Eaton Electrical UPS 225275 User Manual
Powerware 9395 UPS
450–550 kVA (2x225 - 2x275 kVA)
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.
WARNING
This is a product for commercial and industrial application in the second environment .
Installation restrictions or additional measures may be needed to prevent disturbances.
©2008 Eaton Corporation
All Rights Reserved
The contents of this manual are the copyright of the publisher
and may not be reproduced (even extracts) unless permission granted.
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.
Powerware 9395 UPS 450–550 kVA (2x225 - 2x275 kVA)
User’s and Installation Guide
1027574 Revision B
Contents
1 Introduction ..................................................................................................................................................................................................5
1.1 UPS standard features .......................................................................................................................................................................... 5
1.1.1 Control panel ...................................................................................................................................................................................5
1.1.2 Customer Interface ........................................................................................................................................................................7
1.1.3 Advanced Battery Management .................................................................................................................................................7
1.1.4 Power Management Software .....................................................................................................................................................7
1.1.5 Installation features .......................................................................................................................................................................7
1.2 Options and accessories ......................................................................................................................................................................7
1.2.1 Integrated battery cabinet ............................................................................................................................................................7
1.2.2 Optional X-Slot Cards ....................................................................................................................................................................7
1.3 Basic systemcConfigurations ..............................................................................................................................................................8
1.4 Using this manual ..................................................................................................................................................................................8
1.5 Conventions used in this manual ........................................................................................................................................................8
1.6 Symbols, controls, and indicators ....................................................................................................................................................... 8
1.7 For more information .............................................................................................................................................................................9
1.8 Getting help ............................................................................................................................................................................................. 9
2 UPS installation plan and unpacking ......................................................................................................................................................10
2.1 Creating an installation plan ................................................................................................................................................................10
2.2 Preparing the site ..................................................................................................................................................................................10
2.2.1 Environmental and installation considerations .........................................................................................................................10
2.2.2 UPS system power wiring preparation .......................................................................................................................................14
2.2.3 UPS system interface wiring preparation ..................................................................................................................................17
2.3 Inspecting and unpacking the UPS cabinet ......................................................................................................................................19
3 UPS system installation .............................................................................................................................................................................21
3.1 Preliminary installation information ....................................................................................................................................................21
3.2 Unloading the UPS cabinet from the pallet and mechanical installation.....................................................................................21
3.3 Battery cabinet installation ..................................................................................................................................................................23
3.4 Installing UPS external and battery power wiring ...........................................................................................................................25
3.4.1 External power wiring installation ...............................................................................................................................................25
3.4.2 Battery wiring .................................................................................................................................................................................29
3.5 Installing interface connections .........................................................................................................................................................29
3.5.1 TB1, TB2, and TB3 connections (other than TB1 battery interface connections)...............................................................29
3.5.2 TB1 battery interface connections ..............................................................................................................................................34
3.5.3 X-Slot connections ......................................................................................................................................................................... 35
3.6 Installing a remote EPO switch ...........................................................................................................................................................36
3.7 Initial startup ........................................................................................................................................................................................... 39
3.8 Completing the installation checklist .................................................................................................................................................39
4 Understanding UPS operation ..................................................................................................................................................................41
4.1 Looking inside the UPS system ...........................................................................................................................................................41
4.2 Modes ......................................................................................................................................................................................................42
4.2.1 Normal mode ................................................................................................................................................................................... 42
4.2.2 Bypass mode ................................................................................................................................................................................... 43
4.2.3 Battery mode ................................................................................................................................................................................... 44
4.3 UPS system oneline configurations ....................................................................................................................................................45
5 UPS operating instructions .......................................................................................................................................................................48
5.1 UPS controls and indicators ................................................................................................................................................................49
5.1.1 Control panel ...................................................................................................................................................................................49
5.1.2 Circuit breakers ..............................................................................................................................................................................49
5.2 Using the control panel ......................................................................................................................................................................... 50
5.2.1 Status indicators ............................................................................................................................................................................50
5.2.2 Using the LCD and pushbuttons ...................................................................................................................................................51
5.2.3 Using the menu ...............................................................................................................................................................................52
5.2.4 Mimic screen ..................................................................................................................................................................................52
5.2.5 Display menu operation ................................................................................................................................................................52
5.2.6 System controls screen ................................................................................................................................................................57
5.2.7 Load off screen ...............................................................................................................................................................................58
5.3 Operation ................................................................................................................................................................................................. 58
5.3.1 Starting the UPS in normal mode ................................................................................................................................................58
5.3.2 Starting the UPS in bypass mode ................................................................................................................................................59
5.3.3 Starting the power module ...........................................................................................................................................................60
5.3.4 Transfer from normal to bypass mode ........................................................................................................................................60
5.3.5 Transfer from bypass to normal mode ........................................................................................................................................61
5.3.6 Transfer from normal to bypass mode and shut down UPS ....................................................................................................61
5.3.7 UPS and critical load shutdown ..................................................................................................................................................61
5.3.8 Charger control ............................................................................................................................................................................... 62
5.3.9 Using the UPS LOAD OFF pushbutton .........................................................................................................................................62
5.3.10 Using the Remote Emergency Power-off switch ....................................................................................................................63
5.3.11 Using Mechanical Bypass Switch ............................................................................................................................................64
6 Responding to system events ....................................................................................................................................................................66
6.1 General ....................................................................................................................................................................................................66
6.2 System event horns ...............................................................................................................................................................................66
6.3 System event indicators .......................................................................................................................................................................66
6.4 System event messages .......................................................................................................................................................................66
7 Communication ............................................................................................................................................................................................67
7.1 X-Slot cards ............................................................................................................................................................................................67
7.2 Powerware LanSafe Power Management Software ......................................................................................................................68
7.3 Terminal mode ........................................................................................................................................................................................ 68
7.3.1 Display UPS control panel ............................................................................................................................................................68
7.3.2 Event History Log ............................................................................................................................................................................ 68
7.4 Building alarm monitoring ....................................................................................................................................................................70
7.5 General purpose relay contact ............................................................................................................................................................ 70
8 UPS maintenance ........................................................................................................................................................................................71
8.1 Important safety instructions ............................................................................................................................................................... 71
8.2 Performing preventive maintenance ..................................................................................................................................................72
8.2.1 DAILY maintenance ........................................................................................................................................................................72
8.2.2 MONTHLY maintenance ................................................................................................................................................................ 72
8.2.3 ANNUAL maintenance ..................................................................................................................................................................72
8.2.4 BATTERY maintenance ..................................................................................................................................................................72
8.2.5 Maintenance training ....................................................................................................................................................................72
8.3 Installing batteries .................................................................................................................................................................................73
9 Recycling the used UPS or batteries .......................................................................................................................................................74
10 Product specifications ...............................................................................................................................................................................74
10.1 Model numbers ....................................................................................................................................................................................74
10.2 Single module specifications ............................................................................................................................................................. 74
10.2.1 UPS system input .........................................................................................................................................................................74
10.2.2 UPS system output .......................................................................................................................................................................74
10.2.3 Environmental ...............................................................................................................................................................................75
11 Warranty .......................................................................................................................................................................................................75
1 Introduction
The Eaton® Powerware® 9395 uninterruptible power supply (UPS) is a true online, continuousduty, transformerless, double-conversion, solid-state, three-phase system, providing
conditioned and uninterruptible AC power to protect the customer’s load from all nine power
failures. The Powerware 9395 UPS is available as a single module system.
The Powerware online power protection system is used to prevent loss of valuable electronic
information, minimize equipment downtime, and minimize the adverse effect on production
equipment due to unexpected power problems.
The Powerware 9395 UPS continually monitors incoming electrical power and removes the
surges, spikes, sags, and other irregularities that are inherent in commercial utility power.
Working with a building’s electrical system, the UPS system supplies clean, consistent
power that sensitive electronic equipment requires for reliable operation. During brownouts,
blackouts, and other power interruptions, batteries provide emergency power to safeguard
operation.
The UPS system is housed in a single, free-standing cabinet with safety shields behind the door
for hazardous voltage protection. The cabinet matches the battery and distribution cabinets in
style and color and can be installed in line-up-and-match or standalone configurations.
Figure 1-1 shows the Powerware 9395 UPS (450–550 kVA).
NOTE
Startup and operational checks must be performed by an authorized Eaton Customer
Service Engineer, or the warranty terms specified on page 75 become void. This service is
offered as part of the sales contract for the UPS. Contact service in advance (usually a twoweek notice is required) to reserve a preferred startup date.
1.1 UPS standard features
The UPS has many standard features that provide cost-effective and consistently reliable
power protection. The descriptions in this section provide a brief overview of the UPS standard
features.
1.1.1 Control panel
The control panel, located on the UPS front door, contains an LCD and pushbutton switches to
control the operation of the UPS, and to display the status of the UPS system. See Chapter 6,
“UPS operating instructions,” for additional information.
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Figure 1-1.Powerware 9395-550 (2*275) cabinet
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1.1.2 Customer Interface
Building Alarm Monitoring – Up to five inputs in the UPS are available to connect the •
facility’s alarm system contacts. Some system configurations may limit the number of
inputs available. The UPS uses these inputs to monitor the building alarms in addition to
the UPS status. See Chapter 7, “Communication,” for additional information.
Alarm Contact – One alarm contact is provided for connection to equipment at the facility, •
such as a light, an audible alarm, or a computer terminal. The equipment connected to
this contact alerts you to a UPS alarm. See Chapter 7, “Communication,” for additional
information.
X-Slot Communication Bay – A four-slot communication bay is standard equipment. •
Four optional X-Slot cards can be installed in the UPS module at any time. See Chapter 7,
“Communication,” for additional information.
ConnectUPS -X Web/SNMP Card – This X-Slot card is provided as standard equipment •
and provides remote monitoring through a Web browser interface, e-mail, and a network
management system (NMS) using SNMP. See Chapter 7, “Communication,” for additional
information.
1.1.3 Advanced Battery Management
A three-stage charging system increases battery service life by optimizing recharge time, and
protects batteries from damage due to high current charging and inverter ripple currents.
Charging at high currents can overheat and damage batteries.
1.1.4 Power Management Software
Powerware LanSafe® Power Management Software is bundled as part of the Software Suite CD
shipped with the UPS. See Chapter 7, “Communication,” for additional information.
1.1.5 Installation features
Cabinets can be permanently bolted to the floor or left standing on leveling feet. Power and
control wiring can be routed through the top or bottom of the cabinet with connections made to
easily accessible terminals. External sensing and monitoring control wire must be installed in
accordance with Class 1 wiring methods. Line-up-and-match battery cabinets are wired through
the side panels of the units. Optional X-Slot connectivity cards are quickly installed at the front
of the unit and are hot-pluggable.
1.2 Options and accessories
Contact a Powerware sales representative for information about the following options.
1.2.1 Integrated battery cabinet
Battery backup protection can be enhanced by equipping the UPS system with up to four
Powerware 9395 battery cabinets containing sealed lead-acid, maintenance-free batteries. The
battery cabinet is available in one size, with a 240-cell configuration. The cabinets are designed
for line-up-and-match installation, but may be installed separate from the UPS cabinet.
1.2.2 Optional X-Slot Cards
The optional X-Slot cards support several protocols, such as SNMP, HTTP, AS/400®, and
Modbus®. See Chapter 7, “Communication,” for additional information.
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1.3 Basic system configurations
The following basic UPS system configurations are possible:
Single module UPS and one to four battery cabinets•
Single module UPS and a standalone battery system•
The UPS system configuration can be enhanced by adding optional accessories such as a
Remote Emergency Power-off (REPO) control, or X-Slot® communication cards.
1.4 Using this manual
This manual describes how to install and operate the Powerware 9395 UPS (450–550 kVA)
cabinet. Read and understand the procedures described in this manual to ensure trouble-free
installation and operation. In particular, be thoroughly familiar with the REPO procedure (see
paragraph 5.3.10 on page 62).
The information in this manual is divided into sections and chapters. The system, options, and
accessories being installed dictate which parts of this manual should be read. At a minimum,
Chapters 1 through 3 and Chapter 5 should be examined.
Read through each procedure before beginning the procedure. Perform only those procedures
that apply to the UPS system being installed or operated.
1.5 Conventions used in this manual
This manual uses these type conventions:
Bold type• highlights important concepts in discussions, key terms in procedures, and menu
options, or represents a command or option that you type or enter at a prompt.
Italic• type highlights notes and new terms where they are defined.
Screen type• represents information that appears on the screen or LCD.
Icon Description
Information notes call attention to important features or instructions.
[Keys] Brackets are used when referring to a specific key, such as [Enter] or [Ctrl].
In this manual, the term UPS refers only to the UPS cabinet and its internal elements.
The term UPS system refers to the entire power protection system – the UPS cabinet, the
battery cabinet, and options or accessories installed.
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1.6 Symbols, controls, and indicators
The following are examples of symbols used on the UPS or accessories to alert you to
important information:
RISK OF ELECTRIC SHOCK - Indicates that a risk of electric shock is present and the
associated warning should be observed.
CAUTION: REFER TO OPERATOR’S MANUAL - Refer to your operator’s manual for
additional information, such as important operating and maintenance instructions.
This symbol indicates that you should not discard the UPS or the UPS batteries in
the trash. This product contains sealed, lead-acid batteries and must be disposed of
properly. For more information, contact your local recycling/reuse or hazardous waste
center.
This symbol indicates that you should not discard waste electrical or electronic
equipment (WEEE) in the trash. For proper disposal, contact your local recycling/reuse
or hazardous waste center.
1.7 For more information
Refer to the Powerware 9395 Integrated Battery Cabinet (Model IBC-L) installation manual
(1028181) for the following additional information:
Integrated Battery Cabinet (IBC) installation instructions, including site preparation, •
planning for installation, wiring, and safety information.
Detailed illustrations of the cabinet, including dimension and connection point drawings.•
Visit www.powerware.com or contact your service representative for information on how to
obtain copies of these manuals.
1.8 Getting help
If help is needed with any of the following:
Scheduling initial startup•
Regional locations and telephone numbers•
A question about any of the information in this manual•
A question this manual does not answer•
Call your local service representative
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2 UPS installation plan and unpacking
Use the following basic sequence of steps to install the UPS:
1. Create an installation plan for the UPS system (Chapter 2).
2. Prepare your site for the UPS system (Chapter 2).
3. Inspect and unpack the UPS cabinet (Chapter 2).
4. Unload and install the UPS cabinet, and wire the system (Chapter 3).
5. Complete the Installation Checklist (Chapter 3).
6. Have authorized service personnel perform preliminary operational checks and startup.
NOTE
Startup and operational checks must be performed by an authorized Eaton Customer
Service Engineer, or the warranty terms specified on page W-1 become void. This service is
offered as part of the sales contract for the UPS. Contact service in advance (usually a twoweek notice is required) to reserve a preferred startup date.
2.1 Creating an installation plan
Before installing the UPS system, read and understand how this manual applies to the system
being installed. Use the procedures and illustrations in the paragraph 2.2 and Chapter 3 to
create a logical plan for installing the system.
2.2 Preparing the site
For the UPS system to operate at peak efficiency, the installation site should meet the
environmental parameters outlined in this manual. If the UPS is to be operated at an altitude
higher than 1500 m, contact your service representative for important information about
high altitude operation. The operating environment must meet the weight, clearance, and
environmental requirements specified.
2.2.1 Environmental and installation considerations
The UPS system installation must meet the following guidelines:
The system must be installed on a level floor suitable for computer or electronic •
equipment.
The system must be installed in a temperature and humidity controlled indoor area free of •
conductive contaminants.
The cabinet can be installed in line-up-and-match or standalone configurations.•
Failure to follow guidelines may void your warranty.
The UPS equipment operating environment must meet the weight requirements shown in Table
2-1 and the size requirements shown in Figure 2-1 through Figure 2-7.
Dimensions are in millimeters.
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Model
Shipping Installed
Weight kg
Powerware 9395-2*275 1610 1430
Powerware 9395-550 1610 1430
Table 2-1. UPS cabinet weights
The UPS cabinets use forced air cooling to regulate internal component temperature. Air inlets
are in the front of the cabinet and outlets are in the top. You must allow clearance in front of and
above each cabinet for proper air circulation. The clearances required around the UPS cabinet
are shown in Table 2-2.
From top of cabinet
From front of cabinet
From back of cabinet
From right side of cabinet
From left side of cabinet
Minimum clearance over the UPS cabinet is 458 mm for ventilation
915 mm working space
None required
None required, but for easier service 500 mm is recommended.
None required
Table 2-2. UPS cabinet clearances
The basic environmental requirements for operation of the UPS system are:
Ambient Temperature Range: 0-40°C•
Recommended Operating Range: 20-25°C•
Maximum Relative Humidity: 95%, noncondensing•
The UPS ventilation requirements are shown in Table 2-3.
Rating/kVA Input/output voltage Heat rejection
BTU/hr x 1000/hr (kg-cal/hr)
2*275 kVA 400/400 88.7
550 kVA 400/400 88.7
Table 2-3. Air conditioning or ventilation requirements during full load operation
Ventilation required for cooling air exhaust: approximately 1410 liter/sec /225-275kVA unit.
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Figure 2-1. UPS cabinet dimensions (front view)
Figure 2-2. UPS cabinet dimensions (right side view)
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Figure 2-3. UPS cabinet dimensions (top view)
Front
Figure 2-4. UPS cabinet dimensions (bottom view)
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Figure 2-5. UPS cabinet center of gravity
Figure 2-6. Remote EPO switch dimensions
2.2.2 UPS system power wiring preparation
NOTE
If installing, as part of the UPS system, a maintenance bypass without a rectifier input
breaker, a minimum of two separate feeds with upstream feeder breakers, or one feed
with two upstream feeder breakers, must be provided: one for the UPS and one for the
maintenance bypass input. DO NOT use one feed or a single feeder breaker to supply both
the UPS and the maintenance bypass.
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For external wiring requirements, including the minimum size of external wiring, see Table
2-4. The power wiring connections for this equipment are rated at 70°C. If wire is run in an
ambient temperature greater than 30°C, higher temperature wire and/or larger size wire may be
necessary.
Units Rating 50/60 Hz
Rating
Input and output voltage
kVA kW450 (2*225)
404 (2*202)
550 (2*275)
495 (2*247)
Volts 400/400 400/400
AC input to UPS rectifier
Full load current plus battery recharge current
(3) phases, (1) ground
Minimum conductor size
Number per Phase
Amps 746 912
A
mm
(each)
2
Refer to national
and local rules
AC Output to UPS Bypass
Full load current
(3) phases, (1) neutral–if required, (1) ground B
Minimum conductor size
Number per phase
Amps 672 820
B
mm
(each)
2
Refer to national
and local rules
DC input from battery to UPS
(1) positive, (1) negative c
minimum conductor size
number per pole
Amps 950 1300
C
2
mm
(each)
Refer to national
and local rules
AC output to critical load
full load current
(3) phases, (1) neutral–if required, (1) ground d
minimum conductor size
number per phase
Amps 580 800
D
2
mm
(each)
Refer to national
and local rules
NOTE callout letters A, B, C, and D map to figure 6-5 on page 6-6.
Table 2-4. Input/output ratings and external wiring requirements for the Powerware 9395-550 and
9395-2*275
Read and understand the following notes while planning and performing the installation:
Refer to national and local electrical codes for acceptable external wiring practices.•
Material and labor for external wiring requirements are to be provided by designated •
personnel.
For external wiring, use 70°C copper wire. See the appropriate information in Table 2-4. Wire •
sizes are based on using the specified breakers.
The bypass feed into this equipment uses three or four wires. The rectifier feed into this •
equipment uses three wires. The phases must be symmetrical about ground (from a Wye
source) for proper equipment operation.
If the load requires a neutral, a bypass source neutral must be provided. If the load does not •
require a neutral and there is no neutral conductor connected at the bypass input, a neutral
to ground bonding jumper must be installed. DO NOT install both a source neutral and a
bonding jumper.
The UPS cabinet is shipped with a debris shield covering the ventilation grill on top of the •
unit. Do not remove the debris shield until installation is complete. However, remove the
shield before operating the UPS. Once the debris shield is removed, do not place objects on
the ventilation grill.
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Terminals E1 through E12 are 2-hole bus bar mountings for standard NEMA 2-hole barrel lugs.
See Table 2-5 for power cable terminations and Table 2-6 for recommended installation parts
and tools not supplied by Eaton Corporation. Figure 3-4 and Figure 3-5 show the location of the
power cable terminals inside the UPS.
Terminal function Terminal Function Bus landing
Tightening torgue
Nm
Bolt size
E1 Phase L1 4-2 bolt mounting 76 M12
AC input to UPS rectifier
E2 Phase L2 4-2 bolt mounting 76 M12
E3 Phase L3 4-2 bolt mounting 76 M12
E6 Phase L1 4-2 bolt mounting 76 M12
AC input to bypass
E7 Phase L2 4-2 bolt mounting 76 M12
E8 Phase L3 4-2 bolt mounting 76 M12
E9 Phase L1 4-2 bolt mounting 76 M12
AC output to critical load
E10 Phase L2 4-2 bolt mounting 76 M12
E11 Phase L3 4-2 bolt mounting 76 M12
DC input from battery to UPS
E4 Battery (+) 4-2 bolt mounting 76 M12
E5 Battery (-) 4-2 bolt mounting 76 M12
Input and output neutral E12 Neutral 8-2 bolt mounting 22 M10
Customer ground Ground Ground 7-1 bolt mounting 22 M10
NOTE Customer ground, size1/0, can be run in any conduit.
Table 2-5. UPS cabinet power cable terminations for the Powerware 9395-550/450 and 9395-550/550
Part Size Quantity Manufacturer Part number Notes
Long barrel 2 hole lug 500 MCM As required Thomas & Betts 76 (56) Color code: brown
Die code: 87
Bolt M12 x 50 mm As required N/A N/A Quantity per lug
Bolt M10 x 50 mm As required N/A N/A
hole
Flat washer M12 As required N/A N/A
Lock washer M12 As required N/A N/A
Nut M12 As required N/A N/A
Manual hydraulic crimp tool 14 ton 1 Thomas & Betts TBM14M
Die set N/A 1 Thomas & Betts 15506
Table 2-6. Recommended installation parts and tool (not supplied by Eaton Corporation)
External overcurrent protection is not provided by this product, but is required by codes. Refer
to Table 2-4 for wiring requirements. If an output lockable disconnect is required, it is to be
supplied by the user.
UPS model
Load rating 400 V
Input rating
9395-2*225 100% 800 A
9395-450 100% 800 A
9395-2*275 100% 1000 A
9395-550 100% 1000 A
Table 2-7 Recommended input circuit breaker ratings.
CAUTION
To reduce the risk of fire, connect only to a circuit provided with maximum input circuit breaker
current ratings from Table 2-7 in accordance with the National Electrical Code, ANSI/NFPA 70.
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The line-to-line unbalanced output capability of the UPS is limited only by the full load per
phase current values for AC output to critical load shown in Table 2-4. The recommended line-toline load unbalance is 50% or less.
Source protection for the AC input to bypass should be treated as if supplying a 550 kVA threephase transformer, to allow for inrush current. Bypass input wiring and bypass input breaker
rating should be treated as if supplying a 550 kVA load, regardless of the rating of the UPS.
Bypass and output overcurrent protection and bypass and output disconnect switches are to
be provided by the user. Table 2-8 lists the recommended rating for bypass and output circuit
breakers satisfying the criteria for both.
Circuit breaker rating
UPS model
9395-2*225
9395-450
9395-2*275
9395-550
Load rating
Bypass Output
100% rated 800 A 160 A (B-type breaker)
100% rated 800 A 160 A (B-type breaker)
100% rated 1000 A 200 A (B-type breaker)
100% rated 1000 A 200 A (B-type breaker)
400 V
Table 2-8. Recommended bypass and output circuit breaker ratings
There is no DC disconnect device within the UPS. A battery disconnect switch is recommended,
and may be required by local codes when batteries are remotely located. The battery disconnect
switch should be installed between the battery and the UPS.
External DC input overcurrent protection and disconnect switch for the remote battery location
is to be provided by the user. Table 2-9 lists the maximum rating for continuous-duty rated
circuit breakers satisfying the criteria for both.
UPS model
9395-2*275
9395-550
2*700 A (630 A, depends on end voltage)
1400 A (1250 A, depends on end voltage)
Input rating
600 V
Table 2-9. Recommended DC input circuit breaker ratings
Battery voltage is computed at 2 volts per cell. Rated battery current is computed at 2 volts per
cell. The battery wiring used between the battery and the UPS should not allow a voltage drop
of more than 1% of nominal DC voltage at rated battery current. If the conductors used for DC
input from the battery cabinets to the UPS are those provided by the UPS manufacturer, and the
UPS and battery cabinets are manufactured by the same supplier, then it is acceptable if they
do not meet the noted minimum conductor sizes.
2.2.3 UPS system interface wiring preparation
Control wiring for features and options should be connected at the customer interface terminal
blocks located inside the UPS.
WARNING
Do not directly connect relay contacts to the mains related circuits. Reinforced insulation to
the mains is required.
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Read and understand the following notes while planning and performing the installation:
Install the interface wiring (for example, building alarm, relay output, battery breaker trip, •
and X-Slot) separate from the power wiring. The wiring should have double insulation and
rated at Uo/U = 300/500 Volts.
All interface wiring is to be provided by the customer.•
When installing internal interface wiring to X-Slot terminals, route the wiring through the •
internal opening in the X-Slot communication bay.
All building alarm inputs or remote features require an isolated normally-open contact or •
switch (rated at 24 Vdc, 20 mA minimum) connected between the alarm input and common
terminal as shown. All control wiring and relay and switch contacts are customer-supplied.
Use twisted-pair wires for each alarm input and common.
The building alarms can be programmed to display the alarm functional name.•
LAN and telephone drops for use with X-Slot cards must be provided by facility planners or •
the customer.
The UPS Battery Aux and 48 Vdc Shunt Trip signal wiring from the UPS must be connected •
to the DC source disconnect device.
2
Battery Aux and 48 Vdc Shunt Trip wiring should be a minimum of 1.5 mm•
.
The Remote EPO feature opens all contactors in the UPS cabinet and isolates power from •
your critical load. Local electrical codes may also require tripping upstream protective
devices to the UPS.
The Remote EPO switch must be a dedicated switch not tied to any other circuits.•
A jumper wire must be connected between pins 1 and 2 on TB1, if the normally-closed •
Remote EPO contact is not used.
Remote EPO wiring should be a minimum of 0.75 mm•
The maximum distance between the Remote EPO and the UPS cannot exceed 150 meters.•
Alarm relay contacts have a maximum current rating of 5A and a switched voltage rating of •
30 Vac and 28 Vdc.
Alarm relay wiring should be a minimum of 0.75 mm•
2
and a maximum of 2.5 mm2.
2
.
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2.3 Inspecting and unpacking the UPS cabinet
The UPS cabinet is palleted separately for shipping. The cabinet is shipped bolted to a wooden
pallet and protected with outer protective packaging material (see Figure 3-8).
CAUTION
The UPS cabinet is heavy (see Table 2-1 on page 11). If unpacking instructions are not
closely followed, the cabinet may tip and cause serious injury.
1. Carefully inspect the outer packaging for evidence of damage during transit.
CAUTION
Do not install a damaged cabinet. Report any damage to the carrier and contact your
service representative immediately.
NOTE
For the following step. verify that the forklift or pallet jack is rated to handle the weight of
the cabinet (see Table 2-1 on page 11 for cabinet weight).
2. Use a forklift or pallet jack to move the packaged cabinet to the installation site, or as close
as possible, before unpacking. Insert the forklift or pallet jack forks from the right side of the
cabinet, between the supports on the bottom of the pallet (see Figure 2-6 on page 14 for the
UPS cabinet center of gravity measurements).
CAUTION
Do not tilt the UPS cabinet more than 10° from vertical or the cabinet may tip over.
3. Set the pallet on a firm, level surface, allowing a minimum clearance of 3 m on each side
for removing the cabinet from the pallet.
NOTE
The UPS cabinet is shipped with a debris shield covering the ventilation grill on top of the
unit. Do not remove the debris shield until installation is complete.
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4. Remove the protective covering from the cabinet.
5. Remove the packing material, and discard or recycle in a responsible manner.
6. After removing the protective covering, inspect the contents for any evidence of physical
damage, and compare each item with the Bill of Lading. If damage has occurred or
shortages are evident, contact your service representative immediately to determine the
extent of the damage and its impact upon further installation.
NOTE
While waiting for installation, protect the unpacked cabinet from moisture, dust, and other
harmful contaminants. Failure to store and protect the UPS properly may void your warranty.
Figure 2-8. Powerware 9395 UPS (2*275 kVA) cabinet as shipped on pallet
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3 UPS system installation
3.1 Preliminary installation information
WARNING
Installation should be performed only by qualified personnel.
Refer to the following while installing the UPS system:
Chapter 2 for cabinet dimensions, equipment weight, wiring and terminal data, and •
installation notes.
Do not tilt the cabinet more than ±10° during installation.•
The landing plates are to be removed to add holes as required. Plate material is 16 gauge •
steel (1.5 mm/0.06” thick).
If perforated floor tiles are required for ventilation, place them in front of the UPS.•
3.2 Unloading the UPS cabinet from the pallet and mechanical installation
The UPS cabinet is bolted to a wooden pallet supported by wood skids. To remove the pallet
and mechanically install the UPS, perform the following procedure:
NOTE
When a line-up-and-match UPS system is ordered together with battery cabinets, the first
battery cabinet is supplied with two cosmetic covers. The UPS cabinet, additional battery
cabinets, and other ancillary cabinets are supplied without cosmetic covers.
NOTE
When a UPS system is ordered together with battery cabinets for standalone installation,
the first battery cabinet is supplied with two cosmetic covers. Additional battery cabinets
are supplied without cosmetic covers. Cosmetic covers must be ordered for the UPS
cabinet and/or other ancillary cabinets.
WARNING
The UPS cabinet is heavy. See Table 2-1 on page 11 for weight of cabinets. If unloading
instructions are not closely followed, the cabinet may cause serious injury.
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CAUTION
•Donottiltcabinetsmorethan10°fromvertical.
•Liftthecabinetonlywithaforkliftordamagemayoccur.
NOTE
For the following steps, verify that the forklift or pallet jack is rated to handle the weight of
the cabinet (see Table 2-1 on page 11 for cabinet weight).
1. If not already accomplished, use a forklift or pallet jack to move the cabinet to the
installation area, or as close as possible, before unloading from the pallet. Insert the forklift
or pallet jack forks from the right side of the cabinet, between the supports on the bottom of
the pallet (see Figure 2-6 on page 13 for the UPS cabinet center of gravity measurements).
2. Remove the three bolts securing the left side shipping bracket to the cabinet and three bolts
securing the bracket to the pallet (see Figure 3-1). Remove the front shipping bracket. If
installing the cabinet permanently, retain the shipping bracket and securing hardware for
later use.
3. Remove the three bolts securing the right side shipping bracket to the cabinet and three
bolts securing the bracket to the pallet (see Figure 3-2). Remove the front shipping bracket.
If installing the cabinet permanently, retain the shipping bracket and securing hardware for
later use.
4. Using the forklift, raise the UPS cabinet section until the cabinet bottom clears the pallet by
approximately 3 mm.
5. Once the UPS cabinet is clear of the pallet, pull the pallet from under the UPS cabinet.
Discard or recycle the pallet in a responsible manner.
6. Using the forklift, move the UPS cabinet to the final installed location.
7. Carefully lower the UPS cabinet until the cabinet base contacts the floor.
8. If permanently mounting the system, proceed to Step 9; otherwise, continue to Step 11.
9. Using the retained hardware, reinstall the shipping brackets removed in Steps 2 and 3 to
the left and right side of the UPS cabinet with the angle facing outward (see Figure 3-1 and
Figure 3-2).
10. Secure the cabinet to the floor with customer-supplied hardware.
11. If installing a battery cabinet, proceed to paragraphs 3.3; otherwise, proceed to paragraph
3.4.
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Figure 3-1. Removing left side shipping bracket
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