Eaton 93PM User And Installation Manual
Eaton 93PM UPS P-164000249
30-200 kW
User's and Installation Guide
Eaton 93PM UPS
30-200 kW
User's and Installation Guide
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that you should follow during installation and maintenance of the
UPS and batteries. Please read all instructions before operating the equipment and save this manual for future
reference.
This is a product for commercial and industrial application in the second environment. Installation restrictions or additional
measures may be needed to prevent disturbances.
© 2013 Eaton Corporation
All Rights Reserved
The contents of this manual are the copyright of the publisher and may not be reproduced (even extracts) without
the written approval of Eaton Corporation. Every care has been taken to ensure the accuracy of the information
contained in this manual, but no liability can be accepted for any errors or omission. The right to make design
modifications is reserved.
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Contents
1 Safety instructions......................................................................................................................................................................................................................... 1
1.1 Audience...................................................................................................................................................................................... 3
1.2 CE marking.................................................................................................................................................................................. 3
1.3 User precautions......................................................................................................................................................................... 4
1.4 Environment.................................................................................................................................................................................4
1.5 Symbols on the UPS and accessories........................................................................................................................................5
1.6 Conventions used in this manual................................................................................................................................................6
1.7 For more information.................................................................................................................................................................. 6
2 Introduction to Eaton UPS............................................................................................................................................................................................................8
2.1 Looking inside the UPS system..................................................................................................................................................9
2.2 UPS operating modes............................................................................................................................................................... 13
2.2.1 Normal operating modes...............................................................................................................................................13
2.2.1.1 Double conversion mode.......................................................................................................................................13
2.2.1.2 Energy Saver System mode..................................................................................................................................15
2.2.2 Stored energy and battery mode..................................................................................................................................15
2.2.3 Bypass mode.................................................................................................................................................................16
2.3 UPS features............................................................................................................................................................................. 17
2.3.1 Advanced Battery Management....................................................................................................................................18
2.3.2 Powerware Hot Sync.................................................................................................................................................... 18
2.4 Software and connectivity features.......................................................................................................................................... 18
2.4.1 Customer interface........................................................................................................................................................18
2.4.2 Power Management Software...................................................................................................................................... 18
2.5 Options and accessories........................................................................................................................................................... 19
2.5.1 Maintenance Bypass Switch......................................................................................................................................... 19
2.5.2 Top air exhaust kit.........................................................................................................................................................22
2.5.3 Top cable access kit......................................................................................................................................................22
2.5.4 Field Installed UPM....................................................................................................................................................... 22
2.6 Battery system.......................................................................................................................................................................... 22
2.7 Basic system configurations..................................................................................................................................................... 23
3 UPS installation plan and unpacking......................................................................................................................................................................................25
3.1 Creating an installation plan...................................................................................................................................................... 25
3.2 Site preparations........................................................................................................................................................................25
3.2.1 Environmental and installation considerations.............................................................................................................. 25
3.2.2 UPS system power wiring preparation......................................................................................................................... 30
3.2.3 UPS system interface wiring preparation..................................................................................................................... 34
3.3 Unpacking and unloading the UPS........................................................................................................................................... 34
4 UPS system installation.............................................................................................................................................................................................................. 36
4.1 Steps to install the UPS............................................................................................................................................................36
4.2 Battery system installation........................................................................................................................................................ 40
4.3 Installing UPS external battery cabinet and battery power wiring............................................................................................41
4.4 Installing a remote EPO switch................................................................................................................................................ 45
4.5 Installing interface connections.................................................................................................................................................46
4.5.1 Installing customer input signals interface................................................................................................................... 46
4.5.2 Battery breaker wiring interface....................................................................................................................................47
4.5.3 Relay output interface connections.............................................................................................................................. 47
4.5.4 Mini-slot interface connections..................................................................................................................................... 47
4.5.5 Installing signal interface connections in parallel system............................................................................................. 47
4.6 Wiring parallel 93PM UPS systems..........................................................................................................................................48
4.6.1 Power wiring overview................................................................................................................................................. 48
4.6.2 Control signals overview............................................................................................................................................... 50
4.6.3 Installing bypass control wiring.....................................................................................................................................50
5 Communication interfaces......................................................................................................................................................................................................... 53
5.1 Mini-slot cards........................................................................................................................................................................... 53
5.2 Intelligent Power Software....................................................................................................................................................... 56
5.3 Signal input monitoring............................................................................................................................................................. 56
5.4 General purpose relay contact.................................................................................................................................................. 56
6 UPS operating instructions........................................................................................................................................................................................................58
6.1 UPS controls and indicators...................................................................................................................................................... 58
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6.1.1 Control panel................................................................................................................................................................. 58
6.1.2 Status indicators............................................................................................................................................................ 60
6.1.3 System events...............................................................................................................................................................61
6.2 Steps to operate the UPS.........................................................................................................................................................61
6.3 Signing in................................................................................................................................................................................... 62
6.4 System control instructions...................................................................................................................................................... 63
6.4.1 Starting the UPS system in Double conversion mode................................................................................................. 63
6.4.2 Starting the UPS system in Bypass mode................................................................................................................... 64
6.4.3 Transfer from Double conversion mode to Bypass mode............................................................................................64
6.4.4 Transfer from Bypass to Double conversion mode...................................................................................................... 65
6.4.5 Transfer from Double conversion mode to Energy Saver System Mode.....................................................................65
6.4.6 Transfer from Energy Saver System Mode to Double conversion mode.....................................................................65
6.4.7 UPS system and critical load shutdown....................................................................................................................... 66
6.4.8 De-energizing the Critical Load..................................................................................................................................... 66
6.5 UPS control instructions............................................................................................................................................................67
6.5.1 Starting a single UPS.................................................................................................................................................... 67
6.5.2 UPS shutdown...............................................................................................................................................................67
6.5.3 Enabling and disabling the battery charger...................................................................................................................68
6.6 UPM control instructions.......................................................................................................................................................... 68
6.6.1 Starting the UPMs.........................................................................................................................................................68
6.6.2 UPM shutdown............................................................................................................................................................. 68
6.7 Using the Remote Emergency Power-off switch.....................................................................................................................69
6.8 Turning UPS from double conversion mode to mechanical bypass......................................................................................... 69
6.9 Turning UPS from mechanical bypass to double conversion mode......................................................................................... 71
7 UPS maintenance.........................................................................................................................................................................................................................72
7.1 Important safety instructions.................................................................................................................................................... 72
7.2 Performing preventive maintenance......................................................................................................................................... 73
7.2.1 DAILY maintenance.......................................................................................................................................................73
7.2.2 MONTHLY maintenance............................................................................................................................................... 73
7.2.3 PERIODIC maintenance................................................................................................................................................ 73
7.2.4 ANNUAL maintenance.................................................................................................................................................. 74
7.2.5 BATTERY maintenance................................................................................................................................................. 74
7.3 Recycling the used UPS or batteries........................................................................................................................................74
7.4 Maintenance training................................................................................................................................................................. 75
8 Technical data.............................................................................................................................................................................................................................. 76
8.1 Standards................................................................................................................................................................................... 76
8.2 UPS system input..................................................................................................................................................................... 77
8.3 UPS system output................................................................................................................................................................... 77
8.4 Battery specification.................................................................................................................................................................. 78
8.5 UPS environmental specifications.............................................................................................................................................79
9 Warranty.........................................................................................................................................................................................................................................81
10 Installation checklist.................................................................................................................................................................................................................82
11 APPENDIX A: User settings..................................................................................................................................................................................................... 84
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List of Figures
Figure 1-1: Recycling batteries symbol................................................................................................................................................. 5
Figure 1-2: WEEE symbol...................................................................................................................................................................... 6
Figure 2-1: Eaton 93PM UPS................................................................................................................................................................ 9
Figure 2-2: 93PM 50 kW UPS wiring diagram.................................................................................................................................... 11
Figure 2-3: 93PM 150 kW UPS wiring diagram.................................................................................................................................. 12
Figure 2-4: Path of current through the UPS in double conversion mode.......................................................................................... 14
Figure 2-5: Path of current through the UPS in Energy Saver System...............................................................................................15
Figure 2-6: Path of current through the UPS in battery mode............................................................................................................16
Figure 2-7: Path of current through the UPS in bypass mode............................................................................................................17
Figure 2-8: Two-switch MBS electrical connection drawing............................................................................................................... 20
Figure 2-9: Three-switch MBS electrical connection drawing............................................................................................................. 21
Figure 3-1: UPS cabinet clearances. See Table 3-3............................................................................................................................ 27
Figure 3-2: 93PM 30-150 kW UPS dimensions...................................................................................................................................28
Figure 3-3: 93PM 160-200 kW UPS dimensions.................................................................................................................................29
Figure 3-4: Eaton 93PM 80-150 kW UPS Top air exhaust kit dimensions.......................................................................................... 29
Figure 3-5: Eaton 93PM 200 kW UPS Top air exhaust kit dimensions...............................................................................................30
Figure 4-1: 93PM 30-50 kW gland plate and connector locations...................................................................................................... 37
Figure 4-2: 93PM 80-150 kW UPS gland plate and connector locations............................................................................................ 38
Figure 4-3: 93PM 160-200 kW UPS gland plate and connector locations.......................................................................................... 39
Figure 4-4: 93PM 30-150 kW Top cable access kit............................................................................................................................ 40
Figure 4-5: 93PM battery cabinet (EBC-S)...........................................................................................................................................42
Figure 4-6: 93PM battery cabinet (EBC-L)...........................................................................................................................................43
Figure 4-7: UPS cabinet through holes............................................................................................................................................... 44
Figure 4-8: Connections of the EPO switch........................................................................................................................................ 46
Figure 4-9: Principle of paralleled UPS systems................................................................................................................................. 49
Figure 4-10: Communication interfaces...............................................................................................................................................50
Figure 4-11: Simplified CAN and Pull-Chain wiring for parallel UPS system.......................................................................................51
Figure 4-12: CAN and Pull-Chain wiring for parallel UPS with MOBs................................................................................................. 51
Figure 4-13: CAN and Pull-Chain wiring for parallel UPS without MOBs............................................................................................52
Figure 5-1: Communication interfaces.................................................................................................................................................53
Figure 5-2: Network Card-MS.............................................................................................................................................................. 54
Figure 5-3: PX Gateway Card.............................................................................................................................................................. 54
Figure 5-4: Relay Card-MS................................................................................................................................................................... 55
Figure 5-5: Network and MODBUS Card - MS................................................................................................................................... 55
Figure 5-6: Industrial Relay Card-MS................................................................................................................................................... 56
Figure 6-1: Parts of the display........................................................................................................................................................... 59
Figure 6-2: Green symbol.................................................................................................................................................................... 60
Figure 6-3: Yellow symbol — battery mode....................................................................................................................................... 60
Figure 6-4: Yellow symbol — bypass mode....................................................................................................................................... 60
Figure 6-5: Red symbol........................................................................................................................................................................60
Figure 6-6: The normal positions of the MBS switches and rectifier disconnect switch (must be located in the site wiring)............. 70
Figure 6-7: Mechanical bypass mode..................................................................................................................................................70
Figure 6-8: Mechanical bypass mode..................................................................................................................................................71
Figure 6-9: Double conversion mode.................................................................................................................................................. 71
Figure 7-1: WEEE symbol.................................................................................................................................................................... 74
Figure 7-2: Recycling batteries symbol............................................................................................................................................... 75
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List of Tables
Table 2-1: UPS configurations..............................................................................................................................................................23
Table 2-2: Standard and optional UPS options.................................................................................................................................... 23
Table 3-1: Dimensions......................................................................................................................................................................... 26
Table 3-2: UPS cabinet weights.......................................................................................................................................................... 26
Table 3-3: UPS cabinet minimum clearances...................................................................................................................................... 26
Table 3-4: UPS cabinet minimum clearances with top air exhaust kit................................................................................................ 27
Table 3-5: Air conditioning or ventilation requirements during full load operation.............................................................................. 28
Table 3-6: Minimum recommended multi-core cable and fuse sizes................................................................................................. 31
Table 3-7: Rated and maximum currents for rated power and voltage.............................................................................................. 31
Table 3-8: UPS power cable terminations........................................................................................................................................... 33
Table 4-1: Remote EPO wire terminations..........................................................................................................................................46
Table 6-1: UPS menu structure........................................................................................................................................................... 61
Table 8-1: Standards............................................................................................................................................................................ 76
Table 8-2: UPS system input............................................................................................................................................................... 77
Table 8-3: UPS system output.............................................................................................................................................................77
Table 8-4: Battery specification............................................................................................................................................................78
Table 8-5: UPS environmental specifications...................................................................................................................................... 79
Table 11-1: User settings.....................................................................................................................................................................84
Table 11-2: Config settings.................................................................................................................................................................. 84
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1 Safety instructions
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during installation and
maintenance of the UPS and batteries. Please read all instructions before operating the equipment
and save this manual for future reference.
The UPS operates with mains, battery or bypass power. It contains components that carry high
currents and voltages. The properly installed enclosure is earthed and IP21 rated against electrical
shock and foreign objects. However, the UPS is a sophisticated power system and only qualified
personnel is allowed to install and service the UPS.
WARNING
Operations inside the UPS must be performed by a service engineer from the manufacturer or
from an agent authorized by the manufacturer.
DANGER
This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by
AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS inside
the UPS.
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WARNING
• The UPS is powered by its own energy source (batteries). The output terminals may be
energised even when the UPS is disconnected from an AC source. To reduce the risk of
fire or electric shock, install this UPS in a temperature and humidity controlled, indoor
environment, free of conductive contaminants. Ambient temperature must not exceed
40 °C (104 °F). Do not operate near water or excessive humidity (95 % maximum). The
system is not intended for outdoor use.
• Ensure all AC and DC power sources are disconnected before performing installation or
service. Power may come from multiple sources.
• In parallel system, output terminals may be energised even when the UPS is turned off.
• Ensure system grounding/PE continuity when undertaking installation or service.
• Batteries can present a risk of electrical shock or burn from high short-circuit current.
• ELECTRIC ENERGY HAZARD. Do not attempt to alter any battery wiring or connectors.
Attempting to alter wiring can cause injury.
• Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes. It
may be toxic.
• IMPORTANT: the battery may consist of multiple parallel strings, disconnect all strings
before installation.
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CAUTION
• Installation or servicing should be performed by qualified service personnel
knowledgeable of batteries and required precautions. Keep unauthorized personnel away
from batteries. Consider all warnings, cautions, and notes before installing or replacing
batteries. DO NOT DISCONNECT the batteries while the UPS is in Battery mode.
• Replace batteries with the same number and type of batteries as originally installed in the
UPS.
• Disconnect the charging source prior to connecting or disconnecting terminals.
• Determine if the battery is inadvertently grounded. If it is, remove the source of the
ground. Contacting any part of a grounded battery can cause a risk of electric shock. An
electric shock is less likely if you disconnect the grounding connection before you work
on the batteries.
• Proper disposal of batteries is required. Refer to local codes for disposal requirements.
• Do not dispose of batteries in a fire. Batteries may explode when exposed to flame.
• Keep the UPS door closed and front panels installed to ensure proper cooling airflow and
to protect personnel from dangerous voltages inside the unit.
• Do not install or operate the UPS system close to gas or electric heat sources.
• The operating environment should be maintained within the parameters stated in this
manual.
• Keep surroundings uncluttered, clean, and free from excess moisture.
• Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside
of the equipment.
1.1 Audience
The intended audience of this manual are people who plan the installation, install, and use the UPS.
This manual provides guidelines for checking the delivery, installing, and operating of the UPS.
The reader is expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols. This manual is written for a global reader.
NOTE
Read the manual before operating or working on the UPS.
1.2 CE marking
The product has the CE marking in compliance with the following European directives:
• LV Directive (Safety) 2006/95/EC
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• EMC Directive 2004/108/EC
Declaration of conformity with UPS harmonised standards and directives EN 62040-1 (Safety) and EN
62040-2 (EMC) are available at www.eaton.eu/93PM or by contacting your nearest Eaton office or
authorized partner.
1.3 User precautions
The only user operations permitted are:
• Start up and shut down of the UPS, excluding the commissioning start up.
• Use of the LCD control panel and Maintenance Bypass Switch (MBS).
• Use of optional connectivity modules and their software.
The user must follow the precautions and only perform the described operations. Any deviation from
the instructions could be dangerous to the user or cause accidental load loss.
WARNING
The user is not permitted to open any screws excluding connectivity plates and the MBS
locking plate. Failure to recognise the electrical hazards could prove fatal.
WARNING
The 30-50 kW models are available as C2 UPS product which can be placed both in
a residential and commercial/industrial environment. When included in a residential
environment, this product may cause radio interference, in which case the user may be
required to take additional measures.
By standard, the 30-200 kW models are category C3 UPS products, meant for all commercial
and industrial establishments.
1.4 Environment
The UPS must be installed according to the recommendations in this manual. Under no
circumstances should the UPS be installed in an airtight room, in the presence of flammable gases, or
in an environment exceeding the specifications.
Excessive amount of dust in the operating environment of the UPS may cause damage or lead to
malfunction. The UPS should always be protected from the outside weather and sunshine. In order
to maximize internal battery service life time, the recommended operating temperature range is from
+20 to +25 ºC.
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WARNING
Hydrogen and oxygen gases are emitted from batteries into the surrounding atmosphere
during charge, float charge, heavy discharge, and overcharge. Explosive gas mixture may be
created if the hydrogen concentration exceeds 4 % by volume in air. Necessary air flow rate for
ventilation of UPS location must be ensured.
As an example, for 93PM 30-50 kW UPS, a minimum air flow is 5 m³/ hour for the room where
one 93PM UPS with internal VRLA batteries is placed. If more than one UPS with internal
VRLA batteries are located in the same room, ventilation air flow must be dimensioned
accordingly. If external flooded cell batteries are used in same location, ventilation air flow
must be recalculated and dimensioned accordingly.
1.5 Symbols on the UPS and accessories
The following are examples of symbols used on the UPS or accessories to alert you to important
information:
DANGER
RISK OF ELECTRIC SHOCK - Indicates that a
risk of electric shock is present and the associated warning should be observed.
CAUTION
CAUTION: REFER TO OPERATOR’S MANUAL
- Refer to your operator’s manual for additional information, such as important operating and
maintenance instructions.
Figure 1-1: Recycling batteries symbol
This symbol indicates that you should not discard the UPS or the UPS batteries in the trash.
This product involves sealed, lead-acid batteries
and must be disposed of properly. For more information, contact your local recycling/reuse or
hazardous waste center.
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Figure 1-2: WEEE symbol
This symbol indicates that you should not discard waste electrical or electronic equipment
(WEEE) in the trash. For proper disposal, contact
your local recycling/reuse or hazardous waste
center.
1.6 Conventions used in this manual
This manual uses these type conventions:
• Bold type highlights important concepts in discussions, key terms in procedures, and menu
options, or represents a command or option that you type or enter at a prompt.
•
Italic type highlights notes and new terms where they are defined.
•
Screen type
represents information that appears on the screen or LCD.
Icon Description
NOTE
Information notes call attention to important 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.
1.7 For more information
Address any inquiries about the UPS and battery cabinet to the local office or agent authorized by the
manufacturer. Please quote the type code and the serial number of the equipment.
Call your local service representative if help is needed with any of the following:
• Scheduling initial startup
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• Regional locations and telephone numbers
• A question about any of the information in this manual
• A question this manual does not answer
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2 Introduction to Eaton UPS
The Eaton® 93PM uninterruptible power supply (UPS) is a true online, continuous-duty,
transformerless, double-conversion, solid-state, three-phase system, supplying conditioned and
uninterruptible AC power to critical load and protecting it from power failures.
The UPS is used to prevent loss of valuable electronic information, minimize equipment downtime,
and minimize the adverse effect on production equipment due to unexpected power problems.
The Eaton UPS continually monitors incoming electrical power and removes the surges, spikes,
sags, and other irregularities that are inherent in commercial utility power. Working with a
building’s electrical system, the UPS system supplies clean, consistent power that sensitive
electronic equipment requires for reliable operation. During brownouts, blackouts, and other power
interruptions, batteries provide emergency power to safeguard operation.
The UPS system is housed in a single, free-standing cabinet with safety shields behind the door for
hazardous voltage protection. Each UPS cabinet has a centralised system static bypass. The available
static bypass ratings are 50 kW, 100 kW, 150 kW and 200 kW. The static bypass size is chosen
according to UPS system power. For example, if future requirement is to upgrade the UPS capacity,
the UPS bypass rating will have to be selected accordingly. In addition, the bypass ratings of all UPS
cabinets in a parallel system need to be matched.
Eaton 93PM output power ratings are based on 50 kW rated uninterruptible power modules (UPMs).
A single UPS cabinet can house one to four UPM modules to get ratings of:
• 1 x 50 kW = 50 kW
• 2 x 50 kW = 100 kW
• 3 x 50 kW = 150 kW
• 4 x 50 kW = 200 kW
A UPM includes a rectifier, inverter, battery converter, and independent controls. Each UPM is able to
operate independently from the other power modules.
NOTE
Startup and operational checks must be performed by an authorized Eaton Customer Service
Engineer, or the warranty terms specified in Chapter 9 Warranty on page 81 become void.
This service is offered as part of the sales contract for the UPS. Contact service in advance
(usually a two-week notice is required) to reserve a preferred startup date.
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Figure 2-1: Eaton 93PM UPS
2.1 Looking inside the UPS system
The system level static bypass in the Eaton 93PM UPS cabinet determines the attainable output
power of the UPS. The static bypass line consists of static switch and a backfeed protection isolation
device connected in series. In addition, there is a system level control unit that constantly monitors
the power delivered through the bypass line or to the input of the UPS. Transfers to static bypass are
seamless and performed automatically by the system as needed, for example, in case of an extended
system overload.
Each UPM power module includes a rectifier, battery converter, inverter and independent controls.
Each UPM is able to operate and share the load independently, despite the status of the other UPMs.
In addition, the system can have a UPS internal maintenance bypass switch as a factory installed
option.
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The 30-50 kW 93PM UPS includes a 50 kW rated static bypass section, one UPM power module, and
internal batteries. In addition to the internal batteries, also external batteries can be connected. The
main components of this UPS are depicted in Figure 2-2: 93PM 50 kW UPS wiring diagram on page
11.
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Figure 2-2: 93PM 50 kW UPS wiring diagram
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In the 80-200 kW units, the UPM power modules are paralleled internally. These units do not
include internal batteries. Figure 2-3: 93PM 150 kW UPS wiring diagram on page 12 shows the
construction of the 150 kW 93PM UPS with three power modules.
Figure 2-3: 93PM 150 kW UPS wiring diagram
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The rectifier input switch and battery breaker are available as standard for the 30-50 kW units, and as
optional for the 80-150 kW units. The internal MBS is available as optional for the 30-150 kW units.
These options are not available for the 160-200 kW units, and will have to be included externally in the
installation.
If utility power is interrupted or falls outside the parameters specified in Chapter 8 Technical data
on page 76, the UPS uses a backup battery supply to maintain power to the critical load for a
specified period of time or until the utility power returns. For extended power outages, the UPS
allows you to either transfer to an alternative power system (such as a generator) or shut down
your critical load in an orderly manner. The UPS bypass consists of a continuous-duty static switch
and backfeed protection isolation device K5. The backfeed protection is located in series with the
static switch. Transfers to static bypass are seamless and performed automatically by the system as
needed, for example, in case of an extended system overload.
2.2 UPS operating modes
UPS operating modes:
• Normal operating modes:
• In double conversion mode, the critical load is supplied by the inverter, which derives
its power from rectified utility AC power. In this mode, the battery charger also provides
charging current for the battery, if needed.
• In Energy Saver System (ESS) mode, the critical load is supported securely by utility power
through static bypass switch with double conversion available on-demand with typically
less than a 2 ms transition time, should any abnormal condition be detected in the utility.
When operating in ESS mode, the load is protected with inherent surge suppression.
Operating the UPS in ESS mode increases system efficiency to 99 % allowing significant
savings in energy losses without compromising system reliability.
• In stored energy mode, the energy is drawn from a DC backup power source and converted to
AC power by the UPS inverter. Most commonly VRLA batteries are introduced to the system for
this purpose, and the mode of operation is called battery mode.
• In bypass mode, the critical load is supported directly by utility power through the UPS static
switch.
2.2.1 Normal operating modes
During normal UPS operation, power for the system is derived from a utility input source. “Unit
Online” is displayed on the front panel, indicating that the incoming power is within voltage and
frequency acceptance windows.
2.2.1.1 Double conversion mode
Figure 2-4: Path of current through the UPS in double conversion mode on page 14 shows the
path of electrical power through the UPS system when the UPS is operating in double conversion
mode.
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Internal relay contacts
Figure 2-4: Path of current through the UPS in double conversion mode
Three-phase AC input power is converted to DC using a multilevel converter with IGBT devices to
produce a regulated DC voltage to the inverter. The UPS status indicated on the display is “Unit
Online” and the UPM status is “Active”.
The battery converter derives its input from the regulated DC output of the rectifier and provides
regulated charge current to the battery. The battery is always connected to the UPS and ready to
support the inverter should the utility input become unavailable.
The inverter produces a three-phase AC output to the critical load. The inverter derives regulated
DC from the rectifier and uses multilevel converter technology with IGBT devices and pulse-width
modulation (PWM) to produce a regulated and filtered AC output.
If the utility AC power is interrupted or is out of specification, the UPS automatically switches to
Battery mode to support the critical load without interruption. When utility power returns, the UPS
returns to double conversion mode automatically.
If the UPS becomes overloaded or unavailable, the UPS seamlessly switches to Bypass mode and
continues supplying the load through the static bypass. The UPS automatically returns to double
conversion mode when the abnormal condition, such as an extended time overload, is cleared and
system operation is restored within specified limits.
If a UPM power module within the UPS suffers an internal failure, the remaining UPMs will continue
supporting the load in double conversion. The UPS is automatically internally redundant when the UPS
is not operating in full load. However, if there is no redundancy between the UPMs due to high load
level, the UPS switches automatically to Bypass mode and remains in that mode until the failure is
corrected and the UPS is back in service.
In an external parallel redundant system, each one UPS can be isolated from the system for service
while the remaining UPSs support the load in double conversion.
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2.2.1.2 Energy Saver System mode
In ESS mode the UPS safely provides mains current directly to the load when the input is within the
acceptable limits by its voltage and frequency. The UPS status indicated on the display is “Unit Online
ESS”, and the UPM status is “Active”. Surge protection and some filtering is also provided, ensuring
that clean power is delivered to the load equipment. Should there be any disturbances detected in
the incoming power, the UPS switches to double conversion and continues to supply the critical load
through its inverter. In case of a complete utility outage or if input power is outside the tolerances of
the system, the UPS transfers to battery mode and continues to supply conditioned, clean power to
the critical load.
When operating in ESS, the UPS superior detection and control algorithms continuously monitor
incoming power quality and allow the fast engagement of power converters. Typical transition time to
double conversion is less than two milliseconds, which is practically seamless.
When power conditions are within acceptable limits, the UPS operates as a high-efficiency, energysaving system — providing surge protection for IT equipment and ensuring clean power is delivered
to the facility. Energy saver system increases system efficiency to 99 % when supplying 20-100 %
nominal load, reducing energy losses by up to 80 %.
Internal relay contacts
Figure 2-5: Path of current through the UPS in Energy Saver System
2.2.2 Stored energy and battery mode
When running normally in double conversion or ESS mode, the UPS automatically transfers to supply
the load from batteries or other stored energy source if a utility power outage occurs, or if the utility
power does not conform to specified parameters. The UPS status indicated on the display is “On
Battery”, and the UPM status is “Active”. In battery mode, the battery provides emergency DC
power which is converted to regulated output power by the inverter. Figure 2-6: Path of current
through the UPS in battery mode on page 16 shows the path of electrical power through the UPS
system when operating in battery mode.
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Internal relay contacts
Battery breaker
Figure 2-6: Path of current through the UPS in battery mode
During a utility power failure, the rectifier no longer has an AC utility source from which to supply
the DC output current required to support the inverter. The input relay K1 opens and the UPS output
is powered from batteries through the inverter. As the inverter operates uninterrupted through the
transition, the load remains supported continuously without disturbance. If the UPS static bypass is
supplied from the same source as the UPS rectifier, the backfeed protection contactor K5 also opens.
The opening of K1 and K5 prevent system voltages from bleeding backwards and re-entering the
input source through the static switch or rectifier.
If the input power fails to return or is not within the acceptance windows required for normal
operation, the battery continues discharging until a DC voltage level is reached where the inverter
output can no longer support the connected loads. When this event occurs, the UPS issues a set of
audible and visual alarms indicating that the batteries are having a minimal capacity left and a system
shutdown is imminent. Unless utility power is restored, the output can be supported for maximum
two minutes before the output of the system shuts down. If the bypass source is available, the UPS
transfers to bypass instead of shutting down.
If at any time during the battery discharge the input power becomes available again, K1 and K5 close
and the UPS returns to normal operation. The UPS will also start to recharge batteries to restore the
capacity.
2.2.3 Bypass mode
The UPS automatically switches to bypass mode if it detects an overload, load fault, or internal failure.
The bypass source supplies the commercial AC power to the load directly. The UPS can also be
commanded to transfer to bypass manually through the display. The UPS status indicated on the
display is “On Bypass”. Figure 2-7: Path of current through the UPS in bypass mode on page 17
shows the path of electrical power through the UPS system when operating in Bypass mode.
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NOTE
The critical load is not protected while the UPS is in Bypass mode.
Internal relay contacts
Figure 2-7: Path of current through the UPS in bypass mode
In bypass mode, the output of the system is provided with three-phase AC power directly from the
system input. While in this mode, the output of the system is not protected from voltage or frequency
fluctuations or power outages from the source. Some power line filtering and transient protection is
provided to the load but no active power conditioning or battery support is available to the output of
the system in the bypass mode of operation.
The static bypass is comprised of a solid-state, silicon-controlled rectifier (SCR) static switch (SSW)
and a backfeed protection isolation device K5. The static switch is rated as a continuous-duty device
that is used anytime the inverter is unable to support the applied load. The static switch is wired in
series with the backfeed protection. The static switch, being an electronically-controlled device, can
be turned on immediately to pick up the load from the inverter without interruption. The backfeed
protection is normally always closed, ready to support the static switch unless the bypass input
source becomes unavailable.
2.3 UPS features
The Eaton UPS has many features that provide cost-effective and consistently reliable power
protection. The feature descriptions provide a brief overview of the UPS standard features.
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2.3.1 Advanced Battery Management
Advanced Battery Management technology uses sophisticated sensing circuitry and a three-stage
charging technique that extends the useful service life of UPS batteries while optimizing the battery
recharge time. ABM also protects batteries from damage caused by high current charging and
inverter ripple currents. Charging at high currents can overheat and damage batteries.
In charge mode, the batteries are recharged. Charging lasts only as long as it takes to bring the
battery system up to a predetermined float level. Once this level is reached, the UPS battery charger
enters float stage and the charger is operating in constant voltage mode.
Rest mode begins at the end of charge mode; that is, after 48 hours of float charging (customer
adjustable). In Rest mode, the battery charger is completely turned off. The battery system receives
no charge current during this rest period of about 28 days (customer adjustable). During Rest mode,
the open circuit battery voltage is monitored constantly, and battery charging is resumed when
necessary.
2.3.2 Powerware Hot Sync
Eaton Powerware Hot Sync technology is an algorithm that eliminates the single point of failure
in a parallel system and therefore enhances the system reliability. The Hot Sync technology is
incorporated in all Eaton 93PM UPSs, and it is utilised in both multi-module internal parallel and
external parallel systems.
Hot Sync technology enables all uninterruptible power modules (UPMs) to operate independently in
a parallel system, even without inter-module communications. The power modules utilising the Hot
Sync technology are completely autonomous; each module monitors their own output independently,
to remain in complete synchronization with the other modules. The UPM power modules share the
load perfectly even in changing capacity or changing load conditions.
Powerware Hot Sync technology combines digital signal processing and an advanced control
algorithm to provide automatic load sharing and selective tripping in a parallel UPS system. The load
share control algorithms maintain synchronization and load balance by constantly making minute
adjustments to variations in the output power requirements. The modules conform to demand
and are not in conflict with each other for the load. Powerware Hot Sync systems are capable of
paralleling for both redundancy and capacity.
2.4 Software and connectivity features
2.4.1 Customer interface
Mini-Slot Communication Bays — there are three communication bays for mini-slot connectivity cards.
Mini-slot cards are quickly installed and are hot-pluggable. See Chapter 5 Communication interfaces
on page 53 for additional information.
2.4.2 Power Management Software
Intelligent Power software products offer tools for monitoring and managing power devices across
the network. See Chapter 5 Communication interfaces on page 53 for more information.
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2.5 Options and accessories
Contact an Eaton sales representative for information about the available options.
2.5.1 Maintenance Bypass Switch
The Maintenance Bypass Switch (MBS) enables power to completely bypass and isolate the UPS so
that the UPS can be safely serviced or replaced without interrupting power to critical systems.
An internal maintenance bypass switch is provided as a factory installed option for 30-150 kW units.
Alternatively, MBS solutions are also available in external enclosure as accessory items.
External Maintenance Bypass Switch Panel
The external MBS is enclosed in its own separate cabinet, and it can be either a wall-mounted or
stand-alone cabinet depending on the MBS power rating. The MBS wiring has two different options:
two- and three-switch configuration. The two-switch model contains a Maintenance Isolation Switch
(MIS) and a Maintenance Bypass Switch (MBP). The three-switch model contains a Bypass Input
Breaker (BIB) in addition to a MIS and an MBP.
The two-switch model assumes that the UPS rectifier and bypass are coupled through dedicated
breakers and separate cables from the switchgear. However, the three-breaker model can be
connected to the switchgear with only a single cable, and the cable connections between the panel
and UPS are run separately.
For more information, see Figure 2-8: Two-switch MBS electrical connection drawing on page 20
and Figure 2-9: Three-switch MBS electrical connection drawing on page 21.
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1. Maintenance Bypass Switch (MBP)
2. Maintenance Isolation Switch (MIS)
Figure 2-8: Two-switch MBS electrical connection drawing
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