 2 2 UPS system power wiring preparation N nore If installing as part of the UPS system a maintenance bypass without a rectifier input breaker a minimum of two separate feeds with upstream feeder breakers or one feed with two upstream feeder breakers must be provided one for the UPS and one for the maintenance bypass input DO NOT use one feed or a single feeder breaker to supply both the UPS and the maintenance bypass 1027574 14 UPS 450 550 kVA 2x225 2x275 kVA Revision B User s and Installation Guide For external wiring requirements including the minimum size of external wiring see Table 2 4 The power wiring connections for this equipment are rated at 70 C If wire is run in an ambient temperature greater than 30 C higher temperature wire and or larger size wire may be necessary Units Rating 50 60 Hz Rating kVA 450 2 225 550 2 275 kW 404 2 202 495 2 247 Input and output voltage Volts 400 400 400 400 AC input to UPS rectifier Full load current plus battery recharge current A 746 912 3 phases 1 ground eas Minimum conductor size mm Refer to national Number per Phase each and local rules AC Output to UPS Bypass Full load current Amps 672 870 3 phases 1 neutral
25. if required 1 ground B Minimum conductor size mm Refer to national Number per phase each and local rules DC input from battery to UPS 1 positive 1 negative c Amps 950 1300 mo a size mi Refer to national POMBE CREE Ree each and local rules AC output to critical load full load current A 580 800 3 phases 1 neutral if required 1 ground d mps minimum conductor size mm Refer to national number per phase each and local rules NOTE callout letters A B C and D map to figure 6 5 on page 6 6 Table 2 4 Input output ratings and external wiring requirements for the Powerware 9395 550 and 9395 2 275 Read and understand the following notes while planning and performing the installation Refer to national and local electrical codes for acceptable external wiring practices Material and labor for external wiring requirements are to be provided by designated personnel For external wiring use 70 C copper wire See the appropriate information in Table 2 4 Wire sizes are based on using the specified breakers 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 t
26. imputan bawan io UPS iEn Battery 4 2 bolt mounting 76 M12 Input and output neutral E12 Neutral 8 2 bolt mounting 22 M10 Customer ground Ground Ground 7 1 bolt mounting 22 M10 NOTE Customer ground size1 0 can be run in any conduit Table 2 5 UPS cabinet power cable terminations for the Powerware 9395 550 450 and 9395 550 550 Part Size Quantity Manufacturer Part number Notes Long barrel 2 hole lug 500 MCM As required Thomas amp Betts 76 56 Color code brown Die code 87 Bolt M12 x 50 mm As required N A N A Quantity per lug Bolt M10 x 50 mm As required N A N A hole Flat washer M12 As required N A N A Lock washer M12 As required N A N A Nut M12 As required N A N A Manual hydraulic crimp tool 14 ton 1 Thomas amp Betts TBM14M Die set N A 1 Thomas amp Betts 15506 Table 2 6 Recommended installation parts and tool not supplied by Eaton Corporation External overcurrent protection is not provided by this product but is required by codes Refer to Table 2 4 for wiring requirements If an output lockable disconnect is required it is to be supplied by the user Input rating Urs model Load rating 400 V 9395 2 225 100 800 A 9395 450 100 800 A 9395 2 275 100 1000 A 9395 550 100 1000 A Table 2 7 Recommended input circuit breaker ratings CAUTION To reduce the risk of fire connect only to a circuit provided with maximum input circuit breaker current ratings from Table 2
27. light emitting diode LED lamps and they work in conjunction with the alarm horn to let you know the operating status of the UPS The Table 5 1 shows the status indicators and provides a functional description Indicator Status Descritions oe On The UPS is operating normally The power module is supplying power to the critical load Green Off The UPS is turned off Oe On The UPS is in Battery mode Because Battery mode is a normal condition of the UPS the Yellow Normal indicator also remains illuminated Ce On The UPS is in Bypass mode The critical load is supported by the bypass source The Yellow Normal indicator is not illuminated when the system is in Bypass mode The UPS has an active alarm and requires immediate attention The LCD shows the high OR On est priority active alarms All alarms are accompanied by an audible horn To silence the horn press any control panel pushbutton once The Alarm indicator may be illuminated Red along with other indicators Flashin There is a new UPS alarm condition The indicator flashes until acknowledged by press g ing any control panel pushbutton once Table 5 1 Status indicators For more information about audible horns see System event horns on page 63 50 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 5 2 2 Using the LCD and pushbuttons The LCD on the control panel provides an operator interface with the UPS system
28. menu to display the Calculation Method Setup screen Use the up or down arrow pushbuttons to highlight the calculation method desired then press the SELECT pushbutton The action is completed and the Maximum Current Log Setup screen 2 displays To return to the Maximum Current Log Setup screen 1 press the return arrow pushbutton on the menu bar 1027574 Revision B UPS 450 550 kVA 2x225 2x275 kVA 55 User s and Installation Guide Function Subfunction Operation 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 pushbuttons to highlight the setup function screen desired then press the SELECT pushbutton to display the function screen Contrast Adjust Select CONTRAST from the System Setup Level 0 menu to display the Contrast Adjust screen Use the left or right arrow pushbuttons 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 pushbut ton Firmware Versions The Versions screen provides
29. the firmware version numbers installed on the UPS Select VERSIONS from the System Setup Level 0 menu to display the Ver sions screen To scroll through the firmware types press the up or down arrow pushbuttons 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 Password screen Use the left or right arrow pushbuttons to select the password character position Use the up or down arrow pushbuttons 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 pushbuttons to highlight the setup function screen desired then press the SELECT pushbutton to display the function screen The Level 1 screen times out a
30. 027574 UPS 450 550 kVA 2x225 2x275 kVA Revision B User s and Installation Guide 51 5 2 3 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 5 2 shows the basic menu structure 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 System Controls 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 toMainMenu andMimic screen from the Events Meters Controls or Setup ESC screens Returns to the main System Setup Level screen from a setup submenu Return arrow acknowledges or executes a command or saves a setting Up or down arrows scroll through screens and lists or highlight settings Left or right arrows select or adjust settings displayed on the screen Table 5 2 Display function menu map 5 2 4 Mimic screen Figure 5 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
31. ES DISCONNECTED PM1 ACTIVE ALARMS 11 NOTICE OUTPUT UNDER OR OVER FREQ 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 7 3 Sample Event History Log 69 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1027574 Revision B 7 4 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 7 5 General purpose relay contact One general purpose relay contact is provided as a standard feature on the UPS The alarm contact is located inside 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 maximu
32. For more information contact your local recycling reuse or hazardous waste ma center pd This symbol indicates that you should not discard the UPS or the UPS batteries in equipment WEEE in the trash For proper disposal contact your local recycling reuse pzd This symbol indicates that you should not discard waste electrical or electronic or hazardous waste center 1 7 For more information Refer to the Powerware 9395 Integrated Battery Cabinet Model IBC L installation manual 1028181 for the following additional information e Integrated Battery Cabinet IBC installation instructions including site preparation planning for installation wiring and safety information e Detailed illustrations of the cabinet including dimension and connection point drawings Visit www powerware com or contact your service representative for information on how to obtain copies of these manuals 1 8 Getting help If help is needed with any of the following e Scheduling initial startup e Regional locations and telephone numbers e A question about any of the information in this manual e A question this manual does not answer Call your local service representative 1027574 UPS 450 550 kVA 2x225 2x275 kVA Revision B User s and Installation Guide 2 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 Chapter 2 Prepare your site
33. LF gt 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 2 sdigits KYDW Keyword ALARM NOTICE COMMAND or STATUS Message System Diagnostic Information lt CR gt Carriage Return Character ASCII 13 lt LF gt 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 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 DISPLAY 1 06 TIME 19 17 16 DATE 03 23 2099 03 16 2099 21 25 20 355 138 CONTROL POWER ON PM1 03 16 2099 21 25 20 515 NO11 OUTPUT UNDER OR OVER FREQ PM1 03 16 2099 21 25 20 675 302 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 FREQ OK PM1 03 23 2099 18 59 20 450 A199 BATTERI
34. PS X Web SNMP card amp P oooom Modem card RP S ee Modbus card PEE Pose QO Sod Industrial relay card Relay interface card om Figure 7 1 Optional X Slot cards UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 7 2 Powerware LanSafe Power Management Software Each Powerware 9395 UPS ships with LanSafe Power Management Software To begin installing 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 Powerware LanSafe Power Management Software 7 3 Terminal mode NOTE The brackets in the following bullets indicate standard keyboard characters To use a keycombination hold down the Escape key and press the indicated letter key InTerminal mode the user can request the following e ESC A displays the Active Alarms e ESC H displays the Event History e ESC N displays the Node Bits Setup e ESC V displays the UPS control panel e ESC O Quit 7 3 1 Display UPS control panel
35. Powerware 9395 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 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 AN WARNING This is a product for commercial and industrial application in the second environment Installation restrictions or additional measures may be needed to prevent disturbances 2008 Eaton Corporation All Rights Reserved The contents of this manual are the copyright of the publisher and may not be reproduced even extracts unless permission granted Every care has been taken to ensure the accuracy of the information contained in this manual but no liability can be accepted for any errors or omission The right to make design modifications is reserved Powerware 9395 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1027574 Revision B Contents 1 Introduction 1 1 UPS standard features 1 1 1 Control panel 1 1 2 Customer Interface 1 1 3 Advanced Battery Management 1 1 4 Power Management Software 1 1 5 Installation features 1 2 Options and accessories 1 2 1 Integrated battery cabinet 1 2 2 Optional X Slot Cards 1 3 Basic systemcConfigurations 1 4 Using this manual 1 5 Conventions used in this manual 1 6 Symbols co
36. S and the maintenance bypass Figure 4 6 Typical maintenance bypass panel 1027574 UPS 450 550 kVA 2x225 2x275 kVA 47 Revision B User s and Installation Guide 5 UPS operating instructions This section describes how to operate the UPS AN NOTE Before starting the UPS ensure all installation tasks are complete and a preliminary startup has been performed by authorized service personnel The preliminary startup verifies all electrical interconnections to ensure the installation was 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 48 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 5 1 UPS controls and indicators The controls and indicators identified and described in this section are used to control and monitor UPS operation Figure 6 1 shows the UPS controls and indicators Control panel AC input breaker CB1
37. abinet between the supports on the bottom of the pallet see Figure 2 6 on page 14 for the UPS cabinet center of gravity measurements AN CAUTION Do not tilt the UPS cabinet more than 10 from vertical or the cabinet may tip over 3 Set the pallet on a firm level surface allowing a minimum clearance of 3 m on each side for removing the cabinet from the pallet NOTE The UPS cabinet is shipped with a debris shield covering the ventilation grill on top of the unit Do not remove the debris shield until installation is complete 1027574 UPS 450 550 kVA 2x225 2x275 kVA 19 Revision B User s and Installation Guide 4 Remove the protective covering from the cabinet 5 Remove the packing material and discard or recycle in a responsible manner 6 After removing the protective covering inspect the contents for any evidence of physical damage and compare each item with the Bill of Lading If damage has occurred or shortages are evident contact your service representative immediately to determine the extent of the damage and its impact upon further installation NOTE While waiting for installation protect the unpacked cabinet from moisture dust and other harmful contaminants Failure to store and protect the UPS properly may void your warranty Figure 2 8 Powerware 9395 UPS 2 275 kVA cabinet as shipped on pallet 20 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s
38. aceieainess 4 1 Looking inside the UPS system 4 2 Modes 4 2 1 Normal mode 4 2 2 Bypass mode 4 2 3 Battery mode 4 3 UPS system oneline configurations 5 UPS operating instructions 5 1 UPS controls and indicators 5 1 1 Control panel 5 1 2 Circuit breakers 5 2 Using the control panel 5 2 1 Status indicators 5 2 2 Using the LCD and pushbuttons 5 2 3 Using the menu 5 2 4 Mimic screen 5 2 5 Display menu operation 5 2 6 System controls screen re 5 2 7 Load off SCr en nisuna a healed dace a laed kina aig en nae eis 10 11 FBO DON ati OM scivecdess cdvezeszdssscvsssshowserssecessbetaactsbcbeascezagaawncanahcu ucadscoaslas haaa a a aa a 5 3 1 Starting the UPS in normal mode 5 3 2 Starting the UPS in bypass mode 5 3 3 Starting the power module 5 3 4 Transfer from normal to bypass mode 5 3 5 Transfer from bypass to normal mode 5 3 6 Transfer from normal to bypass mode and shut down UPS 5 3 7 UPS and critical load shutdown 5 3 8 Charger control 5 3 9 Using the UPS LOAD OFF pushbutton 5 3 10 Using the Remote Emergency Power off switch 5 3 11 Using Mechanical Bypass Switch Responding to system events 6 1 General 6 2 System event horns 6 3 System event indicators G4 SYSTEM EVENT MESSAGES chide ccs T T rE a aa e eaa a aa aaa Communication 7 1 X Slot cards 7 2 Powerware LanSafe Power Management Software 7 3 Terminal mode 7 3 1 Display UPS control panel 7 3 2 Even
39. and Installation Guide Revision B 3 UPS system installation 3 1 Preliminary installation information AN WARNING Installation should be performed only by qualified personnel Refer to the following while installing the UPS system e Chapter 2 for cabinet dimensions equipment weight wiring and terminal data and installation notes e Do not tilt the cabinet more than 10 during installation e The landing plates are to be removed to add holes as required Plate material is 16 gauge steel 1 5 mm 0 06 thick e f perforated floor tiles are required for ventilation place them in front of the UPS 3 2 Unloading the UPS cabinet from the pallet and mechan ical installation The UPS cabinet is bolted to a wooden pallet supported by wood skids To remove the pallet and mechanically install the UPS perform the following procedure AN NOTE When a line up and match UPS system is ordered together with battery cabinets the first battery cabinet is supplied with two cosmetic covers The UPS cabinet additional battery cabinets and other ancillary cabinets are supplied without cosmetic covers NOTE When a UPS system is ordered together with battery cabinets for standalone installation the first battery cabinet is supplied with two cosmetic covers Additional battery cabinets are supplied without cosmetic covers Cosmetic covers must be ordered for the UPS cabinet and or other ancillary cabinets AN WARNING The UPS ca
40. be installed on a level floor suitable for computer or electronic equipment e The system must be installed in a temperature and humidity controlled indoor area free of conductive contaminants e The cabinet can be installed in line up and match or standalone configurations Failure to follow guidelines may void your warranty The UPS equipment operating environment must meet the weight requirements shown in Table 2 1 and the size requirements shown in Figure 2 1 through Figure 2 7 Dimensions are in millimeters 10 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B Weight kg Model Tare Shipping Installed Powerware 9395 2 275 1610 1430 Powerware 9395 550 1610 1430 Table 2 1 UPS cabinet weights The UPS cabinets use forced air cooling to regulate internal component temperature Air inlets are in the front of the cabinet and outlets are in the top You must allow clearance in front of and above each cabinet for proper air circulation The clearances required around the UPS cabinet are shown inTable 2 2 From top of cabinet Minimum clearance over the UPS cabinet is 458 mm for ventilation From front of cabinet 915 mm working space From back of cabinet None required From right side of cabinet None required but for easier service 500 mm is recommended From left side of cabinet None required Table 2 2 UPS cabinet clearances The basic environmental requirement
41. binet is heavy See Table 2 1 on page 11 for weight of cabinets If unloading instructions are not closely followed the cabinet may cause serious injury 1027574 UPS 450 550 KVA 2x225 2x275 kVA 21 Revision B User s and Installation Guide CAUTION e Do not tilt cabinets more than 10 from vertical e Lift the cabinet only with a forklift or damage may occur IN NOTE For the following steps verify that the forklift or pallet jack is rated to handle the weight of the cabinet see Table 2 1 on page 11 for cabinet weight o oN 10 11 22 If not already accomplished use a forklift or pallet jack to move the cabinet to the installation area or as close as possible before unloading from the pallet Insert the forklift or pallet jack forks from the right side of the cabinet between the supports on the bottom of the pallet see Figure 2 6 on page 13 for the UPS cabinet center of gravity measurements Remove the three bolts securing the left side shipping bracket to the cabinet and three bolts securing the bracket to the pallet see Figure 3 1 Remove the front shipping bracket If installing the cabinet permanently retain the shipping bracket and securing hardware for later use Remove the three bolts securing the right side shipping bracket to the cabinet and three bolts securing the bracket to the pallet see Figure 3 2 Remove the front shipping bracket If installing the cabinet permanently retain the shipping bra
42. block diagrams to show the power flow during each mode of operation 4 2 1 Normal mode Figure 4 2 shows the path of electrical power through the UPS system when the UPS is operating in normal mode switch KS Rectifier Inverter K3 Battery converter Breakers Contactors mum Main power flow 6d H Closed Y Battery m Trickle current o breaker Energized 6 6 Il Open De energized Battery Figure 4 2 Path of current through the UPS 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 The battery is charged directly from the regulated rectifier output through a buck or boost DC converter depending on whether 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 42 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B The inverter produces a thr
43. cal 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 Corporation 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 Press the REPO pushbutton switch 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 CAUTION Do not attempt to restart the system after Load Off until the cause of the shutdown has been identified and cleared 2 To restart the UPS after using the REPO pushbutton reset the REPO switch and then follow the procedure in paragraph 5 3 1 or 5 3 2 63 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 5 3 11 Using Mechanical Bypass Switch The operation of the integral MBS is allowed for a trained person only who is familiar with the UPS behaviour and functions The full UPS wiring diagram with a MBS switch is presented in the installation part of the manual AN NOTE The integral MBS and Static Bypass need to supplied by the same source Maintenance bypass Maintenance switch S10 bypass input Static bypass input Rectifier input Figure 5 8 T
44. card waste electrical or electronic equipment in the trash For proper disposal contact your local collecting recycling reuse or hazardous waste center and follow the local legislation These symbols indicate on a product Use proper local collecting centers meeting local legislation when handling waste of electrical and electronic equipment JN WARNING HAZARDOUS MATERIALS Batteries may contain HIGH VOLTAGES and CAUSTIC TOXIC and FLAMMABLE substances Batteries can injure or kill people and damage equipment if used improperly DO NOT DISCARD unwanted batteries or battery material in the public waste disposal system Follow ALL applicable local regulations for storage handling and disposal of batteries and battery materials Pb 73 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 10 Product specifications 10 1 Model numbers The UPS systems are housed in free standing cabinets with safety shields behind the doors The UPS systems are available in 50 60 Hz with various output power ratings Power Rating Models Powerware 9395 550 450 450 kVA Powerware 9395 550 550 550 kVA 50 60 Hz 50 60 Hz The following sections detail the input output environmental and battery specifications for the UPS 10 2 Single module specifications 10 2 1 UPS system input Operating Input Voltage Nominal 15 400 Vac for operation from 340 Vac to 460 Vac Operating Input Frequ
45. cket and securing hardware for later use Using the forklift raise the UPS cabinet section until the cabinet bottom clears the pallet by approximately 3 mm Once the UPS cabinet is clear of the pallet pull the pallet from under the UPS cabinet Discard or recycle the pallet in a responsible manner Using the forklift move the UPS cabinet to the final installed location Carefully lower the UPS cabinet until the cabinet base contacts the floor If permanently mounting the system proceed to Step 9 otherwise continue to Step 11 Using the retained hardware reinstall the shipping brackets removed in Steps 2 and 3 to the left and right side of the UPS cabinet with the angle facing outward see Figure 3 1 and Figure 3 2 Secure the cabinet to the floor with customer supplied hardware If installing a battery cabinet proceed to paragraphs 3 3 otherwise proceed to paragraph 3 4 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B Removable front Shipping bracket bolts Left side shipping bracket Shipping bracket bolts bracket ipping left side sh 3 1 Removi Figure 23 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1027574 Revision B Removable front panels Pallet Shipping bracket Shipping bracket bolts Right side shipping bracket Figure 3 2 Removing right side shipping bracket
46. cks 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 service in advance usually a two week notice is required to reserve a preferred startup date 3 8 Completing the installation checklist The final step in installing the UPS system is completing the following installation checklist This checklist ensures that you 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 If installing a parallel system complete the parallel system installation checklist in addition to the installation checklist After the installation is complete your service representative 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 AN NOTE The installation checklist MUST be completed prior to starting the UPS system for the first time 1027574 UPS 450 550 KVA 2x225 2x275 kVA 39 Revision B User s and Installation Guide Insta
47. d be inspected periodically to verify that the units are operating normally and that the batteries are in good condition 8 2 1 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 2 Ensure the air intakes vents on the front doors and exhaust opening on top of the UPS cabinet sections are not blocked 3 Ensure the operating environment is within the parameters specified in paragraph 2 2 1 on page 10 and Chapter 10 Product Specifications 4 Ensure the 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 your service representative 8 2 2 MONTHLY maintenance Perform the following steps monthly 1 Monitor system parameters as described in paragraph 5 2 Using the Control Panel on page 49 2 Check the air filters located behind the front doors and wash or replace as necessary The left ISBM filter size is 12 x20 x1 and the right UPM filter sizes are 19 5 x21 5 x0 5 Contact your service representative for replacement filters To remove the filters a Open the front door latch and swing the doors open b Grasp foam filters and remove filters from cabinet mounted studs c Push the washed or new filters onto the cabinet mounted studs until seated against cabinet d Close the doors and
48. dental or consequential damages losses or penalties The technical data information and specifications are valid at the time of printing The UPS manufacturer reserves the right to modifications without prior notice 75 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B
49. dicates READY The system is now on bypass and the UPS power processor remains on J N WARNING Power is present inside the UPS cabinets 1027574 UPS 450 550 kVA 2x225 2x275 kVA 60 Revision B User s and Installation Guide 5 3 5 Transfer from bypass to normal mode To transfer the critical load to Normal mode perform the following procedure 1 Press the CONTROLS pushbutton on the main menu bar The System Controls screen appears 2 Press the NORMAL pushbutton on the System Controls menu bar The UPS transfers to Normal mode If the power processor is not available the system remains on bypass and an alarm sounds 3 The UPS is now operating in Normal mode and the NORMAL status indicator is illuminated The power module PM status indicates ONLINE 5 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 perform the following procedure 1 Transfer the critical load to bypass by performing the procedure in paragraph 5 3 4 2 Press the CONTROLS pushbutton on the main menu bar The System Control screen appears 3 Press the pushbutton to display System Controls Screen 2 4 Press the PM OFF pushbutton on the System Controls menu bar The power module PM status indicates SHUTDOWN The input and output contactors open the battery breaker or disconnect is tripped and the power module is turned off The bypass source supplies the critical load
50. e 3 10 If battery cabinets are installed attached to the UPS cabinet proceed to Step 7 if battery cabinets are installed separated from the UPS cabinet or a battery system is being used proceed to Step 10 Route the Shunt trip and Aux wiring harness supplied with the battery cabinet from the battery cabinet to the UPS cabinet Refer to the Powerware 9395 Integrated Battery Cabinet Model IBC L installation manual for battery cabinet wiring access information Connect the wiring toTB1 terminals Proceed to Step 15 Remove the UPS cabinet interface entry plates to drill or punch holes see Figure 3 3 on page 26 Reinstall the interface entry plates Route the Shunt trip and Aux wiring from the battery cabinet or battery system breaker to the UPS Connect the wiring to the TB1 terminals When all wiring is complete reinstall the small top internal safety shield panel and secure with the cabinet mounted screws If wiring X Slot connections proceed to paragraph 3 5 3 otherwise proceed to Step 16 Reinstall the left and center front panels removed in previous steps and secure with the retained hardware UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B Battery breaker or disconnect Battery aux Battery aux return Battery shunt trip Battery shunt trip NOTE Battery Aux and DC ShuntTrip wiring should be a minimum of 1 5 mm Figure 3 10 Typical battery in
51. ee 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 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 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 4 2 2 Bypass mode The UPS automatically switches to bypass mode if it detects an overload load fault or internal failure The bypass source supplies the commercial AC power to the load directly Figure 4 3 shows the path of electrical power through the UPS system when operating in Bypass mode AN CAUTION The critical load is not protected while the UPS is in Bypass mode switch Rectifier Inverter Battery converter Breakers Contactors m Main power flow 6d H Closed O Battery m Trickle c
52. emoves 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 system is housed in a single free standing cabinet with safety shields behind the door for hazardous voltage protection The cabinet matches the battery and distribution cabinets in style and color and can be installed in line up and match or standalone configurations Figure 1 1 shows the Powerware 9395 UPS 450 550 kVA NOTE Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer or the warranty terms specified on page 75 become void This service is offered as part of the sales contract for the UPS Contact service in advance usually a two week notice is required to reserve a preferred startup date 1 1 UPS standard features 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 1 1 1 Control panel The control panel located on the UPS front door contains an LCD and pushbutton switches to control the operation of the UPS and to display the status of the UPS sys
53. ency Range 5 Hz Operating Input Current See Table 3 4 on page 3 6 Reduced for Generator Adjustable Input Current Harmonic Content 5 THD at full load Power Factor Minimum 0 98 Line Surges 6 kV OC 3kA SC per ANSI 62 41 and IEC 801 4 Battery Voltage 480 Vdc 10 2 2 UPS system output UPS Output Capacity 100 rated current Output Voltage Regulation 1 10 to 100 load Output Voltage Adjustment Nominal 3 380 Vac nominal adjustable from 368 6 Vac to 391 4 Vac 400 Vac nominal adjustable from 388 Vac to 412 Vac 415 Vac nominal adjustable from 402 5 Vac to 427 5 Vac Output Voltage Harmonic Content 1 5 max THD linear load 5 max THD nonlinear load Output Current See Table 3 4 on page 3 6 Output Voltage Balance 3 for 100 maximum load imbalance linear load Output Voltage Phase Displacement 3 for 100 maximum load imbalance linear load Output Transients 5 for 100 load step or removal Frequency Regulation 0 1 Hz free running Synchronous to Bypass Bypass within voltage limits of 5 8 of output setting bypass within 3 Hz Frequency Slew Rate 1 Hz per second maximum 110 for 10 minutes Overload Capability 125 for 30 seconds 150 for 10 seconds Max battery charging current 120A 1027574 UPS 450 550 kVA 2x225 2x275 kVA 74 Revision B User s and Installation Guide 10 2 3 Environmental
54. ent Log Summary menu bar to display the Maximum Current Log Setup screen 1 To return to the Maximum Current Log Summary screen press the return arrow pushbutton on the menu bar Screen 2 The Maximum Current Log Setup screen can be used to set up or change the time interval the maximum percent of load and the calculation method three phase average or individual phases log settings Press the CHANGE pushbutton on the Maximum Current Log Setup menu bar to display the Maximum Current Log Setup screen 2 Use the up or down arrow pushbuttons to highlight the setup function screen desired then press the SELECT pushbutton to display the function screen To return to the Maximum Current Log Setup screen 1 press the return arrow pushbutton on the menu bar Time Interval Moni tored Setup The Time Interval Monitored Setup screen allows the time duration of the event being monitored to be changed Select TIME INTERVAL MONITORED from the Maximum Current Log Setup screen 2 menu to display the Time Interval Moni tored Setup screen Use the left or right arrow pushbuttons to select the char acter position Use the up or down arrow pushbuttons to change the character value Once the new value is entered press the DONE pushbutton The Time Interval Monitored Setup Save screen is displayed Time Interval Moni tored Save The Time Interval Monitored Setup Save screen lets you save the new time interval retry another time interval or ab
55. for the UPS system Chapter 2 Inspect and unpack the UPS cabinet Chapter 2 2 3 4 Unload and install the UPS cabinet and wire the system Chapter 3 5 Complete the Installation Checklist Chapter 3 6 Have authorized service personnel perform preliminary operational checks and startup AN 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 service in advance usually a two week notice is required to reserve a preferred startup date 2 1 Creating an installation plan Before installing the UPS system read and understand how this manual applies to the system being installed Use the procedures and illustrations in the paragraph 2 2 and Chapter 3 to create a logical plan for installing the system 2 2 Preparing the site 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 1500 m contact your service representative for important information about high altitude operation The operating environment must meet the weight clearance and environmental requirements specified 2 2 1 Environmental and installation considerations The UPS system installation must meet the following guidelines e The system must
56. fter 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 pushbuttons to select the password character position Use the up or down arrow pushbuttons 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 an other 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 redis played Time Format The Time Format Setup screen allows the selection of either 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 pushbuttons 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
57. he UPS system to the facility power and critical load be sure to ground the system according to local and or national electrical wiring codes 8 If wiring interface connections proceed to paragraph 3 5 otherwise proceed to Step 9 9 When all wiring is complete reinstall the left front panel removed in paragraph 3 4 1 and secure with the retained hardware 3 5 Installing interface connections J N WARNING Hazardous voltages are present near the user interface terminal area if the UPS is not totally disconnected 3 5 1TB1 TB2 and TB3 connections other than TB1 battery interface connections A NOTE Interface wiring must be installed from the top of the UPS cabinet 1027574 UPS 450 550 KVA 2x225 2x275 kVA 29 Revision B User s and Installation Guide To install wiring to connections 1 Verify the UPS system is turned off and all power sources are removed See Chapter 5 UPS Operating Instructions for shutdown instructions 2 If not already accomplished remove one top screw and two bottom screws securing the UPS left front panel see Figure 3 1 Lift the panel straight up to remove from the panel hanger bracket at the top of the cabinet 3 Remove one top screw and two bottom screws securing the UPS center front panel see Figure 3 1 Lift the panel straight up to remove from the panel hanger bracket at the top of the cabinet 4 Terminal blockTB3 is accessible on the left side of the X Slot communicati
58. he normal positions of the MBS switches and rectifier disconnect switch must be located in the site wiring Turn UPS from normal mode to mechanical bypass The procedure to turn the UPS to mechanical bypass switch is described below 1 The normal start position should be following Maintenance bypass Maintenance switch S10 bypass input e Static bypass input Out Rectifier input Fara 2 Perform transfer from normal mode to bypass mode as described in paragraph 5 3 4 Remember to verify the transfer before proceeding the next step Turn the switch S10 from UPS II position to Bypass I position Perform LOAD OFF procedure contained in paragraph 5 3 9 Turn OFF the rectifier switch to disconnect UPS rectifier input Turn OFF the Static bypass switch to disconnect UPS bypass input NO 7 Bw UPS is now in the mechanical bypass mode see below Maintenance bypass Maintenance switch 10 bypass input Static bypass input 1027574 UPS 450 550 kVA 2x225 2x275 kVA 64 Revision B User s and Installation Guide Turn UPS from mechanical bypass to normal mode The procedure to turn the UPS back to normal mode is described below 1 The normal start position should be following Maintenance bypass Maintenance bypass input Static bypass input Turn ON rectifier switch to connect rectifier input to UPS Turn ON Static bypass switch to connect bypass input to UPS Perform UPS start up procedure bypass mode
59. ices A normally open NO contact is provided between terminals 6 and 7 of the remote EPO switch as shown in Figure 3 12 Remote EPO switch wiring must be in accordance with UL Class II requirements 12 When all wiring is complete reinstall the small top internal safety shield panel and secure with the cabinet mounted screws 13 Reinstall the center front panel removed in previous steps and secure with the retained hardware 14 Figure 3 14 and Figure 3 15 show alternative methods of connecting a remote EPO switch if using another manufacturer s switch 1 NC Remote epo switch NC Twisted wires UPS TB1 Os 2 Return 4 Return Note Remote EPO switch rating is 24 Vdc 1 A minimum Note Remote EPO normally open and normally closed return terminals are separated on the terminal board but are electrically in common Figure 3 14 Normally closed remote EPO switch wiring 38 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B Remote epo Twisted switch wires NC 2 Return UPS TB1 3 NO Remote epo Twisted switch wires NO 4 Return Note Remote EPO switch rating is 24 Vdc 1 A minimum Note Remote EPO normally open and normally closed return terminals are separated on the terminal board but are electrically in common Figure 3 15 Normally closed and normally open remote EPO switch wiring 3 7 Initial startup Startup and operational che
60. ied 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 The emergency bypass consists of a continuous duty static switch and backfeed protection contactor K5 The backfeed protection contactor is located in series with the static switch For manual transfers to bypass the static switch is also used The static switch is armed and ready during both types of transfers 1027574 UPS 450 550 kVA 2x225 2x275 kVA 41 Revision B User s and Installation Guide 4 2 Modes The Powerware 9395 UPS supports a critical load in three different modes of operation The UPS can automatically use all three modes as required The standard operation modes are e In 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 e In Battery mode the battery provides DC power which maintains inverter operation The battery supports the critical load e In Bypass mode the critical load is directly supported by utility power The following paragraphs describe the differences in the three UPS operating modes using
61. ker does not de energize the voltage within the battery string DO NOT ATTEMPTTO ACCESS ANY INTERNAL AREA OFTHE BATTERY STRING YOURSELF VOLTAGES ARE ALWAYS PRESENT IN THE BATTERY STRING If you suspect that a battery string needs service you should contact your service representative If the string requires service refer to the battery manufacturer s operating manual for instructions on battery maintenance or contact your service representative Observe these precautions when working on or around batteries e Remove watches rings or other metal objects e Use tools with insulated handles e Wear rubber gloves and boots e Do not lay tools or metal parts on top of batteries or battery cabinets e Disconnect the charging source prior to connecting or disconnecting terminals e Determine if the battery is inadvertently 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 e When replacing batteries use the same number of sealed lead acid batteries e Proper disposal of batteries is required Refer to your local codes for disposal requirements 71 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 8 2 Performing preventive maintenance The UPS system requires very little preventive maintenance However the system shoul
62. llation checklist g g g uuu ED ey a ec Ee a a tee oS E Q Q 40 All packing materials and restraints have been removed from each cabinet Each cabinet in the UPS system is placed in its installed location A cabinet grounding mounting kit is installed between any cabinets that are bolted together All conduits 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 as per requirements Battery cables are terminated on E4 and E5 Battery Shunt trip and Aux contact signal wiring is connected from the UPS to the battery breaker 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 230 Vac service outlet is located within 75 meters of the UPS equipment The Remote Emergency Power off REPO device is mounted in its installed location and its wiring is terminated inside the UPS cabinet The normally closed NC Emergency Poweroff contact pins 1 and 2 on TB1
63. lling a remote EPO switch AN NOTE Remove the UPS cabinet interface entry plates to punch holes see Figure 3 3 NOTE This switch must be a dedicated switch not tied into any other circuits AN NOTE This procedure is intended to be used for the installation of the Powerware remote EPO switch If installing another manufacturer s switch only use this procedure as a guide A remote EPO 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 3 12 shows a remote EPO switch 36 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B Securely mount the remote EPO switch Recommended locations include operator s consoles or near exit doors See Figure 2 7 for enclosure dimensions and wiring knockouts Verify the UPS system is turned off and all power sources are removed See Chapter 5 UPS operating instructions for shutdown instructions Remove one top screw and two bottom screws securing the UPS center front panel see Figure 3 1 Lift the panel straight up to remove from the panel hanger bracket at the top of the cabinet ery sasesana ie o ao o o MALLAN E ToUPS To other equipment Figure 3 12 Remote EPO switch 4 To gain access to terminal blocksTB1 and TB2 and the interface entry plates loosen the screws securing the small top internal safety shield panel and rem
64. llows selection of the serial COM port to set up Select COM PORT SETUP from the System Setup Level 1 menu to display the COMPort Setup screen Use the up or down arrow pushbuttons 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 pushbut ton to return to the COM Port Setup screen Use the up or down arrow pushbut tons 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 appears Control See paragraph 5 2 6 for details Table 5 3 Display menu operation 5 2 6 System controls screen Press the CONTROLS pushbutton on the main menu bar to display the System Controls screen LOAD OFF normal operation transfer to bypass charger control and power module startup and shutdown functions are controlled from 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 power module PM and battery charger Figure 5 5 and Figure 5 6 show the Sys
65. lluminated 5 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 perform the following procedure AN CAUTION In Bypass mode the critical load is not protected from commercial power interruptions and abnormalities 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 Controls screen appears 6 Onthe System Controls screen the power module PM status should indicate SHUTDOWN 7 If the UPS contains input breaker CB1 close input breaker CB1 8 Press the BYPASS pushbutton on the System Controls menu bar The critical load is immediately supplied by the bypass source in Bypass mode 9 The UPS is now operating in Bypass mode and the BYPASS status indicator is illuminated 1027574 UPS 450 550 kVA 2x225 2x275 kVA 59 Revision B User s and Installation Guide 5 3 3 Starting the power module To start the power module without transferring the critical load to normal perform the following procedure 1 2 3 4 5 6 N 10 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 in
66. m 1027574 UPS 450 550 kVA 2x225 2x275 kVA 70 Revision B User s and Installation Guide 8 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 8 1 Important safety instructions Remember that your UPS system is designed to supply power EVEN WHEN DISCONNECTED FROMTHE UTILITY POWER The UPS module interiors are unsafe until the DC power source 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 AN WARNING e Servicing and maintenance should be performed by qualified service personnel only e LETHALVOLTAGE PRESENT This unit should not be operated with the cabinet doors open or protective panels removed Do not make any assumptions about the electrical state of any cabinet in the UPS system Since each battery string is an energy source in itself opening the battery circuit brea
67. mode other than Normal Only the Normal 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 descriptions of the status indicators see paragraph 5 2 1 Status indicators on page 49 6 4 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 Events History log The messages are divided into four categories alarms notices status and commands The top line of the LCD scrolls all active notices and alarms 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 1027574 UPS 450 550 kVA 2x225 2x275 kVA 66 Revision B User s and Installation Guide 7 Communication This chapter describes the communication features of the Powerware 9395 450 550 kVA UPS and provides information about connecting hardware and using Terminal mode For terminal wiring information see paragraph 2 2 3 on page 17 and paragraph 3 5 on page 28 For location of the customer interface panels and terminals see Figure 3 3 on page 26 and Figure 3 7 through Figure 3 9 starting on page 30 7 1 X Slot cards The Powerware 9395 UPS four
68. nd two bottom screws securing the UPS left front panel see Figure 3 1 Lift the panel straight up to remove from the panel hanger bracket at the top of the cabinet Route the input and output cables through either the top or bottom of the cabinet to the UPS terminals See Figure 3 3 through Figure 3 5 for wiring access information and terminal locations Connect phase L1 L2 and L3 E1 E2 E3 rectifier input power wiring from the utility source to the rectifier input terminals in the UPS cabinet See paragraph 2 2 2 on page 14 for wiring and termination requirements Connect phase L1 L2 and L3 E6 E7 E8 and Neutral if required bypass input power wiring from the utility source to the bypass input terminals and neutral terminals in the UPS cabinet See paragraph 2 2 2 on page 14 for wiring and termination requirements Connect phase L1 L2 and L3 E9 E10 E11 and Neutral if required power wiring from output terminals and neutral terminals to the critical load See paragraph 2 2 2 on page 14 for wiring and termination requirements Proceed to paragraph 3 4 2 1027574 UPS 450 550 KVA 2x225 2x275 kVA 25 Revision B User s and Installation Guide Top entry conduit landing for AC input and output and DC input Remove panel to drill or punch conduit holes Bottom entry condut landing for AC input and output and DC input Remove pand to drill or punch conduit holes Exhaus grill debris shields Remo
69. nning and performing the installation Install the interface wiring for example building alarm relay output battery breaker trip and X Slot separate from the power wiring The wiring should have double insulation and rated at Uo U 300 500 Volts All interface wiring is to be provided by the customer 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 as shown All control wiring and relay and switch contacts are customer supplied Use twisted pair wires for each alarm input and common The building alarms can be programmed to display the alarm functional name LAN and telephone drops for use with X Slot cards must be provided by facility planners or the customer The UPS Battery Aux and 48 Vdc ShuntTrip signal wiring from the UPS must be connected to the DC source disconnect device Battery Aux and 48 Vdc ShuntTrip wiring should be a minimum of 1 5 mm The Remote EPO 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 Remote EPO switch must be a dedicated switch not tied to any other circuits A jumper wire must be connected
70. ntrols and indicators 1 7 For more information 1 8 Getting help w o o ooo uyusun 2 UPS installation plan and unpacking 2 1 Creating an installation plan 2 2 Preparing the site 2 2 1 Environmental and installation considerations 2 2 2 UPS system power wiring preparation 2 2 3 UPS system interface wiring preparation ai 2 3 Inspecting and unpacking the UPS Cabinet sceeseccssessssssssecsesssneesseecsneesssessuceessecsueessuecsnseesnsecsusesueesssessueessseesueeeseesuteesueesnseesess 3 UPS system installation c ssssssssssesssssesseessesssesssesseessees 3 1 Preliminary installation information 3 2 Unloading the UPS cabinet from the pallet and mechanical installation 3 3 Battery cabinet installation cecsseeseseesseeseesteeseeeteseeeees 3 4 Installing UPS external and battery power wiring 3 4 1 External power wiring installation 3 4 2 Battery wiring 3 5 Installing interface connections 3 5 1 TB1 TB2 and TB3 connections other than TB1 battery interface connections 3 5 2 TB1 battery interface connections 3 5 3 X Slot CONNECTIONS 3 6 Installing a remote EPO switch 3 7 Initial Startup eseeeeeeseeseeseeeteeseeeees 3 8 Completing the installation checklist 4 Understanding UPS operation seisisesssssiesssssssssnisssassececeessssctessiscatesessascansiessstsioacasecsenieiesnassussinieaicebainisstetieiesuscouscanssasesiacessd scesinicaiesb
71. o ground bonding jumper must be installed DO NOT install both a source neutral and a bonding jumper The UPS cabinet is shipped with a debris shield covering the ventilation grill on top of the unit Do not remove the debris shield until installation is complete However remove the shield before operating the UPS Once the debris shield is removed do not place objects on the ventilation grill 1027574 UPS 450 550 kVA 2x225 2x275 kVA 15 Revision B User s and Installation Guide Terminals E1 through E12 are 2 hole bus bar mountings for standard NEMA 2 hole barrel lugs See Table 2 5 for power cable terminations and Table 2 6 for recommended installation parts and tools not supplied by Eaton Corporation Figure 3 4 and Figure 3 5 show the location of the power cable terminals inside the UPS Tightening torgue Terminal function Terminal Function Bus landing Nm Bolt size E1 Phase L1 4 2 bolt mounting 76 M12 AC input to UPS rectifier E2 Phase L2 4 2 bolt mounting 76 M12 E3 Phase L3 4 2 bolt mounting 76 M12 E6 Phase L1 4 2 bolt mounting 76 M12 AC input to bypass Phase L2 4 2 bolt mounting 76 M12 E8 Phase L3 4 2 bolt mounting 76 M12 E9 Phase L1 4 2 bolt mounting 76 M12 AC output to critical load E10 Phase L2 4 2 bolt mounting 76 M12 E11 Phase L3 4 2 bolt mounting 76 M12 E4 Battery 4 2 bolt mounting 76 M12 UC
72. on bay To gain access to terminal blocksTB1 andTB2 and the interface entry plates loosen the screws securing the small top internal safety shield panel and remove the panel This panel is to the right of the X Slot Communication Bay see Figure 3 7 on page 30 5 Remove the UPS cabinet top interface entry plates to drill or punch holes see Figure 3 3 on page 26 6 Reinstall the entry plates J N WARNING Do not directly connect relay contacts to the mains related circuits Reinforced insulation to the mains is required 7 To locate the appropriate terminals and review the wiring and termination requirements see paragraph 2 2 2 on page 14 Table 3 1 and Figure 3 6 through Figure 3 9 8 Route and connect the wiring If wiring TB1 battery interface connections proceed to paragraph 3 5 2 if wiring the X Slot connections only proceed to paragraph 3 5 3 otherwise proceed to Step 10 10 When all wiring is complete reinstall the small top internal safety shield panel and secure with the cabinet mounted screws 11 Reinstall the left and center front panels removed in previous steps and secure with the retained hardware Alarm relay NC Alarm relay return l Alarm relay Alarm relay NO Alarm relay return NOTE Alarm relay contacts have a maximum current rating of 5A and a switched voltage rating of 30 Vac and 28 Vdc NOTE Alarm relay normally open and normally closed return terminals are sepa
73. ort the change Press SAVE RETRY or ABORT If SAVE or ABORT is pressed the action is completed and the Maximum Current Log Setup screen 2 displays If RETRY is pressed the Time Interval Moni tored Setup screen is redisplayed Maximum of Full Load Setup The Maximum of Full Load Setup screen allows the full load limit of the event being monitored to be changed Select MAXIMUM of FULL LOAD from the Maximum Current Log Setup screen 2 menu to display the Maximum of Full Load Setup screen Use the left or right arrow pushbuttons to select the char acter position Use the up or down pushbuttons to change the character value Once the new value is entered press the DONE pushbutton The Maximum of Full Load Setup Save screen is displayed Maximum of Full Load Save The Maximum of Full Load Setup Save screen lets you save the new load limit retry another load limit or abort the change Press SAVE RETRY or ABORT If SAVE or ABORT is pressed the action is completed and theMaximum Current Log Setup screen 2 displays If RETRY is pressed the Maximum of Full Load Setup screen is redisplayed Calculation Method Setup The CalculationMethod Setup screen allows the full load limit of the event being monitored to be changed Select CALCULATION METHOD from the Maximum Current Log Setup screen 2 menu to display the Calculation Method Setup screen Select CALCULATION METHOD from the Maximum Current Log Setup screen 2
74. ove the panel This panel is to the right of the X Slot communication bays see Figure 3 7 on page 30 Remove the UPS cabinet interface entry plates to drill or punch holes see Figure 3 3 on page 26 Reinstall the interface entry plates To locate the appropriate terminals and review the wiring and termination requirements see paragraph 2 2 2 on page 14 Table 3 1 and Figure 3 7 through Figure 3 9 Route and connect the wiring as shown in Table 3 2 and Figure 3 13 If the normally closed Remote EPOTB1 connection in the UPS is not used connect a jumper wire between pins 1 and 2 onTB1 A To customer interface From remote EPO switch Terminal board TB1 in UPS cabinet urs TB1 4 TB 3 Twisted wires 2 TB1 5 TB 4 2 5mm 0 75mm 2 Table 3 2 Remote EPO wire terminations 1027574 UPS 450 550 kVA 2x225 2x275 kVA 37 Revision B User s and Installation Guide UPS TB1 Ox 2 Return Remote epo switch no Twisted wires 4 Return Note Remote EPO switch rating is 24 Vdc 1 A minimum Note Remote EPO normally open and normally closed return terminals are separated on the terminal board but are electrically in common Figure 3 13 Normally Open remote EPO switch wiring 10 If you are installing multiple remote EPO switches wire additional switches in parallel with the first remote EPO 11 If required install wiring from the remote EPO switch to the trip circuitry of the upstream protective dev
75. pplied NOTE The building alarms can be programmed to display the alarm functional name NOTE A jumper wire must be connected between pins 1 and 2 onTB1 if the normally closed Remote EPO contact is not used Figure 3 9 Terminal blocks TB1 TB2 and TB3 connector assignments 1027574 UPS 450 550 kVA 2x225 2x275 kVA 33 Revision B User s and Installation Guide 3 5 2TB1 battery interface connections To install wiring to connections 1 15 16 34 Verify the UPS system is turned off and all power sources are removed See Chapter 6 UPS operating instructions for shutdown instructions If not already accomplished remove one top screw and two bottom screws securing the UPS left front panel see Figure 3 1 Lift the panel straight up to remove from the panel hanger bracket at the top of the cabinet If not already accomplished remove one top screw and two bottom screws securing the UPS center front panel see Figure 3 1 Lift the panel straight up to remove from the panel hanger bracket at the top of the cabinet To gain access to terminal blocksTB1 and the interface entry plates loosen the screws securing the small top internal safety shield panel and remove the panel This panel is to the right of the X Slot Communication Bay see Figure 3 7 on page 30 To locate the appropriate terminals and review the wiring and termination requirements see paragraph 2 2 2 on page 14 Table 3 1 and Figure 3 7 through Figur
76. put feeder circuit breaker Observe the UPS control panel becoming active indicating logic power Press the CONTROLS pushbutton on the main menu bar The System Controls screen appears On the System Controls screen the power module PM status should indicate SHUTDOWN If the UPS contains input breaker CB1 close input breaker CB1 Press the pushbutton to display System Controls screen 2 Press the PM ON pushbutton on the System Controls menu bar Observe the following messages appear sequentially on the power module PM status line DC STARTIN INVERTER STARTING INVERTER SYNCING READY The 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 5 3 4 Transfer from normal to bypass mode To transfer the critical load to Bypass mode perform the following procedure CAUTION 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 Controls screen appears Press the BYPASS pushbutton on the System Controls 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 processor remains on and an alarm sounds The UPS is now operating in Bypass mode and the BYPASS status indicator is illuminated The power module PM status in
77. rated on the terminal board but are electrically 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 75 mm2 Figure 3 6 Typical alarm relay connection 30 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B X Slot communication bays TB1 and TB2 See figure 3 11 for detail A See figure 3 8 for detail AA See figure 3 9 for terminal assigni ents Control panel m E E H _ SSS sa SSS sa SSS Sa SSS Sea SSS Ss _ S lt A ea SSS Sea SS SS E a SS Se SSS SS SS a SS Ss SSS SS SS Ss LSS SS SSS Se LSS SS SS Ss SSS SSS SS a LSS SSS SSS a LSS SS m SSS SS r a a a a aN H E SSS aS SSS SS SS SSS SS SSS PESEE SSS SSS E E n SSS SS SS SSeS SSS aE aE J e SSeS Se SSS SS _
78. ration The cabinets are designed for line up and match installation but may be installed separate from the UPS cabinet 1 2 2 Optional X Slot Cards The optional X Slot cards support several protocols such as SNMP HTTP AS 400 and Modbus See Chapter 7 Communication for additional information 1027574 UPS 450 550 kVA 2x225 2x275 kVA 7 Revision B User s and Installation Guide 1 3 Basic system configurations The following basic UPS system configurations are possible e Single module UPS and one to four battery cabinets e Single module UPS and a standalone battery system The UPS system configuration can be enhanced by adding optional accessories such as a Remote Emergency Power off REPO control or X Slot communication cards 1 4 Using this manual This manual describes how to install and operate the Powerware 9395 UPS 450 550 kVA cabinet 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 5 3 10 on page 62 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 3 and Chapter 5 should be examined Read through each procedure before beginning the procedure Perform only those procedures that apply to the UPS system being in
79. rm 3 return closure 7 Building alarm 4 Programmable UPS alarm Activated by a remote dry contact 8 Building alarm 4 return closure 9 Building alarm 5 Programmable UPS alarm Activated by a remote dry contact 10 Building alarm 5 return closure Table 3 1 TB1 TB2 and TB3 interface connections 32 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1027574 Revision B X Slot communication bays TB1 See figure 3 9 for terminal assignments TB2 Figure 3 8 Interface terminal detail AA Remote EPO NC Pull chain return Alarm relay NC Alarm relay return Alarm relay NO Alarm relay return Building alarm 4 Building alarm 4 return Building alarm 5 Building alarm 5 return o Remote EPO return 8 H Remote EPO NO S i Remote EPO return TB1 Q i Battery aux H Building alarm 1 3 j Battery aux return Building alarm 1 return i Battery shunt trip ro Building alarm 2 Ol TTO Battery shunt trip TB3 H Building alarm 2 return T ol a Building alarm 3 Fey Pull chain WO Building alarm 3 return iS TB2 DOOODDOOOODD NOTE All 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 su
80. s for operation of the UPS system are e AmbientTemperature Range 0 40 C e Recommended Operating Range 20 25 C e Maximum Relative Humidity 95 noncondensing The UPS ventilation requirements are shown in Table 2 3 Rating kVA Input output voltage Heat rejection BTU hr x 1000 hr kg cal hr 2 275 kVA 400 400 88 7 550 kVA 400 400 88 7 Table 2 3 Air conditioning or ventilation requirements during full load operation Ventilation required for cooling air exhaust approximately 1410 liter sec 225 275kVA unit 1027574 UPS 450 550 kVA 2x225 2x275 kVA 11 Revision B User s and Installation Guide 1882 1878 A Figure 2 1 UPS cabinet dimensions front view m 872 l Figure 2 2 UPS cabinet dimensions right side view 12 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1027574 Revision B 42 356 42 i 613
81. secure the latch 3 Record the check results and any corrective actions in a suitable log 8 2 3 ANNUAL maintenance Annual preventive maintenance should be performed only by authorized service personnel familiar with maintenance and servicing of the UPS system Contact your service representative for more information about service offerings 8 2 4 BATTERY maintenance Contact your service representative for battery maintenance Battery replacement and maintenance should be performed only by authorized service personnel 8 2 5 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 1027574 UPS 450 550 kVA 2x225 2x275 kVA 72 Revision B User s and Installation Guide 8 3 Installing batteries A N NOTE There is no DC disconnect device within the UPS Install batteries in accordance with the battery and battery cabinet or battery rack manufacturer s instructions 9 Recycling the used UPS or batteries Before scrapping UPS or its battery cabinet the battery bank must be removed Local requirements must be followed in battery recycling or discard The removal of batteries is allowed only by authorised service personnel due to high energy and voltage Do not dis
82. stalled or operated 1 5 Conventions used in this manual This manual uses these type conventions e Bold type 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 e Screen type represents information that appears on the screen or LCD Icon Description AN 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 cabinet and options or accessories installed 8 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 1 6 Symbols controls and indicators The following are examples of symbols used on the UPS or accessories to alert you to important information RISK OF ELECTRIC SHOCK Indicates that a risk of electric shock is present and the associated warning should be observed CAUTION REFERTO OPERATOR S MANUAL Refer to your operator s manual for additional information such as important operating and maintenance instructions the trash This product contains sealed lead acid batteries and must be disposed of properly
83. t History Log 7 4 Building alarm monitoring 1 5 General purpose relay GONta tsasoa n n e N eed N RE R ARR 70 UPS maintenance 8 1 Important safety instructions 71 8 2 Performing preventive maintenance 8 2 1 DAILY maintenance 8 2 2 MONTHLY maintenance 8 2 3 ANNUAL maintenance 8 2 4 BATTERY maintenance 8 2 5 Maintenance training 8 3 Installing batteries Recycling the used UPS or batteries ccscsssessesssssessessessesessesessessessessessessessesssasesseseeseeseeaeeaseaeeaeeaeeaeeaeeneeseeneeateateneeneeaesaeeateneeneene 74 Product specifications 10 1 Model numbers 10 2 Single module specifications 10 2 1 UPS system input 10 2 2 UPS system output 10 2 3 Environmental Wealtraitty sts teeta EEE BE EEA A E E stncaetvaces E eb ea E A E EA T A 75 1 Introduction The Eaton Powerware 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 all nine power failures The Powerware 9395 UPS is available as a single module system The Powerware 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 r
84. talled between the battery and the UPS External DC input overcurrent protection and disconnect switch for the remote battery location is to be provided by the user Table 2 9 lists the maximum rating for continuous duty rated circuit breakers satisfying the criteria for both Input rating P del UPS mode 600 V 9395 2 275 2 700 A 630 A depends on end voltage 9395 550 1400 A 1250 A depends on end voltage Table 2 9 Recommended DC input circuit breaker ratings Battery voltage is computed at 2 volts per cell 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 1 of nominal DC voltage at rated battery current If the conductors used for DC input from the battery cabinets to the UPS are those provided by the UPS manufacturer and the UPS and battery cabinets are manufactured by the same supplier then it is acceptable if they do not meet the noted minimum conductor sizes 2 2 3 UPS system interface wiring preparation Control wiring for features and options should be connected at the customer interface terminal blocks located inside the UPS J N WARNING Do not directly connect relay contacts to the mains related circuits Reinforced insulation to the mains is required 1027574 fo UPS 450 550 kVA 2x225 2x275 kVA 17 Revision B User s and Installation Guide Read and understand the following notes while pla
85. tem Controls screens Use the or pushbutton on the menu bar to toggle the menu bar functions between the two System Controls screens For detailed information about using the System Controls see paragraph 5 3 BYPASS Figure 5 5 System Controls screen 1 1027574 Revision B SYSTEM CONTROLS MAINTENANCE BYPASS OFF OFF POWER MODULE PM ONLINE CHARGER OFF LOAD OFF NORMAL BYPASS UPS 450 550 kVA 2x225 2x275 kVA 57 User s and Installation Guide SYSTEM CONTROLS MAINTENANCE BYPASS OFF BYPASS OFF POWER MODULE PM ONLINE CHARGER OFF LOAD OFF CHGRON PM OFF Figure 5 6 System controls screen 2 5 2 7 Load off screen The load off screen appears when the LOAD OFF pushbutton is selected from the main menu bar or System Controls menu bar This screen allows the LOAD OFF process to be aborted if the LOAD OFF pushbutton was pressed accidentally Figure 5 7 shows the Load Off screen For detailed information about using the LOAD OFF and shutdown screens see Chapter 5 UPS operating instructions HOLD LOAD OFF BUTTON FOR 3 SECONDS TO TURN OFF LOAD CANCEL LOAD OFF Figure 5 7 Load off screen 5 3 Operation 5 3 1 Starting the UPS in normal mode To start the UPS system 1 Ifthe 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
86. tem See Chapter 6 UPS operating instructions for additional information 1027574 UPS 450 550 kVA 2x225 2x275 kVA 5 Revision B User s and Installation Guide Figure 1 1 Powerware 9395 550 2 275 cabinet 1027574 Revision B UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide 1 1 2 Customer Interface e 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 7 Communication for additional information 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 7 Communication for additional information e X Slot Communication Bay A four slot communication bay is standard equipment Four optional X Slot cards can be installed in the UPS module at any time See Chapter 7 Communication for additional information e ConnectUPS X Web SNMP Card This X Slot card is provided as standard equipment and provides remote monitoring through a Web browser interface e mail and a network management system NMS using SNMP See Chapter 7 Comm
87. terface connection 3 5 3 X Slot connections NOTE LAN and telephone drops for use with X Slot cards must be provided by the customer AN NOTE 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 please contact Eaton Corporation To install wiring to connections 1 If not already installed install the LAN and telephone drops 2 If not already accomplished remove one top screw and two bottom screws securing the UPS center front panel see Figure 3 1 Lift the panel straight up to remove from the panel hanger bracket at the top of the cabinet 3 Remove the UPS cabinet interface entry plates to drill or punch holes see Figure 3 3 on page 26 4 Reinstall the interface entry plates 5 Route and install the LAN telephone and other cables to the appropriate X Slot cards See Figure 3 7 and Figure 3 11 for X Slot location 6 When all wiring is complete reinstall the front panel removed in previous steps and secure with the retained hardware 7 Refer to the manual supplied with the X Slot card for operator instructions 1027574 UPS 450 550 kVA 2x225 2x275 kVA 35 Revision B User s and Installation Guide X Slot communications bay 1 X Slot communications bay 2 X Slot communications bay 3 X Slot communications bay 4 Figure 3 11 X Slot communication bays 3 6 Insta
88. time frame the maximum reading during the interval the total time over limit during the interval an estimated number of total kWh used during the interval and the number of times over limit during the interval If no events have occurred the screen displays LOG EMPTY Press the LOG pushbutton on the kW Demand Log Summary menu bar to display the kW Demand Log screen To scroll through the individual events press the up or down arrow pushbuttons on the menu bar To return to the kW Demand Log Summary screen press the SUMMARY pushbutton on the menu bar To clear the kWDemand Log press the RESET pushbutton on the menu bar kW Demand Log Setup Screen 1 The Current kW Demand Log Setup screen 1 displays the current user defined log settings If no log settings are configured the screen will display kWLOG DISABLED Press the SETUP pushbutton on the kW Demand Log Summary menu bar to display the Current kW Demand Log Setup screen 1 To return to the kWDemand Log Summary screen press the return arrow pushbutton on the menu bar Screen 2 The Current kW Demand Log Setup screen can be used to set up or change the time interval and maximum level log settings Press the CHANGE pushbutton on the Current kW Demand Log Setup menu bar to display the Current kW Demand Log Setup screen 2 Use the up or down arrow pushbuttons to highlight the setup function screen desired then press the SELECT pushbutton to display the func tion screen To return
89. to the Current kW Demand Log Setup screen 1 press the return pushbutton on the menu bar Time Interval Moni tored Setup The Time Interval Monitored Setup screen allows the time duration of the event being monitored to be changed Select TIME INTERVAL MONITORED from the Current kW Demand Log Setup screen 2 menu to display the Time Interval Monitored Setup screen Use the left or right arrow pushbuttons to select the character position Use the up or down arrow pushbuttons to change the char acter value Once the new value is entered press the DONE pushbutton The Time Interval Monitored Setup Save screen is displayed Time Interval Moni tored Save The Time Interval Monitored Setup Save screen lets you save the new time interval retry another time interval or abort the change Press SAVE RETRY or ABORT If SAVE or ABORT is pressed the action is completed and the Current kW Demand Log Setup screen 2 displays If RETRY is pressed the Time Interval Monitored Setup screen is redisplayed Maximum Level kW Setup The Maximum Level kW Setup screen allows the kW limit of the event being monitored to be changed Select MAXIMUM LEVEL kW from the Current kW Demand Log Setup screen 2 menu to display the Maximum Level kW Setup screen Use the left or right arrow pushbuttons to select the character position Use the up or down arrow pushbuttons to change the character value Once the new value is entered press the DONE pushbu
90. tomatically 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 4 4 shows the path of electrical power through the UPS system when operating in battery mode Static 3 Beal 5 Rectifier Inverter K3 Battery converter Breakers Contactors mus Main power flow 6d H Closed Gees Trickle current ai c _ Energized oO oO Open f De energized Figure 4 4 Path of current through the UPS in battery mode 44 UPS 450 550 kVA 2x225 2x275 kVA 1027574 User s and Installation Guide Revision B 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 input source If the input power fails to return or is not within the acceptance windows required for normal operation the battery contin
91. tton The Maximum Level kW Setup Save screen is displayed Maximum Level kW Save The Maximum Level kW Setup Save screen lets you save the new kW limit retry another kW limit or abort the change Press SAVE RETRY or ABORT If SAVE or ABORT is pressed the action is completed and the Current kW Demand Log Setup screen 2 displays If RETRY is pressed the Maximum Level kW Setup screen is redisplayed Maximum Current Log Summary The maximum current log collects information on events where the unit load exceeds a user defined current limit within a user defined time interval The user can choose a time period up to 9999 minutes and a load limit up to 100 The user can also select whether the limit defined is a three phase average of the individual phase currents or is a limit defined for each phase individually In the first case an event is logged if the average across the phases exceeds the de fined limit within a given time period and in the second case an event is logged if any individual phase exceeds the defined limit within a given time period The Maximum Current Log Summary screen displays the number of times the limit has been exceeded the date of the last log reset the maximum percent of full load and the total time over the limit It also displays the average percent load over the limit This measurement differs depending on whether a three phase average or an individual phase measurement is selected Press the
92. ues 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 4 3 UPS system one line configurations Volt One line drawing UPS model inne WENE Output System type Single module Reverse transfer Figure 4 5 9395 450 550 400 400 dual feed Single module reverse transfer Figure 4 6 9395 450 550 400 400 dual feed with typical maintenance bypass panel 1027574 UPS 450 550 kVA 2x225 2x275 kVA 45 Revision B User s and Installation Guide Building alarms AC input to AC input to UPS rectifier bypass Battery Alarm relays 3wireAB C 30o0r4wireA B C shunt trip rotation rotation X Slot A B oO
93. unication for additional information 1 1 3 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 1 1 4 Power Management Software Powerware LanSafe Power Management Software is bundled as part of the Software Suite CD shipped with the UPS See Chapter 7 Communication for additional information 1 1 5 Installation features Cabinets can be permanently bolted to the floor or left standing on leveling feet Power and control wiring can be routed through the top or bottom of the cabinet with connections made to easily accessible terminals External sensing and monitoring control wire must be installed in accordance with Class 1 wiring methods Line up and match battery cabinets are wired through the side panels of the units Optional X Slot connectivity cards are quickly installed at the front of the unit and are hot pluggable 1 2 Options and accessories Contact a Powerware sales representative for information about the following options 1 2 1 Integrated battery cabinet Battery backup protection can be enhanced by equipping the UPS system with up to four Powerware 9395 battery cabinets containing sealed lead acid maintenance free batteries The battery cabinet is available in one size with a 240 cell configu
94. urrent an Q breaker Energized O oO O pen De energized Battery Figure 4 3 Path of current through the UPS in bypass mode 1027574 UPS 450 550 kVA 2x225 2x275 kVA 43 Revision B User s and Installation Guide 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 The internal bypass is comprised of a solid state silicon controlled rectifier SCR static switch SSW and a backfeed protection contactor K5 The static switch is rated as a continuous duty device that is used anytime the inverter is unable to support the applied load The static switch is wired in series with the backfeed protection contactor and 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 the inverter output contactor K3 opens to isolates the inverter The backfeed protection contactor is normally always closed ready to support the static switch unless the bypass input source becomes unavailable 4 2 3 Battery mode The UPS au
95. ve covering before operating system aS Interface entry for TB1 through TB3 wiring and X Slot connections Remove panels to drill or punch conduit holes Front mi I Figure 3 3 Conduit and wire entry locations 26 UPS 450 550 kVA 2x225 2x275 kVA User s and Installation Guide Top view Bottom view 1027574 Revision B Front view Figure 3 4 a UPS power terminal locations Ground terminals Ground terminal bus can be relocated below Phase L1 E1 Phase L2 E2 Phase L3 E3 AC input to UPS rectifier 1398 Phase L1 E9 AC output tod Phase L2 E10 critical load Phase L3 E11 1033 Neutral E12 697 Ac mit Phase L3 E8 input to UPS bypass Phase L2 E7 Phase L1 E6 Side view Alternate ground terminal bus location 0 REPSSRR8 NO OMT WO Figure 3 4 b UPS power terminal locations 1027574 UPS 450 550 kVA 2x225 2x275 kVA 27 Revision B User s and Installation Guide RECTIFIER INPUT LOAD OUTPUT MBS INPUT BY PASS INPUT BATTERY NEUTRAL BATTERY Figure 3 5 a front view 1398 I 4 l 1180 wool o 1 0 q 1100 7 mE 1020 oo 940 her P 1 Cc 697 gt 7 ale

Eaton Electrical UPS 225275 kVA Powerware 9395 User's Manual

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