Powerware 9390, UPS 100160 kVA User Manual
Powerware 9390 UPS
®
100–160 kVA
Installation and Operation Manual
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, X-Slot, and ABM are registered trademarks and ConnectUPS is a trademark of Eaton Electrical
Inc. Modbus is a registered trademark of Modicon. IBM and AS/400 are registered trademarks of
International Business Machines Corp.
ECopyright 2004-2006 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document
may be reproduced in any way without the express written approval of Eaton 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 2-3....................................
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 Integrated Accessory Cabinet Installation 3-6..................................
3.2.5 UPS Sidecar Wiring 3-6.....................................................
3.2.6 Installing UPS External and Battery Power Wiring 3-6............................
3.2.6.1 External Wiring Installation Procedure A 3-7..............................
3.2.6.2 External Wiring Installation Procedure B 3-9...............................
3.2.6.3 Battery Wiring 3-10....................................................
3.2.7 Installing Interface Connections 3-11..........................................
3.2.7.1 TB1 and TB2 Connections 3-11...........................................
3.2.7.2 TB2 Battery Cabinet Connections 3-12....................................
3.2.7.3 X-Slot Connections 3-13................................................
3.2.8 Installing Accessories and Parallel System Control Wiring 3-14.....................
3.3 Initial Startup 3-14.............................................................
3.4 Completing the Installation Checklist 3-14.........................................
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
i
Table of Contents
4 Batteries 4-1...............................................................
4.1 Important Safety Instructions 4-1................................................
4.2 Installing Batteries 4-2.........................................................
4.3 Recycling the Used Battery or UPS 4-2...........................................
5 Installing a Remote Emergency Power-off Switch 5-1..........................
6 Installing Options and Accessories 6-1........................................
6.1 Installing a Powerware Hot Sync CAN Bridge Card 6-1..............................
6.2 Installing Parallel System Control Wiring 6-2......................................
6.3 Installing a Remote Monitor Panel II 6-3..........................................
6.4 Installing a Relay Interface Module II 6-4.........................................
6.5 Installing a Supervisory Contact Module II 6-6.....................................
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..............................................................
ii
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
Table of Contents
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..........................................
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 Integrated Accessory Cabinet (IAC-B, IAC-T, and IAC-D) 8-3......................
8.2.4 Powerware Hot Sync Parallel System 8-3......................................
8.2.5 Sync Control 8-3..........................................................
8.2.6 Optional X-Slot Cards 8-3...................................................
8.2.7 Mini-CSB 8-3.............................................................
8.2.8 Remote Monitor Panel II 8-4................................................
8.2.9 Relay Interface Module II 8-4................................................
8.2.10 Supervisory Contact Module II 8-4...........................................
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 Battery Discharge Log 9-9..................................................
9.2.5 KW Demand Log 9-11.......................................................
9.2.6 Maximum Current Log 9-19..................................................
9.2.7 System Meters Screens 9-28.................................................
9.2.8 System Setup Level 0 Screens 9-33............................................
9.2.9 System Setup Level 1 Screens 9-36............................................
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
iii
Table of Contents
9.3 System Controls Screen 9-45....................................................
9.4 Load Off Screen 9-47...........................................................
9.5 Reading the Status Indicators 9-48................................................
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.............................
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 II 11-2...........................................
11.4 Relay Interface Module II 11-4...................................................
11.5 Supervisory Contact Module II 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.....................................................
iv
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
Table of Contents
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......................................................
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.............................................
Appendix A – Installation Information A-1.........................................
Warranty W-1...................................................................
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
v
Table of Contents
This page intentionally left blank.
vi
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
Table of Contents
Figure 1-1. Powerware 9390 UPS (100–160 kVA) Cabinet 1-1...................................
Figure 2-1. Powerware 9390 UPS (100–160 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 Switch 5-1...............................................................
Figure 6-1. Powerware Hot Sync CAN Bridge Card 6-1........................................
Figure 6-2. Supervisory Contact Module II TB2 6-7...........................................
Figure 7-1. Main Elements of the UPS System 7-1............................................
Figure 7-2. Path of Current Through the UPS in Normal Mode – RT 7-4..........................
Figure 7-3. Path of Current Through the UPS in Bypass Mode – RT 7-6..........................
Figure 7-4. Path of Current Through the UPS in Battery Mode – RT 7-8..........................
Figure 7-5. Path of Current through the UPMs in Normal Mode – Parallel 7-11.....................
Figure 7-6. Path of Current through the UPMs in Bypass Mode – Parallel 7-12.....................
Figure 7-7. Path of Current through the UPMs in Battery Mode – Parallel 7-14.....................
Figure 9-1. UPS Control Panel 9-1..........................................................
Figure 9-2. Parts of the LCD 9-2...........................................................
Figure 9-3. Main Menu and Mimic Screen (Normal Mode) 9-3..................................
Figure 9-4. Active Events Screen 9-4........................................................
Figure 9-5. History Screen 9-5.............................................................
Figure 9-6. Unit Output Meter Screen 9-6...................................................
Figure 9-7. Unit Input Meter Screen 9-7....................................................
Figure 9-8. Unit Bypass Meter Screen 9-7...................................................
Figure 9-9. Unit Battery Meter Screen 9-8...................................................
Figure 9-10. Unit Output Current (Load) Meter Screen 9-8....................................
Figure 9-11. Battery Discharge Log Summary Screen 9-9.......................................
Figure 9-12. Battery Discharge Log Screen 9-10...............................................
Figure 9-13. KW Demand Log Summary Screen 9-11...........................................
Figure 9-14. KW Demand Log Screen 9-12...................................................
Figure 9-15. Current KW Demand Log Setup Screen 1 9-13.....................................
Figure 9-16. Current KW Demand Log Setup Screen 2 9-14.....................................
Figure 9-17. Time Interval Monitored Setup Screen 9-15.......................................
Figure 9-18. Time Interval Monitored Setup Save Screen 9-16...................................
Figure 9-19. Maximum Level (KW) Setup Screen 9-17..........................................
Figure 9-20. Maximum Level (KW) Setup Save Screen 9-18......................................
Figure 9-21. Maximum Current Log Summary Screen 9-19......................................
Figure 9-22. Maximum Current Log Screen (Three-Phase Measurement) 9-20......................
Figure 9-23. Maximum Current Log Screen (Individual Phase Measurement) 9-21..................
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
vii
Table of Contents
Figure 9-24. Maximum Current Log Setup Screen 1 9-21.......................................
Figure 9-25. Maximum Current Log Setup Screen 2 9-22.......................................
Figure 9-26. Time Interval Monitored Setup Screen 9-23.......................................
Figure 9-27. Time Interval Monitored Setup Save Screen 9-24...................................
Figure 9-28. Maximum % of Full Load Setup Screen 9-25.......................................
Figure 9-29. Maximum % of Full Load Setup Save Screen 9-26...................................
Figure 9-30. Calculation Method Setup Screen 9-27...........................................
Figure 9-31. System Meters Screen 9-28.....................................................
Figure 9-32. Total System Output Meter Screen 9-29..........................................
Figure 9-33. Output Unit X Meter Screen 9-30................................................
Figure 9-34. Input Unit X Meter Screen 9-31..................................................
Figure 9-35. Bypass Unit X Meter Screen 9-31................................................
Figure 9-36. Battery Unit X Meter Screen 9-32................................................
Figure 9-37. Output Current (Load) Unit X Meter Screen 9-32...................................
Figure 9-38. System Setup Level 0 Screen 9-33................................................
Figure 9-39. Contrast Adjust Screen 9-34.....................................................
Figure 9-40. Versions Screen 9-35...........................................................
Figure 9-41. Unit Type Screen 9-35..........................................................
Figure 9-42. Enter Password Screen 9-36.....................................................
Figure 9-43. System Setup Level 1 Screen 9-37................................................
Figure 9-44. Change Password Screen 9-38...................................................
Figure 9-45. Change Password Save Screen 9-39...............................................
Figure 9-46. Time Format Screen 9-40.......................................................
Figure 9-47. Set Date and Time MM/DD/YYYY Screen 9-41......................................
Figure 9-48. Set Date and Time DD/MM/YYYY Screen 9-42......................................
Figure 9-49. COM Port Setup Screen 9-43....................................................
Figure 9-50. COM Setup Screen 9-44........................................................
Figure 9-51. System Controls Screen 1 9-45..................................................
Figure 9-52. System Controls Screen 2 9-46..................................................
Figure 9-53. Load Off Screen 9-47..........................................................
Figure 11-1. Remote Monitor Panel II 11-2...................................................
Figure 11-2. Relay Interface Module II 11-4...................................................
Figure 11-3. Supervisory Contact Module II 1 1-5..............................................
Figure 13-1. Optional X-Slot Cards 13-2......................................................
Figure 13-2. Sample Event History Log 13-5..................................................
viii
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
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 cabinet es 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 (100–160 kVA).
Figure 1-1. Powerware 9390 UPS (100–160 kVA) Cabinet
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
1-1
Introduction
1.1 Basic System Configurations
The following basic UPS system configurations are possible:
쑺 Single module UPS and one to four battery cabinets
쑺 Single module UPS with UPS Sidecar (maintenance bypass or 1+1 tie configuration) and
one to four battery cabinets
쑺 Single module UPS, one to four battery cabinets, and an optional Integrated Distribution
Cabinet (IDC)
쑺 Single module UPS, one to four battery cabinets, and an optional Integrated Accessory
Cabinet (IAC) (maintenance bypass, 1+1 tie, or 1+1 tie with maintenance bypass
configuration)
쑺 Single module UPS, one to four battery cabinets, and an optional Integrated Accessory
Cabinet (IAC) (distribution configuration)
쑺 Powerware Hot Sync parallel system with two UPS modules, one to four battery cabinets
for each UPS, and an optional module tie cabinet
- One capacity/one redundant (1+1)
- Two capacity (2+0)
쑺 Powerware Hot Sync parallel system with three UPS modules, one to four battery
cabinets for each UPS, and an optional module tie cabinet
- Two capacity/one redundant (2+1)
- Three capacity (3+0)
쑺 Powerware Hot Sync parallel system with four UPS modules, one to four battery cabinets
for each UPS, and an optional module tie cabinet
- Three capacity/one redundant (3+1)
- Four capacity (4+0)
쑺 Powerware Hot Sync parallel system with two UPS modules, one to four battery cabinets
for each UPS, an optional module tie cabinet, and an optional IDC
- One capacity/one redundant (1+1)
- Two capacity (2+0)
쑺 Powerware Hot Sync parallel system with three UPS modules, one to four battery
cabinets for each UPS, an optional module tie cabinet, and an optional IDC
- Two capacity/one redundant (2+1)
- Three capacity (3+0)
쑺 Powerware 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)
1-2
The UPS system configuration can be enhanced by adding optional accessories such as a
Remote Emergency Power-off (REPO) control, Remote Monitor Panel II (RMP II), or X-Slot
®
communication cards.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
1.2 Using This Manual
This manual describes how to install and operate the Powerware 9390 UPS (100–160 kVA)
cabinet. Read and understand the procedures described in this manual to ensure
trouble-free installation and operation. In particular, be thoroughly familiar with the REPO
procedure (see page 10-7).
The information in this manual is divided into the sections and chapters listed. The system,
options, and accessories being installed dictate which parts of this manual should be read.
At a minimum, Chapters 1 through 3 and 8 through 10 should be examined.
쑺 Chapter 1, “Introduction” – provides a brief description of the UPS system, a
description of the content of each chapter, text conventions used in the manual, safety
warnings, and reference information.
Section I, Installation
쑺 Chapter 2, “UPS Installation Plan and Unpacking” – explains how to prepare the site
for the installation of the UPS system. It discusses equipment environmental
requirements, inspecting, and unpacking cabinets.
Introduction
쑺 Chapter 3, “Installing the UPS System” – describes how to install and wire the UPS
cabinet and optional equipment.
쑺 Chapter 4, “Batteries” – provides battery safety and installation information.
쑺 Chapter 5, “Installing a Remote Emergency Power-off Control” – contains information
for installing the optional REPO control.
쑺 Chapter 6, “Installing Options and Accessories” – contains information for installing an
X-Slot Powerware Hot Sync CAN Bridge Card, parallel control wiring, an RMP II, a Relay
Interface Module II (RIM II), or a Supervisory Contact Module II (SCM II).
Section II, Operation
쑺 Chapter 7, “Understanding UPS Operation” – provides information on why and how a
UPS works.
쑺 Chapter8,“Features,Options,andAccessories”–describes the standard and optional
UPS features and available accessories.
쑺 Chapter 9, “Using the Control Panel” – describes the controls and indicators found on
the control panel and shows the various information screens displayed on the LCD.
쑺 Chapter 10, “UPS Operating Instructions” – contains startup and shutdown procedures
for the UPS system.
쑺 Chapter 11, “Using Features and Options” – contains descriptions and instructions for
the UPS system features and options.
쑺 Chapter 12, “Responding to System Events” – listsallthealarmsandnoticesthatoccur
during operation of the UPS system.
쑺 Chapter 13, “Communication” – describes the communication features of the UPS
system.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
1-3
Introduction
Chapter 14, “Maintaining the UPS System” – contains maintenance instructions for the
쑺
UPS system.
쑺 Chapter 15, “Product Specifications” – provides detailed specifications for the UPS
system.
쑺 Appendix A, “Installation Information” – contains important information on wiring
requirements and recommendations, and important diagrams of the cabinets’
mechanical details and electrical access.
쑺 Warranty – provides the Powerware warranty for this product.
Read through each procedure before beginning the procedure. Perform only those
procedures that apply to the UPS system being installed or operated.
1.3 Conventions Used in This Manual
This manual uses these type conventions:
쑺 Bold type highlights important concepts in discussions, key terms in procedures, and
menu options, or represents a command or option that you type or enter at a prompt.
쑺 Italic type highlights notes and new terms where they are defined.
쑺 Screen type represents information that appears on the screen or LCD.
Icon Description
Information notes call attention to important features or instructions.
[Keys] Brackets are used when referring to a specific key, such as [Enter] or [Ctrl].
In this manual, the term UPS refers only to the UPS cabinet and its internal elements. The
term UPS system refers to the entire power protection system – the UPS cabinet, the
battery cabinet, and options or accessories installed.
1-4
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
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 b ehind the doors. However, the
should be handled with appropriate care.
This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by
AUTHORIZED SERVICE PERSONNEL ONLY.ThereareNO USER SERVICEABLE PARTS inside
the UPS.
Introduction
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
UPS system is a sophisticated power system and
DANGER
WARNING
쑺 The UPS system contains its own energy source (batteries). The output terminals may carry
live voltage even when the UPS is disconnected from an AC source.
쑺 To reduce the risk of fire or electric shock, install this UPS in a temperature and humidity
controlled, indoor environment, free of conductive contaminants. Ambient temperature
must not exceed 40°C (104°F). Do not operate near water or excessive humidity
(95% maximum). The s ystem is not intended for outdoor use.
쑺 Ensure all power is disconnected before performing installation or service.
CAUTION
쑺 Batteries can present a risk of electrical shock or burn from high short-circuit current.
Observe proper precautions. Servicing should be performed by qualified service personnel
knowledgeable of batteries and required precautions. Keep unauthorized personnel away
from batteries.
쑺 Proper disposal of batteries is required. Refer to local codes for disposal requirements.
쑺 Never dispose of batteries in a fire. Batteries may explode when exposed to flame.
쑺 Keep the UPS doors closed to ensure proper cooling airflow and to protect personnel from
dangerous voltages inside the unit.
쑺 Do not operate the UPS system close to gas or electric heat sources.
쑺 The operating environment should be maintained within the parameters stated in this
manual.
쑺 Keep surroundings uncluttered, clean, and free from excess moisture.
쑺 Observe all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of
the equipment.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
1-5
Introduction
1.5 For More Information
Refer to the Powerware 9390 Integrated Battery Cabinet (Models IBC -S and IBC-L)
Installation Manual (164201536) for the following additional information:
쑺 Integrated Battery Cabinet (IBC) installation instructions, including site preparation,
planning for installation, wiring, and safety information.
쑺 Detailed illustrations of the cabinet, including dimension and connection point drawings.
Refer to the Powerware 9390 Integrated Distribution Cabinet (160 kVA) Installation and
Operation Manual, (164201560), the Powerware 9390 Integrated Accessory Cabinet (IAC-B
and IAC-T Configurations) Installation and Operation Manual (164201590), the Powerware
9390 Integrated Accessory Cabinet (IAC-D Configuration) Installation and Operation Manual
(164201591), the Powerware 9390 UPS Sidecar Installation and Operation Manual
(164201586), or the Powerware 9390 Sync Control Installation and Operation Manual
(164201571), as applicable, for the following additional information:
쑺 Installation instructions, including site preparation, planning for installation, and wiring
and safety information. Detailed illustrations of the cabinet with dimensional and
connection point drawings are provided.
쑺 Operation, including controls, functions of the standard and optional features,
procedures for using with the UPS, and information about maintenance.
Visit
www.powerware.com or contact your Eaton service representative for information on
how to obtain copies of these manuals
1.6 Getting Help
If help is needed with any of the following:
쑺 Scheduling initial startup
쑺 Regional locations and telephone numbers
쑺 A question about any of the information in this manual
쑺 A question this manual does not answer
Please call the Eaton Help Desk for Powerware products at:
In the United States 1-800-843-9433 or 1-919-870-3028
In Canada 1-800-461-9166
All other countries Call your service representative
1-6
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
Section I Installation
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
1-1
This page intentionally left blank.
1-2
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
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 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 Eaton
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 Eaton service representative for
important information about high altitude operation. The operating environment must
meet the weight, clearance, and environmental requirements specified in Drawing
164201604-2 on page A-3 and size requirements specified on Drawing 164201604 -9
starting on page A-46.
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.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
2-1
UPS Installation Plan and Unpacking
2.2.1 Environmental Considerations
The life of the UPS system is adversely affected if the installation does not meet the
following guidelines:
쑺 The system must be installed on a level floorsuitableforcomputerorelectronic
equipment.
쑺 The system must be installed in a temperature and humidity controlled indoor area free
of conductive contaminants.
Failure to follow guidelines may void your warranty.
2.2.2 Preparing for Wiring the UPS System
NOTE If installing, as part of the UPS system, a maintenance bypass without a rectifier
input breaker, a minimum of two separate feeds with upstream feeder breakers, or one
feed with two upstream feeder breakers, must be provided: one for the UPS and one for
the maintenance bypass input. DO NOT use one feed or a single feeder breaker to
supply both the UPS and the maintenance bypass.
For external wiring requirements, including the minimum AWG size of external wiring, see
Table E through Table G starting on page A-12. 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.
2-2
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
UPS Installation Plan and Unpacking
2.3 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).
Figure 2-1. Powerware 9390 UPS (100–160 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.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
2-3
UPS Installation Plan and Unpacking
1. Carefully inspect the outer packaging for evidence of damage during transit.
Do not install a damaged cabinet. Report any damage to the carrier and contact your Eaton
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 forks
between the pallet supports on the bottom of the unit.
CAUTION
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.
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 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 Eaton service representative
immediately to determine the extent of the damage and its impact upon further
installation.
2-4
NOTE
and other harmful contaminants. Failure to store and protect the UPS properly may
void your warranty.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
While waiting for installation, protect the unpacked cabinet from moisture, dust,
Chapter 3 Installing the UPS System
3.1 Preliminary Installation Information
WARNING
Installation should be performed only by qualified personnel.
Refer to the following while installing the UPS system:
쑺 Appendix A contains installation drawings and additional installation notes.
쑺 Dimensions are in millimeters and inches.
쑺 Do not tilt the cabinets more than 10° during installation.
쑺 The conduit landing plates are to be removed to add conduit landing holes as required.
Plate material is 16 gauge steel (1.5 mm/0.06″ thick).
쑺 Thecabinetsmustbeinstalledonalevelfloorsuitableforcomputerorelectronic
equipment.
쑺 If perforated floor tiles are required for ventilation, place them in front of the UPS. See
Table A on page A-3 for equipment weight and point loading.
쑺 Details about control wiring are provided in each procedure for connecting options and
features. Drawing 164201604-8 and Table R through Table X 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
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 cabinets,
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
3-1
Installing the UPS System
3.2.1 Unloading the Powerware 9390 UPS Cabinet from the Pallet
The UPS cabinet is bolted to a wooden pallet supported by wood skids. To remove the
pallet, perform the following procedure:
The UPS cabinet is heavy. See Table A on page A-3 for weight of cabinets. If unloading
instructions are not closely followed, the cabinet may cause serious injury.
Donottiltcabinetsmorethan10°fromvertical.
WARNING
CAUTION
1. If not already accomplished, use a forklift or pallet jack to move the cabinet to the
installation area, or as close as possible, before unloading from the pallet. Insert
theforkliftorpalletjackforksbetween 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 doors. Remove the retaining screws located inside each door at the
top and bottom hinge pivot points, 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 the four bolts securing the front shipping bracket to the cabinet and four
bolts securing the bracket to the pallet (see Figure 3-1). Remove the front shipping
bracket. If installing the cabinet permanently, retain the shipping bracket and
securing hardware for later use.
6. Remove the four bolts securing the rear shipping bracket to the pallet. Do NOT
remove the four bolts securing the bracket to the cabinet (see Figure 3-2 on
page 3-4).
7. Remove the four bolts securing the removable skid and remove the skid (see
Figure 3-1).
3-2
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
Front View
Installing the UPS System
Vented Front Doors
Skid Bolts
Pallet
Front Shipping Bracket
Removable Skid
Figure 3-1. Removing Front Shipping Bracket on the Powerware 9390 UPS
Shipping
Bracket Bolts
Shipping
Bracket Bolts
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
3-3
Installing the UPS System
Rear View
Pallet
Rear Shipping Bracket
Figure 3-2. Removing Rear Shipping Bracket on the Powerware 9390 UPS
Shipping
Bracket Bolts
Shipping
Bracket Bolts
3-4
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
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. The rear shipping bracket will act as a brake to assist
restraining the cabinet.
WARNING
Do not stand directly in front of 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 front of the pallet. Once the pallet tilts,
continue rolling the cabinet down the pallet until the cabinet is clear of the pallet.
9. Remove the four bolts securing the rear shipping bracket to the cabinet (see
Figure 3-2). If installing the cabinet permanently, retain the shipping bracket and
securing hardware for later use.
10. Roll the cabinet to the final installation location.
11. If installing the cabinet permanently, retain the shipping brackets and hardware;
otherwise, discard or recycle the pallet and shipping brackets in a responsible
manner.
12. If permanently mounting the system, proceed to Step 15; otherwise, continue to
Step 13.
13. 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.
14. If installing battery and distribution cabinets, proceed to paragraphs 3.2.2 and
3.2.3; otherwise, proceed to paragraph 3.2.6.
15. Using the retained hardware, reinstall the shipping brackets removed in Step 6 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 3.2.6.
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 3.2.6 to wire the UPS and battery cabinet.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
3-5
Installing the UPS System
3.2.3 Integrated Distribution Cabinet Installation
To install and wire an IDC, refer to the Powerware 9390 Integrated Distribution Cabinet
(160 kVA) Installation and Operation Manual. After the IDC is installed and wired, return to
paragraph 3.2.6 to complete the UPS cabinet wiring.
3.2.4 Integrated Accessory Cabinet Installation
To install and wire an IAC, refer to the Powerware 9390 Integrated Accessory Cabinet (IAC-B
and IAC-T Configurations) Installation and Operation Manual or the Powerware 9390
Integrated Accessory Cabinet (IAC-D Configuration) Installation and Operation Manual.
After the IAC is installed and wired, return to paragraph 3.2.6 to complete the UPS cabinet
wiring.
3.2.5 UPS Sidecar Wiring
To wire an UPS Sidecar, refer to the Powerware 9390 UPS Sidecar Installation and
Operation Manual. After the UPS Sidecar is wired, return to paragraph 3.2.6 to complete
the UPS cabinet wiring.
3.2.6 Installing UPS External and Battery Power Wiring
NOTE The UPS cabinet is shipped with a debris shield covering the ventilation grill on
top of the unit. Do not remove the debris shield until installation is complete. However,
remove the 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 164201604-6 on page A-27).
NOTE Iftheloadrequiresaneutral,abypasssourceneutralmustbeprovided.Ifthe
load does not require a neutral and there is no neutral conductor connected at the
bypass input, a neutral to ground bonding jumper must be installed. DO NOT install
both a source neutral and a bonding jumper. See Table E through Table G or Table O
through Table Q for neutral bonding jumper wire sizes. Bonding jumper must be
copper wire.
CAUTION
HIGH IMPEDANCE GROUND SOURCES - If the supply source is a high impedance ground (IT)
type, the input neutral conductor must be connected from the source of supply. If there is no
output neutral connected to the UPS, the neutral-forming transformer kit (PN 103005400) may
be used instead of pulling a neutral from the source. If the load requires a neutral, then an
input neutral conductor must be pulled into the UPS. In no circumstances shall a neutral to
ground bonding jumper be installed in the UPS.
3-6
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
Installing the UPS System
CAUTION
DELTA SOURCES (TN-S) - The 9390 UPS system can be operated only from a delta supply
source that is fully floating and if the neutral-forming transformer kit (PN 103005400) is
installed in the UPS. The UPS cannot be operated from a mid-point or end -point grounded
delta supply source. With this type of supply source, there is no capability to provide an output
neutral. In no circumstances shall a neutral to ground bonding jumper be installed in the
UPS.
Use the applicable procedure from the following list for the UPS model being installed:
쑺 For UPS models 120/100, 120/120, 160/100, 160/120, and 160/160 with 208V/220V input
and UPS models 160/100, 160/120, and 160/160 with 480V input, proceed to
paragraph 3.2.6.1.
쑺 For UPS models 120/100 and 120/120 with 480V input, proceed to paragraph 3.2.6.2.
3.2.6.1 External Wiring Installation Procedure A
To install wiring to connections:
1. Slide the air filters up and remove them 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 and right side internal safety shield panels
and remove the panels 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
164201604-7 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 rectifier 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 13.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
3-7
Installing the UPS System
In the following step, DO NOT move the sensing and EMI wires from the rectifier contactor K1
input terminals. These wires must remain connected to the K1 terminals for proper UPS
operation.
CAUTION
10. Disconnect the phase A, B, and C bypass contactor K5 power input leads only (two
wires per phase) from the rectifier contactor K1 input terminals. Connect these
power leads to the bypass input terminals.
11. Connect phase A, B, and C rectifier input power wiring from the utility source to
the rectifier input terminals in the UPS cabinet. See Appendix A for wiring and
termination requirements and wiring access information. Note wiring connections
for dual-feed systems.
12. Connect phase A, B, and 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 or IAC, proceed to Step 14; otherwise, proceed to Step 17.
14. Route and connect the output cable between the UPS cabinet and the IDC or IAC.
Refer to the applicable IDC or IAC installation and operation manual, referenced in
paragraph 1.5 on page 1-6, for wiring instructions. 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 or
IAC to the UPS cabinet output and neutral terminals. See Appendix A for wiring
and termination requirements.
16. Proceed to paragraph 3.2.6.3.
17. If wiring a parallel system, proceed to Step 18; otherwise, proceed to Step 20.
CAUTION
Parallel system wiring length should be in accordance with Drawing 164201604-5, sheet
15 of 15, 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.
3-8
19. Proceed to paragraph 3.2.6.3.
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.
21. Proceed to paragraph 3.2.6.3.
EATON Powerware®9390 UPS (100–160 kVA) Installation and Operation Manual S 164201604 Rev B powerware.com
Loading...