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Eaton Power Xpert 9395 UPS, Installation And Operation Manual

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UPS Operating Instructions

Power Xpert 

TM 

9395 UPS (450–825 kVA) Installation and Operation Manual    164201725—Rev 10    

www.eaton.com/powerquality

7-41

2.

Transfer the UPSs to bypass by performing the procedure in paragraph 7.4.17.

3.

Perform the LOAD OFF procedure in paragraph 7.4.27.

The input, output, battery, and bypass backfeed contactors open, and the power module is turned off.

WARNING

Power is present inside the UPS cabinet until the upstream input feeder circuit breaker is opened.

4.

If the UPSs contain input breakers (CB1), open all UPS input breakers.

5.

Open the input and bypass feeder circuit breakers on all UPSs.

7.4.26 Charger Control

To turn the battery charger on:

1.

Press the 

CONTROLS

 pushbutton on the main menu bar. The System Status screen is displayed.

2.

On the System Status screen, select the 

CHARGER

 command.

3.

Press the 

CONTROLS

 pushbutton on the System Status menu bar. The Charger Control Command 

screen is displayed.

4.

On the Charger Control Command screen, select 

CHARGER ON

.

5.

Press the 

SELECT

 pushbutton on the Charger Command menu bar.

To turn the battery charger off:

1.

Press the 

CONTROLS

 pushbutton on the main menu bar. The System Status screen is displayed.

2.

On the System Status screen, select the 

CHARGER

 command.

3.

Press the 

CONTROLS

 pushbutton on the System Status menu bar. The Charger Control Command 

screen is displayed.

4.

On the Charger Control Command screen, select 

CHARGER OFF

.

5.

Press the 

SELECT

 pushbutton on the Charger Command menu bar.

7.4.27 Using the UPS LOAD OFF Pushbutton or Command

A UPS Load Off is initiated by the 

LOAD OFF

 pushbutton from the main menu bar, the Load Off command on 

the UPS Control Command screen, or the Load Off command on the Bypass Control Command screen. The 
UPS 

LOAD OFF

 controls the UPSs' outputs by powering down the UPS and de–energizing the critical load.

The UPSs (including Bypass) remain off until restarted.

To use the 

LOAD OFF

 pushbutton:

1.

Press the 

LOAD OFF

 pushbutton on the UPS to shut down.

The Load Off screen is displayed, providing a choice to proceed or abort the shutdown.

CAUTION

All power to the critical load is lost when the LOAD OFF is selected in the following step. You should use 
this feature only when you want to de–energize the critical load.

2.

To shut down the UPS, press 

LOAD OFF

 from the Load Off menu bar, and hold for three seconds. To abort 

the shutdown, press 

CANCEL

.

NOTE

The UPS Load Off controls each UPS independently and does not shut down the 

whole distributed bypass system unless all UPSs have been transferred to bypass. 

To immediately shut down the whole system, use the REPO switch (see 

paragraph 7.4.28).

Summary of Contents for Power Xpert 9395 UPS

Page 1: ...Power Xpert 9395 UPS Plus 1 UPS and 825 550 UPS 450 825 kVA Installation and Operation Manual For use with Two UPM 450 550 kVA Three UPM 650 825 kVA and Plus 1 650 825 kVA UPS Models ...

Page 2: ......

Page 3: ...Power Xpert 9395 UPS Plus 1 UPS and 825 550 UPS 450 825 kVA Installation and Operation Manual For use with Two UPM 450 550 kVA Three UPM 650 825 kVA and Plus 1 650 825 kVA UPS Models ...

Page 4: ...r vous y reporter ultérieurement RNING WARNING This is a product for restricted sales distribution to informed partners Installation restrictions or additional measures may be needed to prevent electromagnetic disturbances Eaton Powerware Powerware Hot Sync PowerXpert and X Slot are registered trademarks IBM and AS 400 are registered trademarks of International Business Machines Corporation Modbus...

Page 5: ...iable Module Management System and High Alert Modes 1 6 1 2 13 Monitoring and Communication 1 7 1 3 Battery System 1 7 1 4 Using This Manual 1 7 1 5 Conventions Used in This Manual 1 8 1 6 Symbols Controls and Indicators 1 9 1 7 For More Information 1 10 1 8 Getting Help 1 10 2 SAFETY WARNINGS 2 1 3 UPS INSTALLATION PLAN AND UNPACKING 3 1 3 1 Creating an Installation Plan 3 1 3 2 Preparing the Sit...

Page 6: ...nstalling an Optional Remote Monitor Panel II 5 8 5 5 Installing an Optional Relay Interface Module II 5 10 5 6 Installing an Optional Supervisory Contact Module II 5 12 5 7 Accessory Mounting Dimensions 5 15 6 UNDERSTANDING UPS OPERATION 6 1 6 1 UPS System Overview 6 1 6 2 Single UPS 6 2 6 2 1 Modes 6 2 6 2 2 Online Mode 6 2 6 2 3 Energy Saver System Mode 6 4 6 2 4 Harmonic Reduction System HRS 6...

Page 7: ... 17 Transfer from Online to Bypass Mode 7 21 7 3 18 Transfer from Bypass to Online Mode 7 22 7 3 19 Transfer from Online to Bypass Mode and Shut Down UPMs 7 22 7 3 20 Single UPM Shutdown 7 23 7 3 21 Single UPM Restart 7 23 7 3 22 UPS and Critical Load Shutdown 7 24 7 3 23 Charger Control 7 24 7 3 24 Using the UPS LOAD OFF Pushbutton or Command 7 25 7 3 25 Using the Remote Emergency Power off Switc...

Page 8: ...Maps Screen Online Mode 7 49 7 6 5 Power Maps Screen Bypass Mode 7 51 7 6 6 Command Confirmation Pop Up 7 51 7 6 7 Meters Summary Screen 7 52 7 6 8 Input Meters Screen 7 53 7 6 9 Input Meters Detail Screen 7 55 7 6 10 Battery Meters Screens 7 56 7 6 11 System Events Main Screen 7 58 7 6 12 User Log 7 58 7 6 13 System Status Screen and Controls 7 60 7 6 14 Settings Screen 7 62 7 6 15 Configuration ...

Page 9: ...ance 9 2 9 2 3 PERIODIC Maintenance 9 6 9 2 4 ANNUAL Maintenance 9 6 9 2 5 BATTERY Maintenance 9 6 9 3 Installing Batteries 9 7 9 4 Recycling the Used Battery or UPS 9 7 9 5 Maintenance Training 9 7 10 PRODUCT SPECIFICATIONS 10 1 10 1 Model Numbers 10 1 10 2 Specifications 10 1 10 2 1 UPS Input 10 1 10 2 2 UPS Output 10 2 10 2 3 UPS Environmental 10 2 WARRANTY W 1 ...

Page 10: ...vi Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality This page intentionally left blank ...

Page 11: ... Removing the Right Side Shipping Bracket 4 3 Figure 4 3 Removing the Three UPM Section Left Side Shipping Bracket 4 4 Figure 4 4 Removing the Three UPM Section Right Side Shipping Bracket 4 5 Figure 4 5 Removing the Two UPM Section Left Side Shipping Bracket 4 6 Figure 4 6 Removing the Two UPM Section Right Side Shipping Bracket 4 7 Figure 4 7 Section Joining Three UPM Section Shown 4 8 Figure 4 ...

Page 12: ...of the UPS System 6 1 Figure 6 2 Path of Current Through the UPS in Online Mode 6 3 Figure 6 3 Path of Current Through the UPS in Bypass Mode 6 6 Figure 6 4 Path of Current Through the UPS in Battery Mode 6 7 Figure 6 5 UPS System Three UPM Common Rectifier Feed Common Battery Dual Feed Configuration Continuous Static Switch 6 10 Figure 6 6 UPS System Three UPM Common Rectifier Feed Separate Batte...

Page 13: ...ystem Continuous Static Switch 3 1 and 4 0 Configurations 6 37 Figure 7 1 UPS Controls and Indicators Continuous Static Switch 7 1 Figure 7 2 UPS Control Panel 7 2 Figure 7 3 Parts of the LCD 7 4 Figure 7 4 Main Menu and Mimic Screen Online Mode 7 5 Figure 7 5 Load Off Screen 7 9 Figure 7 6 Typical System Status Screen 7 10 Figure 7 7 Load Off Screen 7 12 Figure 7 8 REPO Operation 7 26 Figure 7 9 ...

Page 14: ...1 Disable ESS Screen 7 64 Figure 7 42 HRS Metering Screen 7 64 Figure 7 43 High Alert Timer Screen 7 65 Figure 7 44 Statistics Basic Screen 7 65 Figure 7 45 Statistics Data Detail Screen 7 66 Figure 7 46 ESS Comparison Screen 7 66 Figure 7 47 UPS Module Map Screen 7 67 Figure 7 48 System Overview Screen 7 67 Figure 8 1 Optional X Slot Cards 8 1 Figure 8 2 Remote Monitor Panel II 8 3 Figure 8 3 Rel...

Page 15: ...ed bypass system see paragraph 1 2 5 The Power Xpert 9395 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 Power Xpert 9395 UPS continually monitors incoming electrical power and removes the surges spikes sags and other irregularities tha...

Page 16: ...0 www eaton com powerquality Figure 1 1 Power Xpert 9395 Three UPM UPS 650 825 kVA Figure 1 2 Power Xpert 9395 Plus 1 UPS 650 825 kVA with the Field Installed UPM UPM SECTION ISBM or IOM SECTION Older LCD Pushbutton Control Panel UPM SECTION FI UPM ISBM or IOM SECTION Older LCD Pushbutton Control Panel ...

Page 17: ... eaton com powerquality 1 3 Figure 1 3 Power Xpert 9395 825 550 Two UPM UPS 450 550 kVA Figure 1 4 Power Xpert 9395 825 550 Two UPM UPS with the Field Installed UPM 450 825 kVA UPM SECTION ISBM or IOM SECTION Color Touchscreen Control Panel UPM SECTION ISBM or IOM SECTION Color Touchscreen Control Panel ...

Page 18: ...onnectivity cards can be installed in the UPS module at any time X Slot cards are quickly installed at the front of the UPS and are hot pluggable See Chapter 8 Communication for additional information 1 1 4 Advanced Battery Management A three stage charging system increases battery service life by optimizing recharge time and protects batteries from damage due to high current charging and inverter...

Page 19: ...Card provides connectivity and operational mode control The distributed bypass system consists of two to five UPSs each with a parallel CAN card and a customer supplied tie cabinet or load distribution panel to act as a tie point All UPSs in the distributed bypass system must contain the same number of UPMs Mixed UPS kVA ratings are not permitted The tie cabinet must contain Module Output Breakers...

Page 20: ... extra set of sensors CTs on the output bus of the unit These sensors measure the harmonics created by loads attached to the UPS output and the system actively reduces these harmonics The system must be in ESS mode to activate HRS mode In HRS mode the inverter is ON the rectifier is OFF and the output contactor is CLOSED HRS is a normal operating mode not an alarm condition The NORMAL light appear...

Page 21: ...system is required to provide emergency short term backup power to safeguard operation during brownouts blackouts and other power interruptions The battery system should be equipped with lead acid batteries An external battery disconnect switch must be used The UPMs may be powered with either a common or separate battery system In a common battery system single and multiple UPMs are powered from o...

Page 22: ...pe or enter at a prompt l Italic type highlights notes and new terms where they are defined l Screen type represents information that appears on the screen or LCD 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 Icon Descripti...

Page 23: ...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 the UPS or the UPS batteries in the trash This product contains sealed lead acid batteries and must be disposed of properly For more information contact your local recycling reuse or hazardous waste center This sy...

Page 24: ...l 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 l Operation including controls functions of the standard and optional features procedures for using with the UPS and information about maintenance Refer to the Eaton 9395 Field Installed ...

Page 25: ...metal objects 2 Use tools with insulated handles 3 Do not lay tools or metal parts on top of batteries 4 Wear rubber gloves and boots l ELECTRIC ENERGY HAZARD Do not attempt to alter any battery wiring or connectors Attempting to alter wiring can cause injury l Do not open or mutilate batteries Released electrolyte is harmful to the skin and eyes It may be toxic CAUTION l Installation or servicing...

Page 26: ... inserted into the front or rear forklift slots for minor positioning if the forks are kept in a horizontal position with no upward angling l DO NOT use the forklift slots on the end of the cabinet to move the cabinet l End forklift slots may be used for minor positioning if the forks are kept in a horizontal position with no upward angling If these instructions are not followed damage to the wiri...

Page 27: ...Installation ...

Page 28: ......

Page 29: ...st a 1 8 F 1 0 C difference between the dry bulb temperature and the wet bulb temperature at all times to maintain a non condensing environment l The maximum rate of temperature change shall be limited to 3 F over 5 minutes 36 F hour based on the ASHRAE Standard 90 1 2013 Cautions regarding UPS operating environmental conditions The newer more energy efficient data center cooling methods such as a...

Page 30: ...configuration Weights are in kilograms pounds 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 Allow clearance in front of and above each cabinet for proper air circulation The clearances required around the UPS cabinet are shown in Table 3 2 Dimensions are in millimeters inches The basic enviro...

Page 31: ...t Output Voltage Heat Rejection BTU hr 1000 kg cal hr Ventilation Required for Cooling Air Exhaust Power Xpert 9395 825 450 450 kVA 400 400 87 21886 Approximately 1652 liter sec 3500 CFM With Field Installed UPM Approximately 2478 liter sec 5250 CFM 480 480 88 22107 Power Xpert 9395 825 500 500 kVA 400 400 96 24318 480 480 97 24563 Power Xpert 9395 825 550 550 kVA 400 400 106 26479 480 480 107 270...

Page 32: ... 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 3 1 UPS Cabinet Dimensions Three UPM Front View Figure 3 2 UPS Cabinet Dimensions Two UPM Front View Dimensions are in millimeters inches Dimensions are in millimeters inches ...

Page 33: ...stallation and Operation Manual 164201725 Rev 10 www eaton com powerquality 3 5 Figure 3 3 UPS Cabinet Dimensions Right Side View Figure 3 4 ISBM Section Dimensions Front View 871 7 34 3 830 32 7 40 1 6 Dimensions are in millimeters inches Dimensions are in millimeters inches ...

Page 34: ... 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 3 5 UPM Section Dimensions Three UPM Front View Figure 3 6 UPM Section Dimensions Two UPM Front View Dimensions are in millimeters inches Dimensions are in millimeters inches ...

Page 35: ...825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality 3 7 Figure 3 7 ISBM Section Dimensions Top View Figure 3 8 ISBM Section Dimensions Bottom View Front Dimensions are in millimeters inches Front Dimensions are in millimeters inches ...

Page 36: ... kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 3 9 UPM Section Dimensions Three UPM Top View Figure 3 10 UPM Section Dimensions Two UPM Top View Front Dimensions are in millimeters inches Front Dimensions are in millimeters inches ...

Page 37: ...llation and Operation Manual 164201725 Rev 10 www eaton com powerquality 3 9 Figure 3 11 ISBM Section Center of Gravity Continuous Static Switch Figure 3 12 UPM Section Center of Gravity Three UPM Dimensions are in millimeters inches CG Dimensions are in millimeters inches CG CG ...

Page 38: ... eaton com powerquality Figure 3 13 UPM Section Center of Gravity Two UPM Figure 3 14 Remote EPO Switch Dimensions Dimensions are in millimeters inches CG CG Dimensions are in millimeters inches 115 8 4 56 114 3 4 50 0 87 0 22 88 9 3 50 Front View 1 57 0 40 Needed to remove key 95 3 3 57 Square 1 2 Knockout Pattern Typical 5 Sides ...

Page 39: ...t uses three or four wires The rectifier feed into this equipment uses three wires The phases must be symmetrical about ground from a Wye source for proper equipment operation l If the load requires a neutral a bypass source neutral must be provided l DO NOT install both a source neutral and a bonding jumper See Table 3 9 for neutral bonding jumper wire sizes The bonding jumper must be copper wire...

Page 40: ... 825 kVA If the power rating listed on the nameplate of the installed UPS is not found in the following tables wire the UPS using the fully rated specifications Otherwise calculate the required wire conduit and breaker sizes using the following guidelines in addition to those already listed in paragraph 3 2 3 l Select wire size according to the UPS nameplate l Do not use wire larger than the large...

Page 41: ...ve 1 Negative C Total Amps 1280 1280 1503 1503 1600 1600 Minimum Conductor Size Number per Pole AWG or kcmil each 350 6 350 6 500 6 500 6 500 6 500 6 AC Output to Critical Load Four Wire Full Load Current 3 Phases 1 Ground D Amps 938 782 1083 902 1191 992 Minimum Conductor Size Number per Pole AWG or kcmil each 500 3 350 3 500 4 500 5 500 4 500 4 AC Output to Critical Load Five Wire Full Load Curr...

Page 42: ...51 Minimum Conductor Size Number per Pole AWG or kcmil each 250 3 250 3 250 3 250 3 250 3 250 3 AC Output to Critical Load Four Wire Full Load Current 3 Phases 1 Ground D Amps 938 782 1083 902 1191 992 Minimum Conductor Size Number per Pole AWG or kcmil each 500 3 350 3 500 4 500 3 500 4 500 4 AC Output to Critical Load Five Wire Full Load Current 3 Phases 1 Neutral 1 Ground D Amps 938 782 1083 90...

Page 43: ...d B Amps 650 541 722 601 794 662 Minimum Conductor Size Number per Phase AWG or kcmil each 500 4 AC Input to UPS Bypass Five Wire Full Load Current 3 Phases 1 Neutral 1 Ground B Amps 650 541 722 601 794 662 Minimum Conductor Size Number per Phase AWG or kcmil each 500 5 DC Input from Each Battery Disconnect to UPS 1 Positive 1 Negative C Total Amps 902 902 1002 1002 1103 1103 Minimum Conductor Siz...

Page 44: ...794 662 Minimum Conductor Size Number per Phase AWG or kcmil each 500 4 AC Input to UPS Bypass Five Wire Full Load Current 3 Phases 1 Neutral 1 Ground B Amps 650 541 722 601 794 662 Minimum Conductor Size Number per Phase AWG or kcmil each 500 5 DC Input from Each Battery Disconnect to Each UPS UPM 1 Positive 1 Negative C Amps per UPM 551 551 551 551 551 551 Minimum Conductor Size Number per Pole ...

Page 45: ...pert 9395 825 650 9395 825 750 and 9395 825 825 and the Two UPM Power Xpert 9395 825 450 9395 825 500 9395 825 550 Separate Battery Basic Unit Rating Units Rating 50 60 Hz Rating 50 60 Hz kVA kW 275 250 275 250 Input and Output Voltage Volts 400 480 AC Input to UPS Rectifier 0 98 Minimum pF Full load current plus battery recharge current 3 Phases 1 Ground A Amps 453 377 Minimum Conductor Size Numb...

Page 46: ...E4A UPM 3 Positive 6 stud mounting 2 per UPM 14 2 10 4 M8 1E5A UPM 1 2E5A UPM 2 3E5A UPM 3 Negative 6 stud mounting 2 per UPM 14 2 10 4 M8 Table 3 10 UPS Intercabinet Power Cable Terminations for the Three UPM Power Xpert 9395 825 650 9395 825 750 and 9395 825 825 and the Two UPM Power Xpert 9395 825 450 9395 825 500 9395 825 550 Continued Terminal Function Terminal Function Bus Landings Tightenin...

Page 47: ...76 56 M12 E5 Battery 4 2 bolt mounting 76 56 M12 Input and Output Neutral E12 Neutral 12 2 bolt mounting 22 16 M10 Customer Ground Ground Ground 15 1 bolt mounting 22 16 M10 NOTE V Customer ground sized in accordance with NEC Table 250 122 can be run in any conduit listed in Table 3 16 NOTE V Bypass terminations are not applicable to IOM configurations Table 3 12 UPS External Power Cable Terminati...

Page 48: ...d by Eaton Part Size Quantity Manufacturer Part Number Notes Long Barrel 2 Hole Lug 2 0 AWG As required Thomas Betts 54862BE Copper wire only 3 0 AWG Thomas Betts 54864BE 4 0 AWG Thomas Betts 54866BE 250 MCM Thomas Betts 54868BE 300 MCM Thomas Betts 54870BE 350 MCM Thomas Betts 54872BE 400 MCM Thomas Betts 54874BE 500 MCM Thomas Betts 54876BE Manual Hydraulic Crimp Tool 14 Ton 1 Thomas Betts TBM14...

Page 49: ...pert 9395 825 750 400 Vac AC Input to UPS Rectifier A B C Ground 4 3 4 AC Input to UPS Rectifier Separate Feed A B C Ground 4 2 3 Each UPM AC Input to Bypass and Output Four Wire A B C Ground 4 3 4 AC Input to Bypass and Output Five Wire A B C Neutral Ground 5 3 5 480 Vac AC Input to UPS Rectifier A B C Ground 4 3 4 AC Input to UPS Rectifier Separate Feed A B C Ground 4 2 2 Each UPM AC Input to By...

Page 50: ... Ground 5 3 5 DC All ratings Battery Positive Negative Ground See Note 1 NOTE 1 Select conduit taking into consideration the DC input wire sizes listed in Table 3 4 Table 3 5 Table 3 6 and Table 3 7 the DC terminations listed in Table 3 12 type of battery installation and requirements from NEC Table 4 Electrical Metallic Tubing EMT NOTE 2 Because of the future upgradability to a fully rated 825 kV...

Page 51: ...stomer Table 3 20 and Table 3 21 lists the maximum rating for continuous duty rated circuit breakers satisfying the criteria for both Recommended breaker size is based on a maximum full load discharge time less than 3 hours For longer discharge times a larger breaker may be required Table 3 18 Separate Rectifier Input Recommended Input Circuit Breaker Ratings UPS Model Input Rating for Each UPM Lo...

Page 52: ...mum l Use Class 2 wiring methods as defined by the NEC for interface wiring up to 30V l The wire should be rated at 24V 1A minimum l Use shielded twisted pair wires for each input and return or common l All interface wiring and conduit is to be provided by the customer Table 3 20 Recommended DC Input Circuit Breaker Ratings Common Battery UPS Model Input Rating 400V 480V Power Xpert 9395 825 650 1...

Page 53: ...nt trip wiring should be a minimum of 18 AWG l The REPO feature opens all contactors in the UPS cabinet and isolates power from your critical load Local electrical codes may also require tripping upstream protective devices to the UPS l The REPO switch must be a latching type switch not tied to any other circuits l A jumper wire must be connected between pins 1 and 2 onTB1 if the normally closed R...

Page 54: ...two optional ground schemes Both configurations comply with international safety regulations as seen on the UPS name plate 1 Internal reference generated through an earth reference Ground current will be equal to or less than 5 of the unit rating This takes the form of a UPS N bus to ground bond wire 2 Internally generated reference which avoids ground current By locating the center reference insi...

Page 55: ... WARNING The UPS cabinet is heavy see Table 3 1 If unpacking and unloading instructions are not closely followed the cabinet may tip and cause serious injury CAUTION To prevent damage to the wiring channel and wiring in the UPS cabinet base when lifting or moving the cabinet l Lift and move the cabinet using only the front or rear forklift slots l Verify that the forklift forks are in a horizontal...

Page 56: ... 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 4 Remove the protective covering from the cabinet 5 Remove the packing material and discard or recycle in a responsible manner 6 Inspect the contents for any evidence of physical damage and compare each item with the Bill of Lading If damage ...

Page 57: ...nstallation Plan and Unpacking Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality 3 29 Figure 3 15 UPS Cabinet as Shipped on Pallet ISBM Section ...

Page 58: ...lation Plan and Unpacking 3 30 Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 3 16 UPS Cabinet as Shipped on Pallet UPM Section Three UPM ...

Page 59: ...llation Plan and Unpacking Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality 3 31 Figure 3 17 UPS Cabinet as Shipped on Pallet UPM Section Two UPM ...

Page 60: ...UPS Installation Plan and Unpacking 3 32 Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality This page intentionally left blank ...

Page 61: ...ng only the front or rear forklift slots l Verify that the forklift forks are in a horizontal position before inserting them into the forklift slots DO NOT angle fork tips upward l Insert the forks all the way through the base DO NOT insert forks partially into the base to move the cabinet l Forks may be partially inserted into the front or rear forklift slots for minor positioning if the forks ar...

Page 62: ...Figure 4 5 Remove the left side shipping bracket If installing the cabinet permanently retain the shipping bracket and securing hardware for later use 3 Remove the three bolts securing the right side shipping bracket to the cabinet and three bolts securing the bracket to the pallet see Figure 4 2 Figure 4 4 or Figure 4 6 Remove the right side shipping bracket Figure 4 1 Removing the Left Side Ship...

Page 63: ...cedure raise the UPS cabinet section until the cabinet bottom clears the pallet by approximately 3 mm 1 8 5 Pull the pallet from under the UPS cabinet Discard or recycle the pallet in a responsible manner 6 Carefully lower the UPS cabinet until the cabinet base contacts the floor 7 Repeat Steps 2 through 6 for the remaining cabinet 8 Proceed to paragraph 4 5 Shipping Bracket Bolts Shipping Bracket...

Page 64: ...nstallation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 4 3 Removing the Three UPM Section Left Side Shipping Bracket Shipping Bracket Bolts Shipping Bracket Bolts Pallet Left Side Shipping Bracket UPM Removable Front Panels Wireway Panel ...

Page 65: ...PS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality 4 5 Figure 4 4 Removing the Three UPM Section Right Side Shipping Bracket Shipping Bracket Bolts Shipping Bracket Bolts Pallet Right Side Shipping Bracket ...

Page 66: ...Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 4 5 Removing the Two UPM Section Left Side Shipping Bracket Shipping Bracket Bolts Shipping Bracket Bolts Pallet Left Side Shipping Bracket UPM Removable Front Panels Wireway Panel ...

Page 67: ...er brackets at the top of the cabinet 3 Remove the screws securing the top and bottom internal safety shield panels and remove the panels Retain the hardware for later use 4 Remove the screws securing the corner channel and remove the channel see Figure 4 7 Retain the hardware for later use Shipping Bracket Bolts Shipping Bracket Bolts Pallet Right Side Shipping Bracket NOTE The following procedur...

Page 68: ...iring harnesses attached to the left side UPM section from damage 7 Using a forklift with the forks in the front forklift slots position the ISBM section adjacent to the left side of the previously installed UPM section Verify that the ISBM section right side is against the UPM section left side and the front of the cabinet bases are flush with each other see Figure 4 8 8 Reinstall the corner chan...

Page 69: ...n the holes in the flat brackets over holes in the top rear and top front of the ISBM and UPM sections Secure the brackets with the screws from the hardware kit see Figure 4 9 12 Locate one flat bracket and screws from the hardware kit Align the holes in the flat bracket over holes in the front base of the ISBM and UPM sections Secure the bracket with the screws from the hardware kit see Figure 4 ...

Page 70: ...terminals Retain the hardware for later use 4 Locate the AC and DC input intercabinet power wiring harnesses long cables labeled xG1 xG2 and xG3 Remove wire ties as necessary and uncoil the cables Front View Base Bracket UPM Section Base ISBM Section Base Bracket from Kit Screw from Kit Screw from Kit Top View Rear Bracket UPM Section Top ISBM Section Top Screw from Kit Screw from Kit Bracket from...

Page 71: ... UPMs terminals See Figure 4 10 for common rectifierfeed with CSS terminal locations 11 Using hardware from the intercabinet wiring terminal hardware kit see Table 3 11 connect phase A B and C and Neutral cable lug connections to the AC Output from UPMs terminals Follow the callout details in Figure 4 13 to connect the correct cable lug to the proper terminals See paragraph 3 2 3 for wiring and te...

Page 72: ...UPM section wireway see B in Figure 4 14 and connect the P70 connector to the J70 connector 20 In the UPM section see B in Figure 4 14 locate the coiled RJ 45 CAN cable Remove the wire ties securing the cable to the interior left side panel of the UPM section Route this cable through the round wiring access in the right side panel of the ISBM section see B in Figure 4 14 21 In the ISBM section loc...

Page 73: ...binet Power Terminal Locations Common Rectifier Feed Continuous Static Switch See Figure 4 11 for detail AC Input to UPMs AC Output from UPMs Phase C Phase A Phase B Neutral from UPMs See Figure 4 13 for detail See Figure 4 13 for detail Phase C Phase A Phase B See Figure 4 12 for detail AC Input Breaker CB1 DC Input to UPMs E5 See Figure 4 12 for detail DC Input to UPMs E4 ...

Page 74: ...arrel portion facing the back of the cabinet Install the second lug with the raised barrel portion facing the front of the cabinet UPM 2 Cable 2G1 2G2 Brown UPM 3 Cable 3G1 3G2 Brown Phase B E2A UPM 1 Cable 1G1 1G2 Brown Phase B E2A UPM 4 FI UPM AC Input to UPMs UPM 1 Cable 1G1 1G2 Yellow Phase C E3A UPM 2 Cable 2G1 2G2 Yellow UPM 3 Cable 3G1 3G2 Yellow UPM 4 FI UPM UPM 4 FI UPM UPM 1 Cable 1G1 1G...

Page 75: ...tery Input Power Terminal Detail DC Input to UPMs Cable 1G3 Black UPM 1 1E5A Cable 1G3 Black DC Input to UPMs Cable 1G3 Red UPM 1 1E4A Cable 1G3 Red Cable 2G3 Black UPM 2 2E5A Cable 2G3 Black Cable 3G3 Black UPM 3 3E5A Cable 3G3 Black Cable 2G3 Red UPM 2 2E4A Cable 2G3 Red Cable 3G3 Red UPM 3 3E4A Cable 3G3 Red Not used with Two UPM systems Not used with Two UPM systems ...

Page 76: ...aised barrel portion facing the front of the cabinet AC Output from UPMs UPM 1 Cable 1G4 1G5 Orange Phase A E9A UPM 2 Cable 2G4 2G5 Orange UPM 3 Cable 3G4 3G5 Orange UPM 1 Cable 1G4 1G5 Brown UPM 2 Cable 2G4 2G5 Brown UPM 3 Cable 3G4 3G5 Brown UPM 1 Cable 1G4 1G5 Yellow UPM 2 Cable 2G4 2G5 Yellow UPM 3 Cable 3G4 3G5 Yellow UPM 1 Cable 1G4 1G5 Gray UPM 2 Cable 2G4 2G5 Gray UPM 3 Cable 3G4 3G5 Gray ...

Page 77: ...uality 4 17 Figure 4 14 ISBM Section Battery Input Power Terminal Detail Wiring Access Location of J50 J51 J61 and J70 Coiled Harnesses Location of RJ 45 Coiled CAN Cable UPM Wireway Location of P61 Harness Location of P50 P51 and P70 Harnesses UPM Section Left Side View ISBM Section Right Side View A B Front Front Protective Cage ...

Page 78: ...allation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 4 15 Pl1 Interface Board Location Figure 4 16 J39 Location on Pl1 Interface Board ISBM Section Right Side Inside View Pl1 Interface Board Front Pl1 Interface Board J39 Inverter CAN Connector ...

Page 79: ...ly 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 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 bo...

Page 80: ...ut to the torque value listed in Table 3 12 Figure 4 17 Typical Bus Bar Barrel Lug Mounting Hardware Assembly Sequence NOTE Conical washers are special purpose washers that look similar to flat washers except for a slight conical shape When installing conical washers the top of the dome should be next to the nut and the base of the washer should be against a flat surface such as a bus bar flat was...

Page 81: ...ISBM section Identify all conduit requirements and mark their location Drill and punch all conduit holes in the top conduit plate prior to mounting on the ISBM section Install the conduit plate and install all conduit runs into the plate Pull wiring through conduit into the ISBM section wiring area Bottom Access Wiring Remove the bottom conduit plate from the inside bottom of the ISBM section Iden...

Page 82: ...rquality Figure 4 18 ISBM and UPM Section Debris Shields ISBM Section Front Ventilation Grill Debris Shields Remove shields before operating system Three UPM Section Front Two UPM Section Front Ventilation Grill Debris Shields Remove shields before operating system Ventilation Grill Debris Shield Remove shield before operating system ...

Page 83: ... Locations Top Entry Conduit Landing for AC Input and Output and DC Input Remove panel to drill or punch conduit holes TOP VIEW Interface Entry Conduit Landings for TB1 through TB3 Wiring and X Slot Connections Remove panels to drill or punch conduit holes Bottom Entry Conduit Landing for AC Input and Output and DC Input Remove panel to drill or punch conduit holes BOTTOM VIEW Front Front ...

Page 84: ...rnal wiring terminal hardware kit see Table 3 13 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 ISBM section See paragraph 3 2 3 for wiring and termination requirements 11 If wiring a distributed bypass system proceed to Step 12 otherwise proceed to Step 14 12 Using hardware from the exter...

Page 85: ...c Switch NOTE AC Input to Bypass terminals are not applicable to an IOM configuration See Figure 4 21 for Detail AA DC Input from Battery E4 E5 DC Input from Battery AC Input to UPS Rectifier A B C AC Input to UPS Bypass A B C See Figure 4 21 for Detail AA ISBM See Figure 4 22 or Figure 4 23 for Detail BB See Figure 4 22 or Figure 4 23 for Detail BB AC Output to Critical Load Phase C E11 Phase A E...

Page 86: ...nual 164201725 Rev 10 www eaton com powerquality Figure 4 21 ISBM Section Power Terminal Detail AA Common Rectifier Feed Continuous Static Switch Phase A E6 Phase C E8 Phase B E7 AC Input to UPS Rectifier Phase A E1 Phase C E3 Phase B E2 AC Input to UPS Bypass Front Section A A Ground Terminals ...

Page 87: ...ee Table 3 13 connect the positive negative and ground DC power wiring from the battery systems or disconnects to the ISBM section battery and ground terminals Use one set of terminals for each UPM as shown in Figure 4 23 See paragraph 3 2 3 for wiring and termination requirements 6 After wiring the UPS system to the facility power and critical load be sure to ground the system according to local ...

Page 88: ...er Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 4 22 UPS Power Terminal Detail BB Common Battery DC Input from Battery E4 E5 DC Input from Battery Section B B Front ...

Page 89: ...inal Detail BB Separate Battery DC Input from Battery E4 E5 DC Input from Battery DC Input from Battery E4 UPM 1 UPM 3 E5 DC Input from Battery UPM 2 Section B B Front E5 DC Input from Battery E5 DC Input from Battery UPM 1 DC Input from Battery E4 UPM 2 DC Input from Battery E4 UPM 3 UPM 4 FI UPM UPM 4 FI UPM Not used with Two UPM systems Not used with Two UPM systems ...

Page 90: ...o terminal block TB1 TB2 and the left interface entry conduit landing plates remove the screws securing the top internal safety shield panel and remove the panel Retain the hardware for later use see Figure 4 24 5 Remove the interface entry conduit landing plates to drill or punch holes see Figure 4 19 6 Reinstall the interface entry plates and install the conduit WARNING Do not directly connect r...

Page 91: ...tion and Operation Manual 164201725 Rev 10 www eaton com powerquality 4 31 Figure 4 24 ISBM Section Interface Terminal Locations X Slot Communication Bays TB3 TB1 and TB2 See Figure 4 25 for detail See Figure 4 27 for terminal assignments See Figure 4 30 for detail ISBM ...

Page 92: ...eral purpose normally closed NC relay contact 4 Alarm Relay Common 5 Alarm Relay NO Output General purpose normally open NO relay contact 6 Alarm Relay Common 7 Not Used 8 Not Used 9 Not Used 10 Not Used Terminal TB3 Name Description 1 Building Alarm 1 Input Programmable UPS alarm activated by a remote dry contact closure 2 Building Alarm 1 Return 3 Building Alarm 2 Input Programmable UPS alarm ac...

Page 93: ...E Alarm relay contacts have a maximum current rating of 5A and a switched voltage rating of 30 Vac and 28 Vdc NOTE Alarm relay normally open and normally closed return terminals are separated on the terminal board but are electrically in common NOTE Do not directly connect relay contacts to the mains related circuits Reinforced insulation to the mains is required NOTE Alarm relay wiring should be ...

Page 94: ...ng alarm inputs can be programmed for use with either normally open or normally closed contacts All control wiring and relay and switch contacts are customer supplied NOTE The building alarms can be programmed to display the alarm functional name NOTE A jumper wire must be connected between pins 1 and 2 on TB1 if the normally closed REPO contact is not used 1 10 1 10 TB1 TB2 Alarm Relay NC Alarm R...

Page 95: ...Table 4 1 and Figure 4 24 through Figure 4 29 6 Remove the UPS cabinet interface entry conduit landing plates to drill or punch holes see Figure 4 19 7 Reinstall the interface entry plates and install the conduit 8 Route the shunt trip optional and battery aux wiring from the battery disconnects to the UPS cabinet See Figure 4 19 for UPS wiring access information and terminal locations 9 Connect t...

Page 96: ...attery Breaker or Disconnect TB1 Battery Aux Battery Aux Common 48 Vdc Battery Shunt Trip 48 Vdc Battery Shunt Trip UPS ST 5 6 7 8 NOTE Battery Aux and DC Shunt Trip wiring should be a minimum of 18 AWG UPM 1 Battery Disconnect TB1 UPS ST UPM 2 Battery Disconnect ST UPM 4 Battery Disconnect ST UPM 3 Battery Disconnect ST 48 Vdc Battery Aux Battery Aux Return 48 Vdc Battery Shunt Trip 48 Vdc Batter...

Page 97: ...plates and install the conduit 5 Route and install the LAN telephone and other cables to the appropriate X Slot cards See Figure 4 24 and Figure 4 30 for X Slot communication bay locations 6 Close the front door and secure the latch 7 Refer to the manual supplied with the X Slot card for operator instructions Figure 4 30 X Slot Communication Bays NOTE LAN and telephone drops for use with X Slot ca...

Page 98: ... 1 4 Remove the door Remove the retaining screw located inside the door at the bottom hinge pivot point then lift the door off Retain the hardware for later use Figure 4 31 REPO Switch NOTE Before installing a REPO switch verify that the UPS was installed according to the instructions in paragraphs 4 2 through 4 9 NOTE When installing the REPO switch you must install conduit between the device and...

Page 99: ...ring from the REPO switch to the trip circuitry of the upstream protective devices A second contact block is provided on the REPO switch for this function see Figure 4 31 The REPO switch wiring must be in accordance with NEC Article 725 Class 2 requirements 13 Reinstall the top internal safety shield panel and secure with the retained hardware 14 Reinstall the front door removed in Step 4 and secu...

Page 100: ...minimum NOTE The REPO switch must be a latching type switch not tied to any other circuits NOTE REPO normally open and normally closed return terminals are separated on the terminal board but are electrically in common 1 2 3 NO UPS TB1 REPO Switch NO Twisted Wires 1 NC 2 Return 4 Return REPO Switch NC NOTE REPO switch rating is 24 Vdc 1A minimum NOTE The REPO switch must be a latching type switch ...

Page 101: ... the Installation Checklist The final step in installing the UPS system is completing the following Installation Checklist This checklist ensures that you have completely installed all hardware cables and other equipment Complete all items listed on the checklist to ensure a smooth installation Make a copy of the Installation Checklist before filling it out and retain the original After the instal...

Page 102: ...ning equipment is installed and operating correctly o The area around the installed UPS system is clean and dust free It is recommended that the UPS be installed on a level floor suitable for computer or electronic equipment o Adequate workspace exists around the UPS and other cabinets o Adequate lighting is provided around all UPS equipment o A 120 Vac service outlet is located within 7 5 meters ...

Page 103: ...rly routed to the UPS cabinets and to the tie cabinet or distribution panel o All power cables are properly sized and terminated o A ground conductor is properly installed o Controller Area Network CAN wiring between the UPS cabinets is properly installed o Pull chain wiring between the UPS cabinets is properly installed o Adequate workspace exists around the UPS cabinets the tie cabinet and other...

Page 104: ...________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _______________________________________...

Page 105: ... 1 wiring methods as defined by the NEC for interface and power wiring from 30 to 600V l Use Class 2 wiring methods as defined by the NEC for interface and power wiring up to 30V The wire should be rated at 24V 1A minimum l Signal wiring should be a minimum of 22 AWG and a maximum of 14 AWG The wire should be shielded twisted pair rated for 5A maximum Power wiring should be a minimum of 22 AWG and...

Page 106: ...ntact Module II to the UPS Figure 5 1 Powerware Hot Sync CAN Bridge Card To install the card 1 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS Operating Instructions for shutdown instructions 2 Unfasten the front door latch and swing the door open see Figure 4 1 3 Install the Powerware Hot Sync CAN Bridge Card into an open X Slot communication bay on the fro...

Page 107: ...scription 1 Alarm Programmable UPS alarm Activated by a remote dry contact closure 2 Alarm Return 3 Alarm Relay NC Normally closed contact opens when UPS is on bypass 4 Alarm Relay Com Bypass contact return 5 Alarm Relay NO Normally open contact closes when UPS is on bypass 6 TX RMP II RIM II and SCM II connections 7 TX 8 CAN L CAN Input for parallel operation 9 Can H 10 Shield Connections for Par...

Page 108: ...s See Figure 5 2 and Table 5 1 for the Powerware Hot Sync CAN Bridge Card terminal location and Figure 5 3 Figure 5 4 and Table 5 2 for wiring information 8 If a tie cabinet with Module Output Breakers MOBs is being wired proceed to Step 11 otherwise proceed to Step 9 9 Route and install distributed bypass system pull chain wiring between the UPS cabinets See Figure 5 5 and Table 5 3 for wiring in...

Page 109: ...es and is not a floor layout plan UPSs can be placed in any physical order Shielded Twisted Pair Shielded Twisted Pair Shielded Twisted Pair UPS 1 CAN Bridge Card J3 UPS 2 CAN Bridge Card J3 UPS 3 CAN Bridge Card J3 If Installed UPS 4 CAN Bridge Card J3 If Installed NOTE External CAN connections between UPSs require shielded twisted pair wire Table 5 2 CAN Bridge Card Wiring Terminations From UPS ...

Page 110: ...7 8 6 9 10 UPS 2 1 2 3 4 5 7 8 6 9 10 1 2 3 4 5 7 8 6 9 10 UPS 3 If Installed 1 2 3 4 5 7 8 6 9 10 1 2 3 4 5 7 8 6 9 10 1 2 3 4 5 7 8 6 9 10 Twisted Pair UPS 4 If Installed TB1 TB1 1 B T 1 B T 2 B T 2 B T 2 B T 2 B T NOTE Use twisted pair wiring between the UPS and MOB AUX contacts Table 5 3 Pull Chain Wiring Terminations From UPS 1 To UPS 2 To UPS 3 If Installed To UPS 4 If Installed TB2 1 Pull C...

Page 111: ...ed pair wiring between the UPS and MOB AUX contacts NOTE Always confirm contact operation prior to wiring 1 2 3 4 5 6 7 8 9 10 2 S P U 1 S P U 2 B T 2 B T 2 B T TB2 1 B T 1 B T 1 B T UPS 3 If Installed UPS 4 If Installed 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 7 8 9 10 7 8 9 10 7 8 9 10 7 8 9 10 TB1 AUX 1 AUX 2 Customer Supplied Tie Cabinet MOB 1 MOB 2 MOB 3 MOB 4 COM COM CO...

Page 112: ...TB2 1 Pull Chain MOB 1 Aux 2 NO Pull Chain UPS 1 TB2 2 Pull Chain Common UPS 2 TB2 2 Pull Chain Common Pull Chain Common UPS 2 CAN Bridge Card J3 1 Alarm MOB 2 Aux 1 NC MOB Open Alarm UPS 2 CAN Bridge Card J3 2 Alarm Return MOB 2 Aux 1 Com UPS 2 TB2 1 Pull Chain MOB 2 Aux 2 NO Pull Chain UPS 2 TB2 2 Pull Chain Common UPS 3 TB2 2 Pull Chain Common Pull Chain Common UPS 3 CAN Bridge Card J3 1 Alarm ...

Page 113: ... and wiring information 8 Install 120 Vac power wiring from the critical bus to the RMP II See Figure 5 7 Figure 5 8 and Table 5 5 for the terminal location and wiring information 9 Close the front door and secure the latch 10 Restart the UPS See Chapter 7 UPS Operating Instructions for startup instructions Figure 5 7 Remote Monitor Panel II and Remote Monitor Panel II Terminal Locations NOTE 120 ...

Page 114: ...t the problem contact an Eaton service representative for verification that the RMP II is working correctly 12 To test the indicator lamps press and hold the horn silence pushbutton for three seconds All lamps should illuminate and the horn sounds continuously until you release the pushbutton 5 5 Installing an Optional Relay Interface Module II To install RIM II wiring 1 Verify the UPS system is t...

Page 115: ...entative for verification and testing of the RIM II and its connections prior to making connections with J1 through J4 see Table 5 6 and Figure 5 9 You can order interface cables separately for connecting to the 15 Pin D Sub Connectors NOTE If mounting to a hollow wall secure the enclosure to a wood or metal stud within the wall Do not use hollow wall anchors NOTE When installing signal wiring for...

Page 116: ...it landing plate 6 Install conduit between the UPS and SCM II See Figure 5 14 for SCM II knockout hole location 7 Install wiring between the UPS and SCM II See Figure 5 2 and Table 5 1 for the Powerware Hot Sync CAN Bridge Card terminal location and wiring information and Figure 5 10 Figure 5 8 and Table 5 5 for the SCM II terminal location and wiring information 8 Install 120 Vac power wiring fro...

Page 117: ...or terminal block location and Figure 5 11 for terminal assignments 10 Close the front door and secure the latch 11 Restart the UPS See Chapter 7 UPS Operating Instructions for startup instructions NOTE Setup of the Powerware Hot Sync CAN Bridge Card must be performed by an authorized Eaton Customer Service Engineer Contact an Eaton service representative to schedule a date Ground Terminal Termina...

Page 118: ...ure 5 11 Supervisory Contact Module II TB2 NOTE Supervisory contacts are rated at 2 0A at 28 Vdc or 120 Vac and 0 15A at 115 Vdc NOTE Supervisory contacts require an external power supply Internal 24 Vdc is not capable of supplying contact current System Normal No Redundancy On Generator Bypass Not Available On Battery UPS Alarm On Bypass Shutdown Imminent ...

Page 119: ...g Dimensions Figure 5 12 through Figure 5 14 show the dimensions of the RMP II the RIM II and the SCM II Figure 5 12 Remote Monitor Panel II Dimensions Flush Mount using 10 Pan Head Screws Mount with vent holes facing up Surface Mount using 10 Pan Head Screws for Hanging Mount with vent holes facing up Knockouts Provided on Five Surfaces Dimensions are in millimeters inches ...

Page 120: ...201725 Rev 10 www eaton com powerquality Figure 5 13 Relay Interface Module II Dimensions Knockouts Provided on Five Surfaces Surface Mount using 10 Pan Head Screws for Hanging Mount with vent holes facing up Flush Mount using 10 Pan Head Screws Mount with vent holes facing up Dimensions are in millimeters inches ...

Page 121: ...Rev 10 www eaton com powerquality 5 17 Figure 5 14 Supervisory Contact Module II Dimensions Knockouts Provided on Five Surfaces Surface Mount using 10 Pan Head Screws for Hanging Mount with vent holes facing up Flush Mount using 10 Pan Head Screws Mount with vent holes facing up Dimensions are in millimeters inches ...

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Page 123: ...Section 2 Operation ...

Page 124: ......

Page 125: ...s the UPS allows you to either transfer to an alternative power system such as a generator or shut down your critical load in an orderly manner Figure 6 1 Main Elements of the UPS System The emergency bypass consists of a continuous static switch and a backfeed protection contactor K5 The bypass breaker if installed is located in parallel with the static switch The backfeed protection contactor is...

Page 126: ...ersion UPS but selectively shifts the load to fewer UPMs to increase the efficiency of the UPS l In Bypass mode the critical load is directly supported by utility power l In Battery mode the battery provides DC power which maintains inverter operation The battery supports the critical load The following paragraphs describe the differences in the UPS operating modes using block diagrams to show the...

Page 127: ...its If the UPS suffers an internal failure it switches automatically to Bypass mode and remains in that mode until the failure is corrected and the UPS is back in service Static Switch r e t r e v n I r e i f i t c e R K1 K3 Battery Converter Battery Battery Breaker Main Power Flow Trickle Current Energized De Energized Closed Open Breakers Contactors Static Switch K5 r e t r e v n I r e i f i t c...

Page 128: ...ut Total Demand Distortion TDD and increase the input power factor while maintaining high efficiency operation in ESS mode The UPS uses one of its UPMs to perform this active harmonic cancellation HRS mode uses an extra set of sensors CTs on the output bus of the unit These sensors measure the harmonics created by loads attached to the UPS output and the system actively reduces these harmonics HRS...

Page 129: ...our the UPS defaults back to VMMS mode If the High Alert command is received during the one hour the one hour timer will be restarted 6 2 6 Bypass Mode The UPS automatically switches to Bypass mode if it detects an overload load fault or internal failure The UPS can also be transferred from Online mode to Bypass mode manually The bypass source supplies the commercial AC power to the load directly ...

Page 130: ... a ten minute period The fourth transfer locks the critical load to the bypass source and requires operator intervention to transfer Static Switch K5 r e t r e v n I r e i f i t c e R K1 K3 Battery Converter Battery Battery Breaker Main Power Flow Trickle Current Energized De Energized Closed Open Breakers Contactors K2 Bypass Input Rectifier Input Output Bypass Breaker CB4 Input Breaker CB1 NOTE ...

Page 131: ...switch and rectifier snubber components to the utility source Figure 6 4 Path of Current Through the UPS in Battery Mode If the input power fails to return or is not within the acceptance windows required for normal operation the battery continues discharging until a DC voltage level is reached where the inverter output can no longer support the connected loads When this event occurs the UPS issue...

Page 132: ... 9395 825 550 400 480 400 480 Single Reverse Transfer UPS Two UPM Common Rectifier Feed Common Battery Dual Feed Configuration Continuous Static Switch Figure 6 10 on page 6 15 9395 825 450 9395 825 500 9395 825 550 400 480 400 480 Single Reverse Transfer UPS Two UPM Common Rectifier Feed Separate Battery Dual Feed Configuration Continuous Static Switch Figure 6 11 on page 6 16 9395 825 450 9395 8...

Page 133: ...fer UPS Three UPM Separate Rectifier Feed Separate Battery Dual Feed Configuration Continuous Static Switch Figure 6 21 on page 6 26 9395 825 650 9395 825 750 9395 825 825 400 480 400 480 Single Reverse Transfer UPS Three UPM Separate Rectifier Feed Separate Battery IOM Configuration Figure 6 22 on page 6 27 9395 825 650 9395 825 750 9395 825 825 400 480 400 480 Single Reverse Transfer UPS Four UP...

Page 134: ...PS CABINET Backfeed Contactor K5 AC Output to Critical Load E9 E10 E11 E12 Static Switch AC Input to UPS Rectifier 3 Wire A B C Rotation AC Input to Bypass 3 or 4 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Bat...

Page 135: ...10 E11 E12 Static Switch AC Input to UPS Rectifier 3 Wire A B C Rotation AC Input to Bypass 3 or 4 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K...

Page 136: ... E11 E12 Static Switch AC Input to UPS Rectifier 3 Wire A B C Rotation AC Input to Bypass 3 or 4 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 ...

Page 137: ...er Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 3 Battery Breaker E4 E5 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse ...

Page 138: ... DO NOT install both a source neutral and a bonding jumper UPS CABINET Backfeed Contactor K5 AC Output to Critical Load E9 E10 E11 E12 Static Switch AC Input to UPS Rectifier 3 Wire A B C Rotation AC Input to Bypass 3 or 4 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Inpu...

Page 139: ...eutral and a bonding jumper UPS CABINET Backfeed Contactor K5 AC Output to Critical Load E9 E10 E11 E12 Static Switch AC Input to UPS Rectifier 3 Wire A B C Rotation AC Input to Bypass 3 or 4 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contacto...

Page 140: ...ABINET Backfeed Contactor K5 AC Output to Critical Load E9 E10 E11 E12 Static Switch AC Input to UPS Rectifier 3 Wire A B C Rotation AC Input to Bypass 3 or 4 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 1 Battery...

Page 141: ...n AC Input to Bypass 3 or 4 Wire A B C Rotation Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 1 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Conta...

Page 142: ...oth a source neutral and a bonding jumper UPS CABINET AC Output to Critical Load E9 E10 E11 E12 AC Input to UPS Rectifier 3 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker BATTERY SYSTEM E4 E5 Battery Co...

Page 143: ...to Critical Load E9 E10 E11 E12 AC Input to UPS Rectifier 3 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery ...

Page 144: ... Critical Load E9 E10 E11 E12 AC Input to UPS Rectifier 3 Wire A B C Rotation Interface Board Battery Aux Remote EPO Building Alarms Alarm Relays Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Co...

Page 145: ... K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 3 Battery Breaker E4 E5 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 1 Bypass Breaker CB4 Battery Converter Inver...

Page 146: ...ation AC Input to Bypass 3 or 4 Wire A B C Rotation Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 3 Battery Breaker E4 E5 Battery Breaker E4 E5 Battery Conve...

Page 147: ... Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 3 Battery Breaker E4 E5 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 1 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 4 X Slot Interface 48V...

Page 148: ...ding jumper UPS CABINET Backfeed Contactor K5 AC Output to Critical Load E9 E10 E11 E12 Static Switch AC Input to UPS Rectifiers 3 Wire A B C Rotation AC Input to Bypass 3 or 4 Wire A B C Rotation Fuse Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 1 Battery Breaker E4 E5 Battery Converter Inverter Output C...

Page 149: ...tor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 1 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 4 X Slot Interface 48V Battery Shunt Trip Interface Board...

Page 150: ...ctifiers 3 Wire A B C Rotation Service Connector Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 2 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 3 Battery Breaker E4 E5 Battery Breaker E4 E5 Battery Converter Inverter Output Conta...

Page 151: ...5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 3 Battery Breaker E4 E5 Battery Breaker E4 E5 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse Fuse Fuse UPM 1 Battery Converter Inverter Output Contactor K3 Fuse Rectifier Input Contactor K1 Battery Contactor K2 Fuse F...

Page 152: ...DISTRIBUTION UNIT NOTE Ifi nstalling a maintenance bypass a minimum of two separate feeds with upstream feeder breakers or a single feed with two upstream feeder breakers must be provided one for the UPS or rectifier input breaker RIB ifi nstalled and one for the maintenance bypass input DO NOT use a single feed or a single feeder breaker to supply both the UPS or RIB and the maintenance bypass If...

Page 153: ...ry communication path This arrangement ensures bypass control even if the CAN bus is lost The system is paralleled for redundancy 1 1 in a system where two UPMs are paralleled together and the load is less than the supporting capability of one of the UPMs The system is paralleled for capacity 2 0 if both UPMs in a system are required to support the load A parallel capacity system can also be redun...

Page 154: ...ystem event that requires immediate intervention The following paragraphs describe the differences in the parallel system operating modes using block diagrams to show the power flow during each mode of operation 6 4 2 Online Mode Distributed Bypass In Online mode utility AC power is supplied to the UPSs Each UPS then conditions the incoming AC power and provides clean regulated AC power to the tie...

Page 155: ...m dynamically updates the redundancy calculation to determine if the remaining UPSs can support the load If the load can be supported the system does not switch to bypass Figure 6 25 shows the path of electrical power through the parallel system when operating in Bypass mode In a distributed bypass system each UPS operates similar to a single UPS but in parallel with each other The bypass source f...

Page 156: ...urce and requires operator intervention to transfer Bypass mode is a normal operating mode not an alarm condition However if the distributed bypass system is unable to return to Online mode following an automatic transfer to Bypass mode an alarm condition is recorded Bypass may also be used when the UPSs or UPMs in the system must be shut down to perform routine maintenance or repairs In the Paral...

Page 157: ...perating mode until the input power to the rectifier is again within the specified voltage or frequency acceptance windows If the input power fails to return or is not within the acceptance windows required for normal operation the battery continues discharging until a DC voltage level is reached where the inverter output can no longer support the shared loads When this event occurs each UPS issue...

Page 158: ...Bypass System Oneline Configurations The distributed bypass system oneline drawings in this section show the simplified internal structure of the UPS battery supply and basic maintenance bypass in a multiple UPS configuration These onelines do not show each UPM in the UPSs but represent each UPS in the distributed bypass system The internal structure of each UPS is shown in Figure 6 12 through Fig...

Page 159: ... Not supplied with the UPS C E9 E10 E11 E12 D Battery Breaker Battery Converter Inverter K3 Fuse Rectifier K1 K2 Fuse Fuse Fuse E6 E7 E8 E12 K5 Static Switch Fuse E1 E2 E3 CB1 optional UPS 2 A B E4 E5 BATTERY SYSTEM Not supplied with the UPS C E9 E10 E11 E12 D A AC Input to UPS Rectifier B AC Input to Bypass C DC Input from Battery D UPS AC Output to Tie Cabinet E Output to Critical Load Overcurre...

Page 160: ...r K1 K2 Fuse Fuse Fuse E6 E7 E8 E12 K5 Static Switch Fuse E1 E2 E3 CB1 optional UPS 2 A B E4 E5 BATTERY SYSTEM Not supplied with the UPS C E9 E10 E11 E12 D Battery Breaker Battery Converter Inverter K3 Fuse Rectifier K1 K2 Fuse Fuse Fuse E6 E7 E8 E12 K5 Static Switch Fuse E1 E2 E3 CB1 optional UPS 3 A B E4 E5 BATTERY SYSTEM Not supplied with the UPS C E9 E10 E11 E12 D NOTE This oneline does not sh...

Page 161: ...YSTEM Not supplied with the UPS C E9 E10 E11 E12 D Battery Breaker Battery Converter Inverter K3 Fuse Rectifier K1 K2 Fuse Fuse Fuse E6 E7 E8 E12 K5 Static Switch Fuse E1 E2 E3 CB1 optional UPS 3 A B E4 E5 BATTERY SYSTEM Not supplied with the UPS C E9 E10 E11 E12 D Battery Breaker Battery Converter Inverter K3 Fuse Rectifier K1 K2 Fuse Fuse Fuse E6 E7 E8 E12 K5 Static Switch Fuse E1 E2 E3 CB1 opti...

Page 162: ...Understanding UPS Operation 6 38 Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality This page intentionally left blank ...

Page 163: ... the controls and indicators Figure 7 1 UPS Controls and Indicators Continuous Static Switch NOTE Before starting the UPS ensure all installation tasks are complete and a preliminary startup has been performed by authorized service personnel The preliminary startup verifies all electrical interconnections to ensure the installation was successful and the system operates properly NOTE Read this sec...

Page 164: ...The following paragraphs describe the UPS control panel including controls and indicators and how to monitor UPS operation The control panel see Figure 7 2 is located on the front door of the UPS Figure 7 2 UPS Control Panel The control panel consists of l A liquid crystal display LCD 1 l A horizontal row of pushbutton switches 2 l A vertical column of status indicators 3 See paragraph 7 2 1 The f...

Page 165: ... than Online Only the Online indicator is visible during normal UPS system operation The other indicators illuminate to indicate alarms or events When an alarm occurs first check these indicators to see what type of event has taken place For descriptions of the status indicators see paragraph 7 2 1 l System Event Messages When a system event occurs a message appears on the LCD in the UPS status ar...

Page 166: ... control panel pushbutton once Shown is a typical alarm message For more information about alarms and notices see paragraph 7 2 2 B The information area contains data about UPS status and operations C The menu bar lists the titles of the available screens To select a screen press the pushbutton underneath the desired screen D The navigation pushbuttons function depending on the screen displayed Us...

Page 167: ... Map Menu Option Description EVENTS Displays the list of Active System Events and a historical log of system events METERS Displays performance meters for the system or critical load CONTROLS Displays the System Status screen SETUP Allows you to set the display contrast set the date and time for the time stamp configure the UPS serial communication ports and view the firmware version numbers LOAD ...

Page 168: ...n the main menu bar to display the Meter screens To scroll through the meter screens press the up or down arrow pushbutton on the menu bar The current UPS readings are displayed in the information area of the screen Output UPS Output UPM The Output screen shows output voltage phase to neutral output current each phase and frequency being supplied by the UPS as well as the kVA kW and power factor m...

Page 169: ...t power line disturbances are monitored The time can be set in 10 minute increments from 0 to 990 minutes Select STORM DETECTION TIMER from the Energy Saver System Setup screen to display the Storm Detection Timer screen Use the up or down arrow pushbutton to set the time Press SAVE or ABORT Once the action is completed the Energy Saver System Setup screen is displayed High Alert Timer The High Al...

Page 170: ...rmat then press the SELECT pushbutton to display the Set Date and Time screen To return to the System Setup screen press the ESC pushbutton Set Date and Time MM DD YYYY The Set Date and Time MM DD YYYY screen allows the internal date and time of the UPS to be set in the month day year format The date and time information is used for display on the screen and for logging events in the Event and His...

Page 171: ...n Online operation transfer to bypass charger control UPM startup and shutdown and LOAD OFF commands are controlled through this screen In addition the screen displays the current status of the UPS indicates whether the UPS is in Maintenance Bypass or Bypass and displays the state of the UPM and battery charger Figure 7 6 shows the System Status screen Use the or pushbutton on the System Status me...

Page 172: ...g Online Charger Off Online Charging Table 7 5 Command Menu Operation Function Subfunction Operation UPS Control Commands Use the up or down arrow pushbutton to highlight the command function desired then press the SELECT pushbutton to execute the command or proceed to further command screens Go to Online Starts the UPS in Online mode or transfers the UPS to Online mode from Bypass mode Enable Dis...

Page 173: ...de Load Off Displays the Load Off screen see paragraph 7 2 7 Charger Control Commands Use the up or down arrow pushbutton to highlight the command function desired then press the SELECT pushbutton to execute the command Charger On Turns the battery charger on Charger Off Turns the battery charger off UPM Control Commands Use the up or down arrow pushbutton to highlight the command function desired...

Page 174: ...splayed when the LOAD OFF pushbutton is selected from the main menu bar the UPS Control Command screen or the Bypass Control Command screen This screen allows the LOAD OFF process to be aborted if the LOAD OFF pushbutton was pressed accidentally For Load Off procedures see paragraph 7 3 24 or paragraph 7 4 27 Figure 7 7 Load Off Screen HOLD LOAD OFF BUTTON FOR 3 SECONDS TO TURN OFF LOAD LOAD OFF C...

Page 175: ...he UPS command 13 Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed 14 On the UPS Control Command screen select GOTO ONLINE 15 Press the SELECT pushbutton on the UPS Command menu bar If Auto Bypass is enabled factory default the critical load is immediately supplied by the bypass source in Bypass mode until the inverter turns on and the UPS tra...

Page 176: ...RGY SAVER 5 Press the SELECT pushbutton on the UPS Command menu bar The UPS transfers to Battery mode and then to Online mode The Online status indicator is illuminated The UPS status indicates ONLINE The UPM status indicates ONLINE 7 3 4 Start Energy Saver System High Alert Mode from the UPS Command Menu To start High Alert mode 1 Press the CONTROLS pushbutton on the main menu bar The System Stat...

Page 177: ...s the UPS calculates the required number of UPMs needed to support the load The Online status indicator is illuminated The UPS status indicates ONLINE VMMS The UPM status indicates ONLINE 7 3 6 Disable Variable Module Management System Mode from the UPS Command Menu To disable Variable Module Management System mode 1 Press the CONTROLS pushbutton on the main menu bar The System Status screen is di...

Page 178: ...ritical load is not protected from commercial power interruptions and abnormalities 1 Unfasten the front door latch and swing the door open see Figure 4 2 2 If the UPS contains input breaker CB1 verify that input breaker CB1 is open 3 Close the UPS input feeder circuit breaker 4 Close the UPS Bypass input feeder circuit breaker 5 If the UPS contains input breaker CB1 close input breaker CB1 6 Clos...

Page 179: ...rgy Saver System mode 1 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed 2 On the System Status screen select the BYPASS command 3 Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed 4 On the Bypass Control Command screen select DISABLE ENERGY SAVER 5 Press the SELECT pushbutton on the Bypass Command men...

Page 180: ...em Status screen is displayed 2 On the System Status screen select the BYPASS command 3 Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed 4 On the Bypass Control Command screen select ENABLE VAR MODULE MANAGEMENT 5 Press the SELECT pushbutton on the Bypass Command menu bar If the UPS is online the UPS transfers to Variable Module Management ...

Page 181: ...d screen select START HIGH ALERT 5 Press the SELECT pushbutton on the Bypass Command menu bar If the UPS is online the UPS starts High Alert mode with the UPMs online supplying the critical load After one hour the UPS transfers to Variable Module Management System mode The Online status indicator is illuminated The UPS status indicates HIGH ALERT The UPM status indicates ONLINE The power module is...

Page 182: ...reen select UPM ON 19 Press the SELECT pushbutton on the UPM 1 Command menu bar 20 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 1 rectifier and inverter turn on If UPM 4 FI UPM is installed and the Inherent Redundancy option is enabled a loss of redundancy alarm will be issued Silence the alarm an...

Page 183: ...bar The UPM Control Command screen is displayed 18 On the UPM Control Command screen select UPM ON 19 Press the SELECT pushbutton on the UPM Command menu bar 20 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM rectifier and inverter turn on 21 To transfer the UPM to Online mode press the CONTROLS push...

Page 184: ...rm sounds The Online status indicator is illuminated The UPS status indicates ONLINE The UPM status indicates ONLINE 7 3 19 Transfer from Online to Bypass Mode and Shut Down UPMs To transfer the critical load to Bypass mode and shut down the UPMs 1 Transfer the critical load to bypass by performing the procedure in paragraph 7 3 17 2 Press the CONTROLS pushbutton on the main menu bar The System St...

Page 185: ...M Control Command screen is displayed 9 On the UPM Control Command screen select UPM OFF 10 Press the SELECT pushbutton on the UPM Command menu bar The UPM status indicates READY The input output and battery contactors open and the power module remains on The remaining UPMs supply the critical load 11 To turn off the power module press the CONTROLS pushbutton on the UPS Control Command menu bar Th...

Page 186: ... powered by the UPS 2 Perform the LOAD OFF procedure in paragraph 7 3 24 The input output battery and bypass backfeed contactors open and the power module is turned off WARNING Power is present inside the UPS cabinet until the upstream input feeder circuit breaker is opened 3 If the UPS contains input breaker CB1 open the UPS input breaker CB1 4 Open the UPS input and bypass feeder circuit breaker...

Page 187: ... the system after Load Off until the cause of the shutdown has been identified and cleared 3 To restart the UPS after pressing the LOAD OFF pushbutton follow the procedure in paragraph 7 3 1 or 7 3 8 WARNING Power is present inside the UPS cabinet until the upstream input feeder circuit breaker is opened To use the LOAD OFF command 1 Press the CONTROLS pushbutton on the main menu bar The System St...

Page 188: ...sh the red pushbutton until it locks into place The switch latches into the activated state see Figure 7 8 The input output and bypass backfeed contactors open the battery breaker or disconnect is tripped and the power module is turned off immediately without asking for verification CAUTION Do not attempt to restart the system after the REPO until the cause of the shutdown has been identified and ...

Page 189: ...are active 13 On the System Status screen select the UPS command 14 Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed 15 On the UPS Control Command screen select GOTO ONLINE 16 Press the SELECT pushbutton on the UPS Command menu bar If Auto Bypass is enabled factory default the critical load is immediately supplied by the bypass source in Bypas...

Page 190: ...RGY SAVER 5 Press the SELECT pushbutton on the UPS Command menu bar The UPS transfers to Battery mode and then to Online mode The Online status indicator is illuminated The UPS status indicates ONLINE The UPM status indicates ONLINE 7 4 4 Start Energy Saver System High Alert Mode from the UPS Command Menu To start High Alert mode 1 Press the CONTROLS pushbutton on the main menu bar The System Stat...

Page 191: ...s the UPS calculates the required number of UPMs needed to support the load The Online status indicator is illuminated The UPS status indicates ONLINE VMMS The UPM status indicates ONLINE 7 4 6 Disable Variable Module Management System Mode from the UPS Command Menu To disable Variable Module Management System mode 1 Press the CONTROLS pushbutton on the main menu bar The System Status screen is di...

Page 192: ...tem is not available and the critical load needs to be energized CAUTION In Bypass mode the critical load is not protected from commercial power interruptions and abnormalities 1 Unfasten the front door latches and swing the doors open on all of the UPSs 2 If the UPSs contain input breakers CB1 verify that all input breakers are open 3 Close all MOBs 4 Close all UPS input feeder circuit breakers 5...

Page 193: ...the power module is off 7 4 10 Disable Energy Saver System Mode from the Bypass Command Menu To disable Energy Saver System mode 1 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed 2 On the System Status screen select the BYPASS command 3 Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed 4 On the Bypass...

Page 194: ...em Status screen is displayed 2 On the System Status screen select the BYPASS command 3 Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed 4 On the Bypass Control Command screen select ENABLE VAR MODULE MANAGEMENT 5 Press the SELECT pushbutton on the Bypass Command menu bar If the UPS is online the UPS transfers to Variable Module Management ...

Page 195: ...TART HIGH ALERT 5 Press the SELECT pushbutton on the Bypass Command menu bar If the UPS is online the UPS starts High Alert mode with the UPMs online supplying the critical load After one hour the UPS transfers to Variable Module Management System mode The Online status indicator is illuminated The UPS status indicates HIGH ALERT The UPM status indicates ONLINE The power module is on 7 4 15 Starti...

Page 196: ... select UPM ON 19 Press the SELECT pushbutton on the UPM 1 Command menu bar 20 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM 1 rectifier and inverter turn on If UPM 4 FI UPM is installed and the Inherent Redundancy option is enabled a loss of redundancy alarm will be issued Silence the alarm and co...

Page 197: ... The UPM Control Command screen is displayed 18 On the UPM Control Command screen select UPM ON 19 Press the SELECT pushbutton on the UPM Command menu bar 20 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM rectifier and inverter turn on 21 To transfer the UPM to Online mode press the CONTROLS pushbut...

Page 198: ...LINE The UPM status indicates ONLINE 7 4 19 Transfer from Online to Bypass Mode and Shut Down UPMs To transfer the critical load to Bypass mode and shut down all UPMs 1 Transfer the critical load to bypass by performing the procedure in paragraph 7 4 17 2 Press the CONTROLS pushbutton on the main menu bar The System Status screen is displayed 3 If UPM 4 FI UPM is installed proceed to Step 4 otherw...

Page 199: ...PM OFF 10 Press the SELECT pushbutton on the UPM Command menu bar The UPM status indicates READY The input output and battery contactors open and the power module remains on The remaining UPMs supply the critical load 11 To turn off the power module press the CONTROLS pushbutton on the UPS Control Command menu bar The UPM Control Command screen is displayed 12 On the UPM Control Command screen sel...

Page 200: ...S command 4 Press the CONTROLS pushbutton on the System Status menu bar The Bypass Control Command screen is displayed 5 On the Bypass Control Command screen select GOTO BYPASS 6 Press the SELECT pushbutton on the Bypass Command menu bar The UPS being shut down transfers to Bypass mode The BYPASS status indicator is illuminated The Bypass status indicates ON The UPM status indicates READY The powe...

Page 201: ... proceed to Step 8 otherwise proceed to Step 12 8 On the System Status screen select the UPM command The UPS Control Command screen is displayed 9 On the UPS Control Command screen select the UPM 1 command 10 Press the CONTROLS pushbutton on the UPS Control Command menu bar The UPM 1 Control Command screen is displayed 11 Proceed to Step 14 12 On the System Status screen select the UPM command 13 ...

Page 202: ...fy no alarms are active on UPS being restarted 11 Verify the External Communications Failure alarm has cleared and no other alarms are active on the online UPSs 12 On the System Status screen select the UPS command 13 Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed 14 On the UPS Control Command screen select GOTO ONLINE 15 Press the SELECT pu...

Page 203: ... screen select the CHARGER command 3 Press the CONTROLS pushbutton on the System Status menu bar The Charger Control Command screen is displayed 4 On the Charger Control Command screen select CHARGER OFF 5 Press the SELECT pushbutton on the Charger Command menu bar 7 4 27 Using the UPS LOAD OFF Pushbutton or Command A UPS Load Off is initiated by the LOAD OFF pushbutton from the main menu bar the ...

Page 204: ...ushbutton on the System Status menu bar The UPS or Bypass Control Command screen is displayed 4 On the Control Command screen select LOAD OFF 5 Press the SELECT pushbutton on the Command menu bar The Load Off screen is displayed providing a choice to proceed or abort the shutdown CAUTION All power to the critical load is lost when LOAD OFF is selected in the following step You should use this feat...

Page 205: ... off immediately without asking for verification on all UPSs CAUTION Do not attempt to restart the system after the REPO until the cause of the shutdown has been identified and cleared 2 To deactivate the REPO switch in preparation for restarting the UPS insert the supplied key and rotate clockwise until the red pushbutton releases see Figure 7 8 To remove the key rotate the key back to the vertic...

Page 206: ...ructions 7 44 Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 7 9 UPS Color Touchscreen Control Panel Typical Color Touchscreen Control Panel ISBM ...

Page 207: ...ure 7 10 UPS Color Touchscreen Control Panel Typical The color touchscreen control panel consists of l A color liquid crystal touch screen display 1 l A horizontal row of LED indicators 2 Before system power up the panel displays a system status screen similar to the one shown in Figure 7 10 When the unit powers up the screen displays as shown in Figure 7 10 When power is applied to the system the...

Page 208: ...igure 7 12 Figure 7 11 Parts of the Touch Screen Table 7 6 Status Indicators Indicator Status Description Green Lit Steady The UPS is in Online mode operating normally The power module is supplying power to the critical load Yellow Lit Steady The UPS is in Battery mode Because Battery mode is a normal condition of the UPS the Online indicator also remains illuminated Yellow Lit Steady The UPS is i...

Page 209: ...scrolling when the system needs attention Some notices and alarms may be accompanied by an audible horn To silence the horn touch anywhere on the control panel once For more information about alarms and notices see paragraph 7 6 12 B The information area contains data about UPS status and operations C After touching the padlock in the upper right corner the numerical keypad appears to allow entry ...

Page 210: ...e system or critical load CONTROLS Allows access to various system performance control screens POWER MAPS Allows operator to observe system power flow LOGS Allows access to system information logs STATISTICS Allows access to see system specific operation values SETTINGS Allows access to various screen controlled variables for system operation Level 0 1 and 2 are for user operator Level 3 is used o...

Page 211: ... Menu and Power Maps screen The Power Maps screen displays immediately after entering the access code The Power Maps screen shows a real time graphical representation of the operating status Figure 7 14 Main Menu and Power Maps Screen Online Mode Touching the LOAD kVA button displays the Output kVA screen shown in Figure 7 15 Figure 7 15 Output kVA Screen from Home Screen Figure 7 15 Figure 7 16 F...

Page 212: ...25 Rev 10 www eaton com powerquality Touching the AVERAGE EFFICIENCY button displays the system efficiency screen shown in Figure 7 16 Figure 7 16 Average Efficiency Screen from Home Screen Touching the CONSUMPTION button displays the screen shown in Figure 7 17 Figure 7 17 Consumption Screen from Home Screen ...

Page 213: ...screen shows a real time graphical representation of the operating status Touching any of the buttons on the right side of the screen takes the user directly to that information screen Figure 7 18 Bypass Screen 7 6 6 Command Confirmation Pop Up Figure 7 19 is an example of a command request confirmation pop up screen This type of pop up allows the user to confirm that the requested command is vali...

Page 214: ...rall System status The three left items in the OVERVIEW section of the screen are not active buttons but are status detail panels They show individual conditions of the UPS at that time The two items at the far right of the OVERVIEW section are active buttons They can be selected to show a profile of efficiency or consumption over various time periods of 24 hours 7 days 30 days or 1 year This is t...

Page 215: ... powerquality 7 53 7 6 8 Input Meters Screen Figure 7 21 shows the Input Meters screen This screen displays the individual phase and total power values of the system Figure 7 21 Input Meters Screen The Bypass Meters Screen shown in Figure 7 22 displays values pertaining to the Bypass conditions Figure 7 22 Bypass Meters Screen ...

Page 216: ...er Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality The Output Meters Screen shown in Figure 7 23 displays values pertaining to the system output Figure 7 23 Output Meters Screen ...

Page 217: ...nput Meters detail screen This screen displays the individual values of the system in additional detail The Bypass Output and Battery meters screens display similar values relevant to their monitoring of the system Figure 7 24 Input Meters Detail Screen The Select Source screen shown in Figure 7 25 allows the operator to choose the individual source for system readings Figure 7 25 Select Source Sc...

Page 218: ...Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality 7 6 10 Battery Meters Screens Figure 7 26 shows the Battery Meters basic screen Figure 7 27 shows the Battery Log access screen Figure 7 26 Battery Meters Screen Figure 7 27 Battery Log Screen ...

Page 219: ...825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality 7 57 Figure 7 28 shows the Battery Log Detail screen Figure 7 29 shows the Battery Log Summary screen Figure 7 28 Battery Log Detail Figure 7 29 Battery Log Summary Screen ...

Page 220: ...ommands l System Event Horns The system event horn beeps to alert an operator that an event needing attention is taking place The horn cycles at a half second rate l System Event Indicators The status indicators on the UPS control panel work with the event horn to let the operator know when the UPS is operating in any mode other than normal Only the ON indicator is visible during normal UPS system...

Page 221: ... to the number shown to the right of the box Each window shows five events The operator can also use the UP DOWN arrows above and below the blue field 2 showing the number of events in the log See Figure 7 31 Figure 7 31 User Log Screen Selecting an event opens the Event Detail screen shown in Figure 7 32 This screen details the specifics of the event for the user to see Figure 7 32 User Log Detai...

Page 222: ...bypass UPM start up and shutdown and LOAD OFF commands are controlled through this screen In addition the screen displays the current status of the UPS indicates whether the UPS is in Maintenance Bypass or Bypass and displays the state of the UPM Figure 7 33 shows the System Status screen Figure 7 33 System Status Screen Figure 7 34 shows the Module Controls screen This screen allows control of th...

Page 223: ...les shown on the previous screen Figure 7 34 the user can observe full details of an individual module It also allows the user to move through various modules and modes while within this screen Figure 7 35 Module Control Detail Screen The Metering Method screen allows the operator to select line to line or line to neutral monitoring values See Figure 7 36 or Figure 7 37 Figure 7 36 Online Mode Met...

Page 224: ...hod Option Screen 7 6 14 Settings Screen The screen shown in Figure 7 38 gives the operator access to basic system information such as serial number installed firmware version etc Touching the CLEAN SCREEN button disables the screen for 30 seconds to allow the user to safely clean the screen without affecting operation Figure 7 38 Settings Screen Indicates an Event System on Bypass ...

Page 225: ...ffect changes to various system values Figure 7 39 Configuration Options Screen 7 6 16 Energy Advantage Architecture EAA Screen This screen shown in Figure 7 40 allows the operator to activate the various energy saving and power efficiency modes of the system The various Energy Advantage Architecture operations are described in the UPS Installation and Operation manual for your system Figure 7 40 ...

Page 226: ...eration Manual 164201725 Rev 10 www eaton com powerquality Figure 7 41 Disable ESS Screen This screen shown in Figure 7 41 asks the operator to verify disabling the ESS mode running at that time Figure 7 42 HRS Metering Screen The screen shown in Figure 7 42 shows the HRS metering values ...

Page 227: ...7 65 Figure 7 43 High Alert Timer Screen This screen shown in Figure 7 43 asks the operator if they want to start the High Alert mode timer 7 6 17 Statistics Basic Screen The screen shown in Figure 7 44 allows the operator to query the system for various operational statistics such as shown in Figure 7 45 Figure 7 44 Statistics Basic Screen ...

Page 228: ...allation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 7 45 Statistics Data Detail Screen 7 6 18 ESS Comparison Screen The screen shown Figure 7 46 allows the operator to visually obtain EAA mode efficiency values Figure 7 46 ESS Comparison Screen ...

Page 229: ...www eaton com powerquality 7 67 7 6 19 UPS Module Map Screen The screen shown Figure 7 47 allows the operator to control the individual UPMs Figure 7 47 UPS Module Map Screen 7 6 20 System Overview Screen The screen shown Figure 7 48 displays values for all UPS and UPM parameters Figure 7 48 System Overview Screen ...

Page 230: ...the UPS control panel indicates the UPS is in Bypass mode If Auto Bypass is not enabled the UPS output remains off until the UPS transfers to Online mode 14 The UPS START UP screen appears The rectifier and inverter turn on The inverter continues to ramp up to full voltage When the inverter reaches full voltage the UPS output contactor K3 closes and the static switch turns off Power is now supplie...

Page 231: ...o a Building Management System BMS using the Modbus RTU protocol l Relay Interface Card AS 400 has isolated dry contact Form C relay outputs for UPS status Utility failure Low battery UPS alarm OK or On bypass when interfacing with IBM AS 400 computers other relay connected computers and industrial applications l Industrial Relay Card IRC indicates the operating status of the UPS system using the ...

Page 232: ... eNotify Service contact www eaton com enotify The eNotify Service relies on a Power Xpert Gateway card installed with the UPS sending one way status and event e mails to Eaton Remote Monitoring servers that analyze and store the data Those servers also take the appropriate actions of sending notifications and reports The PXGX Connectivity Card gathers information from the UPS directly and from an...

Page 233: ...face terminal board You can use a normally closed or normally open contact If the state of the contact changes from the state you specify as normal a signal is issued You can connect this contact to equipment at your facility such as a light or an alarm bell to let you know when an alarm is active on the UPS This feature is useful if the UPS is located in a remote area where the UPS horn may not b...

Page 234: ...r ON BYPASS The bypass source is supplying the critical load Usually this means that the UPS is not energized The load is not protected in Bypass mode and a horn sounds after 30 seconds UPS ALARM The UPS system is issuing an alarm Conditions that affect the current UPS mode are indicated by the indicators and horn on the UPS ON BATTERY The UPS battery backup is supplying the critical load The util...

Page 235: ... 15 pin connectors labeled J1 through J4 Figure 8 3 Relay Interface Module II The RIM II can provide the status and alarm signals shown in Table 8 2 Table 8 2 Customer Interface Connectors Status J1 through J4 Description UPS AVAILABLE Pins 1 and 12 Contacts are closed when the UPS is operating in Online mode or ready to supply the load UPS OFFLINE Pins 3 and 13 Contacts are open when the UPS is o...

Page 236: ...an be flush mounted or surface mounted on a desktop or secured to a wall Figure 8 4 shows the SCM II Figure 8 4 Supervisory Contact Module II The SCM II provides signals for the indications shown in Table 8 3 Table 8 3 SCM II Status Indicators and Connections Indication TB2 Connections SYSTEM NORMAL TB2 1 through TB2 3 NO REDUNDANCY TB2 4 through TB2 6 ON GENERATOR TB2 7 through TB2 9 BYPASS NOT A...

Page 237: ...trical state of any cabinet in the UPS system Because each battery string is an energy source in itself opening the battery circuit breaker does not de energize the voltage within the battery string DO NOT ATTEMPT TO ACCESS ANY INTERNAL AREA OF THE BATTERY STRING YOURSELF VOLTAGES ARE ALWAYS PRESENT IN THE BATTERY STRING If you suspect that a battery string needs service contact an Eaton service r...

Page 238: ...ons and Table 9 1 for filter sizes Contact an Eaton service representative for replacement filters To remove the filters CAUTION Verify washed filters are thoroughly dry before reinstalling a Remove one top screw and two bottom screws securing each UPM front panel see Figure 4 3 Lift each panel straight up to remove it from the panel hanger bracket at the top of the cabinet b Remove one top screw ...

Page 239: ...395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality 9 3 Figure 9 1 ISBM Section Air Filter Locations Bottom Left ISBM Air Filters Bottom Right ISBM Air Filters Middle Right ISBM Air Filter ...

Page 240: ...UPS Maintenance 9 4 Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality Figure 9 2 Two UPM Section Air Filter Locations UPM Air Filters ...

Page 241: ... screw and two bottom screws securing the FI UPM front panel refer to the Eaton 9395 Field Installed UPM Mechanical Installation Manual Lift the panel straight up to remove it from the panel hanger bracket at the top of the cabinet b Pull the foam filter over the screw heads on the cabinet mounted studs and remove the filter from the cabinet CAUTION Verify washed filter is thoroughly dry before re...

Page 242: ...onnections Maintenance procedures should specify that the bolted connections be retorqued to values listed in this manual 9 2 4 ANNUAL Maintenance Annual preventive maintenance should be performed only by authorized service personnel familiar with maintenance and servicing of the UPS system Contact an Eaton service representative for more information about service offerings 9 2 5 BATTERY Maintenan...

Page 243: ...NTION l Une batterie peut prêsenter un risque de choc êlectrique de brulure ou d incendie Suivre les précautions qui s imposent l Pour le remplacement utiliser le même nombre et modéle des batteries l L élimination des batteries est règlementée Consulter les codes locaux à cet effet CAUTION Do not discard the UPS or the UPS batteries in the trash This product contains sealed lead acid batteries an...

Page 244: ...UPS Maintenance 9 8 Power Xpert TM 9395 UPS 450 825 kVA Installation and Operation Manual 164201725 Rev 10 www eaton com powerquality This page intentionally left blank ...

Page 245: ...Power Xpert 9395 825 750 three UPM 750 kVA 50 60 Hz Power Xpert 9395 825 825 three UPM 825 kVA 50 60 Hz Power Xpert 9395 825 450 two UPM 450 kVA 50 60 Hz Power Xpert 9395 825 500 two UPM 500 kVA 50 60 Hz Power Xpert 9395 825 550 two UPM 550 kVA 50 60 Hz Operating Input Voltage 400 Vac 480 Vac Operating Input Frequency Range 50 60 Hz Operating Input Current See Table 3 4 Table 3 5 Table 3 6 Table 3...

Page 246: ... Frequency Slew Rate 1 Hz per second maximum Load Compatibility 0 9 pF Leading 0 8 pF Lagging Overload Capability 110 for 10 minutes 125 for 30 seconds 150 for 10 seconds NOTE The 110 overload capability in the above table is based on the kVA label rating of the UPS The 125 and 150 overloads are based on the non derated hardware capability of the UPS Operating Temperature 0 to 40 C 32 to 104 F wit...

Page 247: ...han the date indicated on the packaging b shipping and delivery of the Product if shipping is FOB Factory c neglect accident fire flood lightning vandalism acts of God Customer s neglect abuse misuse misapplication incorrect installation d repair or alteration not authorized in writing by Eaton personnel or performed by an authorized Eaton Customer Service Engineer or Agent or e improper testing o...

Page 248: ...unts COSTS NOT RELATED TO WARRANTY The End User shall be invoiced for and shall pay for all services not expressly provided for by the terms of this Warranty including without limitation site calls involving an inspection that determines no corrective maintenance is required Any costs for replacement equipment installation materials freight charges travel expenses or labor of Eaton representatives...

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