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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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
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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. 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................................................
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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
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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
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.
Introduction
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” – listsallthealarmsandnoticesthatoccur
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
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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.
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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
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.
CAUTION
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
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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
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
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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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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:
Appendix A for installation drawings and additional installation notes.
Dimensions are in millimeters and inches.
Do not tilt the cabinets more than á10° 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).
Thecabinetsmustbeinstalledonalevelfloorsuitableforcomputerorelectronic
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.
3.2 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
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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).
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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
3-5
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
Installing the UPS System
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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Installing the UPS System
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
terminals, conduit must be installed between the UPS and battery cabinets.
When installing UV trip and Aux battery interface wiring to the UPS interface
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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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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 isofferedaspartofthesalescontractfortheUPS.Contactserviceinadvance(usuallya two-week notice is required) to reserve a preferred startup date.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Installing the UPS System
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
for the first time.
The Installation Checklist MUST be completed prior to starting the UPS system
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Installing the UPS System
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 three- or 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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Installing the UPS System
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.
- ThebypasssourcefeedingtheoptionalbypassoftheparalleltiecabinetandtheUPMsisfromthesame
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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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Installing the UPS System
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.
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.
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.
CAUTION
WARNING
ELECTRIC ENERGY HAZARD. Do not attempt to alter any battery wiring or connectors.
Attempting to alter wiring can cause injury.
CAUTION
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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
4-1
Batteries
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.
Une mise au rebut réglementaire des batteries est obligatoire. Consulter les règlements en
vigueur dans votre localité.
Ne jamais jeter les batter ies au feu. L’exposition aux flammes risque de les faire exploser.
4.2 Installing Batteries
NOTE There is no DC disconnect device within the UPS.
AVERTISSEMENT!
ATTENTION!
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.
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.
Do not discard the UPS or the UPS batteries in the trash. This product contains sealed, lead-acid b atteries and must be disposed of properly. For more information, contact your local recycling or hazardous waste center.
WARNING
CAUTION
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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
To UPS To Other Equipment
EMERGENCY OFF
Figure 5-1. REPO Control
NOTE
and the UPS cabinet for wiring the switch.
When installing the REPO switch, you must install conduit between the device
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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
5-1
Installing a Remote Emergency Power-Off Control
)
TwistedWires(2)
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
Terminal Board TB1 in UPS Cabinet
TB1-4 TB-7
TB1-5 TB-9
Table 5-2. REPO
REPO
Switch
(NO)
Twisted
Wires
Remarks
Twisted Wires(2
14–22 AWG
7(NO)
UPS TB1
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
Asanoption,aHotSyncCANBridgeCard,asshowninFigure6-1,canbeinstalledto 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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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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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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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).
Installing Options and Accessories
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
performed by an authorized Powerware Customer Service Engineer. Contact service to schedule a date.
Setup of the Hot Sync CAN Bridge Card for parallel operation must be
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
the wall. Do not use hollow wall anchors.
If mounting to a hollow wall, secure the enclosure to a wood or metal stud within
3. Securely mount the RMP at the desired location. See drawing 164201535-11 for
mounting hole locations.
NOTE
installed between the device and the UPS cabinet.
When installing signal wiring for CAN card J3 terminals, conduit must be
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.
6-4
NOTE
or the customer.
120 Vac for the RMP should be supplied from the critical bus by facility planners
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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Installing Options and Accessories
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
the wall. Do not use hollow wall anchors.
NOTE
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).
If mounting to a hollow wall, secure the enclosure to a wood or metal stud within
3. Securely mount the RIM at the desired location. See drawing 164201535-12 for
mounting hole locations.
When installing signal wiring for CAN card J3 terminals, conduit must be
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.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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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
or the customer.
120 Vac for the RIM should be supplied from the critical bus by facility planners
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
Powerware Customer Service Engineer. Contact service to schedule a date.
Setup of the Hot Sync CAN Bridge Card must be performed by an authorized
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
UPS OFFLINE
Pins 1 and 12 Contacts are closed when the UPS is offline.
Pins 3 and 13 Contacts are closed when the UPS is operating in
Normal mode.
BATTERY WEAK
UTILITY FAILURE
Pins 5 and 14 Contacts are closed when approximately two minutes of
battery time is remaining, before the critical load is lost.
Pins 6 and 15 Contacts are closed when Utility Failure is detected.
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
6.6 Installing a Supervisory Contact 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 SCM 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.
Installing Options and Accessories
NOTE
the wall. Do not use hollow wall anchors.
If mounting to a hollow wall, secure the enclosure to a wood or metal stud within
3. Securely mount the SCM at the desired location. See drawing 164201535-13 for
mounting hole locations.
NOTE
installed between the device and the UPS cabinet.
When installing signal wiring for CAN card J3 terminals, conduit must be
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 SCM. See Appendix A for UPS cabinet and
RIM wiring access information.
7. Install wiring between the UPS and SCM. See Drawing 164201535-8 starting on
page A-33 for Hot Sync CAN Bridge Card and SCM location, terminal location, and wiring information.
NOTE
or the customer.
120 Vac for the SCM should be supplied from the critical bus by facility planners
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
Powerware Customer Service Engineer. Contact service to schedule a date.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Setup of the Hot Sync CAN Bridge Card must be performed by an authorized
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Installing Options and Accessories
9. Install wiring between the SCM terminal block TB2 and the monitoring equipment.
See Figure 6-2 for terminal assignments and Drawing 164201535-8 for terminal block location.
System Normal
No Redundancy
On Generator
Bypass Not
Available
TB2
On Battery
UPS Alarm
On Bypass
Shutdown
Imminent
Figure 6-2. Supervisory Contact Module TB2
NOTE
Supervisory contacts are rated at 2.0A at 28 Vdc or 120 Vac and 0.15A at 115 Vdc.
NOTE Supervisory contacts require an external power supply. Internal 24 Vdc is not
capable of supplying contact current.
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Section II Operation
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Chapter 7 Understanding UPS Operation
7.1 Looking Inside the UPS System
The Powerware 9390 UPS is a continuous-duty, solid-state, transformerless (at 208 and 480 Vac), three-phase, true online system that provide conditioned and uninterruptible AC power to the UPS systems output. The UPS supports process control, data processing, telecommunications/PBX, research, and non-patient medical equipment. The Powerware 9390 UPS maintains power to the critical loads during commercial electrical power brownout, blackout, overvoltage, undervoltage, and out-of-tolerance frequency conditions.
The basic system consists of a rectifier, battery converter, inverter, monitoring/operation control panel, integrated communication server, and digital signal processor (DSP) logic.
In this manual, the power required by your equipment is called the critical load.TheUPS supplies the critical load with conditioned power that is synchronized with your utility power. Figure 7-1 shows the main elements of the UPS.
AC Input to
Rectifier/
Charger
AC Input to
Bypass
Input
Contactor
K1
Backfeed
Protection
Contactor
K5
Battery
Breaker
Battery
Converter
Metering
Static
Switch
UPS Cabinet
Battery
Output
Contactor
K3
InverterRectifier
Power Module
Digital
AC Output to Critical Load
Figure 7-1. Main Elements of the UPS System
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
7-1
Understanding UPS Operation
If utility power is interrupted or falls outside the parameters specified in Chapter 15, “Product Specifications,” the UPS uses a backup battery supply to maintain power to the critical load for a specified period of time or until the utility power returns. For extended power outages, the UPS allows you to either transfer to an alternative power system (such as a generator) or shut down your critical load in an orderly manner.
The emergency bypass consists of a continuous-duty static switch and backfeed protection contactor K5. The backfeed protection contactor is located in series with the static switch. For manual transfers to bypass, the static switch is also used. The static switch is armed and ready during both types of transfers.
The operation of the UPS system is described in greater detail in the following paragraphs.
TheUPSmodulemaybeconfiguredforstandalone,singlemodule,ReverseTransfer(RT) operation or multiple module, parallel redundant and/or parallel capacity operation (see paragraphs 7.2 and 7.3).
7.2 Single Module Reverse Transfer (RT)
Asinglemoduleoperatesindependentlytosupportanappliedloadfromtheinverter, providing conditioned and uninterruptible AC power to the critical load from the output of the module. During an outage, the inverter continues to operate, supporting power to the load from the battery supply. If the unit requires service, applied loads are transferred to the internal bypass, continuous-duty static switch either automatically or manually. With the exception of a battery cabinet, no other cabinets or equipment are required for the single module to successfully support its applied loads.
7.2.1 Single Module RT Modes
The Powerware 9390 UPS supports a critical load in three different modes of operation. The UPS can automatically use all three modes, as required. The standard operation modes are:
In Normal mode, the critical load is supplied by the inverter, which derives its power
from rectified utility AC power. In this mode, the battery charger also provides charging current for the battery, if needed.
In Battery mode, the battery provides DC power, which maintains inverter operation.
The battery supports the critical load.
In Bypass mode, the critical load is directly supported by utility power.
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Understanding UPS Operation
The UPS continually monitors itself and the incoming utility power, and automatically switches between these modes as required, without operator intervention. The sophisticated detection and switching logic inside the UPS ensures that operating mode changes are automatic and transparent to the critical load, while internal monitoring systems indicate the current mode of operation. The UPS switches operating modes in response to these system events:
A command is an intervention that is externally initiated by an operator or by some site
action. A command causes the UPS to switch operating modes; it usually does not require any further action.
A notice is a minor system event that may or may not require attention.
An alarm is a system event that requires immediate operator intervention.
System events, alarm horns, and indicator lights are described in Chapter 12, “Responding to System Events.”
The following paragraphs describe the differences in the three UPS operating modes, using block diagrams to show the power flow during each mode of operation.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Understanding UPS Operation
7.2.2 Normal Mode – RT
Figure 7-2 shows the path of electrical power through the UPS system when the UPS is operating in Normal mode.
K1 K3
K1 K3
Breakers Contactors
Breakers Contactors
Static
Static
K5
K5
Rectifier Inverter
Rectifier Inverter
Closed
Closed
Open
Open
Switch
Switch
Battery
Battery
Converter
Converter
Battery
Battery Breaker
Breaker
Main Power Flow
Main Power Flow
Trickle Current
Trickle Current
Energized
Energized
De-Energized
De-Energized
Battery
Battery
Figure 7-2. Path of Current Through the UPS in Normal Mode – RT
During normal UPS operation, power for the system is derived from a utility input source through the rectifier input contactor K1. The front panel displays “Normal,” indicating the incoming power is within voltage and frequency acceptance windows. Three-phase AC input power is converted to DC using IGBT devices to produce a regulated DC voltage to the inverter. The battery is charged directly from the regulated rectifier output through a buck or boost DC converter, depending on whether the system is 208V or 480V and the size of the battery string attached to the unit.
The battery converter derives its input from the regulated DC output of the rectifier and provides either a boosted or bucked regulated DC voltage charge current to the battery. The UPS monitors the battery charge condition and reports the status on the control panel. The battery is always connected to the UPS and ready to support the inverter should the utility input become unavailable.
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Understanding UPS Operation
The neutral from the system input is connected to the neutral regulator in the DC capacitors. The output neutral of the system is connected with the required neutral supplied at the utility bypass input and should never be bonded to ground at the module’s output.
The inverter produces a three-phase AC output to a customer’s load without the use of a transformer. The inverter derives regulated DC from the rectifier and uses IGBT devices and pulse-width modulation (PWM) to produce a regulated and filtered AC output. The AC output of the inverter is delivered to the system output through the output contactor K3.
If the utility AC power is interrupted or is out of specification, the UPS automatically switches to Battery mode to support the critical load without interruption. When utility power returns, the UPS returns to Normal mode.
IftheUPSbecomesoverloadedorunavailable,theUPSswitchestoBypassmode.TheUPS automatically returns to Normal mode when the overload condition is cleared and system operation is restored within specified limits.
If the UPS suffers an internal failure, it switches automatically to Bypass mode and remains in that mode until the failure is corrected and the UPS is back in service.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Understanding UPS Operation
7.2.3 Bypass Mode – RT
The UPS automatically switches to Bypass mode if it detects an overload, load fault, or internalfailure.ThebypasssourcesuppliesthecommercialACpowertotheloaddirectly. Figure 7-3 shows the path of electrical power through the UPS system when operating in Bypass mode.
The critical load is not protected while the UPS is in Bypass mode.
CAUTION
Static
K5
Switch
Rectifier Inverter
K1 K3
Battery
Converter
Main Power Flow
Breakers Contactors
Closed
Open
Battery Breaker
Trickle Current
Energized
De-Energized
Battery
Figure 7-3. Path of Current Through the UPS in Bypass Mode – RT
In Bypass mode, the output of the system is provided with three-phase AC power directly from the system input. While in this mode, the output of the system is not protected from voltage or frequency fluctuations or power outages from the source. Some power line filtering and spike protection is provided to the load but no active power conditioning or battery support is available to the output of the system in the Bypass mode of operation.
7-6
The internal bypass is comprised of a solid-state, silicon-controlled rectifier (SCR) static switch (SSW) and a backfeed protection contactor K5. The static switch is rated as a continuous-duty device that is used anytime the inverter is unable to support the applied load. The static switch is wired in series with the backfeed protection contactor, and together they are wired in parallel with the rectifier and inverter. The static switch, being an electronically -controlled device, can be turned on immediately to pick up the load from the inverter while the inverter output contactor K3 opens to isolates the inverter. The backfeed protection contactor is normally always closed, ready to support the static switch unless the bypass input source becomes unavailable.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Understanding UPS Operation
During an outage, the UPS prohibits transfers to bypass and provides upstream protection. The backfeed protection contactor is opened, preventing system output voltage from bleeding across the static switch snubber components to the bypass input source.
To ensure the load remains energized, the UPS automatically transfers the output to the internal bypass when one of these abnormal conditions occur: the output of the system exceeds acceptable voltage and frequency tolerances, the system is overloaded, or the inverter fails. The transfer is initiated by turning on the static switch and opening the output contactor K3, also called a Make-Before-Break transfer. The transfer occurs in less than 4 mS (quarter cycle) to ensure that the output load is not interrupted. The static switch remains on until either the inverter is able to support the system output or the unit is placed into a maintenance position where repairs can be made.
If the UPS initiates its own transfer to bypass for any reason other than operator intervention, the UPS attempts to restart the inverter (if not running already) and attempts a transfer back online to support the output of the system. Three attempts are made within ten minutes to return the inverter online automatically before the UPS locks out any further attempts. After three attempts, the UPS remains in bypass and an alarm condition is enunciated. The UPS can also be transferred to bypass using the front panel controls.
Bypass mode is a normal operating mode, not an alarm condition. However, if the UPS is unable to return to Normal mode following an automatic transfer to Bypass mode, an alarm condition is recorded.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Understanding UPS Operation
7.2.4 Battery Mode – RT
The UPS automatically transfers to Battery mode if a utility power outage occurs, or if the utility power does not conform to specified parameters. In Battery mode, the battery provides emergency DC power that the inverter converts to AC power.
Figure 7-4 shows the path of electrical power through the UPS system when operating in Battery mode.
Static
K5
Switch
Rectifier Inverter
K1 K3
Battery
Converter
Main Power Flow
Breakers Contactors
Closed
Open
CB2
Trickle Current
Energized
De-Energized
Battery
Figure 7-4. Path of Current Through the UPS in Battery Mode – RT
During a utility power failure, the rectifier no longer has an AC utility source from which to supply the DC output current required to support the inverter. The input contactor K1 opens and the battery instantaneously supplies energy the battery converter. The converter either bucks or boosts the voltage so that the inverter can support the customer’s load without interruption. If bypass is common with the rectifier input, the feed back protection contactor K5 also opens. The opening of contactors K1 and K5 prevent system voltages from bleeding backwards through the static switch and rectifier snubber components and re-entering the input source.
7-8
While in Battery mode, the UPS sounds an audible horn, illuminates a visual indicator lamp on the front panel (System Normal, On Battery), and creates an entry into the alarm event history. As the battery discharges, the converter and inverter constantly make minute adjustments to maintain a steady output. The UPS remains in this operating mode until the input power to the rectifier is again within the specified voltage or frequency acceptance windows.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Understanding UPS Operation
If the input power fails to return or is not within the acceptance windows required for normal operation, the battery continues discharging until a DC voltage level is reached where the inverter output can no longer support the connected loads. When this event occurs, the UPS issues another set of audible and visual alarms indicating SHUTDOWN IMMINENT. Unless the rectifier has a valid AC input soon, the output can be supported for only two minutes before the output of the system shuts down. If the bypass source is available, the UPS transfers to bypass instead of shutting down.
If at any time during the battery discharge the input power becomes available again, contactors K1 and K5 close and the rectifier begins to supply DC current to the converter and inverter. At this point, the unit returns to Normal mode. Depending on the total load and the duration of the battery discharge, battery current limit alarms may be seen for a short time due to the current required to recharge the battery.
The system’s total operating time on battery depends on many factors. Some factors that affect battery support times are battery type and capacity, number of parallel strings, environmental temperatures, age of the battery, and fluctuations in load demand during the discharge. The greater the load, the less support time the battery has. Decreasing the load generally increases the battery support time.
7.3 Multiple Module Parallel System
Parallel operation extends the normal operation of Powerware 9390 UPS units by offering increased capacity and/or redundant capability. The parallel system continues to maintain power to the critical loads during commercial electrical power brownout, blackout, overvoltage, undervoltage, and out-of-tolerance frequency conditions. See Drawing 164201535-4, sheets 3 of 5, 4 of 5, and 5 of 5 in Appendix A, for a detailed relationship of the parallel system.
The output of the system is normally supplied by several uninterruptible power modules. Multiple UPMs are connected with their outputs in parallel (tied together) to provide a load level greater than the rating of one UPM and/or for redundancy. The paralleled UPMs supply the output load with protected power as long as the load does not exceed the combined rating of the paralleled UPMs.
The power system is redundant as long as one of the UPMs can be disconnected from the output bus and the remaining UPMs can continue to supply power to the load without exceeding their ratings.
When the load is being supplied by the UPMs, the system output bus is continuously monitored for an overvoltage o r undervoltage condition. If an out of limits condition is detected, the paralleled UPMs transfer the load to b ypass using the UPM static switches.
Communication is required between the UPMs for system metering and mode control. System level communication and control are accomplished using a Computer Area Network. A single building alarm in each UPM, connected to the other UPMs in parallel, and tied to the bypass contactor auxiliary contacts in each UPM are used for a secondary communication path. This arrangement ensures bypass control even if the CAN bus is lost.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Understanding UPS Operation
Up to four units can be paralleled for redundancy or capacity without any additional cabinets.
The system is paralleled for redundancy (1 + 1) in a system where two UPMs are paralleled together and the load is less than the supporting capability of one of the UPMs. The system is paralleled for capacity (2 + 0) if both UPMs in a system are required to support the load.
A parallel capacity system can also be redundant (2 + 1), as long as there is always one or more UPMs online than required to support the load.
7.3.1 Multiple Module Parallel System Modes
Similar to the single module system, the Powerware 9390 UPS parallel system supports a critical load in three different modes of operation. The standard operation modes are:
In Normal mode, the paralleled UPMs supply the critical load with clean, filtered power.
Each UPM battery charger also provides charging current for the battery if needed.
In Battery mode, the battery provides DC power, which maintains UPM operation. The
UPM batteries supports the critical load.
In Bypass mode, the c ritical load is directly supported by utility power throu gh the
continuous-duty static bypass switch in each UPM.
The UPMs continually monitor themselves and the incoming utility power, and automatically switch between these modes as required, without operator intervention, except when manually switching to Bypass mode. The sophisticated detection and switching logic inside the UPMs ensures that operating mode changes are automatic and transparent to the critical load, while internal monitoring systems indicate the current mode of operation. The UPMs switch operating modes in response to these system events:
A command is an intervention that is externally initiated by an operator or by some site
action. A command causes the UPMs to switch operating modes; it usually does not require any further.
A notice is a minor system event that may or may not require attention.
An alarm is a system event that requires immediate intervention.
System events, alarm horns, and indicator lights are described in Chapter 12, “Responding to System Events.”
To assist in developing an understanding of the parallel systems modes of operation, review and understand thoroughly the single module modes of operation
7-10
The following paragraphs describe the differences in the three parallel system operating modes, using block diagrams to show the power flow during each mode of operation.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
7.3.2 Normal Mode – Parallel
In Normal mode, utility AC power is supplied to the UPMs. Each UPM then conditions the incoming AC power and provides clean, regulated AC power to either a module tie cabinet or distribution panel for parallel systems up to four modules The applied load is equally shared among the available UPMs in the system.
Figure 7-5 shows the path of electrical power through the parallel system when operating in Normal mode.
Understanding UPS Operation
Bypass Input
Battery
Battery
Battery
Battery
Main Power Flow
UPM Input
UPM 1
UPM 2
UPM 3
UPM 4
Breakers
Closed
Open
Module Tie Cabinet
UPM 1 Output
UPM 2 Output
UPM 3 Output
UPM 4 Output
Output to
Critical
Load
Figure 7-5. Path of Current through the UPMs in Normal Mode – Parallel
If the utility AC power is interrupted or is out of specification, the UPMs automatically switch to Battery mode to support the critical load without interruption. When utility power returns, the UPMs returns to Normal mode.
IftheUPMsbecomeoverloadedorunavailable,theparallelsystemswitchestoBypass mode. The parallel system automatically returns to Normal mode when the overload condition is cleared and system operation is restored within specified limits.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Understanding UPS Operation
7.3.3 Bypass Mode – Parallel
In Bypass mode, the output of the system is provided with three-phase AC power directly from the bypass input. While in this mode, the output of the system is not protected from fluctuations, spikes, or power outages from the source. No power filtering, conditioning, or battery support is available to the output of the system in the Bypass mode of operation.
The parallel system automatically switches to Bypass mode if it detects a UPM overload, UPMs unavailable, load fault, or internal failure.
Figure 7-6 shows the path of electrical power through the parallel system when operating in Bypass mode.
Bypass Input
Battery
Battery
Battery
Battery
Main Power Flow
UPM Input
Breakers
UPM 1
UPM 2
UPM 3
UPM 4
Closed
Open
Module Tie Cabinet
UPM 1 Output
UPM 2 Output
UPM 3 Output
UPM 4 Output
Output to
Critical
Load
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Figure 7-6. Path of Current through the UPMs in Bypass Mode – Parallel
In a parallel redundant or capacity type system, each module operates similar to a single module, but in parallel with each other. The bypass source for the load is derived from the bypass input of one, two, three, or four modules, depending on the system configuration through the their internal continuous-duty static switches. If a module is taken offline, the othermodulesremainsonlinetosupporttheload.Ifthemoremodulesthancansupport theloadmustbetakenoffline,theloadmustbetransferredtomaintenancebypassor shut down.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Understanding UPS Operation
The parallel system can be transferred from Normal mode to Bypass mode manually. However, the parallel system automatically switches to Bypass mode whenever the UPMs can no longer supply the critical load. If the parallel system transfers to Bypass mode from Normal mode due to an output voltage deviation, the parallel system automatically attempts to return to Normal mode (up to three times within a 10-minute period). After three transfer attempts or an overload, the system locks the critical load to the bypass source and requires operator intervention to transfer.
Bypass mode is a normal operating mode, not an alarm condition. However, if the parallel system is unable to return to Normal mode following an automatic transfer to Bypass mode, an alarm condition is recorded.
TheBypassmayalsobeusedwhenthemodulesinthesystemmustbeshutdownto perform routine maintenance or repairs.
In the Parallel Redundant (N + 1) arrangement, the continuous-duty static switch in each module operates to support the applied loads on bypass. If both units are in NORMAL and one unit trips offline, the remaining unit does not go to bypass as long as it has the capacity to support the load.
In the Parallel Capacity (N + 0) arrangement, if one unit trips offline and goes to BYPASS, the remaining units also go to BYPASS.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Understanding UPS Operation
7.3.4 Battery Mode – Parallel
The UPMs transfer to Battery mode automatically if a utility power outage occurs, or if the utility power does not conform to specified parameters. In Battery mode, the battery provides emergency DC power that the inverter converts to AC power.
Figure 7-7 shows the path of electrical power through the parallel system when operating in Battery mode.
Bypass Input
Battery
Battery
Battery
Battery
Main Power Flow
UPM Input
Breakers
UPM 1
UPM 2
UPM 3
UPM 4
Closed
Open
Module Tie Cabinet
UPM 1 Output
UPM 2 Output
UPM 3 Output
UPM 4 Output
Output to
Critical
Load
7-14
Figure 7-7. Path of Current through the UPMs in Battery Mode – Parallel
While in Battery mode, the UPMs sounds an audible horn, illuminates a visual indicator lamp on the front panel (System Normal, On Battery), and creates an entry into the alarm event history. As the battery discharges, the boost converter and inverter constantly make minute adjustments maintaining a steady output. The UPMs remains in this operating mode until the input power to the rectifier is again within the specified voltage or frequency acceptance windows.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Understanding UPS Operation
If the input power fails to return or is not within the acceptance windows required for normal operation, the battery continues discharging until a DC voltage level is reached where the inverter output can no longer support the shared loads. When this event occurs on each UPM, UPMs that are about to be shut down issue another set of audible and visual alarms that indicate a two-minute SHUTDOWN IMMINENT warning. Unless the system has a valid AC input soon, redundant UPMs b egin shutting down until there are no longer enough UPMs online to support the connected load. When this event occurs, the system shutsdown.Ifthebypasssourceisavailable,thesystemtransferstobypassinsteadof shuting down.
If at any time during the battery discharge the input power becomes available again, the rectifier begins to supply DC current to the inverter. At this point, the unit returns to Normal mode. If at any time during the battery discharge the AC input power becomes available again, each rectifier turns on, assumes the inverter load from the batteries, and begins recharging the batteries. Depending on the total load and the duration of the battery discharge, battery and rectifier input current limit alarms may be seen for a short time due to the current required to recharge the batteries.
7.4 Functional Description
The UPS is a true online double-conversion unit with a transformerless power train. A high-frequency active rectifier powers a high-frequency three-phase inverter. The bypass circuit uses a solid-state continuous-duty static switch. The UPS operates from battery strings from 192 cells (384V) to 240 cells (480V).
7.4.1 Input Rectifier
The rectifier is a three-phase, high-frequency PWM, IGBT-based power conversion stage that provides input power factor correction and low input current harmonic distortion. The rectifier maintains a DC level that is optimized for maximum inverter efficiency. A precharge system charges the energy storage elements in the power train prior to energizing the rectifier.
7.4.2 Inverter
The inverter is a three-phase, high-frequency PWM, IGBT-based power conversion stage that continuously supplies the critical load with high-quality AC power. The IGBTs are modulated to maintain the highest efficiency.
7.4.3 Battery Charger and Advanced Battery Management
The charger is a high-frequency, IGBT-based power conversion stage. The UPS u ses Advanced Battery Management (ABM) technology, which essentially isolates the battery from the electrical environment, except for periodic charging or reserve mode operation, extending its life.
ABM extends battery life by keeping the batteries charged and performing periodic battery testing.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Understanding UPS Operation
An ABM charging cycle starts with the charger driving the battery voltage, at maximum current limit, to a battery charge level of 2.34 volts/cell. The time it takes for the voltage to reach to the battery charge level is saved as the battery charge time. If the battery charge time exceeds 100 hours, an alarm is annunciated.
As soon as a battery charge level of 2.34 volts/cell is reached, the battery is charged at a float level of 2.31 volts/cell for 48 hours (battery float time) plus 150% of battery charge time. Twenty-four hours into the float period, a series of battery tests are performed to check the battery health. The float level charge continues after a successful test.
At initial startup, the battery run time on the front panel display indicates two minutes. After the 24-hour float charging period and battery testing, the actual battery run time is determined and the actual battery run time is displayed.
After the float period is completed, the charger is disconnected and the batteries are allowed to rest for 672 hours (28 days) maximum rest time. If the battery voltage falls below the opportunity charge level of 2.1 volts/cell during the first 240 hours of the rest period, an alarm is annunciated.
An ABM charge cycle is initiated whenever one of these four conditions occurs since the last charge cycle:
The batteries have rested over the maximum rest time of 672 hours.
Accumulated discharge time is over a maximum battery discharge time of 20 seconds.
Battery voltage is under the opportunity charge level of 2.1 volts/cell and the unit h as
been in rest mode for longer than 240 hours.
An XCP command Initiate Battery Test is received.
7.4.4 Bypass
The bypass has a continuous-duty fully-rated SCR switch in the bypass circuit and a contactor in the inverter leg. In Normal mode, the contactor connects the inverter to the output. A backfeed contactor is also provided.
7.4.5 Batteries
The UPS operates from battery strings from 192 cells (384V nominal) to 240 cells (480V nominal).
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Chapter 8 Features, Options, and Accessories
8.1 UPS Standard Features
The UPS has many standard features that provide cost-effective and consistently reliable power protection.
8.1.1 Control Panel
The control panel, located on the UPS front door, contains an LCD and pushbutton switches to control the operation of the UPS, and to display the status of the UPS system. See Chapter 9, “Using the Control Panel,” for additional information.
8.1.2 Customer Interface
8.1.2.1 Building Alarm Monitoring
The facility’s alarm system contacts can be connected to two inputs in the UPS. The UPS uses these inputs to monitor the building alarms in addition to the UPS status. See Chapter 11, “Using Features and Options,” for additional information.
8.1.2.2 Alarm Contact
One alarm contact is provided for connection to equipment at the facility, such as a light, an audible alarm, or a computer terminal. The equipment connected to this contact alerts you to a UPS alarm. See Chapter 11, “Using Features and Options,” for additional information.
8.1.3 X-Slot Communication Bay
A two-slot communication bay is standard equipment, with an additional two-slot bay available as an option. Two to four optional X-Slot cards can be installed in the UPS module at any time. See Chapter 13, “Communication,” for additional information.
8.1.4 ConnectUPS -X Web/SNMP Card X-Slot Card
AConnectUPS-XWeb/SNMPCardisprovidedasstandardequipmentandprovidesremote monitoring through a Web browser interface, e-mail, and a network management system (NMS) u sing SNMP. See Chapter 13, “Communication,” for additional information.
t
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Features, Options, and Accessories
8.1.5 Advanced Battery Management
A three-stage charging system increases battery service life by optimizing recharge time, and protects batteries from damage due to high current charging and inverter ripple currents. Charging at high currents can overheat and damage batteries.
8.1.6 LanSafe Power Management Software
LanSafe Power Management Software is bundled as part of the Powerware Software Suite CD shipped with the UPS. See Chapter 13, “Communication,” for additional information.
8.1.7 Installation Features
Cabinets can be permanently bolted to the floor or left standing on leveling feet.
Power and control wiring can be routed through the top or bottom of the cabinet with connections made to easily accessible terminals. External sensing and monitoring control wire must be installed in accordance with Class 1 wiring methods. Line-up–and–match battery cabinets are wired through the side panels of the units.
Optional X-Slot connectivity cards are quickly installed at the front of the unit and are hot-pluggable.
8.2 Options and Accessories
Contact a Powerware sales representative for information about the following options.
8.2.1 Integrated Battery Cabinets
Battery backup protection can be enhanced by equipping the UPS system with up to four Powerware 9390 battery cabinets containing sealed lead-acid, maintenance-free batteries. The battery cabinets are available in small and large sizes, with 192-cell (208V units only), 216-cell, and 240-cell configurations. The cabinets are designed for line-up–and–match installation, but may be installed separate from the UPS cabinet.
8.2.2 Integrated Distribution Cabinet
The IDC provides adaptation and expansion with distribution panelboards, distribution circuit breakers, a m aintenance bypass switch, and voltage transformation. The IDC is housed in a single, free-standing cabinet designed for line-up–and–match installation, but may be installed separate from the UPS cabinet.
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
8.2.3 HotSync Parallel System
A parallel UPS system with two to four uninterruptible power modules can b e installed to provide a parallel capacity and/or redundant system. This load sharing system provides more capacity than a single UPS, and can provide backup, depending on the load and configuration. In addition, when one UPM is taken out of service for maintenance or is not operating properly, a redundant UPM continues to supply uninterrupted power to the critical load. A parallel HotSync Computer Area Network Bridge X-Slot card provides connectivity for system metering and operational mode control. The parallel system consists of two to four UPMs each with a parallel CAN card, and a module tie cabinet or load distribution panel to act as a tie point. Each UPM requires a separate battery cabinet.
8.2.4 Optional X-Slot Cards
The optional X-Slot cards support several protocols, such as SNMP, HTTP, AS/400®,and Modbus
®
. See Chapter 13, “Communication,” for additional information.
Features, Options, and Accessories
8.2.5 Remote Monitor Panel
An optional RMP contains backlit status indicators and a local horn, allowing you to monitor the operational status and alarm condition of the UPS from virtually any location within your facility. This option is described further in Chapter 11, “Using Features and Options.”
8.2.6 Relay Interface Module
An optional RIM uses relay contact closures to indicate the operating status and alarm condition of the UPS. This option is described further in Chapter 11, “Using Features and Options.”
8.2.7 Supervisory Contact Module
An optional SCM establishes an interface between the UPS system equipment and the customer’s monitor. This option is described further in Chapter 11, “Using Features and Options.”
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Features, Options, and Accessories
8.3 Symbols, Controls, and Indicators
ThefollowingareexamplesofsymbolsusedontheUPStoalertyoutoimportant information:
RISK OF ELECTRIC SHOCK - Indicates that a risk of electric shock is present and
the associated warning should be observed.
CAUTION: REFER TO OPERATOR’S MANUAL - Refertoyouroperator’smanual
for additional information, such as important operating and maintenance instructions.
This symbol indicates that you should not discard the UPS or the UPS batteries in the trash. The UPS may contain sealed, lead-acid batteries. Batteries must be recycled.
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Chapter 9 Using the Control Panel
This chapter describes the UPS control panel, including controls and indicators, and how to monitor UPS operation. The control panel (see Figure 9-1) is located on the front door of the UPS.
PRESS ANY KEY TO CONTINUE
3
2
1
Figure 9-1. UPS Control Panel
The control panel consists of the following:
A liquid crystal display (LCD) (1)
A horizontal row of pushbutton switches (2)
A vertical column of status indicators (3)
The following paragraphs describe using the UPS control panel to monitor the UPS. See Chapter 10, “UPS Operating Instructions,” for use of the operational controls.
When the unit powers up, the screen displays the Powerware logo as shown in Figure 9-1. To advance to the Main Menu and Mimic screen, press any control panel pushbutton once.
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
9-1
Using the Control Panel
9.1 Using the LCD and Pushbuttons
The LCD on the control panel provides an operator interface with the UPS system. Figure 9-2 identifies the display areas discussed in the following sections.
A
ALARM: INPUT AC UNDER VOLTAGE
INPUT
UPS
B
BATT
STSW
OUTPUT
BYPASS
C
METERSEVENTS SETUP
CONTROLS LOAD OFF
D
Figure 9-2. Parts of the LCD
A The UPS status area automatic ally scrolls between the Powerware model number, current date
and time, active alarms, active notices, and load percent and battery run time for the UPS. Shown is a typical alarm message. (For more information about alarms and notices, see Chapter 12, “Responding to System Events.”)
B The information area contains data about UPS status and operations.
C The menu bar lists the titles of the available screens. To select a screen, press the pushbutton
underneath the desired screen.
D The navigation pushbuttons function depending on the screen displayed. Use the pushbuttons
to select menu screens or scroll through availablescreens.TheLCDoptionsabovethe pushbuttons indicate each pushbutton’s function.
You can use the LCD and the pushbuttons to:
Look at a log of UPS events (alarms, notices, and commands) (see paragraph 9.2.2)
Monitor UPS operation (see paragraph 9.2.3)
Set UPS parameters (see paragraph 9.2.5 and 9.2.6)
Control UPS operation (see paragraph 9.3)
After approximately 30 minutes, the display screen darkens. To restore the screen, press any pushbutton once.
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
9.2 Using the Main Menu
The UPS main menu bar allows you to display data in the information area to help you monitor and control UPS operation. The following menus and options are available:
Using the Control Panel
Menu Option
EVENTS Displays the list of Active System Events and a historical log of
METERS Displays performance meters for the system or critical load.
CONTROLS Displays the System Controls screen.
SETUP Allows you to set the display contrast, set the date and time for the
LOAD OFF De-energizes the critical load and powers down the UPS.
Description
system events.
time stamp, configure the UPS serial communication ports, and view thefirmwareversionnumbers.
Returns to Main Menu and Mimic screen fr om the Events, Meters, Controls, or Setup screens. Returns to the main System Setup Level screen from a setup submenu.
9.2.1 Mimic Screen
Figure 9-3 shows the Main Menu and Mimic screen. To select the Mimic screen from the Events, Meters, Controls, or Setup screens, press the bar.
The Mimic screen shows the internal components of the UPS cabinet and a real-time graphical representation of the operating status of the system.
pushbutton on the current menu
TIME: 11 : 35 : 43 DATE: 02 / 25 / 2004
INPUT
BATT
UPS
STSW
BYPASS
METERSEVENTS SETUP
Figure 9-3. Main Menu and Mimic Screen (Normal Mode)
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
CONTROLS LOAD OFF
OUTPUT
9-3
Using the Control Panel
9.2.2 Event Screens
Press the EVENTS pushbutton on the main menu bar or History Menu bar to display a listing of all system events that are currently active. The most recent event is listed first. As events clear, they are removed from the Active System Events listing. Figure 9-4 shows the Active Events screen.
To scroll through the events, press the
or pushbuttons on the menu bar.
ACTIVE EVENTS
ALARM: INPUT AC UNDERVOLTAGE ALARM: BYPA SS AC UNDER VOLTAGE NOTICE: BATTERY VOLTAGE LOW NOTICE: NO SYNC ON
NOTICE: BYPASS NOT AVAILABLE NOTICE: CONFIGURATION ERROR
HISTORY
Figure 9-4. Active Events Screen
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Using the Control Panel
Press the HISTORY pushbutton on the Active Events Menu bar to display the History Log. The History Log lists up to the 500 system events in chronological order, with the most recent event listed last (once 500 is reached, the earliest event is overwritten). The History Log lists the events in the following groups:
User and service status
User instruction
User alarm
Check UPS
Schedule service
UPS shutdown
Service alarm
The end of the log (the most recent events) appears when you display the screen, and you must scroll upward to view older event listings. Figure 9-5 shows the History Log screen.
To scroll through the events, press the theActiveEventsscreen,presstheEVENTS pushbuttononthemenubar.
or pushbuttons on the menu bar. To return to
HISTORY
NOTICE: ALARM: NOTICE:
NOTICE:
NOTICE:
CONTROL POWER ON BUILDING ALARM 1 OK NORMAL COMMAND
TO BYPASS COMMAND
UPS OFF
5 of 29 02 / 26 / 2004 10 : 20 : 03 . 539
EVENTS
Figure 9-5. History Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
9-5
Using the Control Panel
9.2.3 Unit Meter Screens
The Unit Meter screens show the UPS meter readings for the unit (or units, if a parallel system is installed).
Press the METERS pushbutton on the main menu bar to display the Unit Meter screens. Figure 9-6 through Figure 9-10 show the Unit Meter screens.
To scroll through the meter screens, press the current UPS readings are displayed in the information area of the screen.
NOTE
bar pushbutton selections are visible only when a parallel system is installed.
The Output screen shows output voltage (phase -to-neutral), output current (each phase), and frequency being supplied by the UPS, as well as the kVA, kW, and power factor measurements.
The UNIT designation after the meter type, and the SYSTEM and UNIT menu
or pushbuttons on the menu bar. The
OUTPUT --- UNIT
V1
V2 V3
*** *** ***
I1 I2 I3
***
******
KVA KW
***
FREQ
***
***
PF
***
LEAD
UNITSYSTEM
9-6
Figure 9-6. Unit Output Meter Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Using the Control Panel
The Input screen shows input voltage (phase-to-phase), output current (each phase), and frequency of the incoming utility source, as well as the kVA, kW, and power factor measurements.
INPUT --- UNIT
V1
V2 V3
*** *** ***
KVA KW
***
***
I1 I2 I3
***
******
FREQ
***
PF
***
LEAD
UNITSYSTEM
Figure 9-7. Unit Input Meter Screen
The Bypass screen shows the bypass input voltage (phase-to-neutral), output current (each phase), and frequency of the incoming utility source, as well as the kVA, kW, and power factor measurements.
BY PA S S --- U N I T
V1
V2 V3
KVA KW
*** *** ***
I1 I2 I3
***
Figure 9-8. Unit Bypass Meter Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
******
***
FREQ
***
***
PF
***
LEAD
UNITSYSTEM
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Using the Control Panel
The Battery screen displays the battery voltage (Vdc), the battery current (Idc), and the minutes of battery time remaining. When battery life decreases to less than 20%, Check Battery is displayed.
B A T T E R Y --- U N I T
VDC
IDC
TIME REMAINING
*** ***
***
V A
MINUTES
UNITSYSTEM
Figure 9-9. Unit Battery Meter Screen
The Output Current Screen displays a real-time bar graph of the output current of the UPS. The graph shows the current for each phase.
OUTPUT CURRENT --- UNIT
L1
L2
L3125%
100%
75%
50% 25%
0%
UNITSYSTEM
9-8
Figure 9-10. Unit Output Current (Load) Meter Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
9.2.4 System Meters Screens
The System Meters screens show the total system and individual UPS unit meter readings from any unit, when a parallel system is installed.
Press the METERS pushbutton on the main menu bar to display the Unit Meter screens.
Press the SYSTEM pushbutton on the menu bar to display the System Meters screen.
Using the Control Panel
Use the then press the SELECT pushbutton to display the screen.
or pushbuttons to highlight the Total System meter or Unit meters desired,
SYSTEM METERS
TOTAL S YSTEM
UNIT 1 UNIT 2
ENTER PASS-
UNIT 3
WORD
UNIT 4
SELECT
Figure 9-11. System Meters Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
9-9
Using the Control Panel
The Output Total System screen shows output voltage (phase-to-neutral), output current (each phase), and frequency being supplied by the UPS, as well as the kVA, kW, and power factor measurements for the total system. The displayed voltages and frequency are the highest measured value of all units. The displayed currents, kVA, and kW are totals of all units, and the PF is calculated from the total values for the kVA and kW.
V1
*** *** ***
OUTPUT TOTAL SYSTEM
V2 V3
KVA KW
***
***
I1 I2 I3
***
Figure 9-12. Total System Output Meter Screen
******
FREQ
***
PF
***
LEAD
UNITSYSTEM
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Using the Control Panel
Figure 9-13 through Figure 9-17 show the System Meters screens. To scroll through the meter screens, press the or pushbuttons on the menu bar. The current UPS readings for the selected unit are displayed in the information area of the screen. To return to the present Unit Meter screens, press the UNIT pushbuttononthemenubar.
NOTE
Meters screen.
The Output screen shows output voltage (phase -to-neutral), output current (each phase), and frequency being supplied by the UPS, as well as the kVA, kW, and power factor measurements for the selected unit.
In the following figures, “X” equals the unit number selected from the System
OUTPUT UNIT X
V1
V2 V3
*** *** ***
I1 I2 I3
***
******
KVA KW
***
FREQ
***
***
PF
***
LEAD
UNITSYSTEM
Figure 9-13. Output Unit X Meter Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Using the Control Panel
The Input screen shows input voltage (phase-to-phase), output current (each phase), and frequency of the incoming utility source, as well as the kVA, kW, and power factor measurements for the selected unit.
V1
*** *** ***
V2 V3
INPUTUNITX
KVA KW
***
***
I1 I2 I3
***
******
FREQ
***
PF
***
LEAD
UNITSYSTEM
Figure 9-14. Input Unit X Meter Screen
The Bypass screen shows the bypass input voltage (phase-to-neutral), output current (each phase), and frequency of the incoming utility source, as well as the kVA, kW, and power factor measurements for the selected unit.
BYPASS UNIT X
V1
V2 V3
KVA KW
9-12
*** *** ***
I1 I2 I3
***
Figure 9-15. Bypass Unit X Meter Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
******
***
FREQ
***
***
PF
***
LEAD
UNITSYSTEM
Using the Control Panel
The Battery screen displays the battery voltage (Vdc), the battery current (Idc), and the minutes of battery time remaining for the selected unit. When battery life decreases to less than 20%, Check Battery is displayed.
BATTERY UNIT X
VDC
IDC
TIME REMAINING
*** ***
***
V A
MINUTES
UNITSYSTEM
Figure 9-16. Battery Unit X Meter Screen
The Output Current screen displays a real-time bar graph of the output current of the UPS for the selected unit. The graph shows the current for each phase.
OUTPUT CURRENT UNIT X L1
L2
L3125%
100%
75%
50% 25%
0%
UNITSYSTEM
Figure 9-17. Output Current (Load) Unit X Meter Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
9-13
Using the Control Panel
9.2.5 System Setup Level 0 Screens
Press the SETUP pushbutton on the main menu bar to display the System Setup Level 0 Screen. This screen can be u sed to:
Enter a password to access Level 1 functions (see paragraph 9.2.6)
Set the screen contrast
Showthefirmwareversionsinstalled
Identify the unit type
Figure 9-18 shows the System Setup Level 0 menu screen.
No password is necessary to access Level 0 functions.
Use the SELECT pushbutton to display the function screen.
or pushbuttons to highlight the setup function screen desired, then press the
SYSTEM SETUP LEVEL 0
ENTER PASSWORD
CONTRAST ADJUST VERSIONS UNIT TYPE
Figure 9-18. System Setup Level 0 Screen
SELECT
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Using the Control Panel
Select CONTRAST from the System Setup Level 0 menu to display the Contrast Adjust screen. Figure 9-19 shows the Contrast Adjust screen.
Use the adjustment is complete, press the SAVE pushbutton. Once the setting is saved, the System Setup screen displays. To return to the System Setup screen without saving the setting, press the
or pushbuttons to adjust the contrast for the LCD. When the contrast
pushbutton.
CONTRAST ADJUST
70%
SAVE
Figure 9-19. Contrast Adjust Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
9-15
Using the Control Panel
Select VERSIONS from the System Setup Level 0 menu to display the Versions screen. The Versions screen provides the firmware version numbers installed on the UPS. Figure 9-20 shows the Versions screen.
To scroll through the firmware types, press the return to the System Setup screen, press the
or pushbuttons on the menu bar. To pushbutton.
VERSIONS DSP DISPLAY
MINI CSB GATE DRIVE
57.00
0.54
3.00
0.00 PLD BOOTLOADER 0.00
Figure 9-20. Versions Screen
1
Select UNIT TYPE from the System Setup Level 0 menu to display the Unit Type screen. The Unit Type screen provides the model, CTO, and serial numbers of the UPS unit. Figure 9-21 shows the Unit Type screen. To return to the System Setup screen, press the
pushbutton.
UNIT TYPE
MODEL:
CTO:
SERIAL:
POWERWARE 9390 0000000000000000 0000000000000000
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Figure 9-21. Unit Type Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
9.2.6 System Setup Level 1 Screens
A password is required to access the Level 1 functions. To enter the password, select ENTER PASSWORD from the System Setup Level 0 menu to display the Enter Password screen. Figure 9-22 shows the Enter Password screen.
Using the Control Panel
Use the pushbuttons to change the password character. Once the password is entered, press the DONE pushbutton. The System Setup Level 1 menu screen is displayed. The default password is L1.
or pushbuttons to select the password character position. Use the or
ENTER PASSWORD
L1
DONE
Figure 9-22. Enter Password Screen
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Using the Control Panel
The System Setup Level 1 screen can be used to set the UPS date and time, the serial ports, change the Level 1 password, and log out of Level 1. In addition, the Level 0 functions are available. Figure 9-23 shows the System Setup Level 1 screen.
Use the SELECT pushbutton to display the function screen.
The Level 1 screen times out after 60 minutes or can be logged out at any time by selecting the LOG OUT function from the menu screen.
or pushbuttons to highlight the setup function screen desired, then press the
SYSTEM SETUP LEVEL 1
LOG OUT
ENTER PASSWORD CHANGE PASSWORD
ENTER PASS-
CONTRAST ADJUST
WORD
VERSIONS UNIT TYPE
SELECT
Figure 9-23. System Setup Level 1 Screen
9-18
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Using the Control Panel
Select CHANGE PASSWORD from the System Setup Level 1 menu to display the Change Password screen. The Change Password screen allows the System Setup Level 1 password to be changed. Figure 9-24 shows the Change Password screen.
Use the pushbuttons to change the password character. Once the new password is entered, press the
DONE pushbutton. The Change Password Save screen is displayed.
or pushbuttons to select the password character position. Use the or
CHANGE PASSWORD
OLD: L1
NEW:
L1
DONE
Figure 9-24. Change Password Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Using the Control Panel
The Change Password Save screen lets you save the new password, retry another password, or abort the password change. Figure 9-25 shows the Change Password Save screen.
Press SAVE, RETRY,orABORT. If SAVE or ABORT is pressed, the action is completed, and the System Setup screen displays. If RETRY is pressed, the Change Password screen is redisplayed.
CHANGE PASSWORD
OLD: L1
NEW:
L1
SAVE RETRY
Figure 9-25. Change Password Save Screen
ABORT
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Using the Control Panel
Select DATE AND TIME from the System Setup Level 1 menu to display the Time Format Setup screen. The Time Format Setup screen allows the selection of either month/day/year or day/month/year formats for display on the screen and for logging events in the Event and History Logs. Figure 9-26 shows the Time Format screen.
Use the pushbutton to display the Set Date and Time screen. To return to the System Setup screen, press the
or pushbuttons to highlight the desired format, then press the SELECT
pushbutton.
TIME FORMAT SETUP MM/DD/YYYY DD/MM/YYYY
SELECT
Figure 9-26. Time Format Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Using the Control Panel
The Set Date and Time MM/DD/YYYY screen allows the internal date and time of the UPS to be set in the month/day/year format. The date and time information is used for display on the screen and for logging events in the Event and History Logs. Figure 9-27 shows the Set Date and Time MM/DD/YYYY screen.
Use the pushbuttons to make the change. When finished making changes, use the or pushbuttons to highlight SAVE and the or pushbuttons to select YES. To complete the save function and return to the System Setup screen, select the
or pushbuttons to highlight the setting to be changed. Use the or
pushbutton.
SET DATE AND TIME MM/DD/YYYY
DATEMONTH YEAR HOUR MINUTE SAVE
2702 2004 15 42 YES
Figure 9-27. Set Date and Time MM/DD/YYYY Screen
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Using the Control Panel
The Set Date and Time DD/MM/YYYY screen allows the internal date and time of the UPS to be set in the day/month/year format. The date and time information is used for display on the screen and for logging events in the Event and History Logs. Figure 9-28 shows the Set Date and Time DD/MM/YYYY screen.
Use the pushbuttons to make the change. When finished making changes, use the or pushbuttons to highlight SAVE and the or pushbuttons to select YES. To complete the save function and return to the System Setup screen, select the
or pushbuttons to highlight the setting to be changed. Use the or
pushbutton.
SET DATE AND TIME DD/MM/YYYY
DATE MONTH YEAR HOUR MINUTE SAVE
27 02 2004 15 42 YES
Figure 9-28. Date and Time DD/MM/YYYY Screen
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Using the Control Panel
Select COM PORT SETUP from the System Setup Level 1 menu to display the COM Port Setup screen. This screen allows selection of the serial COM port to set up. Figure 9-29 shows the COM Port Setup screen.
Use the SELECT pushbutton. To return to the System Setup screen, press the
or pushbuttons to highlight the the COM port to be set up, then press the
COM PORT SETUP
COM 1
COM 2 COM 3
SELECT
Figure 9-29. COM Port Setup Screen
pushbutton.
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
Using the Control Panel
The COM Setup screen is used to change and save the settings for the serial communication ports. The COM port number selected from the COM Port Setup screen displays. If the changes are not wanted, use the ABORT pushbutton to return to the COM Port Setup screen. Figure 9-30 shows the COM Setup screen.
Use the to toggle through the values for the setting to make the change. Press SAVE or ABORT. Once the action is completed, the COM Port Setup screen appears.
or pushbuttons to highlight the setting to be changed. Use the pushbutton
COM 1 SETUP
BAUD RATE
DATA BITS STOP BITS
PARITY
SAVE
Figure 9-30. COM Setup Screen
19200
8
1
NONE
ABORT
Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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Using the Control Panel
9.3 System Controls Screen
Press the CONTROLS pushbutton on the main menu bar to display the System Controls screen. LOAD OFF, normal operation, transfer to bypass, charger control, and power module startup and shutdown functions are controlled from this screen. In addition, the screen displays the current status of the UPS and indicates whether the UPS is in Maintenance Bypass or Bypass, and the state of the power module (PM) and battery charger. Figure 9-31 and Figure 9-32 show the System Controls screens.
Use the the two System Controls screens.
or pushbutton on the menu bar to toggle the menu bar functions between
SYSTEM CONTROLS
MAINTENANCE BYPASS BYPASS
POWER MODULE (PM) CHARGER OFF:
LOAD OFF BYPASSNORMAL
Figure 9-31. System Controls Screen 1
OFF: OFF: ONLINE:
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Powerware®9390 UPS (40–80 kVA) Installation and Operation Manual S 164201535 Rev C
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