Powerware 9390 User Manual
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
ClassAEMCStatements
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.
WARNING
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
1Introduction 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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Table of Contents
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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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Table of Contents
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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Table of Contents
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 SingleModuleSpecifications 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...................................................................
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
v
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. Pat h 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 t he UPMs in Battery Mode – Parallel 7-14.....................
Figure 9-1. UPS Control Panel 9-1..........................................................
Figure 9-2. Part s 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................................................
vi Powerware
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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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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:
쑺 Single module UPS and one to four battery cabinets
쑺 Single module UPS, one to four battery cabinets, and an optional Integrated Distribution
Cabinet (IDC)
쑺 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)
쑺 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)
쑺 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)
쑺 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)
쑺 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)
쑺 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
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.
쑺 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
쑺 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.
Introduction
쑺 Chapter 3, “Installing the UPS System” – describes how to install and wire the UPS
cabinet and optional equipment.
쑺 Chapter 4, “Batteries” – provides battery safety and installation information.
쑺 Chapter 5, “Installing a Remote Emergency Power-Off Control” – contains information
for installing the optional REPO control.
쑺 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
쑺 Chapter 7, “Understanding UPS Operation” – provides information on why and how a
UPS works.
쑺 Chapter 8, “Features, Options, and Accessories” – describes the standard and optional
UPS features and available accessories.
쑺 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.
쑺 Chapter 10, “UPS Operating Instructions” – contains startup and shutdown procedures
for the UPS system.
쑺 Chapter 11, “Using Features and Options” – contains descriptions and instructions for
the UPS system features and options.
쑺 Chapter 12, “Responding to System Events” – listsallthealarmsandnoticesthatoccur
during operation of the UPS system.
쑺 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
쑺
Chapter 14, “Maintaining the UPS System” – contains maintenance instructions for the
UPS system.
쑺 Chapter 15, “Product Specifications” – provides detailed specifications for the UPS
system.
쑺 Appendix A, “Installation Information” – contains important information on wiring
requirements and recommendations, and important diagrams of the cabinets’
mechanical details and electrical access.
쑺 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:
쑺 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.
쑺 Italic type highlights notes and new terms where they are defined.
쑺 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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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
1.4 Safety Warnings
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
should be handled with appropriate care.
This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by
AUTHORIZED SERVICE PERSONNEL ONLY.ThereareNO USER SERVICEABLE PARTS inside
the UPS.
Introduction
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
UPS system is a sophisticated power system and
DANGER
WARNING
쑺 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.
쑺 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.
쑺 Ensure all power is disconnected before performing installation or service.
CAUTION
쑺 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.
쑺 Proper disposal of batteries is required. Refer to local codes for disposal requirements.
쑺 Never dispose of batteries in a fire. Batteries may explode when exposed to flame.
쑺 Keep the UPS doors closed to ensure proper cooling airflow and to protect personnel from
dangerous voltages inside the unit.
쑺 Do not operate the UPS system close to gas or electric heat sources.
쑺 The operating environment should be maintained within the parameters stated in this
manual.
쑺 Keep surroundings uncluttered, clean, and free from excess moisture.
쑺 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:
쑺 Integrated Battery Cabinet (IBC) installation instructions, including site preparation,
planning for installation, wiring, and safety information.
쑺 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:
쑺 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.
쑺 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:
쑺 Scheduling initial startup
쑺 Regional locations and telephone numbers
쑺 A question about any of the information in this manual
쑺 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
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.
Startup and operational checks must be performed by an authorized Powerware
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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
2-1
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:
쑺 The system must be installed on a level floor suitable for computer or electronic
equipment.
쑺 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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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
UPS Installation Plan and Unpacking
Figure 2-1. Powerware 9390 UPS (40–80 kVA) Cabinet as Shipped on Pallet
CAUTION
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.
CAUTION
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
(see Table A on page A-3 for cabinet weight).
Verify that the forklift or pallet jack is rated to handle the weight of the cabinet
CAUTION
Do not tilt the UPS cabinet more than 10° from vertical or the cabinet may tip over.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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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
top of the unit. Do not remove the debris shield until installation is complete.
The UPS cabinet is shipped with a debris shield covering the ventilation grill on
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
and other harmful contaminants. Failure to store and protect the UPS properly may
void your warranty.
While waiting for installation, protect the unpacked cabinet from moisture, dust,
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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
WARNING
Installation should be performed only by qualified personnel.
Refer to the following while installing the UPS system:
쑺 Appendix A for installation drawings and additional installation notes.
쑺 Dimensions are in millimeters and inches.
쑺 Do not tilt the cabinets more than á10° during installation.
쑺 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).
쑺 Thecabinetsmustbeinstalledonalevelfloorsuitableforcomputerorelectronic
equipment.
쑺 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.
쑺 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.
3.2 UPS Cabinet Installation
To install a UPS cabinet, perform the procedures in the following paragraphs.
NOTE
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.
When a line-up–and–match UPS system is ordered together with battery
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
3-1
Installing the UPS System
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:
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.
Do not tilt cabinets more than 10° from vertical.
WARNING
CAUTION
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
(see Table A on page A-3 for cabinet weight).
Verify that the forklift or pallet jack is rated to handle the weight of the cabinet
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).
3-2
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Installing the UPS System
NOTE Do not discard the front anti-tip/shipping bracket. This bracket is required for
installation.
Front View
Vented Front Door
Pallet
Shipping Bracket Bolts
Front Anti -tip/Shipping
Bracket (Note Wider Base)
Figure 3-1. Removing Front Shipping Bracket on the Powerware 9390 UPS
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Shipping
Bracket Bolts
3-3
Installing the UPS System
Rear View
Skid Bolts
(3 Places)
Pallet
Shipping Bracket Bolts
Rear Shipping Bracket
Figure 3-2. Removing Rear Shipping Bracket on the Powerware 9390 UPS
Removable Skid
Shipping
Bracket Bolts
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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.
WARNING
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.
WARNING
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.
3.2.2 Battery Cabinet Installation
To install the battery cabinet, refer to the Powerware 9390 Integrated Battery Cabinet
(Models IBC-S and IBC-L) Installation Manual. After the battery cabinet is installed, return
to paragraph 3.2.4 to wire the UPS and battery cabinet.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Installing the UPS System
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 W iring
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.
3-6
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 d ual-feed systems.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Installing the UPS System
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.
CAUTION
Parallel s ystem 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.
CAUTION
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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Installing the UPS System
3.2.5 Installing Interface Connections
23. After wiring the UPS system to the facility power and c ritical load, be sure to
ground the system according to local and/or national electrical wiring codes. DO
NOT b ond 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.
3.2.5.1 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.
3-8
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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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