eaton-9390-ups-100-160-kva-manual-serial-number-7th-digit-at-A-164201554.pdf

Powerware 9390 UPS 100–160 kVA Installation and Operation Manual

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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

Consignes de sécurité

CONSIGNES DE SÉCURITÉ IMPORTANTES

CONSERVER CES INSTRUCTIONS

CE MANUEL CONTIENT DES CONSIGNES DE SÉCURITÉ IMPORTANTES

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.

WARN ING

This is a product for restricted sales distribution to informed partners. Installation restrictions or additional measures may be needed to prevent disturbances.

Powerware, X-Slot, and ABM are registered trademarks and ConnectUPS is a trademark of Eaton Electrical Inc. Modbus is a registered trademark of Modicon. IBM and AS/400 are registered trademarks of International Business Machines Corp.

ECopyright 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.

iEATON Powerware® 9390 UPS (100–160 kVA) Installation and Operation Manual S 164201554 Rev E powerware.com

Table of Contents

1 Introduction 1-1

1.1 Basic System Configurations 1-2

1.2 Using This Manual 1-3

1.3 Conventions Used in This Manual 1-4

1.4 Safety Warnings 1-5

1.5 For More Information 1-6

1.6 Getting Help 1-6

Section I – Installation

2 UPS Installation Plan and Unpacking 2-1

2.1 Creating an Installation Plan 2-1

2.2 Preparing the Site 2-1

2.2.1 Environmental Considerations 2-2

2.2.2 Preparing for Wiring the UPS System 2-2

2.3 Inspecting and Unpacking the UPS Cabinet 2-2

3 Installing the UPS System 3-1

3.1 Preliminary Installation Information 3-1

3.2 UPS Cabinet Installation 3-1

3.2.1 Unloading the Powerware 9390 UPS Cabinet from the Pallet 3-2

3.2.2 Battery Cabinet Installation 3-5

3.2.3 Integrated Distribution Cabinet Installation 3-6

3.2.4 Integrated Accessory Cabinet Installation 3-6

3.2.5 UPS Sidecar Wiring 3-6

3.2.6 Installing UPS External and Battery Power Wiring 3-6

3.2.6.1 208V/220V Input External Wiring Installation 3-7

3.2.6.2 480V Input External Wiring Installation 3-9

3.2.6.3 Battery Wiring 3-10

3.2.7 Installing Interface Connections 3-11

3.2.7.1 TB1 and TB2 Connections 3-11

3.2.7.2 TB1 Battery Cabinet Connections 3-12

3.2.7.3 X-Slot Connections 3-13

3.2.8 Installing Accessories and Parallel System Control Wiring 3-14

3.3 Initial Startup 3-14

3.4 Completing the Installation Checklist 3-14

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4 Batteries 4-1

4.1 Important Safety Instructions 4-1

4.2 Installing Batteries 4-2

4.3 Recycling the Used Battery or UPS 4-2

5 Installing a Remote Emergency Power-off Switch 5-1

6 Installing Options and Accessories 6-1

6.1 Installing a Powerware Hot Sync CAN Bridge Card 6-1

6.2 Installing Parallel System Control Wiring 6-2

6.3 Installing a Remote Monitor Panel II 6-3

6.4 Installing a Relay Interface Module II 6-4

6.5 Installing a Supervisory Contact Module II 6-6

Section II – Operation

7 Understanding UPS Operation 7-1

7.1 Looking Inside the UPS System 7-1

7.2 Single Module Reverse Transfer (RT) 7-2

7.2.1 Single Module RT Modes 7-2

7.2.2 Normal Mode – RT 7-4

7.2.3 Bypass Mode – RT 7-6

7.2.4 Battery Mode – RT 7-8

7.3 Multiple Module Parallel System 7-9

7.3.1 Multiple Module Parallel System Modes 7-10

7.3.2 Normal Mode – Parallel 7-11

7.3.3 Bypass Mode – Parallel 7-12

7.3.4 Battery Mode – Parallel 7-14

7.4 Functional Description 7-15

7.4.1 Input Rectifier 7-15

7.4.2 Inverter 7-15

7.4.3 Battery Charger and Advanced Battery Management 7-15

7.4.4 Bypass 7-16

7.4.5 Batteries 7-16

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8 Features, Options, and Accessories 8-1

8.1 UPS Standard Features 8-1

8.1.1 Control Panel 8-1

8.1.2 Customer Interface 8-1

8.1.2.1 Building Alarm Monitoring 8-1

8.1.2.2 Alarm Contact 8-1

8.1.3 X-Slot Communication Bay 8-1

8.1.4 ConnectUPS-X Web/SNMP Card X-Slot Card 8-1

8.1.5 Advanced Battery Management 8-2

8.1.6 LanSafe Power Management Software 8-2

8.1.7 Installation Features 8-2

8.2 Options and Accessories 8-2

8.2.1 Integrated Battery Cabinets 8-2

8.2.2 Integrated Distribution Cabinet 8-2

8.2.3 Integrated Accessory Cabinet (IAC-B, IAC-T, and IAC-D) 8-3

8.2.4 Powerware Hot Sync Parallel System 8-3

8.2.5 Sync Control 8-3

8.2.6 Optional X-Slot Cards 8-3

8.2.7 Mini-CSB 8-3

8.2.8 Remote Monitor Panel II 8-4

8.2.9 Relay Interface Module II 8-4

8.2.10 Supervisory Contact Module II 8-4

8.3 Symbols, Controls, and Indicators 8-4

9 Using the Control Panel 9-1

9.1 Using the LCD and Pushbuttons 9-2

9.2 Using the Main Menu 9-3

9.2.1 Mimic Screen 9-3

9.2.2 Event Screens 9-4

9.2.3 Unit Meter Screens 9-6

9.2.4 Battery Discharge Log 9-9

9.2.5 KW Demand Log 9-11

9.2.6 Maximum Current Log 9-19

9.2.7 System Meters Screens 9-28

9.2.8 System Setup Level 0 Screens 9-33

9.2.9 System Setup Level 1 Screens 9-36

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9.3 System Controls Screen 9-45

9.4 Load Off Screen 9-47

9.5 Reading the Status Indicators 9-48

10 UPS Operating Instructions 10-1

10.1 Single Module Operation 10-1

10.1.1 Starting the UPS in Normal Mode 10-1

10.1.2 Starting the UPS in Bypass Mode 10-2

10.1.3 Starting the Power Module 10-3

10.1.4 Transfer from Normal to Bypass Mode 10-3

10.1.5 Transfer from Bypass to Normal Mode 10-4

10.1.6 Transfer from Normal to Bypass Mode and Shut Down UPS 10-4

10.1.7 UPS and Critical Load Shutdown 10-5

10.1.8 Charger Control 10-5

10.1.9 Using the UPS LOAD OFF Pushbutton 10-6

10.1.10 Using the Remote Emergency Power-off Switch 10-7

10.2 Multiple Module Parallel Operation 10-8

10.2.1 Starting the Parallel System in Normal Mode 10-8

10.2.2 Starting the Parallel System in Bypass Mode 10-9

10.2.3 Transfer Parallel System from Normal to Bypass Mode 10-10

10.2.4 Transfer Parallel System from Bypass to Normal Mode 10-10

10.2.5 Single UPM Shutdown 10-11

10.2.6 Restarting a Single UPM 10-11

10.2.7 Parallel System and Critical Load Shutdown 10-12

10.2.8 Using the UPS LOAD OFF Pushbutton 10-13

10.2.9 Using the Parallel System Remote Emergency Power-off Switch 10-14

11 Using Features and Options 11-1

11.1 Building Alarm Monitoring 11-1

11.2 General Purpose Relay Contact 11-1

11.3 Optional Remote Monitor Panel II 11-2

11.4 Relay Interface Module II 11-4

11.5 Supervisory Contact Module II 11-5

12 Responding to System Events 12-1

12.1 General 12-1

12.2 System Event Horns 12-1

12.3 System Event Indicators 12-1

12.4 System Event Messages 12-1

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13 Communication 13-1

13.1 X-Slot Cards 13-1

13.2 LanSafe Power Management Software 13-2

13.3 Remote Notification 13-2

13.4 Terminal Mode 13-3

13.4.1 Display UPS Control Panel 13-3

13.4.2 Event History Log 13-4

14 Maintaining the UPS System 14-1

14.1 Important Safety Instructions 14-1

14.2 Performing Preventive Maintenance 14-2

14.2.1 DAILY Maintenance 14-2

14.2.2 MONTHLY Maintenance 14-3

14.2.3 ANNUAL Maintenance 14-3

14.2.4 BATTERY Maintenance 14-3

14.3 Maintenance Training 14-3

15 Product Specifications 15-1

15.1 Model Numbers 15-1

15.2 Single Module Specifications 15-1

15.2.1 UPS System Input 15-1

15.2.2 UPS System Output 15-2

15.2.3 Environmental 15-2

15.3 Multiple Module Parallel Specifications 15-3

15.3.1 UPM Input 15-3

15.3.2 UPM Output 15-3

15.3.3 Environmental 15-3

15.3.4 Battery 15-3

15.3.5 Module Tie Cabinet Input 15-3

15.3.6 Module Tie Cabinet Output 15-3

Appendix A – Installation Information A-1

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viiEATON Powerware® 9390 UPS (100–160 kVA) Installation and Operation Manual S 164201554 Rev E powerware.com

List of Figures

Figure 1-1. Powerware 9390 UPS (100–160 kVA) Cabinet 1-1 Figure 2-1. Powerware 9390 UPS (100–160 kVA) Cabinet as Shipped on Pallet 2-3 Figure 3-1. Removing Front Shipping Bracket on the Powerware 9390 UPS 3-3 Figure 3-2. Removing Rear Shipping Bracket on the Powerware 9390 UPS 3-4 Figure 5-1. REPO Switch 5-1 Figure 6-1. Powerware Hot Sync CAN Bridge Card 6-1 Figure 6-2. Supervisory Contact Module II TB2 6-7 Figure 7-1. Main Elements of the UPS System 7-1 Figure 7-2. Path of Current Through the UPS in Normal Mode – RT 7-4 Figure 7-3. Path of Current Through the UPS in Bypass Mode – RT 7-6 Figure 7-4. Path of Current Through the UPS in Battery Mode – RT 7-8 Figure 7-5. Path of Current through the UPMs in Normal Mode – Parallel 7-11 Figure 7-6. Path of Current through the UPMs in Bypass Mode – Parallel 7-12 Figure 7-7. Path of Current through the UPMs in Battery Mode – Parallel 7-14 Figure 9-1. UPS Control Panel 9-1 Figure 9-2. Parts of the LCD 9-2 Figure 9-3. Main Menu and Mimic Screen (Normal Mode) 9-3 Figure 9-4. Active Events Screen 9-4 Figure 9-5. History Screen 9-5 Figure 9-6. Unit Output Meter Screen 9-6 Figure 9-7. Unit Input Meter Screen 9-7 Figure 9-8. Unit Bypass Meter Screen 9-7 Figure 9-9. Unit Battery Meter Screen 9-8 Figure 9-10. Unit Output Current (Load) Meter Screen 9-8 Figure 9-11. Battery Discharge Log Summary Screen 9-9 Figure 9-12. Battery Discharge Log Screen 9-10 Figure 9-13. KW Demand Log Summary Screen 9-11 Figure 9-14. KW Demand Log Screen 9-12 Figure 9-15. Current KW Demand Log Setup Screen 1 9-13 Figure 9-16. Current KW Demand Log Setup Screen 2 9-14 Figure 9-17. Time Interval Monitored Setup Screen 9-15 Figure 9-18. Time Interval Monitored Setup Save Screen 9-16 Figure 9-19. Maximum Level (KW) Setup Screen 9-17 Figure 9-20. Maximum Level (KW) Setup Save Screen 9-18 Figure 9-21. Maximum Current Log Summary Screen 9-19 Figure 9-22. Maximum Current Log Screen (Three-Phase Measurement) 9-20 Figure 9-23. Maximum Current Log Screen (Individual Phase Measurement) 9-21

List of Figures viii EATON Powerware® 9390 UPS (100–160 kVA) Installation and Operation Manual S 164201554 Rev E powerware.com

Figure 9-24. Maximum Current Log Setup Screen 1 9-21 Figure 9-25. Maximum Current Log Setup Screen 2 9-22 Figure 9-26. Time Interval Monitored Setup Screen 9-23 Figure 9-27. Time Interval Monitored Setup Save Screen 9-24 Figure 9-28. Maximum % of Full Load Setup Screen 9-25 Figure 9-29. Maximum % of Full Load Setup Save Screen 9-26 Figure 9-30. Calculation Method Setup Screen 9-27 Figure 9-31. System Meters Screen 9-28 Figure 9-32. Total System Output Meter Screen 9-29 Figure 9-33. Output Unit X Meter Screen 9-30 Figure 9-34. Input Unit X Meter Screen 9-31 Figure 9-35. Bypass Unit X Meter Screen 9-31 Figure 9-36. Battery Unit X Meter Screen 9-32 Figure 9-37. Output Current (Load) Unit X Meter Screen 9-32 Figure 9-38. System Setup Level 0 Screen 9-33 Figure 9-39. Contrast Adjust Screen 9-34 Figure 9-40. Versions Screen 9-35 Figure 9-41. Unit Type Screen 9-35 Figure 9-42. Enter Password Screen 9-36 Figure 9-43. System Setup Level 1 Screen 9-37 Figure 9-44. Change Password Screen 9-38 Figure 9-45. Change Password Save Screen 9-39 Figure 9-46. Time Format Screen 9-40 Figure 9-47. Set Date and Time MM/DD/YYYY Screen 9-41 Figure 9-48. Set Date and Time DD/MM/YYYY Screen 9-42 Figure 9-49. COM Port Setup Screen 9-43 Figure 9-50. COM Setup Screen 9-44 Figure 9-51. System Controls Screen 1 9-45 Figure 9-52. System Controls Screen 2 9-46 Figure 9-53. Load Off Screen 9-47 Figure 11-1. Remote Monitor Panel II 11-2 Figure 11-2. Relay Interface Module II 11-4 Figure 11-3. Supervisory Contact Module II 11-5 Figure 13-1. Optional X-Slot Cards 13-2 Figure 13-2. Sample Event History Log 13-5

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Chapter 1 Introduction

The Powerware® 9390 uninterruptible power supply (UPS) is a true online, continuous-duty, transformerless, double-conversion, solid-state, three-phase system, providing conditioned and uninterruptible AC power to protect the customer’s load from all nine power failures.

The Powerware 9390 UPS is available as a single module or a multiple module parallel system (see paragraph 1.1).

The Powerware online power protection system is used to prevent loss of valuable electronic information, minimize equipment downtime, and minimize the adverse effect on production equipment due to unexpected power problems.

The Powerware 9390 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. The cabinet matches the battery and distribution cabinets in style and color and can be installed in line-up-and-match or standalone configurations. Figure 1-1 shows the Powerware 9390 UPS (100–160 kVA).

Figure 1-1. Powerware 9390 UPS (100–160 kVA) Cabinet

Introduction

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1.1 Basic System Configurations

The following basic UPS system configurations are possible:

� Single module UPS and one to four battery cabinets

� Single module UPS with UPS Sidecar (maintenance bypass or 1+1 tie configuration) and one to four battery cabinets

� Single module UPS, one to four battery cabinets, and an optional Integrated Distribution Cabinet (IDC)

� Single module UPS, one to four battery cabinets, and an optional Integrated Accessory Cabinet (IAC) (maintenance bypass, 1+1 tie, or 1+1 tie with maintenance bypass configuration)

� Single module UPS, one to four battery cabinets, and an optional Integrated Accessory Cabinet (IAC) (distribution configuration)

� Powerware Hot Sync parallel system with two UPS modules, one to four battery cabinets for each UPS, and an optional module tie cabinet

- One capacity/one redundant (1+1)

- Two capacity (2+0)

� Powerware Hot Sync parallel system with three UPS modules, one to four battery cabinets for each UPS, and an optional module tie cabinet

- Two capacity/one redundant (2+1)

- Three capacity (3+0)

� Powerware Hot Sync parallel system with four UPS modules, one to four battery cabinets for each UPS, and an optional module tie cabinet

- Three capacity/one redundant (3+1)

- Four capacity (4+0)

� Powerware Hot Sync parallel system with two UPS modules, one to four battery cabinets for each UPS, an optional module tie cabinet, and an optional IDC

- One capacity/one redundant (1+1)

- Two capacity (2+0)

� Powerware Hot Sync parallel system with three UPS modules, one to four battery cabinets for each UPS, an optional module tie cabinet, and an optional IDC

- Two capacity/one redundant (2+1)

- Three capacity (3+0)

� Powerware Hot Sync parallel system with four UPS modules, one to four battery cabinets for each UPS, an optional module tie cabinet, and an optional IDC

- Three capacity/one redundant (3+1)

- Four capacity (4+0)

The UPS system configuration can be enhanced by adding optional accessories such as a Remote Emergency Power-off (REPO) control, Remote Monitor Panel II (RMP II), or X-Slot® communication cards.

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1.2 Using This Manual

This manual describes how to install and operate the Powerware 9390 UPS (100–160 kVA) cabinet. Read and understand the procedures described in this manual to ensure trouble-free installation and operation. In particular, be thoroughly familiar with the REPO procedure (see page 10-7).

The information in this manual is divided into the sections and chapters listed. The system, options, and accessories being installed dictate which parts of this manual should be read.

At a minimum, Chapters 1 through 3 and 8 through 10 should be examined.

� Chapter 1, “Introduction” – provides a brief description of the UPS system, a description of the content of each chapter, text conventions used in the manual, safety warnings, and reference information.

Section I, Installation

� Chapter 2, “UPS Installation Plan and Unpacking” – explains how to prepare the site for the installation of the UPS system. It discusses equipment environmental requirements, inspecting, and unpacking cabinets.

� Chapter 3, “Installing the UPS System” – describes how to install and wire the UPS cabinet and optional equipment.

� Chapter 4, “Batteries” – provides battery safety and installation information.

� Chapter 5, “Installing a Remote Emergency Power-off Control” – contains information for installing the optional REPO control.

� Chapter 6, “Installing Options and Accessories” – contains information for installing an X-Slot Powerware Hot Sync CAN Bridge Card, parallel control wiring, an RMP II, a Relay Interface Module II (RIM II), or a Supervisory Contact Module II (SCM II).

Section II, Operation

� Chapter 7, “Understanding UPS Operation” – provides information on why and how a UPS works.

� Chapter 8, “Features, Options, and Accessories” – describes the standard and optional UPS features and available accessories.

� Chapter 9, “Using the Control Panel” – describes the controls and indicators found on the control panel and shows the various information screens displayed on the LCD.

� Chapter 10, “UPS Operating Instructions” – contains startup and shutdown procedures for the UPS system.

� Chapter 11, “Using Features and Options” – contains descriptions and instructions for the UPS system features and options.

� Chapter 12, “Responding to System Events” – lists all the alarms and notices that occur during operation of the UPS system.

� Chapter 13, “Communication” – describes the communication features of the UPS system.

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� Chapter 14, “Maintaining the UPS System” – contains maintenance instructions for the UPS system.

� Chapter 15, “Product Specifications” – provides detailed specifications for the UPS system.

� Appendix A, “Installation Information” – contains important information on wiring requirements and recommendations, and important diagrams of the cabinets’ mechanical details and electrical access.

� Warranty – provides the Powerware warranty for this product.

Read through each procedure before beginning the procedure. Perform only those procedures that apply to the UPS system being installed or operated.

1.3 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

Information notes call attention to important features or instructions.

[Keys] Brackets are used when referring to a specific key, such as [Enter] or [Ctrl].

In this manual, the term UPS refers only to the UPS cabinet and its internal elements. The term UPS system refers to the entire power protection system – the UPS cabinet, the battery cabinet, and options or accessories installed.

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1.4 Safety Warnings

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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

The UPS cabinet is designed for industrial or computer room applications, and contains safety shields behind the doors. However, the UPS system is a sophisticated power system and should be handled with appropriate care.

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.

WARN ING

� The UPS system contains its own energy source (batteries). The output terminals may carry live voltage 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 power is disconnected before performing installation or service.

CAUT ION

� 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 local codes for disposal requirements.

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

� Keep the UPS doors closed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit.

� Do not 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.

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1.5 For More Information

Refer to the Powerware 9390 Integrated Battery Cabinet (Models IBC-S and IBC-L) Installation Manual (164201536) for the following additional information:

� Integrated Battery Cabinet (IBC) installation instructions, including site preparation, planning for installation, wiring, and safety information.

� Detailed illustrations of the cabinet, including dimension and connection point drawings.

Refer to the Powerware 9390 Integrated Distribution Cabinet (160 kVA) Installation and Operation Manual, (164201560), the Powerware 9390 Integrated Accessory Cabinet (IAC-B and IAC-T Configurations) Installation and Operation Manual (164201590), the Powerware 9390 Integrated Accessory Cabinet (IAC-D Configuration) Installation and Operation Manual (164201591), the Powerware 9390 UPS Sidecar Installation and Operation Manual (164201586), or the Powerware 9390 Sync Control Installation and Operation Manual (164201571), as applicable, for the following additional information:

� Installation instructions, including site preparation, planning for installation, and wiring and safety information. Detailed illustrations of the cabinet with dimensional and connection point drawings are provided.

� Operation, including controls, functions of the standard and optional features, procedures for using with the UPS, and information about maintenance.

Visit www.powerware.com or contact your Eaton service representative for information on how to obtain copies of these manuals

1.6 Getting Help

If help is needed with any of the following:

� Scheduling initial startup

� Regional locations and telephone numbers

� A question about any of the information in this manual

� A question this manual does not answer

Please call the Eaton Help Desk for Powerware products at:

In the United States 1-800-843-9433 or 1-919-870-3028 In Canada 1-800-461-9166 All other countries Call your service representative

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Section I Installation

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2-1EATON Powerware® 9390 UPS (100–160 kVA) Installation and Operation Manual S 164201554 Rev E powerware.com

Chapter 2 UPS Installation Plan and Unpacking

Use the following basic sequence of steps to install the UPS:

1. Create an installation plan for the UPS system (Chapter 2).

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

3. Inspect and unpack the UPS cabinet (Chapter 2).

4. Unload and install the UPS cabinet, and wire the system (Chapter 3).

5. Install features, accessories, or options, as applicable (Chapters 5 and 6).

6. Complete the Installation Checklist (Chapter 3).

7. 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 on page W-1 become void.

This service is offered as part of the sales contract for the UPS. Contact service in advance (usually a two-week notice is required) to reserve a preferred startup date.

2.1 Creating an Installation Plan

Before installing the UPS system, read and understand how this manual applies to the system being installed. Use the procedures and illustrations in the following chapters to create a logical plan for installing the system.

2.2 Preparing the Site

For the UPS system to operate at peak efficiency, the installation site should meet the environmental parameters outlined in this manual. If the UPS is to be operated at an altitude higher than 1500m (5000 ft), contact your Eaton service representative for important information about high altitude operation. The operating environment must meet the weight, clearance, and environmental requirements specified in Drawing 164201554-2 on page A-3 and size requirements specified on Drawing 164201554-9 starting on page A-46.

The UPS cabinets use forced air cooling to regulate internal component temperature. Air inlets are in the front of the cabinet and outlets are in the top. You must allow clearance in front of and above each cabinet for proper air circulation.

UPS Installation Plan and Unpacking

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2.2.1 Environmental Considerations

The life of the UPS system is adversely affected if the installation does not meet the following guidelines:

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

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

Failure to follow guidelines may void your warranty.

2.2.2 Preparing for Wiring the UPS System

NOTE If installing, as part of the UPS system, a maintenance bypass without a rectifier input breaker, a minimum of two separate feeds with upstream feeder breakers, or one feed with two upstream feeder breakers, must be provided: one for the UPS and one for the maintenance bypass input. DO NOT use one feed or a single feeder breaker to supply both the UPS and the maintenance bypass.

For external wiring requirements, including the minimum AWG size of external wiring, see Table E through Table G starting on page A-12. The power wiring connections for this equipment are rated at 90°C. If wire is run in an ambient temperature greater than 30°C, higher temperature wire and/or larger size wire may be necessary

Control wiring for Emergency Power-off (EPO) and optional accessories (such as building alarms and monitoring interface) should be connected at the customer interface terminal blocks located inside the UPS.

LAN and telephone drops, for use with X-Slot connectivity cards, must be supplied by facility planners or the customer.

2.3 Inspecting and Unpacking the UPS Cabinet

The cabinet is shipped bolted to a wooden pallet and protected with outer protective packaging material (see Figure 2-1).

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Figure 2-1. Powerware 9390 UPS (100–160 kVA) Cabinet as Shipped on Pallet

CAUT ION

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

1. Carefully inspect the outer packaging for evidence of damage during transit.

CAUT ION

Do not install a damaged cabinet. Report any damage to the carrier and contact your Eaton service representative immediately.

2. Use a forklift or pallet jack to move the packaged cabinet to the installation site, or as close as possible, before unpacking. Insert the forklift or pallet jack forks between the pallet supports on the bottom of the unit.

NOTE Verify that the forklift or pallet jack is rated to handle the weight of the cabinet (see Table A on page A-3 for cabinet weight).

CAUT ION

Do not tilt the UPS cabinet more than 10° from vertical or the cabinet may tip over.

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3. Set the pallet on a firm, level surface, allowing a minimum clearance of 3m (10 ft) on each side for removing the cabinet from the pallet.

NOTE The UPS cabinet is shipped with a debris shield covering the ventilation grill on top of the unit. Do not remove the debris shield until installation is complete.

4. Remove the protective covering from the cabinet.

5. Remove the packing material, and discard or recycle in a responsible manner.

6. After removing the protective covering, inspect the contents for any evidence of physical damage, and compare each item with the Bill of Lading. If damage has occurred or shortages are evident, contact your Eaton service representative immediately to determine the extent of the damage and its impact upon further installation.

NOTE While waiting for installation, protect the unpacked cabinet from moisture, dust, and other harmful contaminants. Failure to store and protect the UPS properly may void your warranty.

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Chapter 3 Installing the UPS System

3.1 Preliminary Installation Information

WARN ING

Installation should be performed only by qualified personnel.

Refer to the following while installing the UPS system:

� Appendix A contains installation drawings and additional installation notes.

� Dimensions are in millimeters and inches.

� Do not tilt the cabinets more than 10° during installation.

� The conduit landing plates are to be removed to add conduit landing holes as required.

Plate material is 16 gauge steel (1.5 mm/0.06″ thick).

� The cabinets must be installed on a level floor suitable for computer or electronic equipment.

� If perforated floor tiles are required for ventilation, place them in front of the UPS. See Table A on page A-3 for equipment weight and point loading.

� Details about control wiring are provided in each procedure for connecting options and features. Drawing 164201554-8 and Table R through Table X starting on page A-33 identify the control wiring terminations.

3.2 UPS Cabinet Installation

To install a UPS cabinet, perform the procedures in the following paragraphs.

NOTE When a line-up-and-match UPS system is ordered together with battery cabinets, the first battery cabinet is supplied with two cosmetic covers. The UPS cabinet, additional battery cabinets, and other ancillary cabinets are supplied without cosmetic covers.

NOTE When a UPS system is ordered together with battery cabinets for standalone installation, the first battery cabinet is supplied with two cosmetic covers. Additional battery cabinets are supplied without cosmetic covers. Cosmetic covers must be ordered for the UPS cabinet and/or other ancillary cabinets.

Installing the UPS System

3-2 EATON Powerware® 9390 UPS (100–160 kVA) Installation and Operation Manual S 164201554 Rev E powerware.com

3.2.1 Unloading the Powerware 9390 UPS Cabinet from the Pallet The UPS cabinet is bolted to a wooden pallet supported by wood skids. To remove the pallet, perform the following procedure:

WARN ING

The UPS cabinet is heavy. See Table A on page A-3 for weight of cabinets. If unloading instructions are not closely followed, the cabinet may cause serious injury.

CAUT ION

Do not tilt cabinets more than 10° from vertical.

1. If not already accomplished, use a forklift or pallet jack to move the cabinet to the installation area, or as close as possible, before unloading from the pallet. Insert the forklift or pallet jack forks between the skids on the bottom of the unit.

NOTE Verify that the forklift or pallet jack is rated to handle the weight of the cabinet (see Table A on page A-3 for cabinet weight).

2. Unfasten the front door latch and swing the door open (see Figure 3-1).

3. Remove the doors. Remove the retaining screws located inside each door at the top and bottom hinge pivot points, then lift the door off. Retain the hardware for later use.

4. If the leveling feet are not fully retracted, turn the leveling feet until they are retracted.

5. Remove the four bolts securing the front shipping bracket to the cabinet and four bolts securing the bracket to the pallet (see Figure 3-1). Remove the front shipping bracket. If installing the cabinet permanently, retain the shipping bracket and securing hardware for later use.

6. Remove the four bolts securing the rear shipping bracket to the pallet. Do NOT remove the four bolts securing the bracket to the cabinet (see Figure 3-2 on page 3-4).

7. Remove the four bolts securing the removable skid and remove the skid (see Figure 3-1).

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Shipping Bracket Bolts

Front View

Pallet

Vented Front Doors

Front Shipping Bracket

Shipping Bracket Bolts

Removable Skid

Skid Bolts

Figure 3-1. Removing Front Shipping Bracket on the Powerware 9390 UPS

3-4 EATON Powerware® 9390 UPS (100–160 kVA) Installation and Operation Manual S 164201554 Rev E powerware.com

Rear Shipping Bracket

Pallet

Rear View

Shipping Bracket Bolts

Shipping Bracket Bolts

Figure 3-2. Removing Rear Shipping Bracket on the Powerware 9390 UPS

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NOTE In the following step the pallet tilts and acts as a ramp once the cabinet is rolled beyond the the center of the pallet. Be sure to restrain the cabinet as it continues to roll down the pallet/ramp. The rear shipping bracket will act as a brake to assist restraining the cabinet.

WARN ING

Do not stand directly in front of the pallet while unloading the cabinet. If unloading instructions are not closely followed, the cabinet may cause serious injury.

8. Slowly roll the cabinet toward the front of the pallet. Once the pallet tilts, continue rolling the cabinet down the pallet until the cabinet is clear of the pallet.

9. Remove the four bolts securing the rear shipping bracket to the cabinet (see Figure 3-2). If installing the cabinet permanently, retain the shipping bracket and securing hardware for later use.

10. Roll the cabinet to the final installation location.

11. If installing the cabinet permanently, retain the shipping brackets and hardware;

otherwise, discard or recycle the pallet and shipping brackets in a responsible manner.

12. If permanently mounting the system, proceed to Step 15; otherwise, continue to Step 13.

13. Secure the UPS cabinet in position by lowering the leveling feet until the cabinet is not resting on the casters and the cabinet is level.

14. If installing battery and distribution cabinets, proceed to paragraphs 3.2.2 and 3.2.3; otherwise, proceed to paragraph 3.2.6.

15. Using the retained hardware, reinstall the shipping brackets removed in Step 6 to the front and rear of the UPS cabinet with the angle facing outward (see Figure 3-1 and Figure 3-2).

16. Secure the cabinet to the floor with contractor-supplied hardware.

17. If installing battery and distribution cabinets, proceed to paragraphs 3.2.2 and 3.2.3; otherwise, proceed to paragraph 3.2.6.

3.2.2 Battery Cabinet Installation

To install the battery cabinet, refer to the Powerware 9390 Integrated Battery Cabinet (Models IBC-S and IBC-L) Installation Manual. After the battery cabinet is installed, return to paragraph 3.2.6 to wire the UPS and battery cabinet.

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3.2.3 Integrated Distribution Cabinet Installation

To install and wire an IDC, refer to the Powerware 9390 Integrated Distribution Cabinet (160 kVA) Installation and Operation Manual. After the IDC is installed and wired, return to paragraph 3.2.6 to complete the UPS cabinet wiring.

3.2.4 Integrated Accessory Cabinet Installation

To install and wire an IAC, refer to the Powerware 9390 Integrated Accessory Cabinet (IAC-B and IAC-T Configurations) Installation and Operation Manual or the Powerware 9390 Integrated Accessory Cabinet (IAC-D Configuration) Installation and Operation Manual.

After the IAC is installed and wired, return to paragraph 3.2.6 to complete the UPS cabinet wiring.

3.2.5 UPS Sidecar Wiring

To wire an UPS Sidecar, refer to the Powerware 9390 UPS Sidecar Installation and Operation Manual. After the UPS Sidecar is wired, return to paragraph 3.2.6 to complete the UPS cabinet wiring.

3.2.6 Installing UPS External and Battery Power Wiring

NOTE The UPS cabinet is shipped with a debris shield covering the ventilation grill on top of the unit. Do not remove the debris shield until installation is complete. However, remove the shield before operating the UPS. Once the debris shield is removed, do not place objects on the ventilation grill.

NOTE Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes (see Drawing 164201554-6 on page A-27).

NOTE If the load requires a neutral, a bypass source neutral must be provided. If the load does not require a neutral and there is no neutral conductor connected at the bypass input, a neutral to ground bonding jumper must be installed. DO NOT install both a source neutral and a bonding jumper. See Table E through Table G or Table O through Table Q for neutral bonding jumper wire sizes. Bonding jumper must be copper wire.

CAUT ION

HIGH IMPEDANCE GROUND SOURCES - If the supply source is a high impedance ground (IT) type, the input neutral conductor must be connected from the source of supply. If there is no output neutral connected to the UPS, the neutral-forming transformer kit (PN 103005400) may be used instead of pulling a neutral from the source. If the load requires a neutral, then an input neutral conductor must be pulled into the UPS. In no circumstances shall a neutral to ground bonding jumper be installed in the UPS.

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CAUT ION

DELTA SOURCES (TN-S) - The 9390 UPS system can be operated only from a delta supply source that is fully floating and if the neutral-forming transformer kit (PN 103005400) is installed in the UPS. The UPS cannot be operated from a mid-point or end-point grounded delta supply source. With this type of supply source, there is no capability to provide an output neutral. In no circumstances shall a neutral to ground bonding jumper be installed in the

UPS.

3.2.6.1 208V/220V Input External Wiring Installation To install wiring to connections:

1. Slide the air filters up and remove them from the cabinet.

2. Remove the screws securing the control panel door and swing the door open.

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

4. If installing power wiring from the top of the cabinet, proceed to Step 5;

otherwise, proceed to Step 6.

5. FOR TOP ACCESS WIRING - Remove the screws securing the top internal safety shield panel and remove the panel to gain access to the top wiring entry. Retain the hardware for later use. Remove the top conduit plate from its storage location on the top of the UPS. Identify all conduit requirements and mark their location.

Drill and punch all conduit holes in top conduit plate prior to mounting on UPS.

Install conduit plate and install all conduit runs into plate. Pull wiring through conduit into UPS wiring area.

6. FOR BOTTOM ACCESS WIRING - Remove the bottom conduit plate from its location on the bottom of the UPS. Identify all conduit requirements and mark their location. Drill and punch all conduit holes in bottom conduit plate prior to mounting on UPS. Install conduit plate and install all conduit runs into plate. Pull wiring through conduit into UPS wiring area.

7. Route the input and output cables to the UPS terminal blocks. See Drawing 164201554-7 starting on page A-29 for wiring access information and terminal locations.

8. If wiring a single-feed system, proceed to Step 9; if wiring a dual-feed system, proceed to Step 11.

9. Connect phase A, B, C, and Neutral (if required) input power wiring from the utility source to the rectifier input terminals and neutral terminals in the UPS cabinet. See Appendix A for wiring and termination requirements and wiring access information. Note wiring connections for single-feed systems.

10. Proceed to Step 14.

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CAUT ION

In the following step, DO NOT move the sensing and EMI wires from the rectifier contactor K1 input terminals. These wires must remain connected to the K1 terminals for proper UPS operation.

11. Disconnect the phase A, B, and C bypass contactor K5 power input leads only (two 1/0 AWG wires per phase) from the rectifier contactor K1 input terminals. Connect these power leads to the bypass input terminals.

12. Connect phase A, B, and C rectifier input power wiring from the utility source to the rectifier input terminals in the UPS cabinet. See Appendix A for wiring and termination requirements and wiring access information. Note wiring connections for dual-feed systems.

13. Connect phase A, B, and C, and Neutral (if required) bypass input power wiring from the utility source to the bypass input terminals and neutral terminals in the UPS cabinet. See Appendix A for wiring and termination requirements and wiring access information. Note wiring connections for dual-feed systems.

14. If wiring an IDC or IAC, proceed to Step 15; otherwise, proceed to Step 18.

15. Route and connect the output cable between the UPS cabinet and the IDC or IAC.

Refer to the applicable IDC or IAC installation and operation manual, referenced in paragraph 1.5 on page 1-6, for wiring instructions. See Appendix A for UPS cabinet wiring access information.

16. Connect phase A, B, and C, and Neutral (if required) power wiring from the IDC or IAC to the UPS cabinet output and neutral terminals. See Appendix A for wiring and termination requirements.

17. Proceed to paragraph 3.2.6.3.

18. If wiring a parallel system, proceed to Step 19; otherwise, proceed to Step 21.

CAUT ION

Parallel system wiring length should be in accordance with Drawing 164201554-5, sheet 15 of 15, to ensure approximately equal current sharing when in Static Bypass mode.

19. Connect phase A, B, and C, and Neutral (if required) power wiring from the output and neutral terminals of each uninterruptible power module (UPM) to the module tie cabinet. See Appendix A for UPM wiring and termination requirements and wiring access information.

20. Proceed to paragraph 3.2.6.3.

21. Connect phase A, B, and C, and Neutral (if required) power wiring from the output and neutral terminals to the critical load. See Appendix A for wiring and termination requirements and wiring access information.

22. Proceed to paragraph 3.2.6.3.

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3.2.6.2 480V Input External Wiring Installation To install wiring to connections:

1. Slide the air filters up and remove them from the cabinet.

2. Remove the screws securing the control panel door and swing the door open.

Retain the hardware for later use.

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

4. If installing power wiring from the top of the cabinet, proceed to Step 5;

otherwise, proceed to Step 6.

5. Remove the screws securing the top and right side internal safety shield panels and remove the panels to gain access to the top wiring entry. Retain the hardware for later use.

6. Route the input and output cables to the UPS terminal blocks. See Drawing 164201554-7 starting on page A-29 for wiring access information and terminal locations.

7. If wiring a single-feed system, proceed to Step 9; if wiring a dual-feed system, proceed to Step 11.

8. Connect phase A, B, C, and Neutral (if required) input power wiring from the utility source to the bypass input terminals and neutral terminals in the UPS cabinet. See Appendix A for wiring and termination requirements and wiring access information. Note the wiring connections for single-feed systems.

9. Proceed to Step 13.

10. Disconnect the single-feed jumper bus from the phase A, B, and C terminals on the rectifier input terminals and bypass input terminals. Remove the jumpers from the cabinet.

11. Connect phase A, B, and C rectifier input power wiring from the utility source to the rectifier input terminals in the UPS cabinet. See Appendix A for wiring and termination requirements and wiring access information. Note the wiring connections for dual-feed systems.

12. Connect phase A, B, and C, and Neutral (if required) bypass input power wiring from the utility source to the bypass input terminals and neutral terminals in the UPS cabinet. See Appendix A for wiring and termination requirements and wiring access information. Note the wiring connections for dual-feed systems.

13. If wiring an IDC or IAC, proceed to Step 15; otherwise, proceed to Step 18.

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14. Route and connect the output cable between the UPS cabinet and the IDC or IAC.

Refer to the applicable IDC or IAC installation and operation manual, referenced in paragraph 1.5 on page 1-6, for wiring instructions. See Appendix A for UPS cabinet wiring access information.

15. Connect phase A, B, and C, and Neutral (if required) power wiring from the IDC or IAC to the UPS cabinet output and neutral terminals. See Appendix A for wiring and termination requirements.

16. Proceed to paragraph 3.2.6.3.

17. If wiring a parallel system, proceed to Step 19; otherwise, proceed to Step 20.

CAUT ION

Parallel system wiring length should be in accordance with Drawing 164201554-5, sheet 15 of 15, to ensure approximately equal current sharing when in Static Bypass mode.

18. Connect phase A, B, and C, and Neutral (if required) power wiring from the output and neutral terminals of each uninterruptible power module (UPM) to the module tie cabinet. See Appendix A for UPM wiring and termination requirements and wiring access information.

19. Proceed to paragraph 3.2.6.3.

20. Connect phase A, B, and C, and Neutral (if required) power wiring from output terminals and neutral terminals to the critical load. See Appendix A for wiring and termination requirements and wiring access information.

21. Proceed to paragraph 3.2.6.3.

3.2.6.3 Battery Wiring

CAUT ION

When sizing the battery system, do not exceed the internal battery charger capabilities. See Chapter 15, “Product Specifications,” for maximum battery charger currents.

To install wiring to connections:

1. Route and connect the battery cables between the UPS and battery cabinets in accordance with the instructions in the Powerware 9390 Integrated Battery Cabinet (Models IBC-S and IBC-L) Installation Manual. See Appendix A for UPS cabinet wiring access information.

2. Connect the positive, negative, and ground DC power wiring from the battery cabinet to the UPS cabinet battery terminal block and ground terminals. See Appendix A for wiring and termination requirements.

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

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4. If wiring interface connections, proceed to paragraph 3.2.7; otherwise, proceed to Step 5.

5. When all wiring is complete, reinstall the safety shield panels removed in previous steps. Secure with the retained hardware.

6. Close the control panel door and secure with the retained hardware.

7. Reinstall the doors removed in paragraph 3.2.1 and secure with the retained hardware.

8. Close the doors and secure the latch.

3.2.7 Installing Interface Connections

3.2.7.1 TB1 and TB2 Connections

NOTE When installing interface wiring for TB1 and TB2 connections, conduit must be installed between each device and the UPS cabinet.

To install wiring to connections:

1. Verify the UPS system is turned off and all power sources are removed. See Chapter 10, “UPS Operating Instructions,” for shutdown instructions.

2. If not already open, unfasten the front door latch and swing the door open.

3. If not already removed, remove the doors. Remove the retaining screws located inside each door at the top and bottom hinge pivot points, then lift the…