93PM_user_manual_including_HS_201412.pdf

Eaton 93PM UPS 30-200 kW

User's and Installation Guide

Eaton 93PM UPS 30-200 kW

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.

This is a product for commercial and industrial application in the second environment. Installation restrictions or additional measures may be needed to prevent disturbances.

© 2013 Eaton Corporation All Rights Reserved

The contents of this manual are the copyright of the publisher and may not be reproduced (even extracts) without the written approval of Eaton Corporation. 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.

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Contents

1 Safety instructions

1.1 Audience

1.2 CE marking

1.3 User precautions

1.4 Environment

1.5 Symbols on the UPS and accessories

1.6 Conventions used in this manual

1.7 For more information

2 Introduction to Eaton UPS

2.1 Looking inside the UPS system

2.2 UPS operating modes

2.2.1 Normal operating modes

2.2.1.1 Double conversion mode

2.2.1.2 Energy Saver System mode

2.2.2 Stored energy and battery mode

2.2.3 Bypass mode

2.3 UPS features

2.3.1 Advanced Battery Management

2.3.2 Powerware Hot Sync

2.4 Software and connectivity features

2.4.1 Customer interface

2.4.2 Power Management Software

2.5 Options and accessories

2.5.1 Maintenance Bypass Switch

2.5.2 Top air exhaust kit

2.5.3 Top cable access kit

2.5.4 Field Installed UPM

2.6 Battery system

2.7 Basic system configurations

3 UPS installation plan and unpacking

3.1 Creating an installation plan

3.2 Site preparations

3.2.1 Environmental and installation considerations

3.2.2 UPS system power wiring preparation

3.2.3 UPS system interface wiring preparation

3.3 Unpacking and unloading the UPS

4 UPS system installation

4.1 Steps to install the UPS

4.2 Battery system installation

4.3 Installing UPS external battery cabinet and battery power wiring

4.4 Installing a remote EPO switch

4.5 Installing interface connections

4.5.1 Installing customer input signals interface

4.5.2 Battery breaker wiring interface

4.5.3 Relay output interface connections

4.5.4 Mini-slot interface connections

4.5.5 Installing signal interface connections in parallel system

4.6 Wiring parallel 93PM UPS systems

4.6.1 Power wiring overview

4.6.2 Control signals overview

4.6.3 Installing bypass control wiring

5 Communication interfaces

5.1 Mini-slot cards

5.2 Intelligent Power Software

5.3 Signal input monitoring

5.4 General purpose relay contact

6 UPS operating instructions

6.1 UPS controls and indicators

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6.1.1 Control panel

6.1.4 System events

6.2 Steps to operate the UPS

6.3 Signing in

6.4 System control instructions

6.4.1 Starting the UPS system in Double conversion mode

6.4.2 Starting the UPS system in Bypass mode

6.4.3 Transfer from Double conversion mode to Bypass mode

6.4.4 Transfer from Bypass to Double conversion mode

6.4.5 Transfer from Double conversion mode to Energy Saver System Mode

6.4.6 Transfer from Energy Saver System Mode to Double conversion mode

6.4.7 UPS system and critical load shutdown

6.4.8 De-energizing the Critical Load

6.5 UPS control instructions

6.5.1 Starting a single UPS

6.5.2 UPS shutdown

6.5.3 Enabling and disabling the battery charger

6.6 UPM control instructions

6.6.1 Starting the UPMs

6.6.2 UPM shutdown

6.7 Using the Remote Emergency Power-off switch

6.8 Turning UPS from double conversion mode to mechanical bypass

6.9 Turning UPS from mechanical bypass to double conversion mode

7 UPS maintenance

7.1 Important safety instructions

7.2 Performing preventive maintenance

7.2.1 DAILY maintenance

7.2.2 MONTHLY maintenance

7.2.3 PERIODIC maintenance

7.2.4 ANNUAL maintenance

7.2.5 BATTERY maintenance

7.3 Recycling the used UPS or batteries

7.4 Maintenance training

8 Technical data

8.1 Standards

8.2 UPS system input

8.3 UPS system output

8.4 Battery specification

8.5 UPS environmental specifications

9 Warranty

10 Installation checklist

11 APPENDIX A: User settings

6.1.2 Status indicators

6.1.3 LPS

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List of Figures

Figure 1-1: Recycling batteries symbol Figure 1-2: WEEE symbol Figure 2-1: Eaton 93PM UPS Figure 2-2: 93PM 50 kW UPS wiring diagram Figure 2-3: 93PM 150 kW UPS wiring diagram Figure 2-4: Path of current through the UPS in double conversion mode Figure 2-5: Path of current through the UPS in Energy Saver System Figure 2-6: Path of current through the UPS in battery mode Figure 2-7: Path of current through the UPS in bypass mode Figure 2-8: Two-switch MBS electrical connection drawing Figure 2-9: Three-switch MBS electrical connection drawing Figure 3-1: UPS cabinet clearances. See Table 3-3 Figure 3-2: 93PM 30-150 kW UPS dimensions Figure 3-3: 93PM 160-200 kW UPS dimensions Figure 3-4: Eaton 93PM 80-150 kW UPS Top air exhaust kit dimensions Figure 3-5: Eaton 93PM 200 kW UPS Top air exhaust kit dimensions

Figure 4-1: 93PM 30-50 kW gland plate and connector locations

Figure 4-2: 93PM 80-150 kW UPS gland plate and connector locations Figure 4-3: 93PM 160-200 kW UPS gland plate and connector locations Figure 4-4: 93PM 30-150 kW Top cable access kit Figure 4-5: 93PM battery cabinet (EBC-S) Figure 4-6: 93PM battery cabinet (EBC-L) Figure 4-7: UPS cabinet through holes Figure 4-8: Connections of the EPO switch Figure 4-9: Principle of paralleled UPS systems Figure 4-10: Communication interfaces Figure 4-11: Simplified CAN and Pull-Chain wiring for parallel UPS system Figure 4-12: CAN and Pull-Chain wiring for parallel UPS with MOBs Figure 4-13: CAN and Pull-Chain wiring for parallel UPS without MOBs Figure 5-1: Communication interfaces Figure 5-2: Network Card-MS Figure 5-3: PX Gateway Card Figure 5-4: Relay Card-MS Figure 5-5: Network and MODBUS Card - MS Figure 5-6: Industrial Relay Card-MS Figure 6-1: Parts of the display Figure 6-2: Green symbol Figure 6-3: Yellow symbol — battery mode Figure 6-4: Yellow symbol — bypass mode Figure 6-5: Red symbol Figure 6-6: The normal positions of the MBS switches and rectifier disconnect switch (must be located in the site wiring) Figure 6-7: Mechanical bypass mode Figure 6-8: Mechanical bypass mode Figure 6-9: Double conversion mode Figure 7-1: WEEE symbol Figure 7-2: Recycling batteries symbol

Figure 3-6: Eaton 93PM 160-200kW hot swap kit for structure information in detail iv 30-200 kW

List of Tables

Table 2-1: UPS configurations Table 2-2: Standard and optional UPS options Table 3-1: Dimensions Table 3-2: UPS cabinet weights Table 3-3: UPS cabinet minimum clearances Table 3-4: UPS cabinet minimum clearances with top air exhaust kit Table 3-5: Air conditioning or ventilation requirements during full load operation Table 3-6: Minimum recommended multi-core cable and fuse sizes Table 3-7: Rated and maximum currents for rated power and voltage Table 3-8: UPS power cable terminations Table 4-1: Remote EPO wire terminations Table 6-1: UPS menu structure Table 8-1: Standards Table 8-2: UPS system input Table 8-3: UPS system output Table 8-4: Battery specification Table 8-5: UPS environmental specifications Table 11-1: User settings Table 11-2: Config settings

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1 Safety instructions

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions that should be followed during installation and maintenance of the UPS and batteries. Please read all instructions before operating the equipment and save this manual for future reference.

The UPS operates with mains, battery or bypass power. It contains components that carry high currents and voltages. The properly installed enclosure is earthed and IP21 rated against electrical shock and foreign objects. However, the UPS is a sophisticated power system and only qualified personnel is allowed to install and service the UPS.

WARNING

Operations inside the UPS must be performed by a service engineer from the manufacturer or from an agent authorized by the manufacturer.

DANGER

This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS inside the UPS.

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WARNING

• The UPS is powered by its own energy source (batteries). The output terminals may be energised even when the UPS is disconnected from an AC source. To reduce the risk of fire or electric shock, install this UPS in a temperature and humidity controlled, indoor environment, free of conductive contaminants. Ambient temperature must not exceed 40 °C (104 °F). Do not operate near water or excessive humidity (95 % maximum). The system is not intended for outdoor use.

• Ensure all AC and DC power sources are disconnected before performing installation or service. Power may come from multiple sources.

• In parallel system, output terminals may be energised even when the UPS is turned off.

• Ensure system grounding/PE continuity when undertaking installation or service.

• Batteries can present a risk of electrical shock or burn from high short-circuit current.

• ELECTRIC ENERGY HAZARD. Do not attempt to alter any battery wiring or connectors.

Attempting to alter wiring can cause injury.

• Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic.

• IMPORTANT: the battery may consist of multiple parallel strings, disconnect all strings before installation.

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CAUTION

• Installation or servicing should be performed by qualified service personnel knowledgeable of batteries and required precautions. Keep unauthorized personnel away from batteries. Consider all warnings, cautions, and notes before installing or replacing batteries. DO NOT DISCONNECT the batteries while the UPS is in Battery mode.

• Replace batteries with the same number and type of batteries as originally installed in the

UPS.

• Disconnect the charging source prior to connecting or disconnecting terminals.

• Determine if the battery is inadvertently grounded. If it is, remove the source of the ground. Contacting any part of a grounded battery can cause a risk of electric shock. An electric shock is less likely if you disconnect the grounding connection before you work on the batteries.

• Proper disposal of batteries is required. Refer to local codes for disposal requirements.

• Do not dispose of batteries in a fire. Batteries may explode when exposed to flame.

• Keep the UPS door closed and front panels installed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit.

• Do not install or operate the UPS system close to gas or electric heat sources.

• The operating environment should be maintained within the parameters stated in this manual.

• Keep surroundings uncluttered, clean, and free from excess moisture.

• Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the equipment.

1.1 Audience

The intended audience of this manual are people who plan the installation, install, and use the UPS.

This manual provides guidelines for checking the delivery, installing, and operating of the UPS.

The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols. This manual is written for a global reader.

NOTE

Read the manual before operating or working on the UPS.

1.2 CE marking

The product has the CE marking in compliance with the following European directives:

• LV Directive (Safety) 2006/95/EC

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• EMC Directive 2004/108/EC

Declaration of conformity with UPS harmonised standards and directives EN 62040-1 (Safety) and EN 62040-2 (EMC) are available at www.eaton.eu/93PM or by contacting your nearest Eaton office or authorized partner.

1.3 User precautions

The only user operations permitted are:

• Start up and shut down of the UPS, excluding the commissioning start up.

• Use of the LCD control panel and Maintenance Bypass Switch (MBS).

• Use of optional connectivity modules and their software.

The user must follow the precautions and only perform the described operations. Any deviation from the instructions could be dangerous to the user or cause accidental load loss.

WARNING

The user is not permitted to open any screws excluding connectivity plates and the MBS locking plate. Failure to recognise the electrical hazards could prove fatal.

WARNING

The 30-50 kW models are available as C2 UPS product which can be placed both in a residential and commercial/industrial environment. When included in a residential environment, this product may cause radio interference, in which case the user may be required to take additional measures.

By standard, the 30-200 kW models are category C3 UPS products, meant for all commercial and industrial establishments.

1.4 Environment

The UPS must be installed according to the recommendations in this manual. Under no circumstances should the UPS be installed in an airtight room, in the presence of flammable gases, or in an environment exceeding the specifications.

Excessive amount of dust in the operating environment of the UPS may cause damage or lead to malfunction. The UPS should always be protected from the outside weather and sunshine. In order to maximize internal battery service life time, the recommended operating temperature range is from +20 to +25 ºC.

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WARNING

Hydrogen and oxygen gases are emitted from batteries into the surrounding atmosphere during charge, float charge, heavy discharge, and overcharge. Explosive gas mixture may be created if the hydrogen concentration exceeds 4 % by volume in air. Necessary air flow rate for ventilation of UPS location must be ensured.

As an example, for 93PM 30-50 kW UPS, a minimum air flow is 5 m³/ hour for the room where one 93PM UPS with internal VRLA batteries is placed. If more than one UPS with internal VRLA batteries are located in the same room, ventilation air flow must be dimensioned accordingly. If external flooded cell batteries are used in same location, ventilation air flow must be recalculated and dimensioned accordingly.

1.5 Symbols on the UPS and accessories

The following are examples of symbols used on the UPS or accessories to alert you to important information:

DANGER

RISK OF ELECTRIC SHOCK - Indicates that a risk of electric shock is present and the associat-ed warning should be observed.

CAUTION

CAUTION: REFER TO OPERATOR’S MANUAL

- Refer to your operator’s manual for addition-al information, such as important operating and maintenance instructions.

Figure 1-1: Recycling batteries symbol

This symbol indicates that you should not dis-card the UPS or the UPS batteries in the trash.

This product involves sealed, lead-acid batteries and must be disposed of properly. For more in-formation, contact your local recycling/reuse or hazardous waste center.

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Figure 1-2: WEEE symbol

This symbol indicates that you should not dis-card waste electrical or electronic equipment (WEEE) in the trash. For proper disposal, contact your local recycling/reuse or hazardous waste center.

1.6 Conventions used in this manual

This manual uses these type conventions:

• 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.

• Italic type highlights notes and new terms where they are defined.

• Screen type represents information that appears on the screen or LCD.

Icon Description

NOTE

Information notes call attention to important fea-tures 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.

1.7 For more information

Address any inquiries about the UPS and battery cabinet to the local office or agent authorized by the manufacturer. Please quote the type code and the serial number of the equipment.

Call your local service representative if help is needed with any of the following:

• Scheduling initial startup

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• Regional locations and telephone numbers

• A question about any of the information in this manual

• A question this manual does not answer

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2 Introduction to Eaton UPS The Eaton® 93PM uninterruptible power supply (UPS) is a true online, continuous-duty, transformerless, double-conversion, solid-state, three-phase system, supplying conditioned and uninterruptible AC power to critical load and protecting it from power failures.

The UPS 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 Eaton UPS continually monitors incoming electrical power and removes the surges, spikes, sags, and other irregularities that are inherent in commercial utility power. Working with a building’s electrical system, the UPS system supplies clean, consistent power that sensitive electronic equipment requires for reliable operation. During brownouts, blackouts, and other power interruptions, batteries provide emergency power to safeguard operation.

The UPS system is housed in a single, free-standing cabinet with safety shields behind the door for hazardous voltage protection. Each UPS cabinet has a centralised system static bypass. The available static bypass ratings are 50 kW, 100 kW, 150 kW and 200 kW. The static bypass size is chosen according to UPS system power. For example, if future requirement is to upgrade the UPS capacity, the UPS bypass rating will have to be selected accordingly. In addition, the bypass ratings of all UPS cabinets in a parallel system need to be matched.

Eaton 93PM output power ratings are based on 50 kW rated uninterruptible power modules (UPMs).

A single UPS cabinet can house one to four UPM modules to get ratings of:

• 1 x 50 kW = 50 kW

• 2 x 50 kW = 100 kW

• 3 x 50 kW = 150 kW

• 4 x 50 kW = 200 kW

A UPM includes a rectifier, inverter, battery converter, and independent controls. Each UPM is able to operate independently from the other power modules.

NOTE

Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer, or the warranty terms specified in Chapter 9 Warranty on page 81 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.

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Figure 2-1: Eaton 93PM UPS

2.1 Looking inside the UPS system

The system level static bypass in the Eaton 93PM UPS cabinet determines the attainable output power of the UPS. The static bypass line consists of static switch and a backfeed protection isolation device connected in series. In addition, there is a system level control unit that constantly monitors the power delivered through the bypass line or to the input of the UPS. Transfers to static bypass are seamless and performed automatically by the system as needed, for example, in case of an extended system overload.

Each UPM power module includes a rectifier, battery converter, inverter and independent controls.

Each UPM is able to operate and share the load independently, despite the status of the other UPMs.

In addition, the system can have a UPS internal maintenance bypass switch as a factory installed option.

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The 30-50 kW 93PM UPS includes a 50 kW rated static bypass section, one UPM power module, and internal batteries. In addition to the internal batteries, also external batteries can be connected. The main components of this UPS are depicted in Figure 2-2: 93PM 50 kW UPS wiring diagram on page 11.

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Figure 2-2: 93PM 50 kW UPS wiring diagram

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In the 80-200 kW units, the UPM power modules are paralleled internally. These units do not include internal batteries. Figure 2-3: 93PM 150 kW UPS wiring diagram on page 12 shows the construction of the 150 kW 93PM UPS with three power modules.

Figure 2-3: 93PM 150 kW UPS wiring diagram

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The rectifier input switch and battery breaker are available as standard for the 30-50 kW units, and as optional for the 80-150 kW units. The internal MBS is available as optional for the 30-150 kW units.

These options are not available for the 160-200 kW units, and will have to be included externally in the installation.

If utility power is interrupted or falls outside the parameters specified in Chapter 8 Technical data on page 76, 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 UPS bypass consists of a continuous-duty static switch and backfeed protection isolation device K5. The backfeed protection is located in series with the static switch. Transfers to static bypass are seamless and performed automatically by the system as needed, for example, in case of an extended system overload.

2.2 UPS operating modes

UPS operating modes:

• Normal operating modes:

• In double conversion 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.

• In Energy Saver System (ESS) mode, the critical load is supported securely by utility power through static bypass switch with double conversion available on-demand with typically less than a 2 ms transition time, should any abnormal condition be detected in the utility.

When operating in ESS mode, the load is protected with inherent surge suppression.

Operating the UPS in ESS mode increases system efficiency to 99 % allowing significant savings in energy losses without compromising system reliability.

• In stored energy mode, the energy is drawn from a DC backup power source and converted to AC power by the UPS inverter. Most commonly VRLA batteries are introduced to the system for this purpose, and the mode of operation is called battery mode.

• In bypass mode, the critical load is supported directly by utility power through the UPS static switch.

2.2.1 Normal operating modes

During normal UPS operation, power for the system is derived from a utility input source. “Unit Online” is displayed on the front panel, indicating that the incoming power is within voltage and frequency acceptance windows.

2.2.1.1 Double conversion mode

Figure 2-4: Path of current through the UPS in double conversion mode on page 14 shows the path of electrical power through the UPS system when the UPS is operating in double conversion mode.

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Internal relay contacts

Figure 2-4: Path of current through the UPS in double conversion mode

Three-phase AC input power is converted to DC using a multilevel converter with IGBT devices to produce a regulated DC voltage to the inverter. The UPS status indicated on the display is “Unit Online” and the UPM status is “Active”.

The battery converter derives its input from the regulated DC output of the rectifier and provides regulated 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.

The inverter produces a three-phase AC output to the critical load. The inverter derives regulated DC from the rectifier and uses multilevel converter technology with IGBT devices and pulse-width modulation (PWM) to produce a regulated and filtered AC output.

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 double conversion mode automatically.

If the UPS becomes overloaded or unavailable, the UPS seamlessly switches to Bypass mode and continues supplying the load through the static bypass. The UPS automatically returns to double conversion mode when the abnormal condition, such as an extended time overload, is cleared and system operation is restored within specified limits.

If a UPM power module within the UPS suffers an internal failure, the remaining UPMs will continue supporting the load in double conversion. The UPS is automatically internally redundant when the UPS is not operating in full load. However, if there is no redundancy between the UPMs due to high load level, the UPS switches automatically to Bypass mode and remains in that mode until the failure is corrected and the UPS is back in service.

In an external parallel redundant system, each one UPS can be isolated from the system for service while the remaining UPSs support the load in double conversion.

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2.2.1.2 Energy Saver System mode

In ESS mode the UPS safely provides mains current directly to the load when the input is within the acceptable limits by its voltage and frequency. The UPS status indicated on the display is “Unit Online ESS”, and the UPM status is “Active”. Surge protection and some filtering is also provided, ensuring that clean power is delivered to the load equipment. Should there be any disturbances detected in the incoming power, the UPS switches to double conversion and continues to supply the critical load through its inverter. In case of a complete utility outage or if input power is outside the tolerances of the system, the UPS transfers to battery mode and continues to supply conditioned, clean power to the critical load.

When operating in ESS, the UPS superior detection and control algorithms continuously monitor incoming power quality and allow the fast engagement of power converters. Typical transition time to double conversion is less than two milliseconds, which is practically seamless.

When power conditions are within acceptable limits, the UPS operates as a high-efficiency, energy-saving system — providing surge protection for IT equipment and ensuring clean power is delivered to the facility. Energy saver system increases system efficiency to 99 % when supplying 20-100 % nominal load, reducing energy losses by up to 80 %.

Internal relay contacts

Figure 2-5: Path of current through the UPS in Energy Saver System

2.2.2 Stored energy and battery mode

When running normally in double conversion or ESS mode, the UPS automatically transfers to supply the load from batteries or other stored energy source if a utility power outage occurs, or if the utility power does not conform to specified parameters. The UPS status indicated on the display is “On Battery”, and the UPM status is “Active”. In battery mode, the battery provides emergency DC power which is converted to regulated output power by the inverter. Figure 2-6: Path of current through the UPS in battery mode on page 16 shows the path of electrical power through the UPS system when operating in battery mode.

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Internal relay contacts

Battery breaker

Figure 2-6: Path of current through the UPS in battery mode

During a utility power failure, the rectifier no longer has an AC utility source from which to supply the DC output current required to support the inverter. The input relay K1 opens and the UPS output is powered from batteries through the inverter. As the inverter operates uninterrupted through the transition, the load remains supported continuously without disturbance. If the UPS static bypass is supplied from the same source as the UPS rectifier, the backfeed protection contactor K5 also opens.

The opening of K1 and K5 prevent system voltages from bleeding backwards and re-entering the input source through the static switch or rectifier.

If the input power fails to return or is not within the acceptance windows required for normal operation, the battery continues discharging until a DC voltage level is reached where the inverter output can no longer support the connected loads. When this event occurs, the UPS issues a set of audible and visual alarms indicating that the batteries are having a minimal capacity left and a system shutdown is imminent. Unless utility power is restored, the output can be supported for maximum 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, K1 and K5 close and the UPS returns to normal operation. The UPS will also start to recharge batteries to restore the capacity.

2.2.3 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. The UPS can also be commanded to transfer to bypass manually through the display. The UPS status indicated on the display is “On Bypass”. Figure 2-7: Path of current through the UPS in bypass mode on page 17 shows the path of electrical power through the UPS system when operating in Bypass mode.

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NOTE

The critical load is not protected while the UPS is in Bypass mode.

Internal relay contacts

Figure 2-7: Path of current through the UPS in bypass mode

In bypass mode, the output of the system is provided with three-phase AC power directly from the system input. While in this mode, the output of the system is not protected from voltage or frequency fluctuations or power outages from the source. Some power line filtering and transient 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 static bypass is comprised of a solid-state, silicon-controlled rectifier (SCR) static switch (SSW) and a backfeed protection isolation device 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. The static switch, being an electronically-controlled device, can be turned on immediately to pick up the load from the inverter without interruption. The backfeed protection is normally always closed, ready to support the static switch unless the bypass input source becomes unavailable.

2.3 UPS features

The Eaton UPS has many features that provide cost-effective and consistently reliable power protection. The feature descriptions provide a brief overview of the UPS standard features.

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2.3.1 Advanced Battery Management

Advanced Battery Management technology uses sophisticated sensing circuitry and a three-stage charging technique that extends the useful service life of UPS batteries while optimizing the battery recharge time. ABM also protects batteries from damage caused by high current charging and inverter ripple currents. Charging at high currents can overheat and damage batteries.

In charge mode, the batteries are recharged. Charging lasts only as long as it takes to bring the battery system up to a predetermined float level. Once this level is reached, the UPS battery charger enters float stage and the charger is operating in constant voltage mode.

Rest mode begins at the end of charge mode; that is, after 48 hours of float charging (customer adjustable). In Rest mode, the battery charger is completely turned off. The battery system receives no charge current during this rest period of about 28 days (customer adjustable). During Rest mode, the open circuit battery voltage is monitored constantly, and battery charging is resumed when necessary.

2.3.2 Powerware Hot Sync

Eaton Powerware Hot Sync technology is an algorithm that eliminates the single point of failure in a parallel system and therefore enhances the system reliability. The Hot Sync technology is incorporated in all Eaton 93PM UPSs, and it is utilised in both multi-module internal parallel and external parallel systems.

Hot Sync technology enables all uninterruptible power modules (UPMs) to operate independently in a parallel system, even without inter-module communications. The power modules utilising the Hot Sync technology are completely autonomous; each module monitors their own output independently, to remain in complete synchronization with the other modules. The UPM power modules share the load perfectly even in changing capacity or changing load conditions.

Powerware Hot Sync technology combines digital signal processing and an advanced control algorithm to provide automatic load sharing and selective tripping in a parallel UPS system. The load share control algorithms maintain synchronization and load balance by constantly making minute adjustments to variations in the output power requirements. The modules conform to demand and are not in conflict with each other for the load. Powerware Hot Sync systems are capable of paralleling for both redundancy and capacity.

2.4 Software and connectivity features

2.4.1 Customer interface

Mini-Slot Communication Bays — there are three communication bays for mini-slot connectivity cards.

Mini-slot cards are quickly installed and are hot-pluggable. See Chapter 5 Communication interfaces on page 53 for additional information.

2.4.2 Power Management Software

Intelligent Power software products offer tools for monitoring and managing power devices across the network. See Chapter 5 Communication interfaces on page 53 for more information.

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2.5 Options and accessories

Contact an Eaton sales representative for information about the available options.

2.5.1 Maintenance Bypass Switch

The Maintenance Bypass Switch (MBS) enables power to completely bypass and isolate the UPS so that the UPS can be safely serviced or replaced without interrupting power to critical systems.

An internal maintenance bypass switch is provided as a factory installed option for 30-150 kW units.

Alternatively, MBS solutions are also available in external enclosure as accessory items.

External Maintenance Bypass Switch Panel

The external MBS is enclosed in its own separate cabinet, and it can be either a wall-mounted or stand-alone cabinet depending on the MBS power rating. The MBS wiring has two different options:

two- and three-switch configuration. The two-switch model contains a Maintenance Isolation Switch (MIS) and a Maintenance Bypass Switch (MBP). The three-switch model contains a Bypass Input Breaker (BIB) in addition to a MIS and an MBP.

The two-switch model assumes that the UPS rectifier and bypass are coupled through dedicated breakers and separate cables from the switchgear. However, the three-breaker model can be connected to the switchgear with only a single cable, and the cable connections between the panel and UPS are run separately.

For more information, see Figure 2-8: Two-switch MBS electrical connection drawing on page 20 and Figure 2-9: Three-switch MBS electrical connection drawing on page 21.

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1. Maintenance Bypass Switch (MBP)

2. Maintenance Isolation Switch (MIS)

Figure 2-8: Two-switch MBS electrical connection drawing

30-200 kW 21

1. Bypass Input Breaker (BIB)

2. Maintenance Isolation Switch (MIS)

3. Maintenance Bypass Switch (MBP)

Figure 2-9: Three-switch MBS electrical connection drawing

For external MBS installation instructions, see a separate manual.

22 30-200 kW

2.5.2 Top air exhaust kit

The top air exhaust kit is used to direct the UPS cooling air front-to-top. The kit will eliminate the cooling clearance requirement from the back of the unit, and enable installing the 93PM UPS even against a wall, in a corner or back-to-back. The kit increases the depth of the unit by 200 mm.

Refer to Chapter 3.2 Site preparations on page 25 for further information.

2.5.3 Top cable access kit

The top cable access kit is designed to support top cabling to the 30-150 kW 93PM UPS in sites where the cabling is distributed through overhead cable trays. The kit is installed at the right hand side of the UPS unit.

The 200 kW 93PM UPS does not require this kit, since the unit supports bottom, rear, and top cable entry by standard.

Refer to Chapter 3.2 Site preparations on page 25 and Chapter 4.1 Steps to install the UPS on page 36 for further information.

See also Figure 4-4: 93PM 30-150 kW Top cable access kit on page 40.

2.5.4 Field Installed UPM

A Field Installed UPM (FI-UPM) can be installed in the cabinet any time in the future when power needs change. This enables the UPS system to grow with the business, thus lowering the initial investment required for the system Day1.

In order to install an FI-UPM, the UPS cabinet needs to have upgradeability, which is determined by the power rating of the static bypass. For example, if the static bypass is rated for 150 kW, the fourth UPM cannot be installed into the frame. For listing of upgradeable configurations, see Table 2-1: UPS configurations on page 23.

2.6 Battery system

The battery system provides emergency short-term backup power to safeguard operation during brownouts, blackouts, and other power interruptions. By default, UPS is configured to use VRLA batteries. Should there be a need to connect other type of batteries or other energy storage means, a certified service technician should be consulted prior to proceeding with installation.

93PM 30-50 kW units

The Eaton 93PM 30-50 kW UPS can be equipped with internal batteries to provide a 10-20 min full load runtime depending on UPS rating. In addition, external battery cabinets can be introduced to the system to allow extended autonomy. Internal and external batteries can be used in parallel.

93PM 80-200 kW units

The Eaton 93PM 80-200 kW UPS can be equipped with an external battery, and no internal batteries are available.

For detailed battery specifications, see Chapter 8 Technical data on page 76.

30-200 kW 23

2.7 Basic system configurations

UPS power rating

The maximum attainable UPS system power rating is determined by the size of static bypass. The number of UPM power modules determines the nominal power rating of the UPS. If upgradeability is required, the system static bypass should be chosen according to the future maximum load rating, and number of UPMs is chosen according to Day1 capacity requirements.

The following UPS configurations with different static bypass sizes and number of UPMs are possible:

Description UPS power rating Upgradeability Size of bypass and size of the frame

93PM-50(50) 50 kW - 50 kW

93PM-50(100) 50 kW to 100 kW 100 kW

93PM-50(150) 50 kW to 100 kW and 150 kW 150 kW

93PM-50(200) 50 kW to 100 kW, 150 kW, and 200 kW

200 kW

93PM-100(100) 100 kW - 100 kW

93PM-100(150) 100 kW to 150 kW 150 kW

93PM-100(200) 100 kW to 150 and 200 kW 200 kW

93PM-150(150) 150 kW - 150 kW

93PM-150(200) 150 kW to 200 kW 200 kW

93PM-200(200) 200 kW - 200 kW

Table 2-1: UPS configurations

A single UPS frame can house maximum four UPM power modules, resulting in maximum power rating of 200 kW. In addition, the UPS frames can be connected in parallel to create even larger systems. A maximum of four UPSs can be connected in parallel.

UPS Options

The following table shows different standard and optional UPS options and the models where they apply.

30-50 kW 80-100 kW 120-150 kW 160-200 kW

Smart touch screen display for system control and monitoring

Standard Standard Standard Standard

SNMP web interface

Standard Option OptionInternal MBS

Option Option Option

Option

24 30-200 kW

Rectifier input switch IS Standard Option Option -

Internal battery breaker BB Standard Option Option -

Chimney / front-to-top air flow - Option Option Option

Battery start Standard Standard Standard Standard

Integrated backfeed protection Standard Standard Standard Standard

Table 2-2: Standard and optional UPS options

Additional options and accessories are also available. These include different software and connectivity options and external switchgear and power distribution options.

Air filter Standard Standard Standard Standard

A single UPS frame can house maximum four UPM power modules, resulting in maximum power rating of 200 kW. In addition, the UPS frames can be connected in parallel to create even larger systems. A maximum of four UPSs can be connected in parallel.

UPS Options

The following table shows different standard and optional UPS options and the models where they apply.

30-50 kW 80-100 kW 120-150 kW 160-200 kW

Smart touch screen display for system control and monitoring

Standard Standard Standard Standard

SNMP web interface

Standard Option OptionInternal MBS

Option Option Option

Option

① A hot swap option is designed to support maintenance and field upgrade for 30-200kW UPS which can be scalable to 200kW based on 200kW unit frame at online mode. The option is installed at the right hand side of the UPS unit and factory customized.

There is one switchgear to isolate utility input, battery input, neutral and output for each UPM, the UPM could be field replaced separately.

For 30-150kW unit frame, it does not support this hot swap kit. Only for 200kW unit frame, it could support this kit and could field upgrade UPM for 30kW-200kW 93PM UPS.

Refer to Figure3-6: 93PM 200kW hot swap kit for structure information in detail.

Option

Standard

Standard

Standard

Standard

Option

200 kW Hot swap ①

30-200 kW 25

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

2. Prepare your site for the UPS system

3. Inspect and unpack the UPS cabinet

4. Unload and install the UPS cabinet, and wire the system

5. Complete the installation checklist (Chapter 10 Installation checklist on page 82)

6. Have authorized service personnel perform preliminary operational checks and startup.

NOTE

Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer, or the warranty terms specified in Warranty 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.

3.1 Creating an installation plan

Before installing the UPS system, read and understand how these instructions apply to the system being installed. Use the procedures and illustrations in Chapter 3.2 Site preparations and Chapter 4 UPS system installation to create a logical plan for installing the system.

3.2 Site preparations

For the UPS system to operate at peak efficiency, the installation site should meet the environmental parameters outlined in these instructions. If the UPS needs to be operated at an altitude higher than 1000 m, contact your service representative for important information about high altitude operation.

The operating environment must meet the weight, clearance, and environmental requirements specified.

3.2.1 Environmental and installation considerations

The UPS system can be installed where there is TN or TT power distribution system.

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 floor must be suitable for heavy weight and wheeling.

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

• The cabinet can be installed in line-up-and-match or standalone configurations.

26 30-200 kW

Failure to follow guidelines may void your warranty.

The UPS equipment operating environment must meet the weight requirements shown in Table 3-2:

UPS cabinet weights on page 26, and the size requirements shown in Table 3-1: Dimensions on page 26, Figure 3-2: 93PM 30-150 kW UPS dimensions on page 28, Figure 3-3: 93PM 160-200 kW UPS dimensions on page 29, Figure 3-4: Eaton 93PM 80-150 kW UPS Top air exhaust kit dimensions on page 29, and Figure 3-5: Eaton 93PM 200 kW UPS Top air exhaust kit dimensions on page 30.

Shipping dimensions (WxDxH)

Cabinet dimensions (WxDxH)

30-150 kW 160-200 kW

900 x 1120 x 2040 mm" 1060 x 1120 x 2040 mm"

560 x 914x 1876 mm" 760 x 914 x 1876 mm

Table 3-1: Dimensions

30-50 kW 80-100 kW 120-150 kW 160-200 kW

Shipping weight 895 kg 360 kg 440 kg 635 kg

Installed weight 825 kg 290 kg 370 kg 555 kg

Floor loading 1600 kg/m² 570 kg/m² 720 kg/m² 800 kg/m²

Table 3-2: UPS cabinet weights

The UPS cabinets use forced air cooling to regulate internal component temperature. By standard, air inlets are in the front of the cabinet and outlets are in the back. You must allow clearance in front of and behind each cabinet for proper air circulation.

With the optional top air exhaust kit, it is possible to configure the air outlets in the top rear of the cabinet. With this option, the UPS can be installed against a wall or back-to-back.

The clearances required around the UPS cabinet in both of these situations are shown in Table 3-3:

UPS cabinet minimum clearances on page 26 and Table 3-4: UPS cabinet minimum clearances with top air exhaust kit on page 27. In addition, a minimum of 20 mm clearance is recommended on the right and left side of the cabinet.

30-50 kW 80-100 kW 120-150 kW 160-200 kW

From top of cabinet 500 mm 800 mm 800 mm 800 mm

From front of cabinet 900 mm 900 mm 900 mm 900 mm

From back of cabinet 200 mm* 400 mm* 500 mm* 500 mm*

Table 3-3: UPS cabinet minimum clearances

*Cabling may require more space.

960 x 931x 1885 mm

30-200kW (Hot Swap)

930 kg/m² 930 kg/m² 930 kg/m² 930 kg/m²

① ① ① ①

① ① ① ①

① ① ① ①

② ② ② ②

① : Standatd ②: With Hot swap

590 kg ② 650 kg ② 710 kg ② 770 kg ②

1260 x 1120x 2040 mm

490 kg ② 550 kg ② 610 kg ② 670 kg ②

30-200 kW 27

30-50 kW 80-200 kW

From top of cabinet 500 mm 800 mm

From front of cabinet 900 mm 900 mm

From back of cabinet 0 mm 0 mm

Table 3-4: UPS cabinet minimum clearances with top air exhaust kit

• X = clearance at back of cabinet

• Y = clearance at top of cabinet

Figure 3-1: UPS cabinet clearances. See Table 3-3.

The basic environmental requirements for operation of the UPS system are:

• Ambient Temperature Range: from +5 to +40 °C

• Recommended Operating Range: from +20 to +25 °C

• Maximum Relative Humidity: 95 %, noncondensing

It is required to arrange ventilation of the UPS room. Sufficient amount of air cooling is needed to keep the maximum room temperature rise at desired level:

• Temperature rise of max. +5 °C requires the airflow of 600 m³ per 1 kW of losses

• Temperature rise of max. +10 °C requires the airflow of 300 m³ per 1 kW of losses

An ambient temperature from +20 to +25 °C is recommended to achieve a long life of the UPS and batteries. The cooling air entering the UPS must not exceed +40 °C. Avoid high ambient temperature, moisture, and humidity.

The UPS ventilation requirements are shown in the following table:

28 30-200 kW

Rating Heat rejection (BTU/h x 1000) Heat rejection (kW)

30 kW 4.30 1.3

40 kW 5.73 1.7

50 kW 7.16 2.1

80 kW 11.45 3.4

100 kW 14.32 4.2

120 kW 17.18 5.0

150 kW 21.48 6.3

160 kW 22.91 6.7

200 kW 28.64 8.4

Table 3-5: Air conditioning or ventilation requirements during full load operation

Figure 3-2: 93PM 30-150 kW UPS dimensions 28 30-200 kW

User's and Installation Guide

Rating Heat rejection (BTU/h x 1000) Heat rejection (kW)

30 kW 4.30 1.3

40 kW 5.73 1.7

50 kW 7.16 2.1

80 kW 11.45 3.4

100 kW 14.32 4.2

120 kW 17.18 5.0

150 kW 21.48 6.3

160 kW 22.91 6.7

200 kW 28.64 8.4

Table 3-5: Air conditioning or ventilation requirements during full load operation

Figure 3-2: 93PM 30-150 kW UPS dimensions

28 30-200 kW User's and Installation Guide

Rating Heat rejection (BTU/h x 1000) Heat rejection (kW)

30 kW 4.30 1.3

40 kW 5.73 1.7

50 kW 7.16 2.1

80 kW 11.45 3.4

100 kW 14.32 4.2

120 kW 17.18 5.0

150 kW 21.48 6.3

160 kW 22.91 6.7

200 kW 28.64 8.4

Table 3-5: Air conditioning or ventilation requirements during full load operation

Figure 3-2: 93PM 30-150 kW UPS dimensions

28 30-200 kW User's and Installation Guide

Rating Heat rejection (BTU/h x 1000) Heat rejection (kW)

30 kW 4.30 1.3

40 kW 5.73 1.7

50 kW 7.16 2.1

80 kW 11.45 3.4

100 kW 14.32 4.2

120 kW 17.18 5.0

150 kW 21.48 6.3

160 kW 22.91 6.7

200 kW 28.64 8.4

Table 3-5: Air conditioning or ventilation requirements during full load operation

Figure 3-2: 93PM 30-150 kW UPS dimensions

30-200 kW 29 User's and Installation Guide

Figure 3-3: 93PM 160-200 kW UPS dimensions

Figure 3-4: Eaton 93PM 80-150 kW UPS Top air exhaust kit dimensions

30-200 kW 29 User's and Installation Guide

Figure 3-3: 93PM 160-200 kW UPS dimensions

Figure 3-4: Eaton 93PM 80-150 kW UPS Top air exhaust kit dimensions

30-200 kW 29

Figure 3-3: 93PM 160-200 kW UPS dimensions

Figure 3-4: Eaton 93PM 80-150 kW UPS Top air exhaust kit dimensions

30-200 kW 29 User's and Installation Guide

Figure 3-3: 93PM 160-200 kW UPS dimensions

Figure 3-4: Eaton 93PM 80-150 kW UPS Top air exhaust kit dimensions

30-200 kW 29 User's and Installation Guide

Figure 3-3: 93PM 160-200 kW UPS dimensions

Figure 3-4: Eaton 93PM 80-150 kW UPS Top air exhaust kit dimensions

30 30-200 kW User's and Installation Guide

Figure 3-5: Eaton 93PM 200 kW UPS Top air exhaust kit dimensions

3.2.2 UPS system power wiring preparation

NOTE

If installing a maintenance bypass, a minimum of two separate feeds with upstream feeder breakers, or a single feed with two upstream feeder breakers, must be provided: one for the UPS or rectifier input breaker (if installed) and one for the maintenance bypass input. DO NOT use a single feed or a single feeder breaker to supply both the UPS or rectifier input breaker and the maintenance bypass. If a bypass input breaker is installed in the maintenance bypass and a single-feed UPS is being installed, a single feed to the maintenance bypass is acceptable for supplying both the UPS and the bypass.

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

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

• To allow for future kVA upgrades (software and/or hardware), consider using conductors sized for full bypass rating of the UPS.

• Material and labor for external wiring requirements are to be provided by designated personnel.

• For external wiring, use 90 °C copper wire. See the appropriate information in Table 3-6:

Minimum recommended multi-core cable and fuse sizes on page 31. Wire sizes are based on using the specified breakers.

• If wire is run in an ambient temperature greater than 30 °C, higher…