S06 Eaton 93PM 180kW 3-Wire UPS Installation Information 7-29-16 Red Lined.pdf

Eaton

180 k

® 93PM UPS

W (480V 3-Wire) UPS Installation Information

Note: This document addresses information specific to the 93PM 180 kW (480V 3-Wire) UPS Electronics Cabinet only. For information regarding the maintenance bypass sidecar, please also refer to the Eaton 93PM 180kW 3-Wire Maintenance Bypass Sidecar Installation Information document.

Chapter 3 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 3).

2. Prepare your site for the UPS system (Chapter 3).

3. Inspect and unpack the UPS cabinet (Chapter 3).

4. Unload and install the UPS cabinet, and wire the system (Chapter 4).

5. Install features, accessories, or options, as applicable (Chapter 4).

6. Have authorized service personnel perform preliminary operational checks and start up the system.

3.1 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 paragraph 3.2 and Chapter 4 to create a logical plan for installing the system.

3.2 Preparing the Site

For the UPS system to operate at peak efficiency, the installation site should meet the environmental parameters outlined in this manual. The operating environment must meet the weight, clearance, and environmental requirements specified.

3.2.1 Environmental and Installation Considerations

The UPS system installation must meet the following guidelines:

● The system must be installed on a level floor suitable for computer or electronic equipment.

● The system must be operated at an altitude no higher than 1500m (5000 ft) without derating. For additional assistance with high altitude operation, contact an Eaton service representative (see paragraph 1.9).

● The system must be installed in a temperature and humidity controlled indoor area free of conductive contaminants.

Failure to follow guidelines may void your warranty.

NOTE Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer, or the warranty terms become void. This service is offered as part of the sales contract for the UPS. Contact an Eaton service representative in advance (a minimum two-week notice is required) to reserve a preferred startup date.

The basic environmental requirements for operation of the UPS are:

Ambient Temperature Range: 5–40C (41–104F)

Recommended Operating Range: 5–40C (41–104F)

Maximum Relative Humidity: 95%, noncondensing

CAUTION

If battery systems are located in the same room as the UPS, the battery manufacturer's environmental requirements should be followed if they are more stringent than the UPS requirements. Operating temperatures above the recommended range will result in decreased battery life and performance, and may reduce or void the battery warranty.

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UPS Installation Plan and Unpacking The UPS ventilation requirements are shown in Table 3-1.

To allow for future power upgrades, Eaton recommends using air conditioning or ventilation sized for the fully rated UPS kW frame size installed instead of the derated kW ordered. Sizing the site cooling infrastructure to be capable of cooling the maximum kW frame size will allow a full power rating upgrade without having to modify the infrastructure.

Table 3-1. Air Conditioning or Ventilation Requirements During Full Load Operation

Model UPS Rating Input/Output Voltage Heat Rejection

BTU/hr x1000 (kg-cal/hr) Minimum Required

Cooling Air Flow at Full Load

756 liter/sec (1600 cfm)

Eaton 93PM-200-4 160 kW 480/480 18.24 (4601)

Eaton 93PM-200-4 170 kW 480/480 19.38 (4888)

Eaton 93PM-200-4 180 kW 480/480 20.52 (5176)

Eaton 93PM-200-4 190 kW 480/480 21.66 (5463)

Eaton 93PM-200-4 200 kW 480/480 22.80 (5751)

The UPS equipment operating environment must meet the weight requirements shown in Table 3-2 and the size requirements shown in Figure 3-1 through Figure 3-4. Dimensions are in millimeters (inches).

The UPS cabinet uses forced air cooling to regulate internal component temperature. Air inlets are in the front of the cabinet and outlets are on top or in the back of the cabinet. Allow clearance in front of and on top or in back of the cabinet for proper air circulation. The clearances required around the UPS cabinet are shown in Table 3-3.

NOTE Refer to the Eaton 93PM Sidecar Integrated Accessory Cabinet-Bypass (150 kW and 200 kW SIAC-B) Installation and Operation Manual for Sidecar Integrated Accessory Cabinet-Bypass weight and size requirements.

Table 3-2. UPS Cabinet Weights

Model

Weight kg (lb)

Shipping Installed Point Loading

Eaton 93PM-200-1 431 (950) 408 (900) 4 at 102 (225)

Eaton 93PM-200-2 495 (1090) 472 (1040) 4 at 118 (260)

Eaton 93PM-200-3 559 (1231) 536 (1181) 4 at 134 (295)

Eaton 93PM-200-4 622 (1371) 599 (1321) 4 at 150 (330)

Table 3-3. UPS Cabinet Clearances

From Front of Cabinet 914.4 mm (36") working space

From Top of Cabinet

From Back of Cabinet None Required

From Back of Cabinet – Seismic Installation 914.4 mm (36") working space

From Right Side of Cabinet None Required

From Left Side of Cabinet None Required

457.2 mm (18") minimum clearance for ventilation 3-2

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Figure 3-1. UPS Cabinet Dimensions (Front and Right Side Views)

Dimensions are in millimeters [inches]

Right Side

Front 3-4

Figure 3-2. UPS Cabinet Dimensions (Top and Bottom Views)

Dimensions are in millimeters [inches] Top View

Front

Front

Bottom View 3-5

Figure 3-4. UPS Cabinet Center of Gravity

Dimensions are in millimeters [inches]

Weight and Center of Gravity

A mm (in)

B mm (in)

C mm (in)

Installed Weight kg (lb)

Eaton 93PM-200-4 UPS 989 (38.9) 543 (21.4) 358 (14.1) 599 (1321) 3-7 e0069194 Highlight

3.2.2 UPS System Power Wiring Preparation

Read and understand the following notes while planning and performing the installation:

WARNING

As a result of the connected loads high leakage current is possible. Connection to earth ground is required for safety and proper product operation. Do not check UPS operation by any action that includes removal of the earth (ground) connection with loads attached.

● Refer to national and local electrical codes for acceptable external wiring practices.

● To allow for future power upgrades, Eaton recommends installing the UPS using wiring and external overcurrent protection breakers sized for the fully rated UPS kW frame size installed instead of the derated kW ordered. Wiring for the maximum kW frame size will allow a full power rating upgrade without having to modify the site wiring infrastructure.

● For external wiring, use 75°C copper wire. Wire sizes listed in Table 3-7 are for copper wiring only. If wire is run in an ambient temperature greater than 40°C, larger size wire may be necessary. Wire sizes are based on using the specified breakers.

● The AC output and output ground wiring to the critical load should be sized the same as the UPS rectifier, bypass, and rectifier and bypass ground wiring if the recommended output breaker listed in Table 3-13 is not installed in the system.

● Recommended wire sizes are based on NFPA National Electrical Code® (NEC®)70 Table 310.15(B)(16) 75°C ampacity with 40°C ambient correction factors.

● Connect to a 3 wire, grounded Wye source or in single source applications, a 3-wire High Resistance Ground (HRG) source. A neutral conductor is not used from the source or supplied to the load.

● Supported single source, single or dual feed power sources

- 3-wire grounded Wye (TN,TT)

- 3-wire High Resistance Ground (IT)

● Supported dual source, dual feed power sources

- 3-wire grounded Wye (TN, TT)

CAUTION

SINGLE HIGH IMPEDANCE GROUND SOURCE – In North American installations, the neutral conductor from the high impedance ground source of supply CANNOT be used.

● Phase rotation must be clockwise starting with phase A (rotation A,B,C).

● Material and labor for external wiring requirements are to be supplied by designated personnel.

NOTE Refer to the Eaton 93PM Sidecar Integrated Accessory Cabinet-Bypass (150 kW and 200 kW SIAC-B) Installation and Operation Manual for Sidecar Integrated Accessory Cabinet-Bypass power wiring preparation and requirements.

● The bypass feed into this equipment uses three wires. The rectifier feed into this equipment uses three wires. The phases must be symmetrical about ground (from a Wye source, phase rotation clockwise A, B, C) for proper equipment operation.

● If installing an external maintenance bypass, all feeds to the UPS including the Rectifier Input Breaker (RIB) (if installed) must have a service disconnect independent of the maintenance bypass power path. Most maintenance bypass solutions provide UPS input feeds derived from but isolated from the maintenance 3-9 bypass power path. If the maintenance bypass solution being installed does not provide such functionality, DO NOT use a single feeder breaker to supply both the UPS and the maintenance bypass.

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For external wiring requirements, including the minimum AWG size of external wiring, see Table 3-7. Wire Table 3-7. Input/Output Ratings and External Wiring Requirements for the Eaton 93PM-200-4

Basic Unit Rating

Units Rating 50/60 Hz kW 160 170 180 190 200

Input and Output Voltage Volts 480/480 480/480 480/480 480/480 480/480

AC Input to UPS Rectifier (0.99 Minimum pF)

Full load current plus battery recharge current

(3) Phases, (1) Ground A

Amps 241 253 266 278 291

Minimum Conductor Size (Phase A, B, and C) Number per Phase

AWG or kcmil (each)

2/0 (2)

3/0 (2)

3/0 (2)

3/0 (2)

4/0 (2)

Minimum Conductor Size (Ground) Number

– AWG or kcmil (each)

(2)

(2)

(2)

(2)

(2)

AC Input to UPS Bypass (Three Wire, Dual-Feed) Full Load Current

(3) Phases, (1) Ground B

Amps 241 253 266 278 291

Minimum Conductor Size (Phase A, B, and C) Number per Phase

AWG or kcmil (each)

2/0 (2)

3/0 (2)

3/0 (2)

3/0 (2)

4/0 (2)

Minimum Conductor Size (Ground) Number

– AWG or kcmil (each)

(2)

(2)

(2)

(2)

(2)

DC Input from External Battery (Line-Up-and-Match Eaton 93PM IBC)

(1) Positive, (1) Negative, (1) Ground

C Total Amps (216 cell) Total Amps (240 cell)

Minimum Conductor Size (Phase Positive and Negative) Number per Pole

AWG or kcmil (each)

2/0 (1 -L or 2 -LH)

See Note

2/0 (1 -L or 2 -LH)

See Note

2/0 (1 -L or 2 -LH)

See Note

2/0 (1 -L or 2 -LH)

See Note

2/0 (1 -L or 2 -LH)

See Note

Minimum Conductor Size (Ground) Number

– AWG or kcmil (each)

(1)

(1)

(1)

(1)

(1)

DC Input from External Battery (Standalone Eaton 93PM IBC)

(1) Positive, (1) Negative, (1) Ground

C Total Amps (216 cell) Total Amps (240 cell)

Minimum Conductor Size (Phase Positive and Negative) Number per Pole

AWG or kcmil (each)

(2)

(2)

(2)

(2)

(2)

Minimum Conductor Size (Ground) Number

– AWG or kcmil (each)

(1)

(1)

(1)

(1)

(1)

AC Output to Critical Load (Three Wire) Full Load Current

(3) Phases, (1) Ground D

Amps 192 204 217 229 240

Minimum Conductor Size (Phase A, B, and C) Number per Phase

AWG or kcmil (each)

(1)

(1)

(1)

2/0 (2)

2/0 (2)

Minimum Conductor Size (Ground) Number

– AWG or kcmil (each)

(1)

(1)

(1)

(2)

(2)

NOTE Callout letters B, C and D map to Figure 5-9.

NOTE Line-up-and-match battery wiring with a 105°C rating is factory supplied with the Eaton 93PM Integrated Battery Cabinet (IBC).

sizes listed are for copper wiring only.

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Power wiring terminals E1 through E11 are 2-hole bus bar mountings for standard NEMA 2-hole barrel lugs.

The power wiring connections for this equipment are rated at 90°C. See Table 3-8 for external power cable terminations, Table 3-9 for supplied external wiring terminal hardware, and Table 3-10 for recommended installation parts and tools not supplied by Eaton Corporation.

Figure 4-7, Figure 4-9, and Figure 4-10 show the location of the UPS power cable terminals.

Table 3-8. UPS External Power Cable Terminations for the Eaton 93PM-200-4

Terminal Function Terminal Function Bus Landings

(using back-to-back lugs) Tightening Torque

Nm (lb ft) Bolt Size and Type

AC Input to UPS Rectifier E1 Phase A 2 – 2 bolt mounting 35 (26) M12 Hex

E2 Phase B 2 – 2 bolt mounting 35 (26) M12 Hex

E3 Phase C 2 – 2 bolt mounting 35 (26) M12 Hex

AC Input to Bypass E6 Phase A 2 – 2 bolt mounting 35 (26) M12 Hex

E7 Phase B 2 – 2 bolt mounting 35 (26) M12 Hex

E8 Phase C 2 – 2 bolt mounting 35 (26) M12 Hex

AC Output to Critical Load E9 Phase A 2 – 2 bolt mounting 35 (26) M12 Hex

E10 Phase B 2 – 2 bolt mounting 35 (26) M12 Hex

E11 Phase C 2 – 2 bolt mounting 35 (26) M12 Hex

DC Input from Battery E4 Battery (+) 6 – 2 bolt mounting 35 (26) M12 Hex

E5 Battery (-) 6 – 2 bolt mounting 35 (26) M12 Hex

Customer Ground Ground Ground 8 – #14-1/0 Pressure Termination

5.6 Nm (50 lb in) Slotted

NOTE Customer ground, sized in accordance with NEC Table 250.122, can be run in any conduit listed inTable 3-11.

Table 3-9. Supplied External Wiring Terminal Hardware Kit

Part Size Quantity Terminal Used On Eaton Part Number

Bolt, Grade 5 M12 x 35 mm 26 Rectifier Input, Bypass Input, Battery Input, and Output to Critical Load 180190078-110

Flat Washer M12 26 Rectifier Input, Bypass Input, Battery Input, and Output to Critical Load 180500036-120

Conical Washer M12 26 Rectifier Input, Bypass Input, Battery Input, and Output to Critical Load 180500037-120

Table 3-10. Recommended Installation Parts and Tools (Not Supplied by Eaton)

Part Size Quantity Manufacturer Part Number Notes

Long Barrel 2-Hole Lug

6 AWG

As Required Thomas & Betts

256-30695-868

Copper wire only

4 AWG 256-30695-733

2 AWG 54711BE

1 AWG 54857BE

1/0 AWG 256-30695-593

2/0 AWG 54862BE

3/0 AWG 54864BE

4/0 AWG 54866BE

250 MCM 54868BE

300 MCM 54870BE

350 MCM 54872BE

Manual Hydraulic Crimp Tool 14 Ton 1 TBM14M

Die Set N/A 1 15506 3-16

Conduit sizes were chosen from NEC Table 4, Electrical Metallic Tubing (EMT). See Table 3-11 for conduit requirements.

Per NEC article 300, 3(B), all three-phase conductors must be run in the same conduit. A ground wire must be run in the same conduit as the phase conductors.

When running parallel wires in multiple conduits a ground wire must be run in each conduit in accordance with NEC Table 250.122.

Conduit is sized to accommodate one ground conductor per conduit, sized in accordance with NEC Table 250.122.

Conduit sizes listed are for copper wiring only.

Table 3-11. Power Cable Conduit Requirements

Eaton 93PM-200-4 160 kW 480 Vac

AC Input to UPS Rectifier and Bypass

(A, B, C, Ground)

24 2

AC Output (Three Wire)

(A, B, C, Ground)

4 2-1/2 1

DC

Battery

(Positive, Negative, Ground) 3 2 2

Eaton 93PM-200-4 170 kW 480 Vac

AC Input to UPS Rectifier and Bypass (A, B, C, Ground)

24 2

AC Output (Three Wire)

(A, B, C, Ground)

4 2-1/2 1

DC

Battery

(Positive, Negative, Ground) 3 2 2

Eaton 93PM-200-4 180 kW 480 Vac

AC Input to UPS Rectifier and Bypass (A, B, C, Ground)

24 2

AC Output (Three Wire)

(A, B, C, Ground)

4 2-1/2 1

DC

Battery

(Positive, Negative, Ground) 3 2 2

Eaton 93PM-200-4 190 kW 480 Vac

AC Input to UPS Rectifier and Bypass (A, B, C, Ground)

24 2

AC Output (Three Wire)

(A, B, C, Ground)

4 2 2

DC

Battery

(Positive, Negative, Ground) 3 2 2

Eaton 93PM-200-4 200 kW 480 Vac

AC Input to UPS Rectifier and Bypass (A, B, C, Ground)

4 2 2

AC Output (Three Wire)

(A, B, C, Ground)

4 2 2

DC

Battery

(Positive, Negative, Ground) 23 2

UPS Model UPS Rating Voltage Terminal Number of Wires in Conduit Minimum Conduit

Trade Size Number of Conduits

NOTE Wires per conduit include ground wire.

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External overcurrent protection and disconnect are not provided by this product, but are required by codes. See Table 3-7 for wiring requirements. If an output lockable disconnect is required, it is to be supplied by the customer.

Table 3-12 lists the recommended rating for input and bypass circuit breakers.

Table 3-12. Recommended Input and Bypass Circuit Breaker Ratings

Input Rating

UPS Model UPS Rating Load Rating 480V

Eaton 93PM-200-4 160 kW 80% Rated 350A

100% Rated 250A

Eaton 93PM-200-4 170 kW 80% Rated 350A

100% Rated 300A

Eaton 93PM-200-4 180 kW 80% Rated 350A

100% Rated 300A

Eaton 93PM-200-4 190 kW 80% Rated 400A

100% Rated 300A

Eaton 93PM-200-4 200 kW 80% Rated 400A

100% Rated 350A

CAUTION

To reduce the risk of fire, connect only to a circuit provided with maximum input circuit breaker current ratings from Table 3-12 in accordance with the NEC, ANSI/NFPA 70.

The line-to-line unbalanced output capability of the UPS is limited only by the full load per phase current values for AC output to critical load shown in Table 3-7. The recommended line-to-line load unbalance is 50% or less.

Output overcurrent protection and bypass and output disconnect switches are to be supplied by the customer.

Table 3-13 lists the recommended rating for output circuit breakers.

Table 3-13. Recommended Output Circuit Breaker Ratings

Output Rating

UPS Model UPS Rating Load Rating 480V

Eaton 93PM-200-4 160 kW 80% Rated 250A

100% Rated 200A

Eaton 93PM-200-4 170 kW 80% Rated 300A

100% Rated 225A

Eaton 93PM-200-4 180 kW 80% Rated 300A

100% Rated 225A

Eaton 93PM-200-4 190 kW 80% Rated 300A

100% Rated 250A

Eaton 93PM-200-4 200 kW 80% Rated 300A

100% Rated 250A 3-20 e0069194 Highlight e0069194 Highlight e0069194 Highlight e0069194 Highlight e0069194 Highlight

There is no manual DC disconnect device within the UPS.

Battery voltage is computed at 2 volts per cell as defined by Article 480 of the NEC. Rated battery current is computed based on 2 volts per cell.

External DC input overcurrent protection and disconnect switch is to be supplied by the customer. Table 3-15 lists the maximum ratings for continuous-duty rated circuit breakers satisfying the criteria for both.

Recommended disconnect size is based on a maximum full load discharge time less than 3 hours. For longer discharge times a larger disconnect may be required.

Table 3-15. Recommended DC Input Battery Disconnect Circuit Breaker Ratings (240 Cell)

Output Rating

UPS Model UPS Rating 480V

Eaton 93PM-200-4 160 kW 100% Rated 500A

Eaton 93PM-200-4 170 kW 100% Rated 500A

Eaton 93PM-200-4 180 kW 100% Rated 500A

Eaton 93PM-200-4 190 kW 100% Rated 500A

Eaton 93PM-200-4 200 kW 100% Rated 600A 3-23

3.2.4 UPS System Interface Wiring Preparation

Control wiring for features and options should be connected at the customer interface terminal blocks located inside the UPS.

WARNING

Do not directly connect relay contacts to the mains related circuits. Reinforced insulation to the mains is required.

Read and understand the following notes while planning and performing the installation:

● Use Class 1 wiring methods (as defined by the NEC) for interface wiring from 30V to 600V. The wire should be rated for 600V, 1A minimum. 12 AWG maximum wire size.

● Use Class 2 wiring methods (as defined by the NEC) for interface wiring up to 30V. The wire should be rated for 24V, 1A minimum.

● Because of the battery shunt trip wiring route in the UPS cabinet, the wire should be rated for a minimum of 600V.

● Use twisted-pair wires for each input and return or common.

● All interface wiring and conduit is to be supplied by the customer.

● When installing external interface wiring between a building alarm, relay output, battery breaker trip, or Minislot and the UPS interface terminals, conduit must be installed between each device and the UPS cabinet.

● If using conduit, install the interface wiring in separate conduit from the power wiring.

● All building alarm inputs require an isolated normally-open contact or switch (rated at 24 Vdc, 20 mA minimum) connected between the alarm input and common terminal. All control wiring and switch contacts are customer-supplied.

● LAN and telephone drops for use with Minislot connectivity cards must be supplied by the customer.

● The UPS battery detect signal wiring from an UPS building alarm must be connected to the battery disconnect device.

● Program the battery detect building alarm to read battery open and for normally open contacts.

● A supplemental 48 Vdc shunt trip signal for the battery disconnect device is provided, but is not required for normal operation.

● Battery detect and 48 Vdc shunt trip wiring should be a minimum of 18 AWG

● The REPO feature opens all switchgear in the UPS cabinet and isolates power from your critical load. Local electrical codes may also require tripping upstream protective devices to the UPS.

● The REPO switch must be a latching-type switch not tied to any other circuits.

● A jumper wire must be connected between pins 3 and 4 on the REPO terminal block if using a normally-closed REPO switch.

● REPO wiring should be a minimum of 18 AWG and a maximum of 16 AWG.

● The REPO switch wiring must be in accordance with NEC Article 725 Class 2 requirements.

NOTE Refer to the Eaton 93PM Sidecar Integrated Accessory Cabinet-Bypass (150 kW and 200 kW SIAC-B) Installation and Operation Manual for Sidecar Integrated Accessory Cabinet-Bypass interface wiring preparation and requirements.

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● The maximum distance between the REPO and the UPS cannot exceed 150 meters (500 feet).

● Alarm relay contacts have a maximum current rating of 5A and a switched voltage rating of 30 Vac.

● Alarm relay wiring should be a minimum of 18 AWG (recommended 18 AWG).

3.3 Inspecting and Unpacking the UPS Cabinet

The cabinet is shipped bolted to a metal and wood pallet (see Figure 3-7) with outer protective packaging material covering the cabinet.

WARNING

The UPS cabinet is heavy (see Table 3-2). If unpacking and unloading 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 an Eaton service representative immediately.

2. Use a forklift or pallet jack to move the packaged cabinet to the installation site, or as close as possible, before unpacking. If possible, move the cabinet using the pallet. Insert the forklift or pallet jack forks between the supports on the bottom of the pallet (see Figure 3-4) for the UPS cabinet center of gravity measurements).

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 3m (10 ft) on each side for removing the cabinet from the pallet.

4. Remove the protective packaging material from the cabinet and recycle in a responsible manner. Retain any parts kits packaged with the cabinet.

5. Inspect the contents for any evidence of physical damage, and compare each item with the Bill of Lading.

If damage has occurred or shortages are evident, contact an Eaton service representative immediately to determine the extent of the damage and its impact on further installation.

NOTE Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer, or the warranty terms become void. This service is offered as part of the sales contract for the UPS. Contact an Eaton service representative in advance (a minimum two-week notice is required) to reserve a preferred startup date.

NOTE For the following step, verify that the forklift or pallet jack is rated to handle the weight of the cabinet (see Table 3-2 for cabinet weight).

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 the warranty.

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Figure 3-7. UPS Cabinet as Shipped on Pallet 3-27

Chapter 4 UPS System Installation

4.1 Preliminary Installation Information

WARNING

Installation should be performed only by qualified personnel.

Refer to the following while installing the UPS system:

● Chapter 3 for cabinet dimensions, equipment weight, wiring and terminal data, and installation notes.

● Do not tilt the cabinets more than ±10 during installation.

● Remove conduit landing plates to add conduit landing holes as required.

● If perforated floor tiles are required for ventilation, place them in front of the UPS.

4.2 Unloading the UPS Cabinet from the Pallet

WARNING

The UPS cabinet is heavy (see Table 3-2). If unpacking and unloading instructions are not closely followed, the cabinet may tip and cause serious injury.

CAUTION

● Do not tilt cabinet more than 10° from vertical.

● Lift the cabinets only with a forklift or damage may occur.

The UPS cabinet is bolted to a pallet consisting of four metal angle supports secured to two wood supports.

To remove the pallet:

1. If not already accomplished, use a forklift or pallet jack to move the UPS cabinet to the installation area, or as close as possible, before unloading from the pallet. Insert the forklift or pallet jack forks between the supports on the bottom of the pallet (see Figure 3-4 for the UPS cabinet center of gravity measurements).

2. Open the front door by lifting the latch from the bottom and turning to the right (counterclockwise) and swing the door open.

3. Remove the UPS right front panel by removing two top screws and one bottom screw from the panel. Lift the panel to disengage the slotted bracket on the left side of the panel. Rotate the panel and remove from the hanger brackets on the right side of the cabinet. Retain the hardware for later use.

4.

5.

Locate the four 1/2" jacking bolts from the parts kit and install them in the threaded holes in the front and rear supports as shown in Figure 4-1. Place a floor protector from the parts kit underneath each jacking bolt, and screw the bolts down against them.

The floor protectors protect the floor from being marred by the jacking bolts.

NOTE For the following steps, verify that the forklift or pallet jack is rated to handle the weight of the cabinet (see Table 3-2 for cabinet weight) 4-1

UPS System Installation I

Figure 4-1. Removing the Pallet Skids and Supports – Eaton 93PM UPS

WARNING

Do not remove or loosen the cabinet mounting or cabinet support bolts until instructed.

6. Loosen, but do not remove, the skid mounting bolts holding the pallet skids to the front and rear supports, and to the left and right side supports (see Figure 4-1).

7.

WARNING

RISK OF INSTABILITY. Turning the jacking bolts unevenly may cause the cabinet to become unbalanced. To prevent tipping the cabinet, raise and lower the jacking bolts evenly.

CAUTION

CABINET MAY TIP. Raise the UPS no more than 3 mm (1/8") above the floor (just enough to allow the removal of the pallet skids).

Cabinet Mounting Bolts (4 places front) (4 places rear)

Pallet Skid

Skid Mounting Bolts (4 places front) (4 places rear)

Right Side Cabinet Support

Rear Cabinet Support

Jacking Bolts (2 places front) (2 places rear)

Front Cabinet Support

Cabinet Support Bolts (2 places at each corner)

Left Side Cabinet Support

Floor Protectors (2 places front) (2 places rear)

Turn each jacking bolt consecutively, two full turns, until the pallet skids clear the floor by approximately 3 mm (1/8").

Remove the hardware loosened in Step 6.8.

9. Pull the pallet skids out from under the metal angle supports without disturbing the jacking bolts. Recycle the pallet skids and hardware in a responsible manner.

CAUTION

CABINET MAY FALL. Do not loosen the hardware attaching the front supports to the cabinet base.

4-2

The cabinet must be lowered by the jacking bolts before the supports can be removed.

13. Remove the cabinet mounting bolts holding the front and rear supports to the cabinet base (see Figure 4-1).

14. If installing the cabinet permanently, retain the cabinet mounting bolts; otherwise, recycle the bolts along with the support brackets in a responsible manner.

15. Close the door and secure the latch.

16. If the leveling feet are not retracted, turn all four leveling feet until they are retracted as far into the cabinet as possible.

CAUTION

To prevent tipping when rolling the cabinet, push the cabinet from the rear whenever possible.

17. Roll the cabinet to the final installation location.

18. Secure the UPS in position by lowering the leveling feet until the cabinet is level and locked in place.

19. If permanently mounting the UPS using the left and right side floor mounting brackets, proceed to Step 20; if using the front and rear floor mounting brackets, proceed to Step 28; otherwise, proceed to Step 28.

20. Locate the left and right side floor mounting brackets from the floor mounting kit.

21. Using the retained cabinet mounting bolts, install the floor mounting brackets to the left and right side of the UPS with the angle facing outward.

22. Secure the cabinet to the floor with customer-supplied hardware.

23. Proceed to paragraph 4.3.

24. Locate the front and back floor mounting brackets from the floor mounting kit.

25. Using the retained cabinet mounting bolts, install the floor mounting brackets to the front and rear of the UPS with the angle facing outward.

26. Secure the cabinet to the floor with customer-supplied hardware.

27. Proceed to paragraph 4.3.

28. Locate the black cover dots from the parts kit and install over the left and right side bracket mounting holes.

NOTE Use the leveling feet to level and lock the cabinet in place.

NOTE Either front and back floor mounting brackets or left and right side floor mounting brackets are available for permanently mounting the UPS.

NOTE Black cover dots are provided, if side mounting bracket holes need to be covered for aesthetic reasons.

10. Carefully and evenly lower the cabinet by turning each jacking bolt consecutively two full turns

(maximum) until the casters contact the floor and the cabinet is no longer supported by the jacking bolts.

11. After the UPS is resting on the floor, remove the jacking bolts and floor protectors. Recycle them in a responsible manner.

12. Remove the cabinet support bolts fastening the front, rear, and side cabinet supports together and remove the side supports (see Figure 4-1).

4-4

29. Proceed to paragraph 4.3.

4.3 Integrated Battery Cabinet Installation

If installing Integrated Battery Cabinets (IBCs), refer to the Eaton 93PM Integrated Battery Cabinet Installation Manual – Large and Large High Rate for installation instructions.

4.4 Sidecar Integrated Accessory Cabinet-Bypass Wiring Installation If an SIAC-B is attached to the UPS, refer to the Eaton 93PM Sidecar Integrated Accessory Cabinet-Bypass (150 kW and 200 kW SIAC-B) Installation and Operation Manual for wiring installation instructions.

4.7 Two-Hole Barrel Lug Terminations to Bus Bar Installation

Paragraphs 4.8 and 4.9 require connecting input, output, and battery power wiring using 2-hole barrel lugs. See Figure 4-4 for the hardware sequence when installing the lugs to the bus bars. Tighten the bolt to the torque value listed in Table 3-8.

Proceed to paragraph 4.8.

Double Lug Installation

Figure 4-4. Typical Bus Bar Barrel Lug Mounting – Hardware Assembly Sequence

NOTE Conical washers are special purpose washers that look similar to flat washers, except for a slight conical shape. When installing conical washers, the top of the dome should be next to the bolt head and the base of the washer should be against a flat surface such as a bus bar, flat washer, or large terminal.

Conical Washer Lug

Bus Bar

Threaded Clinch Nut

Bolt Head

Flat Washer

Single Lug Installation

Conical Washer Lug

Bus Bar

Threaded Clinch Nut

Bolt Head

Flat Washer

Lug 4-5 e0069194 Highlight

4.8 External AC Power Wiring Installation

To install wiring:

1. Open the front door by lifting the latch from the bottom and turning to the right (counterclockwise) and swing the door open.

2. Remove the UPS right front panel by removing two top screws and one bottom screw from the panel. Lift the panel to disengage the slotted bracket on the left side of the panel. Rotate the panel and remove from the hanger brackets on the right side of the cabinet. Retain the hardware for later use.

3. Remove the screws securing the bottom internal safety shield panel and remove the panel to gain access to the ground terminals. Retain the hardware for later use.

4. If wiring the UPS using the top entry wiring access, proceed to Step 8; otherwise proceed to Step 5.

5. Bottom Entry Wiring. Remove the bottom conduit plate (see Figure 4-5) from the inside bottom of the UPS. Identify all conduit requirements and mark their location. Drill and punch all conduit holes in the bottom conduit plate prior to mounting on the UPS. Install the conduit plate and install all conduit runs into the plate. Pull the wiring through conduit into the wiring area.

6. Route the input and output cables through the bottom of the cabinet to the UPS terminals. See Figure 4-5 for wiring access information and Figure 4-7 and Figure 4-8 for terminal locations.

7. Proceed to Step 10.

8. Top Entry Wiring. Remove the top conduit plate (see Figure 4-5) from the top of the cabinet. Identify all conduit requirements and mark their location. Drill and punch all conduit holes in the top conduit plate prior to mounting. Install the conduit plate and install all conduit runs into the plate. Pull the wiring through the conduit into the wiring area.

9. Route the input and output cables through the top of the UPS cabinet to the UPS terminals. See Figure 4-5 for wiring access information and Figure 4-7 and Figure 4-8 for terminal locations.

10. Locate the external wiring terminal hardware kit packed on the bottom right side of the UPS cabinet.

11. Using hardware from the external wiring terminal hardware kit (see Table 3-9), connect phase A, B, and C rectifier input power wiring from the utility source to the rectifier input terminals. See paragraph 3.2.2 for wiring and termination requirements.

For a detailed view of the UPS AC terminals, see Figure 4-9.

12. Using hardware from the external wiring terminal hardware kit (see Table 3-9), connect phase A, B, and C bypass input power wiring from the utility source to the bypass input terminals. See paragraph 3.2.2 for wiring and termination requirements.

For a detailed view of the UPS AC terminals, see Figure 4-9.

13. Using hardware from the external wiring terminal hardware kit (see Table 3-9), connect phase A, B, and C power wiring from output terminals to the critical load. See paragraph 3.2.2 for wiring and termination requirements.

For a detailed view of the UPS AC terminals, see Figure 4-9.

WARNING

As a result of the connected loads high leakage current is possible. Connection to earth ground is required for safety and proper product operation. Do not check UPS operation by any action that includes removal of the earth (ground) connection with loads attached.

14. Ground the UPS according to local and/or national electrical wiring codes by routing and connecting the ground wire to the input ground lug. See Figure 4-8 for UPS ground terminal locations.

15. Proceed to paragraph 4.9.

4-7

Figure 4-5. UPS Conduit and Wire Entry Locations

Front

Top View

Top Entry Conduit Landings for customer interface wiring.

(Remove panels to drill or punch conduit holes.)

Bottom Entry Conduit Landing for AC Input and Output, and DC Input (Remove panel to drill or punch conduit holes.)

Bottom Entry Conduit Landings for customer interface wiring.

(Remove panels to drill or punch conduit holes.)

Front

Bottom View

Top Entry Conduit Landing for AC Input and Output, and DC Input (Remove panel to drill or punch conduit holes.)

4-9

Figure 4-6. UPS Inter-Cabinet Wiring Access Location

Inter-cabinet wiring access to route interface wiring between cabinets.

Inter-cabinet wiring access knockouts. Remove knockouts as required to route power wiring between cabinets.

Left Side View Right Side View 4-10

Figure 4-7. Power Terminal Locations

DC Input from Battery + (E4) (See Figure 4-10 for detail)

AC Input to UPS Rectifier (A, B, C) (See Figure 4-9 for detail)

Front

AC Output to Critical Load (A, B, C) (See Figure 4-9 for detail)

AC Input to UPS Bypass (A, B, C,) (See Figure 4-9 for detail)

DC Input from Battery – (E5) (See Figure 4-10 for detail) 4-11

Figure 4-8. Ground Terminals

Figure 4-9. AC Power Terminal Detail

Cabinet Ground Post

Cabinet Ground Post

Ground Terminals

AC Input to UPS Bypass

AC Output to Critical Load

AC Input to UPS Rectifier

Phase A (E9)

Phase C (E11)

Phase B (E10)

Phase C (E3)

Phase B (E2)

Phase A (E1)

Phase A (E6)

Phase B (E7)

Phase C (E8) 4-12

4.9 Battery Power Wiring

CAUTION

When sizing the battery system, do not exceed the internal battery charger capabilities.

To install wiring:

1. Route and connect the battery cables between the UPS and battery cabinet or battery disconnect according to the instructions in the Eaton 93PM Integrated Battery Cabinet Installation Manual – Large and Large High Rate. See Figure 4-5 and Figure 4-6 for wiring access information and Figure 4-7 for terminal locations.

2. Using hardware from the external wiring terminal hardware kit (see Table 3-9), connect the positive, negative, and ground DC power wiring from the battery cabinet or disconnect to the UPS cabinet battery and ground terminals. See paragraph 3.2.2 for wiring and termination requirements

For a detailed view of the UPS DC terminals, see Figure 4-10.

3. After wiring the UPS system to the facility power and critical load, be sure to ground the system according to local and/or national electrical wiring codes.

4. If wiring interface connections, proceed to paragraph 4.10; otherwise, proceed to Step 5.

5. Reinstall all safety shield panels previously removed and secure with the retained hardware.

6. Reinstall the UPS right front panel and secure with the retained hardware.

7. Close the UPS outside door and secure the latch.

Figure 4-10. DC Power Terminal Detail

DC Input from Battery – (E5)

DC Input from Battery + (E4) 4-13

4.10 Installing Interface Connections

Use the procedures in the following paragraphs to connect the customer and battery interface connections.

4.10.1 Installing Building Alarm and Relay Contact Connections

To install wiring:

1. Verify the UPS system is turned off and all power sources are removed.

2. If not already opened, open the front door by lifting the latch from the bottom and turning to the right (counterclockwise) and swing the door open.

3. If wiring the interface terminals from the bottom of the UPS, proceed to Step 8; otherwise, proceed to Step 4.

4. Top Entry Wiring. Remove the top interface entry conduit landing plates to drill or punch holes (see Figure 4-5).

5. Reinstall the interface entry plates and install the conduit.

6. Route the UPS building alarm and relay output interface wiring through the top interface entry conduit landing plates to the UPS building alarm and relay output terminals. See Figure 4-5 for wiring access information and Figure 4-11 and Figure 4-12 for UPS interface terminal locations.

7. Proceed to Step 13.

8. Bottom Entry Wiring. Remove the bottom interface entry conduit landing plates to drill or punch holes (see Figure 4-13).

9. Reinstall the interface entry plates and install the conduit.

10. Route the UPS building alarm and relay output interface wiring through the bottom interface entry conduit landing plates to the bottom access interface wiring channel along the inside of the front door (see Figure 4-13).

11. Route the wiring along the interface wiring channel (see Figure 4-13) to the UPS building alarm and relay output terminals. See Figure 4-11 and Figure 4-12 for UPS interface terminal locations.

12. Secure the wiring to the wire tie anchors provided (see Figure 4-14) using Zip ties.

13. Connect the building alarm interface wiring to the building alarm terminals. See paragraph 3.2.4 and Table 4-3 for wiring and termination requirements, and Figure 4-15 for terminal assignments.

14. Connect the relay output interface wiring to the relay output terminals. See paragraph 3.2.4 and Table 4-3 for wiring and termination requirements, and Figure 4-16 for terminal assignments.

NOTE 1 If installing interface wiring connections between standalone cabinets or separate devices, conduit must be installed between each cabinet or device.

NOTE 2 Disconnect terminal block plugs from terminal blocks to wire plugs.

15. If wiring battery detect connections, proceed to paragraph 4.10.2; if wiring battery shunt trip connections, proceed to paragraph 4.10.3; if wiring Minislot connections, proceed to paragraph 4.10.7; if wiring REPO connections, proceed to paragraph 4.11; otherwise, proceed to Step 16.

16. Close the UPS outside door and secure the latch.

4-14

Figure 4-11. Interface Terminal Locations

Front

Interface Terminals (See Figure 4-12 for detail)

Minislot Communication Bays (See Figure 4-12 for detail)

Pull Chain and CAN Terminals (See Figure 4-12 for details.)

4-16

Figure 4-12. Interface Terminal Detail

Figure 4-13. Bottom Access Interface Wiring Location

Pull Chain Terminals

Minislot Communication Bay 2

Minislot Communication Bay 1

Minislot Communication Bay 3

Minislot Communication Bay 4

Building Alarm Terminals (See Figure 4-15 for Terminal Assignments)

Pull Chain and CAN Terminals (See Figure 4-21 for Terminal Assignments) Device USB

RS-232

Host USB

REPO Terminals (See Figure 4-24 for Terminal Assignments)

Relay Output Terminals (See Figure 4-16 for Terminal Assignments)

Cabinet Stiffener Bar

Wire Tie Anchors (See Figure 4-14 for Detail)

Bottom Access Interface Wiring Channel

Bottom Entry Conduit Landings for Customer Interface Wiring 4-17

Figure 4-14. Wire Tie Anchors

Figure 4-15. Building Alarm Terminal Block Connector Assignments

Wire Tie Anchors

Table 4-1. Building Alarm Connections and Wire Terminations

Terminal Name Description Recommended

Wire Size Size of Pressure

Termination Tightening Torque

10 Building Alarm 1 Input: Programmable UPS alarm, activated by a remote dry contact closure

Twisted Pair Wires

#18 AWG

#1430 AWG

2 lb in

(0.22-0.25 Nm)9 Building Alarm 1 Return

8 Building Alarm 2 Input: Programmable UPS alarm, activated by a remote dry contact closure

Twisted Pair Wires

#18 AWG

#1430 AWG

2 lb in

(0.22-0.25 Nm)7 Building Alarm 2 Return

6 Building Alarm 3 Input: Programmable UPS alarm, activated by a remote dry contact closure

Twisted Pair Wires

#18 AWG #1430 AWG

2 lb in (0.22-0.25 Nm)5 Building Alarm 3 Return

4 Building Alarm 4 Input: Programmable UPS alarm, activated by a remote dry contact closure

Twisted Pair Wires

#18 AWG #1430 AWG

2 lb in (0.22-0.25 Nm)3 Building Alarm 4 Return

2 Building Alarm 5 Input: Programmable UPS alarm, activated by a remote dry contact closure

Twisted Pair Wires

#18 AWG #1430 AWG

2 lb in (0.22-0.25 Nm)1 Building Alarm 5 Return

UPS Building Alarms

1 2 3 4 5 6 7 8 9 10

Building Alarm 5 Building Alarm 5 Return

Building Alarm 4 Building Alarm 4 Return

Building Alarm 1 Return Building Alarm 1

Building Alarm 2 Return Building Alarm 2

Building Alarm 3 Return Building Alarm 3 4-18

Figure 4-16. Relay Contact Terminal Block Connector Assignments

4.10.2 Installing Battery Detect Interface Connections

To install wiring:

1. Verify the UPS system is turned off and all power sources are removed.

2. If not already opened, open the front door by lifting the latch from the bottom and turning to the right (counterclockwise) and swing the door open.

3. If wiring the battery detect connections using the inter-cabinet wiring access pass-through (line-up-and-match configurations), proceed to Step 4; if wiring the battery interface connections using bottom entry access, proceed to Step 6; if wiring the battery interface connections using top entry access, proceed to Step 12.

4. Pass-through Wiring. Route the battery detect wiring from the battery cabinet through the top UPS inter-cabinet wiring access pass-through to the UPS building alarm terminals. See Figure 4-6 for UPS wiring access information and Figure 4-11 and Figure 4-12 for UPS terminal locations. Refer to the Eaton 93PM Integrated Battery Cabinet Installation Manual – Large and Large High Rate for battery cabinet wiring access information and instructions.

5. Proceed to Step 15.

Table 4-2. Relay Contact Connections and Wire Terminations

Terminal Name Description Recommended

Wire Size Size of Pressure

Termination Tightening Torque

1 Relay Contact NC Output: General purpose normally-closed (NC) relay contact.

Twisted Pair Wires

#18 AWG

#1430 AWG

2 lb in

(0.22-0.25 Nm)3 Relay Contact Common

2 Relay Contact NO Output: General purpose normally-closed (NO) relay contact.

Twisted Pair Wires

#18 AWG

#1430 AWG

2 lb in

(0.22-0.25 Nm)3 Relay Contact Common

NOTE 1 The UPS battery detect signal uses an UPS building alarm input to indicate an open battery breaker.

NOTE 2 Any pair of unused building alarm terminals may be used for the battery detect connections.

NOTE 3 Program the battery detect building alarm to read battery open and for normally open contacts.

NOTE 4 If installing interface wiring connections between standalone cabinets, conduit must be installed between cabinets.

NOTE 5 Disconnect terminal block plugs from terminal blocks to wire plugs.

UPS Relay Output

1 2 3

NO_Out NC_Out

Com 4-19

6. Bottom Entry Wiring. Remove the bottom interface entry conduit landing plate to drill or punch holes

(see Figure 4-13).

7. Reinstall the interface entry plate and install the conduit.

8. Route the battery detect wiring from the battery cabinet through the bottom interface entry conduit landing plate to the bottom access interface wiring channel along the inside of the front door (see Figure 4-13). Refer to the Eaton 93PM Integrated Battery Cabinet Installation Manual – Large and Large High Rate for battery cabinet wiring access information and instructions.

9. Route the wiring along the interface wiring channel (see Figure 4-13) to the UPS building alarm terminals.

See Figure 4-11 and Figure 4-12 for UPS interface terminal locations.

10. Secure the wiring to the wire tie anchors provided (see Figure 4-14) using Zip ties.

11. Proceed to Step 15.

12. Top Entry Wiring. Remove the top interface entry conduit landing plate to drill or punch holes (see Figure 4-5).

13. Reinstall the interface entry plate and install the conduit.

14. Route the battery detect wiring from the battery cabinet through the top interface entry conduit landing plate to the UPS building alarm terminals. See Figure 4-5 for wiring access information and Figure 4-11 and Figure 4-12 for UPS interface terminal locations. Refer to the Eaton 93PM Integrated Battery Cabinet Installation Manual – Large and Large High Rate for battery cabinet wiring access information and instructions.

15. Connect the battery detect wiring to one pair of building alarm terminals. See paragraph 3.2.4 and Table 4-1 for wiring and termination requirements, and Figure 4-15 for terminal assignments.

16. If wiring battery shunt trip connections, proceed to paragraph 4.10.3; if wiring generator interface connections, proceed to paragraph 4.10.4; if wiring Minislot connections, proceed to paragraph 4.10.7;

if wiring REPO connections, proceed to paragraph 4.11; otherwise, proceed to Step 17.

17. Close the UPS outside door and secure the latch.

4.10.3 Installing Battery Shunt Trip Interface Connections

To install wiring:

1. Verify the UPS system is turned off and all power sources are removed.

2. If not already opened, open the front door by lifting the latch from the bottom and turning to the right (counterclockwise) and swing the door open.

3. If not already removed, remove the screws securing the bottom internal safety shield panel and remove the panel. Retain the hardware for later use.

4. Remove the screws securing the internal safety shield panel above the bottom safety panel and remove the panel to gain access to the battery shunt trip wiring terminals. Retain the hardware for later use.

NOTE 1 If installing interface wiring connections between standalone cabinets, conduit must be installed between cabinets.

NOTE 2 Disconnect terminal block plugs from terminal blocks to wire plugs.

5. If wiring the battery shunt trip connections using the inter-cabinet wiring access pass-through (line-up-and-match configurations), proceed to Step 6; if wiring the battery shunt trip connections using bottom entry access, proceed to Step 8; if wiring the battery shunt trip connections using top entry access, proceed to Step 10.

6. Pass-through Wiring. Route the battery shunt trip wiring from the battery cabinet through the bottom UPS inter-cabinet wiring access pass-through and static switch shelf bushing to the UPS battery shunt trip terminals. See Figure 4-6 for UPS wiring access information and Figure 4-17 and Figure 4-18 for UPS terminal locations. Refer to the Eaton 93PM Integrated Battery Cabinet Installation Manual – Large and 4-20

Large High Rate, listed in paragraph 1.8 for battery cabinet wiring access information and instructions.

7. Proceed to Step 11.

8. Bottom Entry Wiring. Route the battery shunt trip wiring from the battery cabinet or battery disconnect through the bottom of the UPS and static switch shelf bushing to the UPS battery shunt trip terminals.

See Figure 4-5 for UPS wiring access information and Figure 4-17 and Figure 4-18 for UPS terminal locations. Refer to the Eaton 93PM Integrated Battery Cabinet Installation Manual – Large and Large High Rate, listed in paragraph 1.8 for battery cabinet wiring access information and instructions.

9. Proceed to Step 11.

10. Top Entry Wiring. Route the battery shunt trip wiring from the battery cabinet or battery disconnect through the top of the UPS cabinet and the bottom UPS internal inter-cabinet wiring access pass-through and static switch shelf bushing to the UPS battery shunt trip terminals. See Figure 4-5 for UPS wiring access information and Figure 4-17 and Figure 4-18 for UPS terminal locations. Refer to the Eaton 93PM Integrated Battery Cabinet Installation Manual – Large and Large High Rate, listed in paragraph 1.8 for battery cabinet wiring access information and instructions.

11. Connect the wiring to the battery shunt trip terminals. See paragraph 3.2.4 and Table 4-3 for wiring and termination requirements, and Figure 4-19 for terminal assignments.

12. If wiring generator interface connections, proceed to paragraph 4.10.4; if wiring external parallel CAN connections, proceed to paragraph 4.10.5; if wiring external parallel pull chain connections, proceed to paragraph 4.10.6; if wiring Minislot…