Eaton 93PM-250(400), 93PM-100(400), 93PM-300(400), 93PM-350(400), 93PM-400(400) User And Installation Manual

...

User's and installation

guide

Eaton 93PM UPS 30–200 kVA

P-164000249

Copyright © 2017 Eaton Corporation plc. All rights reserved. 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. 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. Unauthorized copying and lending are prohibited.

Eaton Power Quality Oy

Address:

Koskelontie 13

FI-02920 Espoo

FINLAND

Internet: www.eaton.eu

Original instructions _X_ / Translation of the original instructions __

Eaton 93PM UPS 30–200 kVA User's and installation guide

Contents

1 How to read this manual.......................................................................... 7

1.1 Safety-related signs.................................................................... 7

1.2 Safety symbols............................................................................7

1.2.1 Hazard symbols............................................................. 7

1.2.2 Prohibited action symbols..............................................7

1.2.3 Mandatory action symbols............................................. 8

1.3 Conventions used in this document............................................ 8

1.4 Glossary......................................................................................8

2 Safety instructions..................................................................................10

2.1 Audience................................................................................... 12

2.2 CE marking............................................................................... 12

2.3 User precautions.......................................................................12

2.4 Environment..............................................................................13

2.5 Symbols on the UPS and accessories......................................13

2.6 For more information.................................................................14

3 Introduction to Eaton UPS......................................................................15

3.1 Looking inside the UPS system................................................ 16

3.2 UPS operating modes...............................................................18

3.2.1 Normal operating modes............................................. 19

3.2.2 Stored energy and battery mode................................. 23

3.2.3 Bypass mode............................................................... 25

3.3 UPS features.............................................................................27

3.3.1 Advanced Battery Management.................................. 27

3.3.2 Powerware Hot Sync................................................... 27

3.3.3 Power Conditioner....................................................... 28

3.3.4 Frequency Converter................................................... 28

3.3.5 Sync Control................................................................ 28

3.4 Software and connectivity features........................................... 29

3.4.1 User interface.............................................................. 29

3.4.2 Power Management Software..................................... 29

3.5 Options and accessories...........................................................29

3.5.1 Maintenance Bypass Switch........................................29

3.5.2 93PM 200 kW SIAC-MBS............................................30

3.5.3 Top air exhaust kit....................................................... 30

3.5.4 Top cable access kit.................................................... 30

3.5.5 Single feed kit.............................................................. 30

3.5.6 Separate battery option............................................... 30

3.5.7 Field Installed UPM......................................................30

3.6 Battery system.......................................................................... 31

Eaton 93PM UPS 30–200 kVA

User's and installation guide

3.6.1 UPS Battery Switchgear.............................................. 31

3.7 Basic system configurations..................................................... 32

4 UPS installation plan and unpacking......................................................35

4.1 Creating an installation plan......................................................35

4.2 Installation checklist.................................................................. 36

4.3 Site preparations.......................................................................36

4.3.1 Environmental and installation considerations.............37

4.3.2 UPS system power wiring preparations.......................41

4.4 Unpacking and unloading the UPS........................................... 46

5 UPS system installation......................................................................... 50

5.1 Installing the UPS 30-50 kW, 80-150 kW and 160-200 kW

frames..............................................................................................50

5.2 Connector and power cable terminal locations......................... 55

5.3 Installing 93PM 160-200kW with side integrated accessory

cabinet MBS.................................................................................... 58

5.4 Installing the battery system..................................................... 62

5.4.1 Installing the battery system for 93PM UPS with

separate battery option.......................................................64

5.4.2 Battery trip wiring......................................................... 65

5.5 Installing a remote EPO switch ................................................ 69

5.6 Installing interface connections.................................................70

5.6.1 Installing customer input signals interface................... 71

5.6.2 Battery breaker wiring interface................................... 71

5.6.3 Relay output interface connections..............................71

5.6.4 Industrial Relay Card interface connections................ 71

5.6.5 MiniSlot interface connections..................................... 72

5.6.6 Installing signal interface connections in a parallel

system................................................................................ 73

5.7 Wiring parallel 93PM UPS systems.......................................... 73

5.7.1 Power wiring overview................................................. 73

5.7.2 Control signals overview..............................................75

5.7.3 Installing bypass control wiring.................................... 76

5.8 UPS system interface wiring preparation..................................79

6 Communication interfaces......................................................................80

6.1 MiniSlot cards........................................................................... 80

6.2 Intelligent Power Software........................................................ 82

6.3 Signal input monitoring............................................................. 83

6.4 General purpose relay contact..................................................83

6.5 Configuring relays..................................................................... 84

Eaton 93PM UPS 30–200 kVA

User's and installation guide

7 UPS operating instructions.....................................................................88

7.1 UPS controls and indicators......................................................88

7.1.1 Control panel............................................................... 88

7.1.2 Status indicators.......................................................... 89

7.1.3 System events............................................................. 91

7.1.4 Menu structure of the 93PM UPS................................ 91

7.2 Signing in.................................................................................. 95

7.3 System control instructions....................................................... 96

7.3.1 Starting the UPS system in the double conversion

mode...................................................................................96

7.3.2 Starting the UPS system in the bypass mode............. 97

7.3.3 Transferring from the double conversion mode to

the bypass mode................................................................ 97

7.3.4 Transferring from the bypass mode to the double

conversion mode................................................................ 98

7.3.5 Transferring from the double conversion mode to

the Energy Saver System mode.........................................98

7.3.6 Transferring from the Energy Saver System mode

to the double conversion mode.......................................... 98

7.3.7 Shutting down the UPS system and critical load......... 99

7.3.8 De-energizing the critical load..................................... 99

7.4 UPS control instructions..........................................................100

7.4.1 Starting a single UPS.................................................100

7.4.2 Shutting down a single UPS...................................... 101

7.4.3 Enabling and disabling the battery charger............... 101

7.5 UPM control instructions......................................................... 101

7.5.1 Starting the UPMs......................................................101

7.5.2 Shutting down the UPMs........................................... 102

7.6 Using the Remote Emergency Power-off switch.....................102

7.7 Turning the UPS from the double conversion mode to the

maintenance bypass mode............................................................103

7.8 Turning the UPS from the maintenance bypass mode to

the double conversion mode..........................................................105

8 UPS maintenance................................................................................ 107

8.1 Important safety instructions................................................... 107

8.2 Preventive maintenance......................................................... 108

8.2.1 Daily maintenance..................................................... 108

8.2.2 Monthly maintenance.................................................108

8.2.3 Periodic maintenance................................................ 109

8.2.4 Annual maintenance.................................................. 109

8.2.5 Battery maintenance..................................................109

8.3 Recycling the used UPS or batteries...................................... 109

8.4 Maintenance training...............................................................110

Eaton 93PM UPS 30–200 kVA

User's and installation guide

9 Technical data......................................................................................111

9.1 Directives and standards........................................................ 111

9.2 UPS system input................................................................... 112

9.3 UPS system output................................................................. 112

9.4 UPS environmental specifications.......................................... 113

9.5 Battery specification................................................................114

10 Warranty...............................................................................................115

10.1 General................................................................................... 115

10.2 Whom to contact in case of Warranty..................................... 116

Appendix A: Relay Alarms.............................................................................117

Eaton 93PM UPS 30–200 kVA User's and installation guide

1 How to read this manual

1.1 Safety-related signs

The following table explains the safety-related signs used in this document.

DANGER

DANGER indicates a hazard with a high level of risk which, if not avoided, will result in serious injury or death.

WARNING

WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in serious injury or death, or damage to your machine.

CAUTION

CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury, or damage to your machine.

Note: Notes are used to indicate important information and useful tips.

1.2 Safety symbols

1.2.1 Hazard symbols

These symbols indicate a hazardous situation or action. Symbols are used to warn of situations, which may cause environmental damage and personal injury.

General warning sign Explosion and fire hazard

Electrical hazard Corrosive hazard

Battery hazard

1.2.2 Prohibited action symbols

These symbols are used to indicate an action that should not be taken.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

General symbol for prohibited action

No smoking

Limited or restricted access

1.2.3 Mandatory action symbols

These symbols are used to indicate an action that must be taken.

General symbol for mandatory action

Disconnect from power source

Read the manual or instructions

1.3 Conventions used in this document

This document uses the following 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 when they are defined.

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

1.4 Glossary

Eaton documentation uses the following acronyms to refer to Eaton UPS products or their parts:

Table 1: Glossary of acronyms

ABM Advanced Battery Management

BIB Bypass Input Breaker

EAA Energy Advanced Architecture

EBC External Battery Cabinet

Eaton 93PM UPS 30–200 kVA User's and installation guide

EPO Emergency Power-off

ESS Energy Saver System

F-UPM Field Installed UPM

IPM Intelligent Power Manager

IPP Intelligent Power Protector

MBP Maintenance Bypass

MBS Maintenance Bypass Switch

MCB Miniature Circuit Breaker

MIS Maintenance Isolation Switch

MOB Module Output Breaker

REPO Remote Emergency Power-off

RIB Rectifier Input Breaker

SCR Silicon-controlled Rectifier

STSW Static Switch

UPM Uninterruptible Power Module

UPS Uninterruptible Power Supply

VMMS Variable Module Management System

Eaton 93PM UPS 30–200 kVA User's and installation guide

2 Safety instructions

DANGER

Important safety instructions!

Keep these instructions!

This document contains important instructions that must be obeyed during the installation, operation and maintenance of the UPS and the batteries. Read all instructions before operating the equipment. Keep this manual for future reference. These instructions are also available for download at www.eaton.eu/ 93pm.

DANGER

Operations inside the UPS must be done by an authorized Eaton Customer Service Engineer or by other qualified service personnel authorized by Eaton. There are no user-serviceable parts in the UPS.

The UPS operates with mains, battery or bypass power. It contains components that carry high currents and voltage. A properly installed enclosure is earthed and IP20 rated against electric shock and unwanted objects. The UPS is a sophisticated power system and only qualified personnel can install and service it.

DANGER

This UPS carries lethal voltages. All repairs and service must be done by authorized personnel only. There are no user-serviceable parts inside the UPS.

WARNING

The UPS is powered by its own energy source (batteries). The output terminals could be energized even when the UPS is disconnected from an AC source. To reduce the risk of fire or electric shock, install the UPS in a temperature and humidity controlled, indoor environment that is free of conductive contaminants. See temperature and humidity limits in Chapter 9.

The ambient temperature limit must not be exceeded. Do not operate the UPS near water or excessive humidity. The system is not intended for outdoor use.

Before you start any installation or service work, make sure that all AC and DC power sources are disconnected. Power can come from multiple sources. Also ensure system grounding / PE continuity.

In a parallel system, the output terminals could be energized even when the UPS is turned off.

Eaton 93PM UPS 30–200 kVA User's and installation guide

WARNING

Batteries present a risk of electric shock or burn from high short-circuit current. Observe proper precautions.

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 can be toxic and is harmful to the skin and eyes.

Batteries can contain HIGH VOLTAGES, and CORROSIVE, TOXIC and EXPLOSIVE substances. Because of the battery string the output terminals can carry high voltage even when the AC supply is not connected to the UPS. Read the shutdown instructions carefully.

IMPORTANT: The battery may consist of multiple parallel strings. Make sure that you disconnect all strings before installation.

CAUTION

Only qualified service personnel knowledgeable of batteries and the required precautions can do the installation or service work on batteries. Keep unauthorized personnel away from the batteries. Before you install or replace batteries, consider all the warnings, cautions, and notes concerning appropriate handling. Do not disconnect the batteries when the UPS is in the Battery mode.

Make sure that your replacement batteries are of the same number and type as the battery that was originally installed in the UPS. See more accurate instructions on the UPS.

Before you connect or disconnect battery terminals, disconnect the charging source by opening the corresponding battery circuit breaker.

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

Dispose of batteries according to your local disposal requirements. Do not dispose of batteries in a fire. When exposed to flame, batteries may explode.

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

Do not install or operate the UPS system close to gas or electric heat sources. Keep the operating environment within the parameters stated in this document.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

CAUTION

Keep the surroundings of the UPS uncluttered, clean, and free from excess moisture.

Obey all DANGER, CAUTION, and WARNING notices on the equipment.

2.1 Audience

This document is intended for:

• People who plan and perform the installation of the UPS

• People who use the UPS

This document provides guidelines for how to examine the UPS delivery and how install and operate the UPS.

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

CAUTION

Read this document before you start to operate or perform work on the UPS.

2.2 CE marking

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

• LV Directive (Safety) 2014/35/EU

• EMC Directive 2014/30/EU

Declarations of conformity with UPS harmonized standards and directives EN 62040-1 (Safety) and EN 62040-2 (EMC) are available at

www.eaton.eu

or by

contacting your nearest Eaton office or authorized partner.

2.3 User precautions

The only permitted user operations.

• Startup and shutdown of the UPS, excluding the commissioning startup.

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

• Use of optional connectivity modules and their software.

Obey the precautions and only perform the described operations. Any deviation from the instructions can be dangerous to the user or cause accidental load loss.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

DANGER

Do not open any other screws in the unit than those holding the cover plates of the MiniSlots and the MBS locking plate. Failure to recognize the electrical hazards can prove fatal.

CAUTION

The 30–50 kW models are available as a C2 category UPS as an option, which can be placed both in residential and commercial or industrial environments. When included in a residential environment, this product may cause radio interference. in which case you may have to take preventive measures.

By standard, this is a C3 category product for commercial and industrial application in the second environment. Installation restrictions or measurements may be needed to prevent disturbances.

2.4 Environment

The UPS must be installed according to the recommendations in this document. Never install the UPS 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. Always protect the UPS from the outside weather and sunshine.

WARNING

During charge, float charge, heavy discharge, and overcharge, hydrogen and oxygen gases are emitted from lead-acid and NiCd batteries into the surrounding atmosphere. Explosive gas mixture may be created if the hydrogen concentration exceeds 4% by volume in air. Ensure the necessary air flow rate for the ventilation of the UPS location.

2.5 Symbols on the UPS and accessories

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

RISK OF ELECTRIC SHOCK

Indicates that a risk of electric shock is present and the associated warning should be observed.

Eaton 93PM UPS 30–200 kVA User's and installation guide

CAUTION: REFER TO OPERATOR'S MANUAL

Refer to your operator's manual for additional information, such as important operating and maintenance instructions.

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

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

2.6 For more information

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

Call your local service representative if you need help 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 that this manual does not answer

Note: For more information about the installation space, safe operation and working, see IEC 62485-2: Safety requirements for secondary batteries and battery installations.

Eaton 93PM UPS 30–200 kVA User's and installation guide

3 Introduction to Eaton UPS

Figure 1. Eaton 93PM UPS

The Eaton® 93PM uninterruptible power supply (UPS) is a true online, continuous-duty, transformerless, double-conversion, solid-state, three-phase system that supplies conditioned and uninterruptible AC power to critical load and protects 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 require 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 protection against hazardous voltage. Each UPS cabinet has

Eaton 93PM UPS 30–200 kVA

User's and installation guide

a centralized system static bypass. The available static bypass ratings are 50 kW, 60 kVA, 100 kW, 150 kW and 200 kW. The static bypass size is chosen according to UPS system power.

Eaton 93PM output power ratings are based on 50 kW rated uninterruptible power modules (UPMs). A single UPS cabinet can house one to four UPMs to get ratings of:

• 1 x 50 kW = 50 kW (or 60 kVA, PF 0.9)

• 2 x 50 kW = 100 kW

• 3 x 50 kW = 150 kW

• 4 x 50 kW = 200 kW

See Section

3.7

for a full list of available configurations.

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 by other qualified service personnel authorized by Eaton, or the terms specified in the Warranty (see Chapter

) 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 necessary) to reserve a preferred start-up date.

3.1 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, a back feed protection isolation device and fuses designed to protect the static switch. The back feed protection and bypass fuses are located in series with the static switch. 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 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.

If utility power is interrupted or falls outside the parameters specified in Chapter

, 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.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

Eaton 93PM UPS 30–200 kVA User's and installation guide

1 Control panel 8 Rectifier input switch (optional)

2 Door latch 9 Battery breaker (optional)

3 Communications area 10 MBS (optional)

4 UPM 1 11 Area for internal batteries

5 UPM 2 12 Communication cable conduit

6 UPM 3 13 Static bypass section

7 UPM 4 14 Power cable connections

3.2 UPS operating modes

The UPS operating modes are as follows:

Operating mode Description

Normal operating modes:

- Double conversion mode 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.

- Variable Module Management System

(VMMS) mode

Critical load is supplied by the inverter. The inverter derives its power from rectified utility AC power, identically to double conversion mode. In the VMMS mode, the 93PM UPS system is able to optimise the load level per power module: the operating efficiency is significantly improved when operating load is below 50% of UPS capacity. The UPS system will automatically place the redundant power modules to suspended mode. In case of any anomalies in utility or a sudden load increase, the suspended power modules are able to transfer to online mode with less than 2 ms transition time.

- Energy Saver System (ESS) mode Critical load is supported securely by utility power through the 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 the ESS mode, the load is protected with inherent surge suppression. Operating the UPS in the ESS mode increases system efficiency up to 99%, allowing significant savings in energy losses without compromising system reliability

Eaton 93PM UPS 30–200 kVA User's and installation guide

Operating mode Description

Stored energy mode 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 the battery mode

Bypass mode Critical load is supported directly by utility

power through the UPS static switch.

3.2.1 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.

3.2.1.1 Double conversion mode

Figure 2 shows the path of electrical power through the UPS system when the UPS is operating in the double conversion mode.

Eaton 93PM UPS 30–200 kVA User's and installation guide

Figure 2. Path of current through the UPS in the double conversion mode

A Static

switch

1 Bypass in-

put

Main power flow

B Rectifier 2 Rectifier in-

put

Energized

C Inverter 3 Output De-energized

D Battery con-

verter

4 Battery

breaker

Trickle current

E Battery Closed Open

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 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 the battery mode to support the critical load without interruption. When utility power returns, the UPS returns automatically to the double conversion mode.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

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

If a UPM within the UPS suffers an internal failure, the remaining UPMs continue to support the load in the double conversion mode. The UPS is automatically internally redundant when the UPS is not operating at full load. However, if internal redundancy between the UPMs is not possible due to high load, the UPS switches automatically to the bypass mode and remains in that mode until the failure is corrected and the UPS is back in operation.

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

3.2.1.2 Variable Module Management System mode

When Variable Module Management System (VMMS) mode is enabled, the load is powered by UPMs in double conversion mode (see Figure

). The UPS status indicated on the display is Unit Online VMMS and the UPM status is Active.

UPS efficiency varies according to the load level at which the UPS operates. VMMS technology enables achieving optimised system efficiency by automatically optimising the UPM load level. As an example, when the load is very low, a minimum of one UPM is online. This enhances the UPS system efficiency by several percentage points.

The remaining UPMs are ready to switch to double conversion mode instantaneously, if the load increases. The load will remain protected by double conversion UPS the entire time, even during and after a load step.

It is possible to configure VMMS mode to include power module redundancy at all times, so that a number of additional redundant UPMs are always online.

When the UPMs are in ready state, the IGBT converters are constantly powered, since the rectifier input and inverter output contactors are closed. The DC link is also powered. Only the IGBT gate signals are suspended. The only step needed to come out of ready state is to gate the IGBT switches. Since DC voltage is constantly present, the inverter is able to start instantaneously: the 2 ms transfer to double conversion is practically seamless.

3.2.1.3 Energy Saver System mode

Figure

shows the path of electrical power through the UPS system when the

UPS is operating in the Energy Saver System (ESS) mode.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

Figure 3. Path of current through the UPS in the Energy saver System mode

A Static

switch

1 Bypass in-

put

Main power flow

B Rectifier 2 Rectifier in-

put

Energized

C Inverter 3 Output De-energized

D Battery con-

verter

4 Battery

breaker

Trickle current

E Battery Closed Open

In the 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, making sure that clean power is delivered to the load equipment. In case any disturbances are detected in the incoming power, the UPS switches to the double conversion mode and continues to supply the critical load through its inverter. In case of a complete utility outage or if the input power is outside the tolerances of the system, the UPS transfers to the battery mode and continues to supply conditioned, clean power to the critical load.

When operating in the ESS mode, the UPS's superior detection and control algorithms continuously monitor the incoming power quality and allow fast engagement of the power converters. Typical transition time to the double conversion mode is less than 2 milliseconds, which is practically seamless.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

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

3.2.2 Stored energy and battery mode

When running normally in the double conversion or ESS mode, the UPS automatically transfers to supply the load from batteries or some other stored energy source if a utility power outage occurs, or if the utility power does not conform to the specified parameters. The UPS status indicated on the display is On Battery, and the UPM status is Active. In the battery mode, the battery provides emergency DC power, which is converted to regulated output power by the inverter.

Figure

shows the path of electrical power through the UPS system when

operating in the battery mode.

Eaton 93PM UPS 30–200 kVA User's and installation guide

Figure 4. Path of current through the UPS in the battery mode

A Static

switch

1 Bypass in-

put

Main power flow

B Rectifier 2 Rectifier in-

put

Energized

C Inverter 3 Output De-energized

D Battery con-

verter

4 Battery

breaker

Trickle current

E Battery Closed Open

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 the 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 have a minimal capacity left and a system shutdown is imminent. Unless utility power is restored, the output can be supported for a

Eaton 93PM UPS 30–200 kVA

User's and installation guide

maximum of 2 minutes before the output of the system shuts down. If the bypass source is available, the UPS transfers to the bypass mode instead of shutting down.

If the input power becomes available again at any time during the battery discharge, K1 and K5 close and the UPS returns to normal operation. The UPS also starts to recharge the batteries to restore the capacity.

3.2.3 Bypass mode

CAUTION

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

The UPS automatically switches to the 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 the bypass mode manually through the display. The UPS status indicated on the display is On Bypass.

The UPS will return from the bypass mode back to online mode, if the condition (for example overload) that caused the transfer is cleared. If there is a condition that will not clear by itself (for example UPS internal failure), the UPS will remain on bypass operation.

Figure

shows the path of electrical power through the UPS system when

operating in the bypass mode.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

Figure 5. Path of current through the UPS in the bypass mode

A Static

switch

1 Bypass in-

put

Main power flow

B Rectifier 2 Rectifier in-

put

Energized

C Inverter 3 Output De-energized

D Battery con-

verter

4 Battery

breaker

Trickle current

E Battery Closed Open

In the 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.

The static bypass consists of a solid-state, silicon-controlled rectifier (SCR) static switch (STSW) 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. As the static switch is an electronically-controlled device, it 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.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

3.3 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.

3.3.1 Advanced Battery Management

The 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 the

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 the

float stage

and the charger

operates in the constant voltage mode.

The

rest mode

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

3.3.2 Powerware Hot Sync

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

The Hot Sync technology enables all UPMs to operate independently in a parallel system, even without inter-module communications. The power modules utilizing the Hot Sync technology are completely autonomous; each module monitors its 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 load conditions.

The 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. The Powerware Hot Sync systems are capable of paralleling for both redundancy and capacity.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

3.3.3 Power Conditioner

The Power Conditioner mode is characterized by the UPS running in the double conversion mode without batteries connected. In the Power Conditioner mode, the UPS provides conditioned output voltage and frequency. The UPS can also support high nonlinear loads without ITHD on the input. The UPS meets the qualifications outlined in this product specification, except for the conditions below.

When in the Power Conditioner mode, the UPS has the following functionality and limitations:

1. The UPS runs in the double conversion mode.

2. Because there is no battery, loss of utility power results in the UPS losing

power and shutting down.

3. The UPS sustains up to -50% input voltage tolerance, unless the current

limit is reached.

4. If the rectifier is turned off, the UPS attempts a transfer to the bypass

mode.

5. The ESS mode is not available.

6. The Power Conditioner mode is available in both 3 and 4 wire

configurations.

3.3.4 Frequency Converter

The Frequency Converter mode is characterized by the UPS running without the bypass mode available. The output frequency can be configured to be different from the standard input frequency (e.g. 60 Hz output, 50 Hz input). The UPS can also support high nonlinear loads without iTHD on the input. The UPS meets the qualifications outlined in this product specification, except for the conditions below.

When in the Frequency Converter mode, the UPS has the following functionality and limitations:

1. Operation is the same as when in the double conversion mode with no

bypass available.

2. Bypass alarms are suppressed.

3.3.5 Sync Control

The Eaton® Sync Control maintains the critical load outputs of two separate UPS systems in synchronization. Use of the Eaton Fixed Master Sync Control provides uninterrupted transfer of the load from one load bus to another by means of downstream, dual-source, solid-state transfer switches. Without the load sync option, the two system output (critical load) buses can become out of phase with each other. This condition occurs when suitable bypass sources are not available or when the bypass sources feeding each system are not in sync with each other. Examples of this condition are two systems supplied by

Eaton 93PM UPS 30–200 kVA

User's and installation guide

separate generator sets, or situation where the bypass sources for the two systems are lost.

3.4 Software and connectivity features

3.4.1 User interface

MiniSlot Communication Bays — there are 3 communication bays for MiniSlot connectivity cards. MiniSlot cards are quickly installed and hot-pluggable. See Chapter

for additional information.

3.4.2 Power Management Software

Intelligent Power software products offer tools for monitoring and managing power devices across the network. See Chapter

for more information.

3.5 Options and accessories

Contact your Eaton sales representative for more information about the available options and accessories.

3.5.1 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 an external enclosure as accessory items.

External Maintenance Bypass Switch Panel

The external MBS is enclosed in its own separate cabinet, which can be either a wall-mounted or stand-alone cabinet depending on the MBS power rating. The MBS includes a Maintenance Bypass Switch (MBS) and a UPS Output Maintenance Isolation Switch (MIS). The panel may additionally include one or two input breakers: one for the rectifier input (RIB) and another for bypass input (BIB). It also includes auxiliary contacts to report the status of the switchgear to the UPS.

For external MBS installation instructions, see a separate manual.

Eaton 93PM UPS 30–200 kVA

User's and installation guide

3.5.2 93PM 200 kW SIAC-MBS

The side integrated accessory cabinet (SIAC-MBS) for 160-200 kW 93PM includes a mechanical maintenance bypass switch and 1 or 2 input breakers for dual or single feed installation.

3.5.3 Top air exhaust kit

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

Refer to Section

4.3

for further information.

3.5.4 Top cable access kit

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

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

Refer to Section

4.3

, Section

5.1

and Figure

for further information.

3.5.5 Single feed kit

The Eaton 93PM UPS is configured for dual feed by standard, requiring a separate feed for rectifier and static bypass input. Single feed kits are available for 80–200kW models for on-site installation. In addition, a single feed configuration can be fitted to the 30–50kW models using jumper-cables during installation.

3.5.6 Separate battery option

By standard, the Eaton 93PM UPS has one external battery connection, through which external batteries supply all UPMs. If needed, the external battery connections can be ordered as a separate battery configuration for the multimodular 80–200kW models. This option enables connecting a separate external battery to each 50 kW UPM. See Section

5.4.1

for more information.

3.5.7 Field Installed UPM

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

Eaton 93PM UPS 30–200 kVA

User's and installation guide

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