Powerware (4080 KVA) 9390 User Manual

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UPS

(40–80 kVA)

INSTALLATION & OPERATION MANUAL

www.powerware.com

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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

Consignes de sécurité

CONSIGNES DE SÉCURITÉ IMPORTANTES

CONSERVER CES INSTRUCTIONS

CE MANUEL CONTIENT DES CONSIGNES DE SÉCURITÉ IMPORTANTES

Class A EMC Statements

FCC Part 15

NOTE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

W A R N I N G

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

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

ECopyright 2004 Powerware Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any way without the express written approval of Powerware Corporation.

Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

1.1

Basic System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

1.2

Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

1.3

Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

1.4

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5

1.5

For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6

1.6

Getting Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6

Section I – Installation

 

2 UPS Installation Plan and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2.1

Creating an Installation Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2.2

Preparing the Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2.2.1 Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

2.2.2 Preparing for Wiring the UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

2.3

Inspecting and Unpacking the UPS Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

3 Installing the UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Preliminary Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 UPS Cabinet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2.1 Unloading the Powerware 9390 UPS Cabinet from the Pallet . . . . . . . . . . . . . . . . . . 3-2 3.2.2 Battery Cabinet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3.2.3 Integrated Distribution Cabinet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.2.4 Installing UPS External and Battery Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.2.5 Installing Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.2.5.1 TB1 and TB2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.2.5.2 TB2 Battery Cabinet Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3.2.5.3 X-Slot Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3.2.6 Installing Accessories and Parallel System Control Wiring . . . . . . . . . . . . . . . . . . . . . 3-11 3.3 Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3.4 Completing the Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

4 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Installing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3 Recycling the Used Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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5 Installing a Remote Emergency Power-Off Control . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

6 Installing Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Installing a Hot Sync Computer Area Network Bridge Card . . . . . . . . . . . . . . . . . . . . . . . 6-1 6.2 Preliminary Wiring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.3 Installing Parallel System Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.4 Installing a Remote Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.5 Installing a Relay Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6.6 Installing a Supervisory Contact Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Section II – Operation

 

7 Understanding UPS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7.1

Looking Inside the UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7.2

Single Module Reverse Transfer (RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

7.2.1 Single Module RT Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

7.2.2 Normal Mode – RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4

7.2.3 Bypass Mode – RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6

7.2.4 Battery Mode – RT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8

7.3

Multiple Module Parallel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9

7.3.1 Multiple Module Parallel System Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10

7.3.2 Normal Mode – Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11

7.3.3 Bypass Mode – Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-12

7.3.4 Battery Mode – Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-14

7.4

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15

7.4.1

Input Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15

7.4.2

Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15

7.4.3 Battery Charger and Advanced Battery Management . . . . . . . . . . . . . . . . . . . . . . . .

7-15

7.4.4

Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16

7.4.5

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16

8 Features, Options, and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 UPS Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1.2 Customer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1.2.1 Building Alarm Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1.2.2 Alarm Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1.3 X-Slot Communication Bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1.4 ConnectUPS-X Web/SNMP Card X-Slot Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1.5 Advanced Battery Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

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8.1.6 LanSafe Power Management Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

8.1.7

Installation Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

8.2 Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

8.2.1

Integrated Battery Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

8.2.2

Integrated Distribution Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

8.2.3

HotSync Parallel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3

8.2.4

Optional X-Slot Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3

8.2.5

Remote Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3

8.2.6

Relay Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3

8.2.7

Supervisory Contact Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3

8.3 Symbols, Controls, and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4

9 Using the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1

9.1 Using the LCD and Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9.2 Using the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.2.1 Mimic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 9.2.2 Event Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9.2.3 Unit Meter Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 9.2.4 System Meters Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 9.2.5 System Setup Level 0 Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 9.2.6 System Setup Level 1 Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17 9.3 System Controls Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26 9.4 Load Off Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 9.5 Reading the Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29

10 UPS Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1

10.1 Single Module Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.1.1 Starting the UPS in Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10.1.2 Starting the UPS in Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 10.1.3 Starting the Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 10.1.4 Transfer from Normal to Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 10.1.5 Transfer from Bypass to Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 10.1.6 Transfer from Normal to Bypass Mode and Shut Down UPS . . . . . . . . . . . . . . . . . . 10-4 10.1.7 UPS and Critical Load Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 10.1.8 Charger Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 10.1.9 Using the UPS LOAD OFF Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 10.1.10 Using the Remote Emergency Power-Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

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10.2 Multiple Module Parallel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-8

10.2.1 Starting the Parallel System in Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-8

10.2.2 Starting the Parallel System in Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-9

10.2.3 Transfer Parallel System from Normal to Bypass Mode . . . . . . . . . . . . . . . . . . . . . . .

10-10

10.2.4 Transfer Parallel System from Bypass to Normal Mode . . . . . . . . . . . . . . . . . . . . . . .

10-10

10.2.5 Single UPM Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-11

10.2.6 Restarting a Single UPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-11

10.2.7 Parallel System and Critical Load Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-12

10.2.8 Using the UPS LOAD OFF Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-13

10.2.9 Using the Parallel System Remote Emergency Power-Off Switch . . . . . . . . . . . . . .

10-14

11 Using Features and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.1 Building Alarm Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.2 General Purpose Relay Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.3 Optional Remote Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11.4 Relay Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.5 Supervisory Contact Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

12 Responding to System Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1

12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.2 System Event Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.3 System Event Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

12.4 System Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

13 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

13.1 X-Slot Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

13.2 LanSafe Power Management Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

13.3 Remote Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

13.4 Terminal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

13.4.1 Display UPS Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3

13.4.2 Event History Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4

14 Maintaining the UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-1

14.1 Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

14.2 Performing Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

14.2.1 DAILY Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

14.2.2 MONTHLY Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

14.2.3 ANNUAL Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

14.2.4 BATTERY Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

14.3 Maintenance Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Table of Contents

15 Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-1

15.1

Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-1

15.2

Single Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-1

15.2.1

UPS System Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-1

15.2.2

UPS System Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-2

15.2.3

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-2

15.3

Multiple Module Parallel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3

15.3.1

UPM Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3

15.3.2

UPM Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3

15.3.3

Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3

15.3.4

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3

15.3.5 Module Tie Cabinet Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3

15.3.6 Module Tie Cabinet Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3

Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W-1

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List of Figures

Figure 1-1. Powerware 9390 UPS (40–80 kVA) Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Figure 2-1. Powerware 9390 UPS (40–80 kVA) Cabinet as Shipped on Pallet . . . . . . . . . . . . . . . . . . . 2-3 Figure 3-1. Removing Front Shipping Bracket on the Powerware 9390 UPS . . . . . . . . . . . . . . . . . . . . 3-3 Figure 3-2. Removing Rear Shipping Bracket on the Powerware 9390 UPS . . . . . . . . . . . . . . . . . . . . 3-4 Figure 5-1. REPO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Figure 6-1. Hot Sync CAN Bridge Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Figure 6-2. Supervisory Contact Module TB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Figure 7-1. Main Elements of the UPS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Figure 7-2. Path of Current Through the UPS in Normal Mode – RT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Figure 7-3. Path of Current Through the UPS in Bypass Mode – RT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Figure 7-4. Path of Current Through the UPS in Battery Mode – RT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Figure 7-5. Path of Current through the UPMs in Normal Mode – Parallel . . . . . . . . . . . . . . . . . . . . 7-11 Figure 7-6. Path of Current through the UPMs in Bypass Mode – Parallel . . . . . . . . . . . . . . . . . . . . . 7-12 Figure 7-7. Path of Current through the UPMs in Battery Mode – Parallel . . . . . . . . . . . . . . . . . . . . . 7-14 Figure 9-1. UPS Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Figure 9-2. Parts of the LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Figure 9-3. Main Menu and Mimic Screen (Normal Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Figure 9-4. Active Events Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Figure 9-5. History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Figure 9-6. Unit Output Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Figure 9-7. Unit Input Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Figure 9-8. Unit Bypass Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Figure 9-9. Unit Battery Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Figure 9-10. Unit Output Current (Load) Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8 Figure 9-11. System Meters Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Figure 9-12. Total System Output Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10 Figure 9-13. Output Unit X Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11 Figure 9-14. Input Unit X Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Figure 9-15. Bypass Unit X Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Figure 9-16. Battery Unit X Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 Figure 9-17. Output Current (Load) Unit X Meter Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13 Figure 9-18. System Setup Level 0 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14 Figure 9-19. Contrast Adjust Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 Figure 9-20. Versions Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 Figure 9-21. Unit Type Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16 Figure 9-22. Enter Password Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-17 Figure 9-23. System Setup Level 1 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Figure 9-24. Change Password Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 Figure 9-25. Change Password Save Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20 Figure 9-26. Time Format Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21 Figure 9-27. Set Date and Time MM/DD/YYYY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22 Figure 9-28. Date and Time DD/MM/YYYY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23 Figure 9-29. COM Port Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24 Figure 9-30. COM Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25 Figure 9-31. System Controls Screen 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26 Figure 9-32. System Controls Screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27 Figure 9-33. Load Off Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 Figure 11-1. Remote Monitor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Figure 11-2. Relay Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 Figure 11-3. Supervisory Contact Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 Figure 13-1. Optional X-Slot Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 Figure 13-2. Sample Event History Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Chapter 1 Introduction

The Powerware® 9390 uninterruptible power supply (UPS) is a true online, continuous-duty, transformerless, double-conversion, solid-state, three-phase system, providing conditioned and uninterruptible AC power to protect the customer’s load from all nine power failures. The Powerware 9390 UPS is available as a single module or a multiple module parallel system (see paragraph 1.1).

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

The Powerware 9390 UPS continually monitors incoming electrical power and removes the surges, spikes, sags, and other irregularities that are inherent in commercial utility power. Working with a building’s electrical system, the UPS system supplies clean, consistent power that sensitive electronic equipment requires for reliable operation. During brownouts, blackouts, and other power interruptions, batteries provide emergency power to safeguard operation.

The UPS system is housed in a single, free-standing cabinet with safety shields behind the door for hazardous voltage protection. The cabinets matches the battery and distribution cabinets in style and color and can be installed in line-up–and–match or standalone configurations. Figure 1-1 shows the Powerware 9390 UPS (40–80 kVA).

Figure 1-1. Powerware 9390 UPS (40–80 kVA) Cabinet

Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

1-1

Introduction

1.1 Basic System Configurations

The following basic UPS system configurations are possible:

Single module UPS and one to four battery cabinets

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

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

-One capacity/one redundant (1+1)

-Two capacity (2+0)

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

-Two capacity/one redundant (2+1)

-Three capacity (3+0)

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

-Three capacity/one redundant (3+1)

-Four capacity (4+0)

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

-One capacity/one redundant (1+1)

-Two capacity (2+0)

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

-Two capacity/one redundant (2+1)

-Three capacity (3+0)

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

-Three capacity/one redundant (3+1)

-Four capacity (4+0)

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

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Introduction

1.2 Using This Manual

This manual describes how to install and operate the Powerware 9390 UPS (40–80 kVA) cabinet. Read and understand the procedures described in this manual to ensure trouble-free installation and operation. In particular, be thoroughly familiar with the REPO procedure (see page 10-7).

The information in this manual is divided into the sections and chapters listed. The system, options, and accessories being installed dictate which parts of this manual should be read. At a minimum, Chapters 1 through 3 and 8 through 10 should be examined.

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

Section I, Installation

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

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

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

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

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

Section II, Operation

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

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

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

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

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

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

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

Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

1-3

Introduction

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

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

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

Warranty – provides the Powerware warranty for this product.

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

1.3 Conventions Used in This Manual

This manual uses these type conventions:

Bold type highlights important concepts in discussions, key terms in procedures, and menu options, or represents a command or option that you type or enter at a prompt.

Italic type highlights notes and new terms where they are defined.

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

Icon Description

Information notes call attention to important features or instructions.

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

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

1-4

Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Introduction

1.4 Safety Warnings

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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

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

D A N G E R

This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by

AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS inside the UPS.

W A R N I N G

The UPS system contains its own energy source (batteries). The output terminals may carry live voltage even when the UPS is disconnected from an AC source.

To reduce the risk of fire or electric shock, install this UPS in a temperature and humidity controlled, indoor environment, free of conductive contaminants. Ambient temperature must not exceed 40GC (104GF). Do not operate near water or excessive humidity (95% max). The system is not intended for outdoor use.

Ensure all power is disconnected before performing installation or service.

C A U T I O N

Batteries can present a risk of electrical shock or burn from high short-circuit current. Observe proper precautions. Servicing should be performed by qualified service personnel knowledgeable of batteries and required precautions. Keep unauthorized personnel away from batteries.

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

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

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

Do not operate the UPS system close to gas or electric heat sources.

The operating environment should be maintained within the parameters stated in this manual.

Keep surroundings uncluttered, clean, and free from excess moisture.

Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the equipment.

Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

1-5

Introduction

1.5 For More Information

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

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

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

Refer to the Powerware 9390 Integrated Distribution Cabinet (80 kVA) Installation and Operation Manual (164201546) for the following additional information:

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

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

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

1.6 Getting Help

If help is needed with any of the following:

Scheduling initial startup

Regional locations and telephone numbers

A question about any of the information in this manual

A question this manual does not answer

Please call Powerware at:

In the United States

1-800-843-9433

In Canada

1-800-461-9166

All other countries

Call your service representative

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Section I Installation

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Chapter 2 UPS Installation Plan and Unpacking

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

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

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

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

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

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

6.Complete the Installation Checklist (Chapter 3).

7.Have authorized service personnel perform preliminary operational checks and startup.

NOTE Startup and operational checks must be performed by an authorized Powerware Customer Service Engineer, or the warranty terms as specified on page W-1 become void. This service is offered as part of the sales contract for the UPS. Contact service in advance (usually a two-week notice is required) to reserve a preferred startup date.

2.1 Creating an Installation Plan

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

2.2 Preparing the Site

For the UPS system to operate at peak efficiency, the installation site should meet the environmental parameters outlined in this manual. If the UPS is to be operated at an altitude higher than 1500m (5000 ft), contact your Powerware service representative for important information about high altitude operation. The operating environment must meet the weight, clearance, and environmental requirements specified in Drawing 164201535-2 on page A-3 and size requirements specified on Drawing 164201535-9 starting on page A-45.

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.

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UPS Installation Plan and Unpacking

2.2.1 Environmental Considerations

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

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

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

Failure to follow guidelines may void your warranty.

2.2.2 Preparing for Wiring the UPS System

For external wiring requirements, including the minimum AWG size of external wiring, see Table E through Table H starting on page A-11. The power wiring connections for this equipment are rated at 90°C. If wire is run in an ambient temperature greater than 30°C, higher temperature wire and/or larger size wire may be necessary. Control wiring for Emergency Power-Off (EPO) and optional accessories (such as building alarms and monitoring interface) should be connected at the customer interface terminal blocks located inside the UPS.

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

2.3 Inspecting and Unpacking the UPS Cabinet

The next step is inspecting and unpacking the UPS cabinet. The cabinet is shipped bolted to a wooden pallet and protected with outer protective packaging material (see

Figure 2-1).

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UPS Installation Plan and Unpacking

Figure 2-1. Powerware 9390 UPS (40–80 kVA) Cabinet as Shipped on Pallet

C A U T I O N

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

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

C A U T I O N

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

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

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

C A U T I O N

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

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UPS Installation Plan and Unpacking

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

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

4.Remove the protective covering from the cabinet.

5.Remove the packing material, and discard or recycle them 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 Powerware service representative immediately to determine the extent of the damage and its impact upon further installation.

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

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Chapter 3 Installing the UPS System

3.1 Preliminary Installation Information

W A R N I N G

Installation should be performed only by qualified personnel.

Refer to the following while installing the UPS system:

Appendix A for installation drawings and additional installation notes.

Dimensions are in millimeters and inches.

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

The conduit landing plates are to be removed to add conduit landing holes as required. Plate material is 16 gauge steel (1.5 mm/0.06I thick).

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

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

Details about control wiring are provided in each procedure for connecting options and features. Drawing 164201535-8 and Table T through Table Y starting on page A-33 identify the control wiring terminations.

3.2UPS Cabinet Installation

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

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

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

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3.2.1 Unloading the Powerware 9390 UPS Cabinet from the Pallet

The UPS cabinet is bolted to a wooden pallet supported by wood skids. To remove the pallet, perform the following procedure:

W A R N I N G

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

C A U T I O N

Do not tilt cabinets more than 10° from vertical.

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

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

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

3.Remove the door. Remove the retaining screw located inside the door at the bottom hinge pivot point, then lift the door off. Retain the hardware for later use.

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

5.Remove three bolts securing the rear shipping bracket to the cabinet and two bolts securing the bracket to the pallet (see Figure 3-2 on page 3-4). Remove the rear shipping bracket. If installing the cabinet permanently, retain the shipping bracket and securing hardware for later use.

6.Remove three bolts securing the front anti-tip/shipping bracket to the cabinet and two bolts securing the bracket to the pallet (see Figure 3-1). Remove the front anti-tip/shipping bracket. Retain the front anti-tip/shipping bracket and securing hardware for later use. Do not discard the front anti-tip/shipping bracket. This bracket is required for installation.

7.Remove three bolts securing the removable skid and remove the skid (see Figure 3-2 on page 3-4).

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NOTE Do not discard the front anti-tip/shipping bracket. This bracket is required for installation.

Front View

Vented Front Door

Shipping

Bracket Bolts

Pallet

Shipping Bracket Bolts

Front Anti-tip/Shipping Bracket (Note Wider Base)

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

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Rear View

Skid Bolts

(3 Places)

Removable Skid

Shipping

Bracket Bolts

Pallet

Shipping Bracket Bolts

Rear Shipping Bracket

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

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Installing the UPS System

NOTE In the following step the pallet tilts and acts as a ramp once the cabinet is rolled beyond the the center of the pallet. Be sure to restrain the cabinet as it continues to roll down the pallet/ramp.

W A R N I N G

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

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

9.Roll the cabinet to the final installation location.

10.If installing the cabinet permanently, retain the shipping brackets and hardware; otherwise, discard or recycle the pallet and rear bracket in a responsible manner.

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

W A R N I N G

The front anti-tip/shipping bracket must be reinstalled; otherwise, injury and damage to the UPS may result when removing components during service. If the bracket is not reinstalled, the cabinet may tip and cause serious injury and damage.

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

13.Using the retained hardware, reinstall the front anti-tip/shipping bracket (bracket with wider base) removed in Step 6 to the front of UPS cabinet with the angle facing outward and adjusted level with the floor (see Figure 3-1).

14.If installing battery and distribution cabinets, proceed to paragraphs 3.2.2 and 3.2.3; otherwise, proceed to paragraph 3.2.4.

15.Using the retained hardware, reinstall the shipping brackets removed in Step 5 to the front and rear of the UPS cabinet with the angle facing outward (see

Figure 3-1 and Figure 3-2).

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

17.If installing battery and distribution cabinets, proceed to paragraphs 3.2.2 and 3.2.3; otherwise, proceed to paragraph 3.2.4.

3.2.2Battery Cabinet Installation

To install the battery cabinet, refer to the Powerware 9390 Integrated Battery Cabinet (Models IBC-S and IBC-L) Installation Manual. After the battery cabinet is installed, return to paragraph 3.2.4 to wire the UPS and battery cabinet.

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3.2.3 Integrated Distribution Cabinet Installation

To install an IDC, refer to the Powerware 9390 Integrated Distribution Cabinet (80 kVA) Installation and Operation Manual. After the distribution cabinet is installed, return to paragraph 3.2.4 to wire the UPS and distribution cabinet.

3.2.4 Installing UPS External and Battery Power Wiring

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

NOTE Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

1.Slide the air filter up and remove from the cabinet.

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

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

4.If installing power wiring from the top of the cabinet, proceed to Step 5; otherwise, proceed to Step 6.

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

6.Route the input and output cables to the UPS terminal blocks. See Drawing 164201535-7 starting on page A-29 for wiring access information and terminal locations.

7.If wiring a single-feed system, proceed to Step 8; if wiring a dual-feed system, proceed to Step 10.

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

9.Proceed to Step 20.

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

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

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

13.If wiring an IDC, proceed to Step 14; otherwise, proceed to Step 17.

14.Route and connect the output cable between the UPS cabinet and the IDC in accordance with the instructions in the Powerware 9390 Integrated Distribution Cabinet (80 kVA) Installation and Operation Manual. See Appendix A for UPS cabinet wiring access information.

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

16.Proceed to Step 21.

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

C A U T I O N

Parallel system wiring length should be in accordance with Drawing 164201535-5, sheet 16 of 16, to ensure approximately equal current sharing when in static bypass mode.

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

19.Proceed to Step 21.

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

C A U T I O N

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

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

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

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23.After wiring the UPS system to the facility power and critical load, be sure to ground the system according to local and/or national electrical wiring codes. DO NOT bond the neutral to ground.

24.If wiring interface connections, proceed to paragraph 3.2.5; otherwise, proceed to Step 25.

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

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

27.Reinstall the door removed in paragraph 3.2.1 and secure with the retained hardware.

28.Close the door and secure the latch.

3.2.5Installing Interface Connections

3.2.5.1 TB1 and TB2 Connections

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

To install wiring to connections:

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

2.If not already open, unfasten the front door latch and swing the door open (see Figure 3-1).

3.If not already removed, remove the door. Remove the retaining screw located inside the door at the bottom hinge pivot point, then lift the door off. Retain the hardware for later use.

4.Remove the screws securing the control panel door and swing the door open. Retain the hardware for later use.

5.Remove the screws securing the top internal safety shield panel. Remove the panel to gain access to the TB1 and TB2 terminal blocks, and the top conduit landing plate (see Drawing 164201535-8 starting on page A-33). Retain the hardware for later use.

6.If installing interface wiring from the bottom of the cabinet, proceed to Step 7; otherwise, proceed to Step 8.

7.Remove the screws securing the bottom internal safety shield panel and remove the panel to gain access to the bottom conduit landing plate.

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8.Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

9.Reinstall the conduit landing plate and install the conduit.

10.To locate the appropriate terminals and review the wiring and termination requirements, see Drawing 164201535-8 starting on page A-33.

11.Route and connect the wiring.

12.If wiring TB2 battery cabinet interface connections, proceed to paragraph 3.2.5.2; if wiring the X-Slot connections only, proceed to paragraph 3.2.5.3; otherwise, proceed to Step 13.

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

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

15.Reinstall the door removed in Step 3 or paragraph 3.2.1 and secure with the retained hardware.

16.Close the door and secure the latch.

3.2.5.2 TB2 Battery Cabinet Connections

To install the wiring to connections:

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

2.If not already open, unfasten the front door latch and swing the door open (see Figure 3-1).

3.If not already removed, remove the door. Remove the retaining screw located inside the door at the bottom hinge pivot point, then lift the door off. Retain the hardware for later use.

4.Remove the screws securing the control panel door and swing the door open. Retain the hardware for later use.

5.Remove the screws securing the top internal safety shield panel. Remove the panel to gain access to the TB2 terminal block (see Drawing 164201535-8 starting on page A-33). Retain the hardware for later use.

6.To locate the appropriate terminals, and for wiring and termination requirements (see Drawing 164201535-8 starting on page A-33).

7.If battery cabinets are installed attached to the UPS cabinet, proceed to Step 8; if battery cabinets are installed separated from the UPS cabinet, proceed to Step 11.

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8.Route the UV trip and Aux wiring harness supplied with the battery cabinet from the battery cabinet to the UPS cabinet. Refer to Appendix A and to the Powerware 9390 Integrated Battery Cabinet (Models IBC-S and IBC-L) Installation Manual for wiring access information.

9.Connect the wiring to TB2 terminals.

10.Proceed to Step 17.

11.If installing interface wiring from the bottom of the cabinet, proceed to Step 12; otherwise, proceed to Step 13.

12.Remove the screws securing the bottom internal safety shield panel and remove the panel to gain access to the bottom conduit landing plate.

NOTE When installing UV trip and Aux battery interface wiring to the UPS interface terminals, conduit must be installed between the UPS and battery cabinets.

13.Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

14.Reinstall the conduit landing plate and install the conduit.

15.Route the UV trip and Aux wiring from the battery cabinet to the UPS.

16.Connect the wiring to the TB2 terminals.

17.If wiring X-Slot connections, proceed to paragraph 3.2.5.3; otherwise, proceed to Step 18.

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

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

20.Reinstall the door removed in Step 3 or paragraph 3.2.1 and secure with the retained hardware.

21.Close the door and secure the latch.

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Installing the UPS System

3.2.5.3 X-Slot Connections

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

NOTE When installing external wiring to X-Slot cards, conduit must be installed to the UPS cabinet. When installing internal wiring to X-Slot terminals, route the wiring through the internal opening in the X-Slot communication bay.

For installation and setup of an X-Slot card, please contact Powerware (see page 1-6).

To install wiring for connections:

1.If not already installed, install the LAN and telephone drops.

2.Unfasten the front door latch and swing the door open.

3.Remove the UPS cabinet X-Slot conduit landing plate to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

4.Reinstall the conduit landing plate and install the conduit.

5.Route and install the LAN, telephone, and other cables to the appropriate X-Slot cards.

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

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

8.Reinstall the door removed in Step 3 or paragraph 3.2.1 and secure with the retained hardware.

9.Close the door and secure the latch.

10.Refer to the manual supplied with the X-Slot card for user instructions.

3.2.6 Installing Accessories and Parallel System Control Wiring

To install an optional Remote Emergency Power-Off Control, see Chapter 5, “Installing a Remote Emergency Power-Off Control.” To install optional accessories, see Chapter 6, “Installing Options and Accessories.” To install parallel system control wiring, see Chapter 6, “Installing Options and Accessories.”

3.3 Initial Startup

Startup and operational checks must be performed by an authorized Powerware Customer Service Engineer, or the warranty terms as specified on page W-1 become void. This service is offered as part of the sales contract for the UPS. Contact service in advance (usually a two-week notice is required) to reserve a preferred startup date.

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3.4 Completing the Installation Checklist

The final step in installing the UPS system is completing the following Installation Checklist. This checklist ensures that you have completely installed all hardware, cables, and other equipment. Complete all items listed on the checklist to ensure a smooth installation. Make a copy of the Installation Checklist before filling it out, and retain the original. If installing a parallel system, complete the Parallel System Installation Checklist in addition to the Installation Checklist.

After the installation is complete, your Powerware service representative must verify the operation of the UPS system and commission it to support the critical load. The service representative cannot perform any installation tasks other than verifying software and operating setup parameters. Service personnel may request a copy of the completed Installation Checklist to verify all applicable equipment installations have been completed.

NOTE The Installation Checklist MUST be completed prior to starting the UPS system for the first time.

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Installation Checklist

-All packing materials and restraints have been removed from each cabinet.

-Each cabinet in the UPS system is placed in its installed location.

-Front shipping bracket is installed and adjusted.

-A cabinet grounding/mounting kit is installed between any cabinets that are bolted together.

-All conduits and cables are properly routed to the UPS and any ancillary cabinets.

-All power cables are properly sized and terminated.

-The bypass source of the supply is a threeor four-wire wye configuration. If using dual-feed, the rectifier source is a three-wire connection from a wye configuration. If the load requires a neutral, a bypass source neutral must be provided.

-Battery cables are terminated on E4 (+) and E5 (-).

-Battery UV trip and Aux contact signal wiring is connected from the UPS to the battery breaker.

-LAN and telephone drops are installed.

-All telephone and LAN connections have been completed.

-A ground conductor is properly installed.

-Air conditioning equipment is installed and operating correctly.

-The area around the installed UPS system is clean and dust-free. (It is recommended that the UPS be installed on a level floor suitable for computer or electronic equipment.)

-Adequate workspace exists around the UPS and other cabinets.

-Adequate lighting is provided around all UPS equipment.

-A 120V service outlet is located within 25 feet of the UPS equipment.

-The REPO device is mounted in its installed location and its wiring is terminated inside the UPS cabinet.

-The normally-closed (NC) Emergency Power-Off contact (pins 8 and 9 on TB1) is jumpered if not used.

-Alarm relays and building alarms are wired appropriately. (OPTIONAL)

-A remote battery disconnect control is mounted in its installed location and its wiring is terminated inside the UPS and battery cabinet. (OPTIONAL)

-Accessories are mounted in installed locations and wiring is terminated inside the UPS cabinet. (OPTIONAL)

-Debris shield covering the UPS cabinet ventilation grill is removed.

-Startup and operational checks are performed by an authorized Powerware Customer Service Engineer.

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Parallel System Installation Checklist

-Each cabinet in the parallel system is placed in its installed location.

-All conduits and cables are properly routed to the UPMs and to the parallel tie or distribution cabinet.

-All power cables are properly sized and terminated.

-The bypass source feeding the optional bypass of the parallel tie cabinet and the UPMs is from the same source of supply and is a four-wire wye configuration.

-A ground conductor is properly installed.

-Computer Area Network wiring between the UPMs is properly installed.

-Backup control (pull chain) wiring between the UPMs is properly installed.

-Adequate workspace exists around the UPMs, parallel tie cabinet, and other cabinets.

-Startup and operational checks are performed by an authorized Powerware Customer Service Engineer.

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Notes

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Chapter 4 Batteries

4.1 Important Safety Instructions

This chapter describes installing the UPS batteries.

C A U T I O N

Only qualified service personnel (such as a licensed electrician) should perform the battery installation. Risk of electrical shock.

NOTE DO NOT DISCONNECT the batteries while the UPS is in Battery mode.

Consider all warnings, cautions, and notes before installing or replacing batteries.

W A R N I N G

Batteries can present a risk of electrical shock or burn from high short-circuit current. The following precautions should be observed: 1) Remove watches, rings, or other metal objects; 2) Use tools with insulated handles; 3) Do not lay tools or metal parts on top of batteries; 4) Wear rubber globes and boots.

ELECTRIC ENERGY HAZARD. Do not attempt to alter any battery wiring or connectors. Attempting to alter wiring can cause injury.

C A U T I O N

The installation of batteries should be performed by qualified service personnel knowledgeable of batteries and required precautions. Keep unauthorized personnel away from batteries.

Replace batteries with the same number and type of batteries as originally installed in the UPS.

Disconnect the charging source prior to connecting or disconnecting terminals.

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

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

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

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Batteries

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

Les batteries peuvent présenter un risque de décharge électrique ou de brûlure par des courts-circuits de haute intensité. Prendre les précautions nécessaires.

Pour le replacement, utiliser le même nombre et modéle des batteries.

A T T E N T I O N !

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

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

4.2Installing Batteries

NOTE There is no DC disconnect device within the UPS.

Install batteries in accordance with the battery and battery rack manufacturer’s instructions.

4.3 Recycling the Used Battery

Contact your local recycling or hazardous waste center for information on proper disposal of the used battery.

W A R N I N G

Do not dispose of the battery or batteries in a fire. Batteries may explode. Proper disposal of batteries is required. Refer to your local codes for disposal requirements.

Do not open or mutilate the battery or batteries. Released electrolyte is harmful to the skin and eyes. It may be toxic.

C A U T I O N

Do 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 or hazardous waste center.

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Chapter 5 Installing a Remote Emergency Power-Off Control

A REPO switch can be used in an emergency to shut down the UPS and remove power to the critical load from a location away from where the UPS is installed. Figure 5-1 shows a REPO switch.

UNINTERRUPTIBLE POWER SYSTEM

EMERGENCY OFF

To UPS To Other Equipment

Figure 5-1. REPO Control

NOTE When installing the REPO switch, you must install conduit between the device and the UPS cabinet for wiring the switch.

NOTE Remove the UPS cabinet top or bottom conduit landing plate to punch conduit holes (see Drawing 164201535-6 on page A-27).

1.Securely mount the REPO station. Recommended locations include operator’s consoles or near exit doors. See Drawing 164201535-10 on page A-49 for enclosure dimensions and wiring knockouts.

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

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

4.If not already removed, remove the door. Remove the retaining screw located inside the door at the bottom hinge pivot point, then lift the door off. Retain the hardware for later use.

5.Remove the screws securing the control panel door and swing the door open. Retain the hardware for later use.

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6.Remove the screws securing the internal panel covering the TB1 and TB2 terminal blocks at the top of the UPS cabinet (see Drawing 164201535-8 starting on

page A-33).

7.If installing interface wiring from the bottom of the cabinet, proceed to Step 8; otherwise, proceed to Step 10.

8.Remove the screws securing the top internal safety shield panel and open the panel to gain access to the bottom wiring entry.

9.Remove the screws securing the bottom internal safety shield panel and remove the panel to gain access to the bottom conduit landing plate.

10.To locate appropriate terminals and to review the wiring and termination requirements (see Figure 5-1 and Drawing 164201535-8 starting on page A-33).

11.Route and connect the wiring as shown in Table 5-1 and Table 5-2.

12.If the normally-closed EPO contact is not used, connect the jumper wire between pins 8 and 9 on TB1.

Table 5-1. REPO Wire Terminations

From REPO Station(s)

To Customer Interface

 

Remarks

 

Terminal Board TB1 in UPS Cabinet

 

TB1-4

TB-7

 

Twisted Wires (2)

TB1-5

TB-9

 

14–22 AWG

Table 5-2. REPO

 

 

 

 

 

7 (NO)

 

REPO

 

 

 

Switch

Twisted

 

 

(NO)

UPS TB1

 

 

Wires

 

 

 

 

9 (RTN)

8 (NC)

REPO switch rating is 24 Vdc. 1A minimum if supplied by user.

NOTE This switch must be a dedicated switch not tied into any other circuits.

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Installing a Remote Emergency Power-Off Control

13.If you are installing multiple REPO stations, wire additional stations in parallel with the first REPO.

14.If required, install wiring from the REPO station to trip circuitry of upstream protective devices. A normally-open (NO) contact is provided between terminals 6 and 7 of REPO, as shown in Figure 5-1. REPO switch wiring must be in accordance with UL Class II requirements.

15.When all wiring is complete, reinstall the safety shield panels removed in the previous steps.

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

17.Reinstall the door removed in Step 4 and secure with the retained hardware.

18.Close the door and secure the latch.

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Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

Chapter 6 Installing Options and Accessories

6.1 Installing a Hot Sync Computer Area Network Bridge Card

As an option, a Hot Sync CAN Bridge Card, as shown in Figure 6-1, can be installed to provide connectivity for operational mode control and metering of a parallel system at any UPM in the system. In addition, this card can be used to connect an optional system monitoring device, such as a Remote Monitor Panel, a Relay Interface Module, or Supervisory Contact Module to the UPS.

Plug-In Terminal

Block J3

Figure 6-1. Hot Sync CAN Bridge Card

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

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

3.Install the Hot Sync CAN Bridge Card into an open X-Slot on the front of the UPS. Remove the X-Slot cover panel to gain access to the X-Slot. See Drawing 164201535-8 starting on page A-33 for location of the X-Slot communication bay.

4.Proceed to paragraph 6.2.

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Installing Options and Accessories

6.2 Preliminary Wiring Procedure

Perform the following procedure before installing wiring:

1.If not already removed, remove the door. Remove the retaining screw located inside the door at the bottom hinge pivot point, then lift the door off. Save the retaining screw for reinstallation of the door.

2.Remove the screws securing the control panel door and swing the door open. Retain the hardware for later use.

3.Remove the screws securing the top internal safety shield panel. Remove the panel to gain access to the TB1 and TB2 terminal blocks, X-Slot communication bays, and the top conduit landing plate (see Drawing 164201535-8 starting on

page A-33). Retain the hardware for later use.

4.If installing interface wiring from the bottom of the cabinet, proceed to Step 5; otherwise, proceed to Step 6.

5.Remove the screws securing the bottom internal safety shield panel and remove the panel to gain access to the bottom conduit landing plate.

6.Install wiring from the Hot Sync CAN Bridge Card in accordance with the instructions listed below:

Parallel system wiring (see paragraph 6.3)

RMP wiring (see paragraph 6.4)

RIM (see paragraph 6.5)

SCM (see paragraph 6.6)

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6.3 Installing Parallel System Control Wiring

NOTE When installing external wiring to the X-Slot CAN card, conduit must be installed to the UPS cabinet. When installing internal wiring to the X-Slot CAN card terminals, route the wiring through the internal opening in X-Slot communication bay.

NOTE When installing interface wiring for the parallel system pull chain, conduit must be installed between UPMs.

To install parallel system control wiring, perform the following procedures:

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

2.Perform procedures listed in paragraphs 6.1 and 6.2.

3.Remove the X-Slot conduit landing plate from the UPS cabinet to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

4.Reinstall the conduit landing plate and install the conduit.

5.Install CAN wiring between UPMs. See Drawing 164201535-8 starting on page A-33 for Hot Sync CAN Bridge Card location, terminal location, and wiring information.

6.Install parallel system backup control (pull chain) wiring between UPMs. See Drawing 164201535-8 starting on page A-33 for terminal locations and wiring information.

7.Install parallel system backup control (pull chain) wiring between the bypass relay and building alarm 2. See Drawing 164201535-8 starting on page A-33 for terminal locations and wiring information.

NOTE Setup of the Hot Sync CAN Bridge Card for parallel operation must be performed by an authorized Powerware Customer Service Engineer. Contact service to schedule a date.

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

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

10.Reinstall the door removed previously and secure with the retained hardware.

11.Close the door and secure the latch.

Powerware® 9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C

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Installing Options and Accessories

6.4 Installing a Remote Monitor Panel

NOTE Only one system monitoring device can be connected to the Hot Sync CAN Bridge Card at one time (see Table 6-1).

Table 6-1. Optional Monitoring Accessories

Number and Type of Accessories Permitted

RMP

RIM

SCM

 

 

 

 

 

1

 

 

 

1

 

 

 

 

1

 

 

 

 

 

To install RMP wiring, perform the following procedure:

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

2.Perform procedures listed in paragraphs 6.1 and 6.2.

NOTE If mounting to a hollow wall, secure the enclosure to a wood or metal stud within the wall. Do not use hollow wall anchors.

3.Securely mount the RMP at the desired location. See drawing 164201535-11 for mounting hole locations.

NOTE When installing signal wiring for CAN card J3 terminals, conduit must be installed between the device and the UPS cabinet.

NOTE Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

4.Remove the X-Slot conduit landing plate from the UPS cabinet to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

5.Reinstall the conduit landing plate.

6.Install conduit between the UPS and RMP. See Appendix A for UPS cabinet and RMP wiring access information.

7.Install wiring between the UPS and RMP. See Drawing 164201535-8 starting on page A-33 for Hot Sync CAN Bridge Card and RMP location, terminal location, and wiring information.

NOTE 120 Vac for the RMP should be supplied from the critical bus by facility planners or the customer.

8.Install 120 Vac power wiring from the critical bus to the RMP. See Drawing 164201535-8 starting on page A-33 for terminal location and wiring information.

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NOTE Setup of the Hot Sync CAN Bridge Card must be performed by an authorized Powerware Customer Service Engineer. Contact service to schedule a date.

9.To check the operation of the RMP, ensure that the UPS is supplying the load via inverter or bypass. If the indicators on the RMP show the appropriate status, then it is operating correctly.

If the communication link between the UPS and the RMP is not present, the RMP performs a self-test (all indicators flash and the horn beeps at one-second intervals). If the self-test occurs, check all harness connectors and the fuse for proper seating. If all connections are secure but the RMP continues to self-test, replace the fuse with the spare included in the hardware kit. If a fuse replacement does not correct the problem, contact your Powerware service representative for verification that the RMP is working correctly.

10.To test the indicator lamps, press and hold the horn silence pushbutton for

3 seconds. All lamps should illuminate, and the horn sounds continuously until you release the pushbutton.

6.5 Installing a Relay Interface Module

NOTE Only one system monitoring device can be connected to the Hot Sync CAN Bridge Card at one time (see Table 6-1).

To install RIM wiring, perform the following procedure:

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

2.Perform procedures listed in paragraphs 6.1 and 6.2.

NOTE If mounting to a hollow wall, secure the enclosure to a wood or metal stud within the wall. Do not use hollow wall anchors.

3.Securely mount the RIM at the desired location. See drawing 164201535-12 for mounting hole locations.

NOTE When installing signal wiring for CAN card J3 terminals, conduit must be installed between the device and the UPS cabinet.

NOTE Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

4.Remove the X-Slot conduit landing plate from the UPS cabinet to drill or punch conduit holes (see Drawing 164201535-6 on page A-27).

5.Reinstall the conduit landing plate.

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Installing Options and Accessories

6.Install conduit between the UPS and RIM. See Appendix A for UPS cabinet and RIM wiring access information.

7.Install wiring between the UPS and RIM. See Drawing 164201535-8 starting on page A-33 for Hot Sync CAN Bridge Card and RIM location, terminal location, and wiring information.

NOTE 120 Vac for the RIM should be supplied from the critical bus by facility planners or the customer.

8.Install 120 Vac power wiring from the critical bus to the RMP. See Drawing 164201535-8 starting on page A-33 for terminal location and wiring information.

NOTE Setup of the Hot Sync CAN Bridge Card must be performed by an authorized Powerware Customer Service Engineer. Contact service to schedule a date.

9.Contact your Powerware service representative for verification and testing of the RIM and its connections prior to making connections with J1 through J4 (see Table 6-2 and Drawing 164201535-12).

You can order interface cables separately for connecting to the 15-Pin D-Sub Connectors.

Table 6-2. J1 through J4 Interface Connectors

Status

J1 through J4

Description

 

 

 

 

 

UPS AVAILABLE

Pins 1 and 12

Contacts are closed when the UPS is offline.

 

 

 

UPS OFFLINE

Pins 3 and 13

Contacts are closed when the UPS is operating in

 

 

Normal mode.

 

 

 

BATTERY WEAK

Pins 5 and 14

Contacts are closed when approximately two minutes of

 

 

battery time is remaining, before the critical load is lost.

 

 

 

UTILITY FAILURE

Pins 6 and 15

Contacts are closed when Utility Failure is detected.

 

 

 

 

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