eaton-9155-user-manual.pdf

Powerware 9155 UPS

8–15 kVA

User's Guide

Class A EMC Statements FCC Part 15

NOTE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.

This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

ICES-003

This Class A Interference Causing Equipment meets all requirements of the Canadian Interference Causing Equipment Regulations ICES‐003.

Cet appareil numérique de la classe A respecte toutes les exigences du Reglement sur le matériel brouilleur du Canada.

IEC 62040-2

Some configurations are classified under IEC 62040-2 as “Class‐A UPS for Unrestricted Sales Distribution.” For these configurations, the following applies:

WARNING This is a Class A‐UPS Product. In a domestic environment, this product may cause radio interference, in which case, the user may be required to take additional measures.

VCCI Notice

Powerware, Powerware Hot Sync, ABM, X-Slot, LanSafe, and FERRUPS are registered trademarks and ConnectUPS is a trademark of Eaton

Electrical Inc.

Greenlee is a registered trademark of Greenlee Textron. Modbus is a registered trademark of Modicon.

�Copyright 2004–2006 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any way without the express written approval of Eaton Corporation.

Requesting a Declaration of Conformity Units that are labeled with a CE mark comply with the following harmonized standards and EU directives:

� Harmonized Standards: IEC 62040-1-1 and IEC 62040-2; IEC 60950 Third Edition

� EU Directives: 73/23/EEC, Council Directive on equipment designed for use within certain voltage limits

93/68/EEC, Amending Directive 73/23/EEC

89/336/EEC, Council Directive relating to electromagnetic compatibility

92/31/EEC, Amending Directive 89/336/EEC relating to EMC

The EC Declaration of Conformity is available upon request for products with a CE mark. For copies of the EC Declaration of Conformity, contact:

Eaton Power Quality Oy

Koskelontie 13

FIN-02920 Espoo

Finland

Phone: +358-9-452 661

Fax: +358-9-452 665 68

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

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

CAUTION: REFER TO OPERATOR'S MANUAL - Refer to your operator's manual for additional information, such as important operating and maintenance instructions.

This symbol indicates that you should not discard the UPS or the UPS batteries in the trash. This product contains sealed, lead‐acid batteries and must be disposed of properly. For more information, contact your local recycling/reuse or hazardous waste center.

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

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality i

Table of Contents

1 Introduction 1

2 Safety Warnings 3

3 UPS Setup 7

Inspecting the Equipment 7

Floor Loading 7

Clearances 8

Unloading the Cabinet(s) 8

Selecting an Installation Option 11

4 UPS Only Installation 13

5 Input Isolation Transformer Installation 17

6 UPS-Mounted Bypass Switch Installation 25

MBM/PDM Setup 25

Wiring the MBM/PDM 28

7 Wall-Mounted Bypass Switch Installation 35

Wall-Mounted Bypass Switch Setup 36

Wiring the Wall-Mounted Bypass Switch 37

8 Stabilizing the Cabinet 43

9 Extended Battery Module Installation 47

10 Communication 49

Installing Communication Options and Control Terminals 50

Communication Options 52

DB-9 Communication Port 52

X-Slot Cards 53

Powerware LanSafe Power Management Software 54

Control Terminals 54

Remote Emergency Power-off 55

Relay Output Contacts 55

Programmable Signal Inputs 56

11 Operation 57

Control Panel Functions 57

Changing the Language 58

Display Functions 58

User Settings 59

UPS Startup 61

Normal Mode Startup 61

Starting the UPS on Battery 62

Internal Bypass Startup 63

Maintenance Bypass Startup 63

Wall-Mounted Maintenance Bypass Startup 64

Configuring the UPS for EBMs 64

UPS Shutdown 65

TABLE OF CONTENTS

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12 UPS Maintenance 67

UPS and Battery Care 67

Storing the UPS and Batteries 67

When to Replace Batteries 68

Recycling the Used Battery or UPS 68

Using the UPS-Mounted Maintenance Bypass Switch 68

Using the Wall-Mounted Bypass Switch 70

13 Specifications 73

14 Troubleshooting 79

Typical Alarms and Conditions 79

Silencing the Alarm 80

Service and Support 80

15 Warranty 81

Two-Year Limited Warranty (US and Canada) 81

Ten-Year Pro-Rated Limited Warranty (US and Canada) 82

Load Protection Guarantee (US and Canada) 84

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 1

Chapter 1 Introduction

The Powerware® 9155 is a double‐conversion, split-phase, online uninterruptible power system (UPS) for protecting computer systems and other intelligent devices. It is ideal for protecting essential information technology and electrical engineering infrastructure in corporate, telecom, health care, banking, and industrial applications.

The UPS provides a steady, well‐regulated power supply for your computing and communications equipment, while protecting it from the frequent irregularities that are inherent in commercially available power. Voltage spikes, power surges, brownouts, and power failures have the potential to corrupt critical data, destroy unsaved work sessions, and in some instances, damage expensive hardware.

With the Powerware 9155, you can safely eliminate the effects of electrical line disturbances and guard the integrity of your systems and equipment. Figure 1 shows the Powerware 9155 UPS and an optional Extended Battery Module (EBM).

Figure 1. The Powerware 9155 UPS and EBM (2-High Cabinets Shown)

Providing outstanding performance and reliability, the Powerware 9155's unique benefits including the following:

� Online UPS design with pure sine wave output. The UPS filters and regulates incoming AC power and provides consistent power to your equipment without draining the battery.

� More wattage in less space with a 0.9 power factor—protecting more equipment and leaving more room for expansion.

� Support for Powerware Hot Sync® paralleling of multiple modules for redundancy or extra capacity.

� Input current total harmonic distortion (THD) of less than five percent, using active input power factor correction.

� ABM® technology that uses advanced battery management to increase battery service life, optimize recharge time, and provide a warning before the end of useful battery life.

INTRODUCTION

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� Start-on-battery capability for powering up the UPS even if utility power is not available.

� Up to four hours of extended runtime with added EBMs.

� Emergency shutdown control through the remote emergency power-off (REPO) port.

� Standard communication options with a DB-9 serial port, relay output contacts, and programmable signal inputs.

� Optional X-Slot® cards with enhanced communication capabilities for increased power protection and control.

� Advanced power management with the Software Suite CD for graceful shutdowns and power monitoring.

� Backed by worldwide agency approvals.

The following options for the Powerware 9155 are available:

� Maintenance Bypass Module (MBM)

The optional MBM is installed on the UPS rear panel and is used to bypass the

UPS during maintenance or servicing. The maintenance bypass switch on the

MBM provides a Make-Before-Break (MBB) wrap-around bypass for UPS service without shutting down the load.

� Power Distribution Module (PDM)

The optional PDM provides the same functionality as the MBM and also comes equipped with several different types of output receptacles.

� Wall-Mounted Bypass Switch

The optional wall-mounted bypass switch is used to bypass the UPS during maintenance or servicing, providing wrap-around bypass for UPS service without shutting down the load.

� Parallel Tie Cabinet

An optional parallel system with up to three UPSs can be installed to provide a parallel capacity and/or redundant system. This load sharing system provides more capacity than a single UPS and can provide backup, depending on the load and configuration. In addition, when one UPS is taken out of service for maintenance or is not operating properly, a redundant UPS continues to supply uninterrupted power to the critical load. A parallel Powerware Hot Sync Controller Area Network

(CAN) Bridge Card provides connectivity for system metering and operational mode control. The parallel system consists of two to three UPSs, each with a parallel

CAN Bridge Card, and a parallel tie cabinet. Refer to the Powerware 9155 Parallel

UPS (8–15 kVA) User's Guide for more information.

� Input Isolation Transformer

The optional input isolation transformer is located at the bottom of a 3-high UPS model. The input isolation transformer provides a neutral from a 208V or 240V input source with 240V output and can be wired to the UPS or to an MBM/PDM.

� Seismic Kit

The optional seismic kit secures the UPS and optional EBMs for Zone 4 seismic installations.

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 3

Chapter 2 Safety Warnings

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.

D A N G E R 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.

W A R N I N G � This UPS contains its own energy source (batteries). The UPS output may carry live voltage even when the UPS is not connected to an AC supply.

� 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).

� To reduce the risk of fire, connect only to a circuit provided with 100 amperes maximum branch circuit overcurrent protection in accordance with the National Electrical Code, ANSI/NFPA 70.

� Output overcurrent protection and disconnect switch must be provided by others.

C A U T I O N � Batteries can present a risk of electrical shock or burn from high short circuit current. Observe proper precautions. Servicing should be performed by qualified service personnel knowledgeable of batteries and required precautions. Keep unauthorized personnel away from batteries.

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

� Never dispose of batteries in a fire. Batteries may explode when exposed to flame.

SAFETY WARNINGS

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality4

Consignes de Sécurité

CONSIGNES DE SÉCURITÉ IMPORTANTES

CONSERVER CES INSTRUCTIONS

Ce manuel comporte des instructions importantes que vous êtes invité à suivre lors de toute procédure d'installation et de maintenance des batteries et de l'onduleur. Veuillez consulter entièrement ces instructions avant de faire fonctionner l'équipement et conserver ce manuel afin de pouvoir vous y reporter ultérieurement.

D A N G E R !

Cet onduleur contient des TENSIONS MORTELLES. Toute opération d'entretien et de réparation doit être

EXCLUSIVEMENT CONFIÉE A UN PERSONNEL QUALIFIÉ AGRÉÉ. AUCUNE PIÈCE RÉPARABLE PAR

L'UTILISATEUR ne se trouve dans l'onduleur.

A V E R T I S S E M E N T !

� Cette onduleur possède sa propre source d'alimentation (batteries). Il est possible que la sortie de l'onduleur soit sous tension même lorsque l'onduleur n'est pas connectée à une alimentation CA.

� Pour réduire les risques d'incendie et de décharge électrique, installer l'onduleur uniquement à l'intérieur, dans un lieu dépourvu de matériaux conducteurs, où la température et l'humidité ambiantes sont contrôlées. La température ambiante ne doit pas dépasser 40 °C. Ne pas utiliser à proximité d'eau ou dans une atmosphère excessivement humide (95 % maximum).

� Afin de réduire les risques d'incendie, n'effectuez le raccordement qu'avec un circuit muni d'une protection de surintensité du circuit de dérivation maximum de 100 ampères conformément au Code Électrique National (National Electrical Code) des États-Unis ANSI/NFPA 70.

� La protection de surintensité de sortie ainsi que le sectionneur doivent être fournis par des tiers.

A T T E N T I O N !

� Les batteries peuvent présenter un risque de choc électrique ou de brûlure provenant d'un courant de court-circuit haute intensité. Observez les précautions appropriées. L'entretien doit être réalisé par du personnel qualifié connaissant bien les batteries et les précautions nécessaires. N'autorisez aucun personnel non qualifié à manipuler les batteries.

� Une mise au rebut réglementaire des batteries est obligatoire. Consulter les règlements en vigueur dans votre localité.

� Ne jamais jeter les batteries au feu. L'exposition aux flammes risque de les faire exploser.

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 5

Advertencias de Seguridad

INSTRUCCIONES DE SEGURIDAD IMPORTANTES

GUARDE ESTAS INSTRUCCIONES

Este manual contiene instrucciones importantes que debe seguir durante la instalación y el mantenimiento del SIE y de las baterías. Por favor, lea todas las instrucciones antes de poner en funcionamiento el equipo y guarde este manual para referencia en el futuro.

P E L I G R O Este SIE contiene VOLTAJES MORTALES. Todas las reparaciones y el servicio técnico deben ser efectuados SOLAMENTE POR PERSONAL DE SERVICIO TÉCNICO AUTORIZADO. No hay NINGUNA PARTE QUE EL USUARIO PUEDA REPARAR dentro del SIE.

A D V E R T E N C I A � Este SIE contiene su propia fuente de energía (baterías). La salida del SIE puede transportar voltaje activo aun cuando el SIE no esté conectado con una fuente de CA.

� Para reducir el riesgo de incendio o de choque eléctrico, instale este SIE en un lugar cubierto, con temperatura y humedad controladas, libre de contaminantes conductores. La temperatura ambiente no debe exceder los 40°C. No trabaje cerca del agua o con humedad excesiva (95% máximo).

� Para reducir el riesgo de incendio, realice la conexión únicamente hacia un circuito que cuente con un máximo de 100 amperios de protección contra sobrecorriente de circuito derivado, de acuerdo con el Código Eléctrico Nacional, ANSI/NFPA 70.

� La protección contra sobrecorriente de salida y el conmutador de desconexión debe suministrarse por parte de terceros.

P R E C A U C I Ó N � Las baterías pueden constituir un riesgo de descarga eléctrica o quemaduras por corriente alta de corto circuito. Adopte las precauciones debidas. Personal calificado de servicio que conozca de baterías y esté al tanto de las precauciones requeridas debe darle servicio al equipo. Mantenga al personal no autorizado alejado de las baterías.

� Es necesario desechar las baterías de un modo adecuado. Consulte las normas locales para conocer los requisitos pertinentes.

� Nunca deseche las baterías en el fuego. Las baterías pueden explotar si se las expone a la llama.

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EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 7

Chapter 3 UPS Setup

This chapter describes:

� Equipment inspection

� Floor loading and clearances

� Unloading the cabinet(s)

� Selecting an installation option

The instructions are intended for the chief operator/system supervisor, electrical consultants, and installation electricians. Local regulations and electrical code must be followed during the UPS installation.

Inspecting the Equipment

If any equipment has been damaged during shipment, keep the shipping and packing materials for the carrier or place of purchase and file a claim for shipping damage. If you discover damage after acceptance, file a claim for concealed damage.

To file a claim for shipping damage or concealed damage: 1) File with the carrier within 15 days of receipt of the equipment; 2) Send a copy of the damage claim within 15 days to your service representative.

NOTE Check the battery recharge date on the packaging label. If the date has expired and the batteries were never recharged, do not use the UPS. Contact your service representative.

Floor Loading

When planning the installation, consider the UPS weight for floor loading. The strength of the installation surface must be adequate for point and distributed loadings. The approximate weights are shown in the following table.

Standard Model Floor Loadings (2-High/3-High Cabinets)

Powerware 9155 Maximum Weight (lb)

Point Loading (lb/in2)

Distributed Loading (lb/ft2)

2-High UPS 352 88 166

3-High UPS 590 148 278

3-High UPS with

Isolation Transformer

558 140 263

2-High EBM 480 120 226

3-High EBM 710 178 335

UPS SETUP

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Clearances

The following clearances are recommended for the Powerware 9155 UPS:

From Front of Cabinet 36” (91.4 cm) working space

From Back of Cabinet 6” (15.2 cm) without a Maintenance Bypass Module (MBM) or Power

Distribution Module (PDM) installed; with an MBM/PDM installed, clearance is determined by the customer-supplied mating plug

Unloading the Cabinet(s)

The following tools are required for unloading the cabinet(s):

� 15 mm wrench or socket

� 7 mm nutdriver or socket

C A U T I O N The UPS and Extended Battery Module (EBM) are heavy (see page 7). Unloading the cabinets requires at least two people to safely remove the cabinets from the pallet.

To remove the UPS or EBM from the shipping pallet:

1. Remove the two M10 bolts securing the stabilizing bracket to the pallet (see

Figure 2).

M10 Bolts

Figure 2. Removing the Stabilizing Bracket Bolts

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 9

2. Remove the four M4 screws securing the stabilizing bracket to the cabinet rear panel and remove the bracket (see Figure 3). Retain the hardware for later use.

NOTE Be sure to retain the stabilizing bracket and hardware for later re-assembly onto the cabinet.

3. Remove the front cover from the bottom cabinet to access the front shipping bracket.

Press and release the handle latch at the bottom of the cover and then lift the cover up and off the cabinet.

4. Remove the three M10 bolts securing the rear shipping pad to the pallet and remove the shipping pad (see Figure 3).

NOTE Hold the back of the cabinet so that the bolts can be removed easily without the cabinet rolling backward.

5. Remove the two M10 bolts securing the front shipping bracket and remove the bracket (see Figure 3).

If needed, adjust the leveling feet to release the bracket.

Stabilizing Bracket

Front Shipping Bracket

Shipping Pad

M4 Screws

M10 Bolts

M10 Bolts

Figure 3. Removing the Brackets and Shipping Pad

6. Reinstall the front cover removed in Step 3.

Hang the top edge of the cover on the cabinet first, then lower the bottom edge and snap into place.

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NOTE Be sure to support the front and back of the cabinet when rolling it off the pallet to prevent tipping.

7. Slowly roll the cabinet toward the rear of the pallet. Once the pallet tilts, continue rolling the cabinet down the pallet until the cabinet touches the floor (see

Figure 4).

If needed, adjust the leveling feet so that the cabinet will roll.

Figure 4. Unloading the Cabinet

8. With the cabinet supported, slowly pull the pallet away from the cabinet (see

Figure 5).

Figure 5. Removing the Pallet

9. Roll the cabinet to the desired location.

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 11

Selecting an Installation Option

You are now ready to install the Powerware 9155 UPS. Select one of the following installation options according to your UPS configuration:

UPS Configuration Installation Chapter

UPS only Chapter 4, “UPS Only Installation” on page 13

UPS with an optional input isolation transformer

Chapter 5, “Input Isolation Transformer Installation” on page 17

UPS with an optional UPS-mounted bypass switch

Chapter 6, “UPS-Mounted Bypass Switch Installation” on

UPS with an optional wall-mounted bypass switch

Chapter 7, “Wall-Mounted Bypass Switch Installation” on

Parallel UPS configuration Refer to the Powerware 9155 Parallel UPS (8–15 kVA) User's

Guide.

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EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 13

Chapter 4 UPS Only Installation

The Powerware 9155 has the following power connections:

� 2‐phase (L1 and L2), neutral, and ground connection for rectifier/bypass input

� 2‐phase (L1 and L2), neutral, and ground connection for load output

The nominal input/output voltages are:

� 100/200, 110/220, or 120/240 Vac with 180° phase displacement

� 120/208 or 127/220 Vac with 120° phase displacement

Output overcurrent protection and disconnect switch must be provided by others.

Figure 8 on page 16 shows a oneline diagram of the UPS.

W A R N I N G Only qualified service personnel (such as a licensed electrician) should perform the UPS installation and initial startup. Risk of electrical shock.

To hardwire the UPS:

1. Verify that the electrical connections to the installation site have been properly installed.

2. A wall-mounted, user‐supplied, readily‐accessible disconnection device must be incorporated in the input wiring.

Compare the circuit breaker ratings and wire sizes to the specifications in Table 1 on page 15.

NOTE To accommodate the feature of easy system expandability, it is recommended that initial installation of the Powerware 9155 UPS contain wiring to support the maximum capacity of the UPS cabinet.

3. Switch off utility power to the distribution point where the UPS will be connected. Be absolutely sure there is no power.

4. Determine your equipment's grounding requirements according to your local electrical code.

5. Verify that the UPS battery circuit breaker is in the OFF position (see Figure 6).

UPS ONLY INSTALLATION

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality14

ON

OFF

UPS Wiring Access Cover

Conduit Landing

Battery Circuit Breaker

Figure 6. UPS Rear View

6. Remove the UPS wiring access cover and retain (see Figure 6).

7. Install conduit and hardwire the input, output, and ground terminations for the

UPS.

See Table 1 for specifications and Figure 7 for a detailed view of the UPS terminal block.

8. Replace the UPS wiring access cover.

9. Continue to “Stabilizing the Cabinet” on page 43 to complete the UPS installation.

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 15

NOTE Input neutral must be wired for proper operation. Failure to connect an input neutral will void the warranty.

Table 1. UPS Terminal Block (TB1) Wiring

Wire Function Terminal Position Input Circuit Breaker Rating

Minimum Wire Size* Tightening Torque

Conduit Connection (Entry Size)

Input Ground TB1‐1 8 AWG

25 lb in

(2.83 Nm)

2” access hole for

1‐1/2” conduit

AUX TB1‐2-1 and 2-2 —

Not Used TB1‐2A-1 and 2A-2 —

L1 TB1‐3 8 kVA

10 kVA

12 kVA

15 kVA

60A

80A

100A

100A

4 AWG (21.2 mm2)

3 AWG (26.7 mm2)

2 AWG (33.6 mm2)

2 AWG (33.6 mm2)

Neutral TB1‐4

L2 TB1‐5

Output L1 TB1‐6 8 AWG

25 lb in

(2.83 Nm)

2” access hole for

1‐1/2” conduit

Neutral TB1‐7 8 AWG

L2 TB1‐8 8 AWG

Not Used TB1‐8A-1 and 8A-2 —

Ground TB1‐9 8 AWG

* Use only 75°C-rated copper wire. Minimum wire size is based on 120/208 full load ratings applied to NEC Code Table 310‐16. Code may require a larger

AWG size than shown in this table because of temperature, number of conductors in the conduit, or long service runs. Follow local requirements.

1 3 4 5 6 7 8 9

Input

TB1 2 2A 8A

Output

Figure 7. UPS Terminal Block

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Figure 8. UPS Only Wiring Diagram

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Chapter 5 Input Isolation Transformer Installation

The Powerware 9155 has the following power connections:

� 2‐phase (L1 and L2), neutral, and ground connection for rectifier/bypass input

� 2‐phase (L1 and L2), neutral, and ground connection for load output

C A U T I O N � The input isolation transformer output is always 240V (180° phase angle).

� If installing a Maintenance Bypass Module (MBM) or Power Distribution Module (PDM), the UPS MUST be set up for 240V output only; otherwise, the “Bypass Not Available” alarm annunciates. Any equipment connected to the output requiring 208V (120° phase angle) is at risk for damage when using the maintenance bypass switch.

� The input isolation transformer cannot be used with a wall-mounted bypass switch.

Output overcurrent protection and disconnect switch must be provided by others.

Figure 12 and Figure 13 beginning on page 22 show the oneline diagrams of the input isolation transformer with the UPS.

W A R N I N G Only qualified service personnel (such as a licensed electrician) should perform the UPS installation and initial startup. Risk of electrical shock.

To hardwire the input isolation transformer and UPS (all hardware is supplied in the accessory kit):

1. Verify that the electrical connections to the installation site have been properly installed.

2. A wall-mounted, user‐supplied, readily‐accessible disconnection device must be incorporated in the input wiring.

Compare the circuit breaker ratings and wire sizes to the specifications in Table 2 on page 19.

NOTE To accommodate the feature of easy system expandability, it is recommended that initial installation of the Powerware 9155 UPS contain wiring to support the maximum capacity of the UPS cabinet.

3. Switch off utility power to the distribution point where the UPS will be connected. Be absolutely sure there is no power.

4. Determine your equipment's grounding requirements according to your local electrical code.

5. Verify that the UPS battery circuit breaker is in the OFF position (see Figure 9).

6. Verify that the input circuit breaker is in the OFF position.

7. Remove the UPS wiring access cover and retain.

8. Remove the input isolation transformer wiring cover and retain.

INPUT ISOLATION TRANSFORMER INSTALLATION

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality18

Input Isolation Transformer Wiring Cover

Input Circuit Breaker

ON

OFF

Battery Circuit Breaker

UPS Wiring Access Cover

Conduit Landing

ON

OFF

Figure 9. UPS with Input Isolation Transformer Rear View

9. If you are also installing an optional MBM or PDM, proceed to Step 15 on page 20; otherwise, continue to Step 10.

10. On the input isolation transformer, punch the two pilot holes in the conduit landing for the input and output conduit using a Greenlee® punch or similar device

(see Figure 10).

11. Hardwire the input, output, and ground terminations for the input isolation transformer.

See Table 2 for specifications and Figure 10 for a detailed view of the input isolation transformer terminal block.

EATON Powerware® 9155 UPS (8–15 kVA) User's Guide � 164201553 Rev F www.eaton.com/powerquality 19

Input

Output

L1

L2

8V

L2

0V

) L1 L2 N

G N

D

Edge Grommet

Pilot Holes in Conduit Landing

Figure 10. Input Isolation Transformer Hardwiring

NOTE Input neutral is supplied by the input isolation transformer.

Table 2. Input Isolation Transformer Terminal Block Wiring

Wire Function Terminal Position Input Circuit Breaker Rating Minimum Wire Size* Tightening Torque

Input L1 TB1‐1 8 kVA

10 kVA

12 kVA

15 kVA

60A

80A

100A

100A

3 AWG (26.7 mm2)

2 AWG (33.6 mm2)

1 AWG (42.4 mm2)

1 AWG (42.4 mm2)

25 lb in

(2.83 Nm)

L2 (208V) TB1‐2

L2 (240V) TB1‐3

Output L1 TB1‐4 8 kVA

10 kVA

12 kVA

15 kVA

4 AWG (21.2 mm2)

3 AWG (26.7 mm2)

2 AWG (33.6 mm2)

2 AWG (33.6 mm2)

25 lb in

(2.83 Nm)

L2 TB1‐5

Neutral TB1‐6

Ground Output TB1‐7 8 AWG 25 lb in

(2.83 Nm)Input TB1‐8 8 AWG

* Use only 75°C-rated copper wire. Minimum wire size is based on 120/208 full load ratings applied to NEC Code Table 310‐16. Code may require a larger

AWG size than shown in this table because of temperature, number of conductors in the conduit, or long service runs. Follow local requirements.

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12. Wire the output of the input isolation transformer terminal block to the UPS input terminal block (see Table 3 and Figure 11).

Table 3. UPS Terminal Block (TB1) Wiring

Wire Function Terminal Position Minimum Wire Size* Tightening Torque Conduit Connection (Entry Size)

Input Ground TB1‐1 8 AWG

25 lb in

(2.83 Nm)

2” access hole for

1‐1/2” conduit

AUX TB1‐2-1 and 2-2 —

Not Used TB1‐2A-1 and 2A-2 —

L1 TB1‐3 8 kVA

10 kVA

12 kVA

15 kVA

4 AWG (21.2 mm2)

3 AWG (26.7 mm2)

2 AWG (33.6 mm2)

2 AWG (33.6 mm2)

Neutral TB1‐4

L2 TB1‐5

Output L1 TB1‐6 8 AWG

25 lb in

(2.83 Nm)

2” access hole for

1‐1/2” conduit

Neutral TB1‐7 8 AWG

L2 TB1‐8 8 AWG

Not Used TB1‐8A-1 and 8A-2 —

Ground TB1‐9 8 AWG

* Use only 75°C-rated copper wire. Minimum wire size is based on 120/208 full load ratings applied to NEC Code Table 310‐16. Code may require a larger

AWG size than shown in this table because of temperature, number of conductors in the conduit, or long service runs. Follow local requirements.

1 3 4 5 6 7 8 9

Input

TB1 2 2A 8A

Output

Figure 11. UPS Terminal Block

13. Replace the UPS wiring access cover and the input isolation transformer wiring cover.

14. Continue to “Stabilizing the Cabinet” on page 43 to complete the UPS installation.

15. On the input isolation transformer, punch one pilot hole in the conduit landing for the input conduit using a Greenlee punch or similar device (see Figure 10 on page 19).

16. Install the supplied edge grommet in the top of the input isolation transformer wiring cover.

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17. Hardwire the input terminations (TB1‐1 through TB1‐3) for the input isolation transformer.

See Table 2 for specifications and Figure 10 for a detailed view of the input isolation transformer terminal block.

18. Punch a hole in the bottom of the MBM/PDM using a Greenlee punch or similar device for wiring access.

Insert the supplied nylon bushing inside the wiring access hole.

19. Continue to the following chapter, “UPS-Mounted Bypass Switch Installation,” to complete the installation.

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Figure 12. UPS with Input Isolation Transformer Wiring Diagram

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Figure 13. UPS with Input Isolation Transformer and MBM/PDM Wiring Diagram

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Chapter 6 UPS-Mounted Bypass Switch Installation

This chapter describes the Maintenance Bypass Module (MBM) and Power

Distribution Module (PDM) installation. Both modules have a Make-Before-Break

(MBB) maintenance bypass switch.

MBM/PDM Setup

If you purchased an optional MBM/PDM, attach the module to the UPS before any wiring installation. All hardware is supplied in the accessory kit.

To attach the optional MBM/PDM to the UPS:

1. Remove the connecting plate between the top cabinet and the cabinet below it on the UPS rear panel (see Figure 14). Discard the plate. Retain the screws for later use.

2. Remove the lowest top cover screw on each side of the UPS and discard.

Connecting Plate (8 screws)

Lowest Top Cover Screw (one each side)

Figure 14. UPS Rear View (2-High Cabinet Shown)

UPS-MOUNTED BYPASS SWITCH INSTALLATION

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3. Attach the supplied L-bracket to the lower rear (for 2-high) or middle rear (for

3-high) cabinet using three screws (see Figure 15).

Repeat for the other side.

4. Remove the UPS wiring access cover and retain.

L-Bracket and Screws

UPS Wiring Access Cover

Figure 15. Attaching the L-Brackets

5. Remove the MBM/PDM wiring access cover and one of the conduit landing plates and retain.

6. Tilt the top of the module forward and slide the module onto the L-brackets. The top left flange on the module fits up under the UPS electronics unit through an access slot.

MBM/PDM Wiring Access Cover

UPS Electronics Unit

Conduit Landing Plates

Figure 16. Installing the MBM or PDM (MBM Shown)

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7. Secure the sides of the module to the L-brackets using six screws (see

Figure 17).

8. Secure the top of the module to the top cabinet using four of the screws removed in Step 1.

9. Continue to the following section, “Wiring the MBM/PDM.”

Screws to L-Bracket (three each side)

Screws for Top of Module

Figure 17. Securing the MBM or PDM (MBM Shown)

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Wiring the MBM/PDM

The Powerware 9155 UPS has the following power connections:

� 2‐phase (L1 and L2), neutral, and ground connection for rectifier/bypass input

� 2‐phase (L1 and L2), neutral, and ground connection for load output

The nominal input/output voltages are:

� 100/200, 110/220, or 120/240 Vac with 180° phase displacement

� 120/208 or 127/220 Vac with 120° phase displacement

Output overcurrent protection and disconnect switch must be provided by others.

Figure 21 and Figure 22 beginning on page 32 show the oneline diagrams of the

MBM and PDM with the UPS.

W A R N I N G Only qualified service personnel (such as a licensed electrician) should perform the UPS installation and initial startup. Risk of electrical shock.

To hardwire the MBM/PDM:

1. Verify that the electrical connections to the installation site have been properly installed.

2. A wall-mounted, user‐supplied, readily‐accessible disconnection device must be incorporated in the input wiring.

Compare the circuit breaker ratings and wire sizes to the specifications in

Table 4.

NOTE To accommodate the feature of easy system expandability, it is recommended that initial installation of the Powerware 9155 UPS contain wiring to support the maximum capacity of the UPS cabinet.

3. Switch off utility power to the distribution point where the UPS will be connected. Be absolutely sure there is no power.

4. Determine your equipment's grounding requirements according to your local electrical code.

5. Verify that the UPS battery circuit breaker is in the OFF position (see Figure 18).

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ON

OFF

Battery Circuit Breaker

Figure 18. UPS with MBM Rear View

6. Punch two holes in the MBM/PDM conduit landing plate for the input and output conduit using a Greenlee punch or similar device.

7. Hardwire the input, output, and ground terminations for the MBM/PDM.

See Table 4 for specifications and Figure 19 for a detailed view of the MBM/PDM terminal block.

TB10

Figure 19. MBM/PDM Hardwiring (PDM Shown)

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NOTE Input neutral must be wired for proper operation. Failure to connect an input neutral will void the warranty. However, when wired with the optional isolation transformer, input neutral is supplied by the isolation transformer.

Table 4. MBM/PDM Terminal Block (TB10) Wiring

Wire Function Input Circuit Breaker Rating

Minimum Wire Size*

Tightening Torque

Conduit Connection (Entry Size)

Input Ground 8 AWG

120 lb in

(13.5 Nm)

2” access hole for

1‐1/2” conduit

L1 8 kVA

10 kVA

12 kVA

15 kVA

60A

80A

100A

100A

4 AWG (21.2 mm2)

3 AWG (26.7 mm2)

2 AWG (33.6 mm2)

2 AWG (33.6 mm2)

Neutral

L2

Output L1 3 AWG

120 lb in

(13.5 Nm)

2” access hole for

1‐1/2” conduit

Neutral 3 AWG

L2 3 AWG

Ground 8 AWG

* Use only 75°C-rated copper wire. Minimum wire size is based on 120/208 full load ratings applied to

NEC Code Table 310‐16. Code may require a larger AWG size than shown in this table because of temperature, number of conductors in the conduit, or long service runs. Follow local requirements.

8. Connect the factory-installed wiring from the maintenance bypass switch to the

UPS terminal block (see Figure 20).

Connect the maintenance bypass (red and black) wires to TB1-2 (the A/B maintenance bypass auxiliary contacts) on the UPS terminal block.

1 2 3 4 5 6 7 8 9

A/B Maintenance Bypass Auxiliary Contacts

TB1

Input Output

2A 8A

Figure 20. Wiring from Maintenance Bypass Switch to UPS

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9. Replace the wiring access cover on the UPS and the optional isolation transformer, if applicable.

10. Replace the MBM/PDM wiring access cover and conduit landing plate.

11. Continue to “Stabilizing the Cabinet” on page 43 to complete the installation.

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Figure 21. UPS with MBM Wiring Diagram

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Figure 22. UPS with PDM Wiring Diagram

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Chapter 7 Wall-Mounted Bypass Switch Installation

This chapter describes the wall-mounted bypass switch installation with the UPS. The wall-mounted bypass switch is a Make-Before-Break (MBB) maintenance bypass switch.

NOTE The input isolation transformer cannot be used with the wall-mounted bypass switch.

Figure 23 shows the wall-mounted bypass switch and dimensions.

Dimension Measurement

Height (A) 21.0” (53.4 cm)

Width (B) 14.0” (35.6 cm)

Depth (C) 6.8” (17.2 cm)

Mounting

Centers

(D) 11.0” (28.0 cm)

(E) 20.0” (50.8 cm)

Weight 31 lb (14.1 kg)

OFF

Figure 23. Wall-Mounted Bypass Switch Dimensions

WALL-MOUNTED BYPASS SWITCH INSTALLATION

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Wall-Mounted Bypass Switch Setup

To set up the wall-mounted bypass switch:

1. Remove the knockouts in the bottom or side of the bypass switch for AC Line

Input, AC to UPS Input, AC from UPS Output, and AC to the UPS load (see

Figure 24).

Figure 24. Wall-Mounted Bypass Switch Knockouts

2. Mount the bypass switch cabinet to a sturdy surface within sight of the UPS.

You may need to rotate the cabinet 90 degrees to enable operator access to the bypass switch.

3. Remove the six screws from the bypass switch front cover and remove the cover (see Figure 24).

4. Remove and discard any packing material from inside the bypass switch.

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Wiring the Wall-Mounted Bypass Switch

The Powerware 9155 UPS has the following power connections:

� 2‐phase (L1 and L2), neutral, and ground connection for rectifier/bypass input

� 2‐phase (L1 and L2), neutral, and ground connection for load output

The nominal input/output voltages are:

� 100/200, 110/220, or 120/240 Vac with 180° phase displacement

� 120/208 or 127/220 Vac with 120° phase displacement

Output overcurrent protection and disconnect switch must be provided by others.

Figure 29 on page 41 shows a oneline diagram of the UPS with a wall-mounted bypass switch.

W A R N I N G Only qualified service personnel (such as a licensed electrician) should perform the hardwired installation.

Risk of electrical shock.

To hardwire the wall-mounted bypass switch:

1. Verify that the electrical connections to the installation site have been properly installed.

2. A wall-mounted, user‐supplied, readily‐accessible disconnection device must be incorporated in the input wiring.

Compare the circuit breaker ratings and wire sizes to the specifications in Table 5 on page 39.

NOTE To accommodate the feature of easy system expandability, it is recommended that initial installation of the Powerware 9155 UPS contain wiring to support the maximum capacity of the UPS cabinet.

3. Switch off utility power to the distribution point where the bypass switch cabinet and UPS will be connected. Be absolutely sure there is no power.

4. Determine your equipment's grounding requirements according to your local electrical code.

5. Verify that the UPS battery circuit breaker is in the OFF position (see Figure 25).

6. Remove the UPS wiring access cover and retain (see Figure 25).

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ON

OFF

UPS Wiring Access Cover

Conduit Landing

Battery Circuit Breaker

Figure 25. UPS Rear View

7. Install the conduit to the bypass switch cabinet. AC input and AC output conductors must be run through separate conduit. UPS output circuits must be installed in a dedicated conduit system and not shared with other electrical circuits.

8. Hardwire the terminal strip inside the bypass switch cabinet. Use copper wire that is the appropriate size for the current draw.

See Figure 26 for a detailed view of the terminal strip label.

Figure 26. Wall-Mounted Bypass Switch Terminal Strip Wiring

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9. Install conduit and connect the wiring from the bypass switch to the UPS terminal block.

See Table 5 for specifications and Figure 27 for a detailed view of the UPS terminal block.

Table 5. UPS Terminal Block (TB1) Wiring

Wire Function Terminal Position Input Circuit Breaker Rating

Minimum Wire Size* Tightening Torque

Conduit Connection (Entry Size)

Input Ground TB1‐1 8 AWG

25 lb in

(2.83 Nm)

2” access hole for

1‐1/2” conduit

AUX TB1‐2-1 and 2-2 —

Not Used TB1‐2A-1 and 2A-2 —

L1 TB1‐3 8 kVA

10 kVA

12 kVA

15 kVA

60A

80A

100A

100A

4 AWG (21.2 mm2)

3 AWG (26.7 mm2)

2 AWG (33.6 mm2)

2 AWG (33.6 mm2)

Neutral TB1‐4

L2 TB1‐5

Output L1 TB1‐6 8 AWG

25 lb in

(2.83 Nm)

2” access hole for

1‐1/2” conduit

Neutral TB1‐7 8 AWG

L2 TB1‐8 8 AWG

Not Used TB1‐8A-1 and 8A-2 —

Ground TB1‐9 8 AWG

* Use only 75°C-rated copper wire. Minimum wire size is based on 120/208 full load ratings applied to NEC Code Table 310‐16. Code may require a larger

AWG size than shown in this table because of temperature, number of conductors in the conduit, or long service runs. Follow local requirements.

1 3 4 5 6 7 8 9

Input

TB1 2 2A 8A

Output

Figure 27. UPS Terminal Block

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10. Route the gray signal cable through the grommet on the left side of the bypass switch cabinet (see Figure 28). Connect the white and black pair of wires to

TB1-2 (the A/B maintenance bypass auxiliary contacts) on the UPS terminal block.

Secure each connection, tightening the terminal screws to a maximum 3.5 lb in

(0.4 Nm). Provide strain relief for cables by installing plastic cable ties.

NOTE DO NOT connect the red and black pair of wires in the gray signal cable.

Signal Cable

To UPS Terminal Block

Do Not Connect Red and Black Wires

Figure 28. Signal Cable Installation

11. Replace the bypass switch front cover and the UPS wiring access cover.

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Figure 29. UPS with Wall-Mounted Bypass Switch Wiring Diagram

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Chapter 8 Stabilizing the Cabinet

NOTE For seismic installations, you MUST order and install a Powerware 9155 UPS seismic kit; do not use the following instructions.

NOTE For non-seismic installations, you MUST install the stabilizing bracket on all 3-high cabinets. The stabilizing bracket is optional for 2-high cabinets.

To stabilize the cabinet(s):

1. Lower the leveling feet to prevent the cabinet from rolling (see Figure 30).

Figure 30. Lowering the Leveling Feet

2. Attach the stabilizing bracket to the bottom of the cabinet rear panel using the retained hardware from the shipping pallet according to the cabinet configuration:

� For one cabinet, see Figure 31.

� For two cabinets, see Figure 32.

� For three cabinets, see Figure 33.

NOTE No more than three cabinets can be attached together. For four cabinets, use two of the two-cabinet installations. For five cabinets, use one three-cabinet and one two-cabinet installation.

3. Use the holes and slots in the bottom of the bracket to attach the cabinet to the flooring if desired.

4. Continue to one of the following sections:

� “Extended Battery Module Installation” on page 47 to install optional EBMs.

� “Communication” on page 49 to install UPS communication options, such as

X-Slot cards or remote emergency power-off (REPO).

� “Operation” on page 57 to start up the UPS system.

STABILIZING THE CABINET

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M4 Screws

Figure 31. Stabilizing Bracket with One Cabinet

M4 Screws

Figure 32. Stabilizing Bracket with Two Cabinets

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M4 Screws

Figure 33. Stabilizing Bracket with Three Cabinets

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Chapter 9 Extended Battery Module Installation

NOTE A maximum of 22 battery strings can be installed in one configuration, including UPS batteries

(4 EBM-64 models or 3 EBM-96 models). UPS-32 models contain 2 strings; UPS-64 models contain 4 strings;

EBM-64 models contain 4 strings; and EBM-96 models contain 6 strings.

NOTE For non-seismic installations, you MUST install the stabilizing bracket on all 3-high cabinets. The stabilizing bracket is optional for 2-high cabinets.

To install the optional Extended Battery Module (EBM):

1. Position the EBM adjacent to the next cabinet.

2. Verify that all battery circuit breakers are in the OFF position (see Figure 34).

3. Remove the two ground straps from the EBM rear panel.

4. Install one ground strap between the UPS and EBM rear panels as shown in

Figure 34.

5. If additional EBMs are installed, attach another ground strap between the first and second EBM as shown in Figure 34. Repeat for each additional EBM.

6. Plug the EBM cable into the UPS battery connector.

7. If additional EBMs are installed, plug the EBM cable of the second cabinet into the battery connector on the first EBM. Repeat for each additional EBM.

UPS Battery Connector

Rear Ground Strap

EBM Battery Circuit Breaker

EBM Battery Connector

EBM

Cable

UPS Battery Circuit Breaker

ON

OFF

Figure 34. Typical EBM Installation (2-High Cabinets Shown)

EXTENDED BATTERY MODULE INSTALLATION

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8. Remove the top front covers of all cabinets.

Press and release the handle latch at the bottom of the cover and then lift the cover up and off the cabinet.

9. Install the remaining ground straps between each cabinet (see Figure 35).

10. Reinstall the top front covers removed in Step 8.

Hang the top edge of the cover on the cabinet first, then lower the bottom edge and snap into place.

11. Continue to one of the following sections:

� “Communication” on page 49 to install UPS communication options, such as

X-Slot cards or remote emergency power-off (REPO).

� “Operation” on page 57 to start up the UPS system.

NOTE After UPS startup, ensure maximum battery runtime by configuring the UPS for the correct number of

EBMs (see page 64).

Front Ground Strap

Figure 35. Front Ground Strap Installation (2-High Cabinets Shown)

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Chapter 10 Communication

This section describes the:

� DB-9 communication port

� X-Slot cards

� Powerware LanSafe® Power Management Software

� Remote emergency power-off (REPO)

� Relay output contacts

� Programmable signal inputs

Figure 36 shows the location of the communication options and control terminals on the UPS.

DB-9 Communication Port

REPO (normally closed) REPO (normally open)

Signal Input 2

Signal Input 1

X-Slot Communication Bay #2

X-Slot Communication Bay #1

Relay Output Contacts

Figure 36. Communication Options and Control Terminals

COMMUNICATION

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Installing Communication Options and Control Terminals

To access and install the communication options and control terminals:

1. Remove the front covers of all cabinets, starting with the top cabinet.

Press and release the handle latch at the bottom of each cover and then lift the cover up and off the cabinet (see Figure 37).

Figure 37. Removing the Front Covers

2. Install the appropriate X-Slot card and/or necessary cable(s) into the top cabinet

(see Figure 36 and Figure 38).

Figure 38. Installing Communication Cables

3. On the bottom cover (and also the middle cover if 3-high), remove a knockout tab in the top edge of the cover for each cable:

With wire cutters, cut either side of the tab and twist down to remove the tab

(see Figure 39).

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Figure 39. Removing Knockout Tabs

4. Route the cable(s) to the approximate location of the cover access holes.

5. Connect the…