Powerware UPS Sidecar Powerware 9390 User Manual

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Powerware® 9390 UPS Sidecar

Installation and Operation Manual

For use with 40–80 kVA and 100–160 kVA UPS Models

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

Eaton and Powerware are registered trademarks of Eaton Corporation or its subsidiaries and affiliates.

ECopyright 2004–2007 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

1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

 

1.1

Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

 

1.2

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

1-4

 

1.3

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

1-5

 

1.4

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

1-6

 

1.5

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

1-6

 

1.6

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

1-7

Section I – Installation

 

2 Installing the UPS Sidecar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

 

2.1

Installation Plan and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

 

2.2

Preliminary Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

 

2.3

UPS Sidecar Installation – Maintenance Bypass Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

 

 

2.3.1

Installing the UPS Cabinet with UPS Sidecar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

 

 

2.3.2

Installing Maintenance Bypass Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

 

2.4

UPS Sidecar Installation – Parallel Redundant Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

 

 

2.4.1

Line-up-and-Match Parallel Redundant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

 

 

2.4.2

Installing Line-up-and-Match Parallel Redundant Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7

 

 

2.4.3

Standalone Parallel Redundant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8

 

 

2.4.4

Installing Standalone Parallel Redundant Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9

 

 

2.4.5

Installing UPS Sidecar TB1 Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10

 

2.5

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10

 

2.6

Completing the Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-10

Section II – Operation

 

3

Understanding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

 

3.1

Maintenance Bypass Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

 

 

3.1.1

UPS Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

 

 

3.1.2

Maintenance Bypass Mode with UPS Sidecar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

 

3.2

Parallel Redundant Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

4 UPS Sidecar Features, Controls, and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

4.1

UPS Sidecar Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

 

4.1.1

Maintenance Bypass Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

 

4.1.2

Parallel Redundant Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

 

4.1.3

Customer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

 

4.1.4

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

4-1

 

 

4.1.5

Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

4.2

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

 

4.2.1

Bypass Input Breaker (BIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

 

 

4.2.2

Rectifier Input Breaker (RIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

 

 

4.2.3

System Load Breaker (SLB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

 

4.3

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

 

4.4

UPS Sidecar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

i

TABLE OF CONTENTS

 

4.5

UPS Sidecar Operation – Maintenance Bypass Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13

 

 

4.5.1

Using the UPS when a UPS Sidecar is Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13

 

 

4.5.2

Transferring the UPS to Maintenance Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13

 

 

4.5.3

Transferring the UPS from Maintenance Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14

 

4.6

UPS Sidecar Operation – Parallel Redundant Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15

 

4.7

Maintaining the UPS Sidecar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15

 

4.8

Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15

5

Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

6

Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1

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EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

List of Figures

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

1-2

Figure 1-2. Powerware 9390 UPS (100–160 kVA) with UPS Sidecar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

Figure 2-1. 80 kVA UPS with UPS Sidecar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3

Figure 2-2. Typical Line-up-and-Match Parallel Redundant System (80 kVA System Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4

Figure 2-3. UPM 1 to UPM 2 Joining Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6

Figure 2-4. Typical Standalone Parallel Redundant System (80 kVA System Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-8

Figure 3-1. Path of Current Through the UPS Sidecar in UPS Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

Figure 3-2. Path of Current Through the UPS Sidecar in Maintenance Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Figure 4-1. UPS Sidecar Controls (Bypass) – 40/20, 40/30, 40/40 kVA, 480/480V with MBP and MIS . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

Figure 4-2. UPS Sidecar Controls (Bypass) – 40/20, 40/30, 40/40 kVA, 480/480V with Optional BIB and RIB . . . . . . . . . . . . . . . . . . . .

4-5

Figure 4-3. UPS Sidecar Controls (Bypass) – 40/20, 40/30, 40/40 kVA, 208/208V and 80/40, 80/50, 80/60,

 

80/80 kVA and 120/100 and 120/120 kVA, 480/480V with MBP and MIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6

Figure 4-4. UPS Sidecar Controls (Bypass) – 40/20, 40/30, 40/40 kVA, 208/208V and 80/40, 80/50, 80/60,

 

80/80 kVA and 120/100 and 120/120 kVA, 480/480V with Optional BIB and RIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7

Figure 4-5. UPS Sidecar Controls (Bypass) – 80/40, 80/50, 80/60, 80/80 kVA, 208/208V and

 

160/100, 160/120, and 160/160 kVA, 480/480V with MBP and MIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8

Figure 4-6. UPS Sidecar Controls (Bypass) – 80/40, 80/50, 80/60, 80/80 kVA, 208/208V and

 

160/100, 160/120, and 160/160 kVA, 480/480V with Optional BIB and RIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9

Figure 4-7. UPS Sidecar Controls (Parallel Redundant) – 40/20, 40/30, 40/40 kVA, 480/480V with MOBs and Optional SLB . . . . . . . . .

4-10

Figure 4-8. UPS Sidecar Controls (Parallel Redundant) – 40/20, 40/30, 40/40 kVA, 208/208V and

 

80/40, 80/50, 80/60, 80/80 kVA and 120/100, and 120/120 kVA, 480/480V with MOBs and Optional SLB . . . . . . . . . . . . . . . . . .

4-11

Figure 4-9. UPS Sidecar Controls (Parallel Redundant) – 80/40, 80/50, 80/60, 80/80 kVA, 208/208V

 

and 160/100, 160/120, and 160/160 kVA, 480/480V with MOBs and Optional SLB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12

EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

iii

LIST OF FIGURES

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EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

Chapter 1

Introduction

The Eaton® Powerware® 9390 UPS Sidecar is designed for use with the Powerware 9390 80 kVA 208/208V and 480/480V and 160 kVA 480/480V three-phase uninterruptible power systems (UPSs). The UPS Sidecar provides maintenance bypass or tie cabinet functions with the following custom configurable features, enabling adaptation and expansion without costly electrical rework:

SMaintenance Bypass Configuration – Maintenance Bypass (MBP) and Maintenance Isolation (MIS) breakers enable power to completely bypass the UPS power module. The UPS module can then be safely serviced or replaced, without interrupting power to critical systems. An optional Bypass Input Breaker (BIB) and Rectifier Input Breaker (RIB) provide a single wiring point input to the UPS and a convenient method for removing power from the UPS when using the maintenance bypass to supply the load.

SParallel Redundant Configuration – Module Output Breakers (MOBs) 1 and 2 enable two UPS modules to be paralleled together for redundancy. An optional System Load Breaker (SLB) provides output control to the critical load for the whole system.

The UPS Sidecar is attached to and directly integrated with the UPS cabinet and has safety shields behind the removable front panel for hazardous voltage protection. The UPS Sidecar matches the UPS cabinet in style and color. Figure 1-1 shows the Powerware 9390 UPS (40–80 kVA) with the UPS Sidecar and Figure 1-2 shows the Powerware 9390 UPS (100–160 kVA) with the UPS Sidecar.

1.1Configurations

The following UPS Sidecar configurations are possible:

S UPS Sidecar with MBP and MIS

S UPS Sidecar with MBP, MIS, and BIB

S UPS Sidecar with MBP, MIS, BIB, and RIB

S UPS Sidecar with MOB 1 and MOB 2

S UPS Sidecar with MOB 1, MOB 2, and SLB

EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

1-1

INTRODUCTION

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

1-2

EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

INTRODUCTION

Figure 1-2. Powerware 9390 UPS (100–160 kVA) with UPS Sidecar

EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

1-3

INTRODUCTION

1.2Using This Manual

This manual describes how to install and operate the Powerware 9390 UPS Sidecar. Read and understand the procedures described in this manual to ensure trouble-free installation and operation.

The information in this manual is divided into the sections and chapters listed. At a minimum, Chapters 1, 2, and 4 should be examined. Read through each procedure before beginning the procedure.

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

Section I, Installation

SChapter 2, “Installing the UPS Sidecar” – describes how to install and wire the UPS Sidecar.

Section II, Operation

SChapter 3, “Understanding Operation” – provides information on how the UPS Sidecar works.

SChapter 4, “UPS Sidecar Features, Controls, and Operation” – describes the standard and optional UPS Sidecar features, the UPS Sidecar controls, and how to use the UPS Sidecar.

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

S Warranty – provides the Eaton warranty for this product.

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EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

INTRODUCTION

1.3Conventions Used in This Manual

This manual uses these type conventions:

SBold type highlights important concepts in discussions, key terms in procedures, and menu options.

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

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

Icon Description

Information notes call attention to important features or instructions.

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, the UPS Sidecar, and options or accessories installed.

The term line-up-and-match refers to cabinets that are physically attached to the UPS, and the wiring between them is internal. The term standalone refers to cabinets that are not physically attached to the UPS, and are wired with external customer-supplied wiring.

EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

1-5

INTRODUCTION

1.4Safety Warnings

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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

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

D A NG E R

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

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

WA RNIN G

SThe 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.

STo reduce the risk of fire or electric shock, install this UPS Sidecar 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 system is not intended for outdoor use.

S Ensure all power is disconnected before performing installation or service.

C A U T I O N

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

S Keep the UPS Sidecar front panel installed to protect personnel from dangerous voltages inside the unit.

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

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

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

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

1.5For More Information

Refer to the Powerware 9390 UPS (40–80 kVA) Installation and Operation Manual or the Powerware 9390 UPS (100–160 kVA) Installation and Operation Manual for the following additional information:

SUPS cabinet, optional components, and accessory installation instructions, including site preparation, planning for installation, and wiring and safety information. Detailed illustrations of cabinets and optional accessories with dimensional and connection point drawings are provided.

SUPS operation, including UPS cabinet controls, functions of the UPS, standard features and optional accessories, procedures for starting and stopping the UPS, and information about maintenance and responding to system events.

S Communication capabilities of the UPS system.

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

1-6

EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

INTRODUCTION

1.6Getting Help

If help is needed with any of the following:

S Scheduling initial startup

S Regional locations and telephone numbers

S A question about any of the information in this manual

S A question this manual does not answer

Please call the Eaton Help Desk for Powerware products at:

United States: 1-800-843-9433 or 1-919-870-3028

Canada: 1-800-461-9166 ext 260

All other countries: Call your local service representative

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INTRODUCTION

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Section I

Installation

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Chapter 2

Installing the UPS Sidecar

2.1Installation Plan and Unpacking

Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for installation planning and unpacking.

2.2Preliminary Installation Information

WA RNIN G

Installation should be performed only by qualified personnel.

Refer to the following while installing the UPS Sidecar:

S Appendix A contains installation drawings and additional installation notes.

S Dimensions are in millimeters and inches.

SThe conduit landing plates are to be removed to add conduit landing holes, or remove knockouts, as required. Plate material is 16 gauge steel (1.5 mm/0.060” thick).

SRefer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for UPS cabinet installation, wiring information, and conduit and terminal locations.

2.3UPS Sidecar Installation – Maintenance Bypass Configuration

2.3.1Installing the UPS Cabinet with UPS Sidecar

The UPS Sidecar is a factory-installed integral part of the standard UPS cabinet. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for UPS cabinet installation.

2.3.2Installing Maintenance Bypass Power Wiring

NOTE Remove the UPS Sidecar top or bottom conduit landing plate to drill or punch conduit holes, or remove knockouts (see Drawing 164201546-5 starting on page A-27).

NOTE Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for UPS cabinet wiring information and conduit and terminal locations.

NOTE If input or output neutrals are required, wire the neutrals to the neutral terminals located inside the

UPS cabinet.

NOTE Wire grounds to the ground terminals located inside the UPS cabinet.

1.Verify the UPS system is turned off and all power sources are removed. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for shutdown instructions.

2.If not already removed, remove the screw securing the bottom of the UPS Sidecar front panel (see Figure 2-1). Lift up the panel and remove.

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INSTALLING THE UPS SIDECAR

3.If not already removed, remove the screws securing the internal safety shield panel and remove the panel to gain access to the terminals.

NOTE If a Bypass Input Breaker is not installed, 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 UPS Sidecar bypass input. DO NOT use one feed or a single-feeder breaker to supply both the UPS and Sidecar.

4.If wiring a single-feed system with or without a Rectifier Input Breaker, continue to Step 5; if wiring a dual-feed system with an RIB, proceed to Step 8.

5.Route the bypass input cables to the UPS Sidecar bypass terminals. See Drawing 164201546-6, starting on page A-30, for UPS Sidecar wiring access information and terminal locations.

6.Connect phase A, B, and C bypass input power wiring from the source to the bypass terminals on the UPS Sidecar.

7.Proceed to Step 12.

8.Disconnect the single-feed jumpers between BIB 1, 3, 5 terminals and RIB 1, 3, 5 terminals.

9.Route the bypass and rectifier input cables to the UPS Sidecar bypass and rectifier input terminals. See Drawing 164201546-6, starting on page A-30, for UPS Sidecar wiring access information and terminal locations.

10.Connect phase A, B, and C bypass input power wiring from the source to the bypass terminals on the UPS Sidecar.

11.Connect phase A, B, and C power wiring from the source to the UPS rectifier input terminals on the UPS Sidecar.

12.Route the output cables to the UPS Sidecar output terminals. See Drawing 164201546-6, starting on page A-30, for UPS Sidecar wiring access information and terminal locations.

13.Connect phase A, B, and C, and Neutral power wiring from the UPS Sidecar output terminals to the critical load.

14.After wiring the UPS system to the facility power and critical load, be sure to ground the system according to local and/or national electrical wiring codes.

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

16.Reinstall the UPS Sidecar front panel and secure with the screw at the bottom of the panel.

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INSTALLING THE UPS SIDECAR

Front Panel

UPS Cabinet

UPS Sidecar

Front Panel

Attaching Screw

Figure 2-1. 80 kVA UPS with UPS Sidecar

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INSTALLING THE UPS SIDECAR

2.4UPS Sidecar Installation – Parallel Redundant Configuration

The method used to install the UPS Sidecar depends on the type of installation being undertaken. The UPS Sidecar can be installed as a line-up-and-match or standalone system.

STo install a line-up-and-match parallel redundant system, continue to paragraph 2.4.1.

S To install a standalone parallel redundant system, proceed to paragraph 2.4.3.

2.4.1Line-up-and-Match Parallel Redundant Installation

Use this procedure to install uninterruptible power module (UPM) 2 adjacent to UPM 1 (see Figure 2-2). UPM 1 has the Sidecar installed. The UPS Sidecar is a factory-installed integral part of the standard UPS cabinet.

Sidecar

UPM 1

UPM 2

Figure 2-2. Typical Line-up-and-Match Parallel Redundant System (80 kVA System Shown)

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INSTALLING THE UPS SIDECAR

1.Verify that the UPM 1 is properly installed and secured. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for installation instructions.

2.On UPM 1, if not already removed, remove the screw securing the bottom of the UPS Sidecar front panel (see Figure 2-1 on page 2-3). Lift up the panel and remove.

3.On UPM 1, if not already removed, remove the screws securing the internal safety shield panel and remove the panel to gain access to the terminals.

4.Remove the field kit from the bottom of the UPS Sidecar and retain for later use.

5.Roll UPM 2 to an area near the right-hand side of UPM 1.

6.Open or remove doors, internal safety shield panels, and cosmetic covers, as required, according to the instructions contained in the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5.

7.Remove the knockouts, as required, on the bottom right side inside panel of the UPM 1 UPS Sidecar (see Drawing 164201546-5, sheet 3 of 3, on page A-29).

8.Remove the knockouts on the bottom left side inside panel of UPM 2. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for the location of the knockout plug.

9.Install the nylon grommets from the field kit around the holes left after removing the knockouts.

10.Push UPM 2 toward the right side of UPM 1 until the doors are flush with each other.

11.If not already installed, mount the hanger brackets to the top right side of the UPM 2 using M4 screws (see Drawing 164201546-5, sheet 3 of 3, on

page A-29).

12.If not already installed, hang the side panel on the hanger brackets and align with the front and rear of the UPM 2.

13.Secure UPM 2 in position. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for installation instructions.

NOTE Two cabinet joining brackets are provided in the field kit for securing each cabinet at the top and bottom. A small flat bracket joins the top of the cabinets and a larger angle bracket joins the cabinets at the bottom. The small flat bracket is attached to the cabinet tops first.

14.Remove the left-hand screw from the top door hinge on UPM 2.

15.Locate the small flat bracket, four washers, and M4 screw from the field kit. Align the holes in the small flat bracket over the hole in the top of the UPS Sidecar attached to UPM 1 and the door hinge screw hole on UPM 2. Use the four washers between the bracket and the top of the UPS Sidecar to match the thickness of hinge on UPM 2. Secure the bracket to the UPS Sidecar using the M4 screw, and to the hinge on UPM 2 using the screw removed in Step 14 (see Figure 2-3).

16.Locate the large angle bracket, M4 screws, and large nut from the field kit. Place one end of the bracket over the bolt on the bottom side of the lower left-hand hinge on UPM 2, and loosely secure the bracket to the hinge with the large nut (see Figure 2-3).

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17.Align the holes in the other end of the bracket with the holes in the bottom right-hand side of the UPS Sidecar attached to UPM 1 (see Figure 2-3). Secure the bracket with M4 screws from the field kit.

18.Secure the large nut on the UPM 2 hinge.

19.Continue to paragraph 2.4.2.

M4 Screw

Existing

and Four Washers

from Kit

Screw

UPM 1 UPS Sidecar

UPM 2

Small Flat Bracket from Kit

 

Top View with Small Bracket

UPM 1 UPS Sidecar

UPM 2

Large Angle Bracket from Kit

Existing Hinge

M4 Screws from Kit

Nut from Kit

Front View with Large Angle Bracket

Figure 2-3. UPM 1 to UPM 2 Joining Brackets

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INSTALLING THE UPS SIDECAR

2.4.2Installing Line-up-and-Match Parallel Redundant Power Wiring

NOTE Remove the UPS Sidecar top or bottom conduit landing plate to drill or punch conduit holes, or remove knockouts (see Drawing 164201546-5 starting on page A-27).

NOTE Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for UPS cabinet wiring information and conduit and terminal locations.

C A U T I O N

Specified wiring and the MOB and SLB breakers for the UPS Sidecar are rated for parallel redundant service only. DO NOT use as a parallel capacity system.

1.Verify the UPS system is turned off and all power sources are removed. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for shutdown instructions.

2.If not already removed, remove the screw securing the bottom of the UPS Sidecar front panel (see Figure 2-1 on page 2-3). Lift up the panel and remove.

3.If not already removed, remove the screws securing the internal safety shield panel and remove the panel to gain access to the terminals.

4.An MOB 2 to UPM 2 wiring harness is supplied inside the UPM 1 UPS Sidecar. Route the harness through the knockout in the side of the cabinets to the UPM 2 output terminals.

5.Connect phase A, B, and C, and Neutral power wiring from MOB 2 to UPM 2.

6.Route the output cables to the UPS Sidecar output terminals. See Drawing 164201546-6, starting on page A-30, for UPS Sidecar wiring access information and terminal locations.

7.Connect phase A, B, and C, and Neutral power wiring from the UPS Sidecar output terminals to the critical load.

8.After wiring the UPS system to the facility power and critical load, be sure to ground the system according to local and/or national electrical wiring codes.

9.If wiring interface connections, proceed to paragraph 2.4.5; otherwise, proceed to Step 10.

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

11.Reinstall the UPS Sidecar front panel and secure with the screw at the bottom of the panel.

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INSTALLING THE UPS SIDECAR

2.4.3Standalone Parallel Redundant Installation

Use this procedure to install separately located UPMs (see Figure 2-4). UPM 1 has the

Sidecar installed. The UPS Sidecar is a factory-installed integral part of the standard

UPS cabinet.

UPS Sidecar

UPM 1

UPM 2

Figure 2-4. Typical Standalone Parallel Redundant System (80 kVA System Shown)

1.Verify that the UPM 1 is properly installed and secured. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for installation instructions.

2.Verify that the UPM 2 is properly installed and secured. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for installation instructions.

3.Continue to paragraph 2.4.4.

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INSTALLING THE UPS SIDECAR

2.4.4Installing Standalone Parallel Redundant Power Wiring

NOTE Remove the UPS Sidecar top or bottom conduit landing plate to drill or punch conduit holes, or remove knockouts (see Drawing 164201546-5 starting on page A-27).

NOTE Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for UPS cabinet wiring information and conduit and terminal locations.

C A U T I O N

Specified wiring and the MOB and SLB breakers for the UPS Sidecar are rated for parallel redundant service only. DO NOT use as a parallel capacity system.

C A U T I O N

Parallel system wiring length should be in accordance with the parallel drawings found in the appendix of the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5. Correct wire length ensures approximate equal current sharing when in Static Bypass mode.

1.Verify the UPS system is turned off and all power sources are removed. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for shutdown instructions.

2.If not already removed, remove the screw securing the bottom of the UPS Sidecar front panel (see Figure 2-1 on page 2-3). Lift up the panel and remove.

3.If not already removed, remove the screws securing the internal safety shield panel and remove the panel to gain access to the terminals.

4.Route and connect output cables from UPM 2 to MOB 2 in the UPM 1 UPS Sidecar. See Drawing 164201546-6, starting on page A-30, for UPS Sidecar wiring access information and terminal locations.

5.Connect phase A, B, and C, and Neutral power wiring from UPM 2 to MOB 2.

6.Route the output cables to the UPS Sidecar output terminals. See Drawing 164201546-6, starting on page A-30, for UPS Sidecar wiring access information and terminal locations.

7.Connect phase A, B, and C, and Neutral power wiring from the UPS Sidecar output terminals to the critical load.

8.After wiring the UPS system to the facility power and critical load, be sure to ground the system according to local and/or national electrical wiring codes.

9.If wiring interface connections, proceed to paragraph 2.4.5; otherwise, proceed to Step 10.

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

11.Reinstall the UPS Sidecar front panel and secure with the screw at the bottom of the panel.

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INSTALLING THE UPS SIDECAR

2.4.5Installing UPS Sidecar TB1 Interface Connections

NOTE When installing control wiring (such as Pull Chain and MOB auxiliary contacts) to the UPS Sidecar interface terminals, conduit must be installed between the the UPS cabinet or device and the UPS Sidecar, if wiring cannot be run through line-up-and-match cabinets. Install the control wiring in separate conduit from the power wiring.

1.Verify the UPS system is turned off and all power sources are removed. Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for shutdown instructions.

2.If not already removed, remove the screw securing the bottom of the UPS Sidecar front panel (see Figure 2-1 on page 2-3). Lift up the panel and remove.

3.If not already removed, remove the screws securing the internal safety shield panel and remove the panel to gain access to the terminals.

4.To locate the appropriate terminals, and for wiring and termination requirements, see Drawing 164201546-7, starting on page A-64, and refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for UPS cabinet terminal locations.

5.Route and connect the MOB monitoring auxiliary contact wiring from the UPS Sidecar to the UPMs.

6.Route and connect the CAN and backup control (pull chain) auxiliary contact wiring from the UPS Sidecar to the UPMs.

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

8.Reinstall the UPS Sidecar front panel and secure with screw at the bottom of the panel.

2.5Initial Startup

Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer, or the warranty terms specified on page 5-1 become void. This service is offered as part of the sales contract for the UPS system. Contact service in advance (usually a two-week notice is required) to reserve a preferred startup date.

2.6Completing the Installation Checklist

The final step in installing the UPS Sidecar is completing the following Installation Checklist. This checklist ensures that you have completely installed all hardware, cables, and other equipment. Completing all items listed on the checklist will ensure a smooth installation. Make a copy of the Installation Checklist before filling it out, and retain the original.

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

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

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INSTALLING THE UPS SIDECAR

Installation Checklist

-All conduits and cables are properly routed to the UPS Sidecar.

-All power cables are properly sized and terminated.

-UPS Sidecar auxiliary contact signal wiring is connected from the UPS Sidecar to the UPMs.

-A ground conductor is properly installed.

-Adequate workspace exists around the UPS Sidecar and other cabinets.

-Adequate lighting is provided around all UPS system equipment.

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

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INSTALLING THE UPS SIDECAR

Notes

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Section II

Operation

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Chapter 3

Understanding Operation

The UPS Sidecar can be configured for either maintenance bypass or parallel redundant operation.

3.1Maintenance Bypass Configuration

3.1.1UPS Mode

When the Maintenance Bypass switch (MBP) is open and the Maintenance Isolation switch (MIS) is closed, conditioned and protected power from the UPS is routed through the MIS to the critical load.

If the optional Bypass Input Breaker (BIB) is installed, power is supplied to the UPS through the BIB, and the UPS rectifier and bypass input terminals are jumpered together. If the optional BIB and Rectifier Input Breaker (RIB) are installed, the UPS rectifier is supplied power through the RIB and the UPS bypass is supplied power through the BIB, for a dual-feed system. In a single-feed system, the BIB and RIB input terminals are jumpered together and power is supplied to the UPS rectifier and bypass input terminals from a single source.

Figure 3-1 shows the path of electrical power through the UPS Sidecar when operating in UPS mode.

TO UPS RECTIFIER INPUT

TO UPS BYPASS INPUT

FROM UPS OUTPUT

AC INPUT

TO UPS

RIB

(OPTIONAL)

BIB (OPTIONAL)

AC INPUT TO BYPASS

MBP

MIS

UPS SIDECAR

MAIN POWER FLOW IN UPS MODE

MAIN POWER FLOW IN MAINTENANCE BYPASS MODE

OUTPUT TO CRITICAL LOAD

Figure 3-1. Path of Current Through the UPS Sidecar in UPS Mode

EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

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UNDERSTANDING OPERATION

3.1.2Maintenance Bypass Mode with UPS Sidecar

An MBP is used to safely supply utility power to the critical load during periods of UPS maintenance or repairs. The bypass source supplies the commercial AC power to the load directly.

When the MBP is closed, the load is wrapped around the UPS while power is still supplied to the load by the UPS through the MIS. The MIS is then opened, isolating the UPS from the Bypass power source. The UPS can be safely shut down and power removed from the UPS without interrupting power to the critical load. If the optional BIB and RIB are installed, the BIB and RIB are opened to remove power from the UPS. Otherwise, external upstream breakers are used to remove power. The UPS now can be serviced or replaced safely.

The critical load is not protected while the UPS is in Maintenance Bypass mode.

Figure 3-2 shows the path of electrical power through the UPS Sidecar when operating in Maintenance Bypass mode.

TO UPS RECTIFIER INPUT

TO UPS BYPASS INPUT

FROM UPS OUTPUT

AC INPUT

TO UPS

RIB

(OPTIONAL)

BIB (OPTIONAL)

AC INPUT TO BYPASS

MIS

MBP

UPS SIDECAR

OUTPUT TO CRITICAL LOAD

MAIN POWER FLOW IN UPS MODE

MAIN POWER FLOW IN MAINTENANCE BYPASS MODE

Figure 3-2. Path of Current Through the UPS Sidecar in Maintenance Bypass Mode

3.2Parallel Redundant Configuration

Refer to the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, for parallel theory of operation.

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EATON Powerware® 9390 UPS Sidecar Installation and Operation Manual S 164201586 Rev E www.powerware.com

Chapter 4

UPS Sidecar Features, Controls, and Operation

4.1UPS Sidecar Standard Features

The UPS Sidecar has many standard features that provide cost-effective and consistently reliable power distribution. The descriptions provide a brief overview of the UPS Sidecar controls, and standard and optional features.

4.1.1Maintenance Bypass Configuration

A Maintenance Bypass switch (MBP), in combination with the Maintenance Isolation switch (MIS), can be used to completely isolate the UPS during service. The UPS can be serviced or replaced without interrupting power to critical systems.

4.1.2Parallel Redundant Configuration

Module Output Breakers 1 and 2 enable two UPS modules to be paralleled together for redundancy. An optional System Load Breaker provides output control to the critical load for the whole system.

4.1.3Customer Interface

The UPS Sidecar uses one UPS building alarm input for Maintenance Bypass Switch Monitoring. The building alarm is used to detect when the Maintenance Bypass switch is closed and the system is on bypass.

4.1.4Installation Features

The UPS Sidecar is factory-installed to the side of the UPS cabinet. Power wiring can be routed through the top or bottom of the cabinet with connections made to easily accessible terminals. Parallel redundant modules can be installed in line-up-and-match or standalone configurations. Line-up-and-match cabinets are wired through the side panels of the units.

4.1.5Expansion

The UPS Sidecar supports custom configurations and scalability to adapt to changing and future power and distribution needs. See paragraph 4.2 for available options.

4.2Options

Contact your sales representative for information about any of these available options:

4.2.1Bypass Input Breaker (BIB)

Maintenance bypass configurations have an optional BIB for single-feed and dual-feed systems. The BIB provides a single point of input power control to the UPS and easily removes power from the UPS for servicing.

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4.2.2Rectifier Input Breaker (RIB)

Maintenance bypass configurations have an optional RIB for dual-feed systems. The RIB provides a single point of rectifier input power control to the UPS and easily removes power from the UPS for servicing.

4.2.3System Load Breaker (SLB)

Parallel redundant configurations with an optional SLB are available to control the output to the critical load for the whole system.

4.3Symbols

The following are examples of symbols used on the UPS Sidecar to alert you to important information:

ON - Indicates the circuit breaker is in the “On” position.

OFF - Indicates the circuit breaker is in the “Off” position.

PHASE - The word “phase.”

RISK OF ELECTRIC SHOCK - Indicates that a risk of electric shock is present and the associated warning should be observed.

CAUTION: REFER TO OPERATOR’S MANUAL - Refer to your operator’s manual for additional information, such as important operating and maintenance instructions.

This symbol indicates that you should not discard waste electrical or electronic equipment (WEEE) in the trash. For proper disposal, contact your local recycling/reuse or hazardous waste center.

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UPS SIDECAR FEATURES, CONTROLS, AND OPERATION

4.4UPS Sidecar Controls

Figure 4-1 through Figure 4-8 identify and show the location of the controls on the

Powerware 9390 UPS Sidecar.

NOTE Read the operation sections of this manual and the applicable Powerware 9390 installation and operation manual, listed in paragraph 1.5, and have thorough knowledge of UPS operation before attempting to operate any of the UPS Sidecar controls.

The UPS Sidecar can contain the following controls:

Maintenance Bypass Configuration

S Maintenance Bypass Switch (Standard)

S Maintenance Isolation Switch (Standard)

S Bypass Input Breaker (Optional)

S Rectifier Input Breaker (Optional)

Parallel Redundant Configuration

S Module Output Breaker 1 (Standard)

S Module Output Breaker 2 (Standard)

S System Load Breaker (Optional)

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UPS SIDECAR FEATURES, CONTROLS, AND OPERATION

 

Interlock Plate

Maintenance Isolation

Maintenance Bypass

Switch (MIS)

Switch (MBP)

Figure 4-1. UPS Sidecar Controls (Bypass) – 40/20, 40/30, 40/40 kVA, 480/480V with MBP and MIS

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UPS SIDECAR FEATURES, CONTROLS, AND OPERATION

Optional Rectifier Input

Breaker (RIB)

Optional Bypass Input

Breaker (BIB)

Interlock Plate

Maintenance Isolation

Maintenance Bypass

Switch (MIS)

Switch (MBP)

Figure 4-2. UPS Sidecar Controls (Bypass) – 40/20, 40/30, 40/40 kVA, 480/480V with Optional BIB and RIB

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UPS SIDECAR FEATURES, CONTROLS, AND OPERATION

Maintenance Bypass

Switch (MBP)

Interlock Plate

Maintenance Isolation

Switch (MIS)

Figure 4-3. UPS Sidecar Controls (Bypass) – 40/20, 40/30, 40/40 kVA, 208/208V and 80/40, 80/50, 80/60, 80/80 kVA and 120/100 and 120/120 kVA, 480/480V with MBP and MIS

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