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TABLE OF CONTENTS

Power Xpert

 9395 UPS (450–550 kVA) Installation and Operation Manual  

  164201701 Rev 3

 www.eaton.com/powerquality

v

List of Figures

Figure 1‐2. Eaton Power Xpert 9395 Plus 1 UPS (450–550 kVA) Cabinet with the Field Installed UPM

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Figure 3‐1. UPS Cabinet Dimensions (Front View)

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Figure 3‐2. UPS Cabinet Dimensions (Right Side View)

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Figure 3‐3. UPS Cabinet Dimensions (Top View)

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Figure 3‐4. UPS Cabinet Dimensions (Bottom View)

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Figure 3‐5. UPS Cabinet Dimensions (Bottom View with Mounting Brackets)

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Figure 3‐6. UPS Cabinet Center of Gravity

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Figure 3‐7. Remote EPO Switch Dimensions

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Figure 3‐8. Eaton 9395 UPS (450–550 kVA) Cabinet as Shipped on Pallet

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Figure 4‐1. Removing the Left Side Shipping Bracket

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Figure 4‐2. Removing the Right Side Shipping Bracket

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Figure 4‐3. Typical Bus Bar Barrel Lug Mounting – Hardware Assembly Sequence

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Figure 4‐4. Conduit and Wire Entry Locations

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Figure 4‐5. Distributed Bypass Wire Length

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Figure 4‐6. UPS Power Terminal Locations – Common Rectifier Feed

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Figure 4‐7. UPS Power Terminal Detail AA – Common Rectifier Feed

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Figure 4‐8. UPS Power Terminal Locations – Separate Rectifier Feed

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Figure 4‐9. UPS Power Terminal Detail AA – Separate Rectifier Feed

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Figure 4‐10. UPM Rectifier Input Power Terminal Block Detail

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Figure 4‐11. UPS Power Terminal Detail BB – Common Battery

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Figure 4‐12. UPS Power Terminal Detail BB – Separate Battery

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Figure 4‐13. Interface Terminal Locations

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Figure 4‐14. Interface Terminal Detail

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Figure 4‐15. Typical Alarm Relay Connection

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Figure 4‐16. Terminal Blocks TB1, TB2, and TB3 Connector Assignments

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Figure 4‐17. Typical Battery Interface Connection – Common Battery System

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Figure 4‐18. Typical Battery Interface Connection – Separate Battery System

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Figure 4‐19. X-Slot Communication Bays

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Figure 4‐20. REPO Switch

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Figure 4‐21. Normally-Open REPO Switch Wiring

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Figure 4‐22. Normally‐Closed REPO Switch Wiring

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Figure 4‐23. Normally‐Closed and Normally‐Open REPO Switch Wiring

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Figure 5‐1. Powerware Hot Sync CAN Bridge Card

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Figure 5‐2. Powerware Hot Sync CAN Bridge Card Connections

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Figure 5‐3. Distributed Bypass System CAN and Pull-Chain Simplified Interface Wiring

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Figure 5‐4. Distributed Bypass System UPS CAN Wiring without MOBs

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Figure 5‐5. Distributed Bypass Pull-Chain Wiring without MOBs

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Figure 5‐6. Distributed Bypass Pull-Chain Wiring with MOBs

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Figure 5‐7. Remote Monitor Panel II and Remote Monitor Panel II Terminal Locations

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Figure 5‐8. Remote Monitor Panel II, Relay Interface Module II, or Supervisory Contact Module II Wiring

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Figure 5‐9. J1, J2, J3, and J4 15-Pin D-Sub Connectors

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Figure 5‐10. Supervisory Contact Module II Terminal Location

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Figure 5‐11. Supervisory Contact Module II TB2

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Figure 5‐12. Remote Monitor Panel II Dimensions

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Figure 5‐13. Relay Interface Module II Dimensions

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Figure 5‐14. Supervisory Contact Module II Dimensions

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Figure 6‐1. Main Elements of the UPS System

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Summary of Contents for Power Xpert Plus 1

Page 1: ...Power Xpert 9395 UPS and Plus 1 UPS 450 550 kVA Installation and Operation Manual...

Page 2: ...NG This is a product for restricted sales distribution to informed partners EN IEC 62040 2 Installation restrictions or additional measures may be needed to prevent electromagnetic disturbances Eaton...

Page 3: ...ttery System 1 7 1 4 Basic System Configurations 1 7 1 5 Using This Manual 1 8 1 6 Conventions Used in This Manual 1 8 1 7 Symbols Controls and Indicators 1 9 1 8 For More Information 1 10 1 9 Getting...

Page 4: ...ace Module II 5 11 5 5 Installing an Optional Supervisory Contact Module II 5 12 5 6 Accessory Mounting Dimensions 5 15 Section II Operation 6 Understanding UPS Operation 6 1 6 1 UPS System Overview 6...

Page 5: ...and 7 23 7 3 23 Using the Remote Emergency Power off Switch 7 25 7 4 Multiple UPS Distributed Bypass Operation 7 26 7 4 1 Starting the Distributed Bypass System in Online Mode 7 26 7 4 2 Starting the...

Page 6: ...7 General Purpose Relay Contact 8 7 8 8 Remote Monitor Panel II 8 7 8 9 Relay Interface Module II 8 9 8 10 Supervisory Contact Module II 8 10 9 UPS Maintenance 9 1 9 1 Important Safety Instructions 9...

Page 7: ...Separate Battery 4 17 Figure 4 13 Interface Terminal Locations 4 19 Figure 4 14 Interface Terminal Detail 4 21 Figure 4 15 Typical Alarm Relay Connection 4 21 Figure 4 16 Terminal Blocks TB1 TB2 and...

Page 8: ...17 Figure 6 15 Plus 1 UPS System Separate Rectifier Feed Separate Battery Dual Feed Configuration 6 18 Figure 6 16 UPS System Separate Rectifier Feed Separate Battery IOM Configuration 6 19 Figure 6...

Page 9: ...utility power Working with a building s electrical system the UPS system supplies clean consistent power that sensitive electronic equipment requires for reliable operation During brownouts blackouts...

Page 10: ...DUCTION Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 1 2 ISBM or IOM SECTION UPM SECTION Figure 1 1 Power Xpert 9395 UPS 450 550 kVA Ca...

Page 11: ...95 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 1 3 ISBM or IOM SECTION UPM SECTION FI UPM Figure 1 2 Power Xpert 9395 Plus 1 UPS 450 550 kVA Cabinet wi...

Page 12: ...ion 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 inver...

Page 13: ...the customer All sources that feed the separate rectifier inputs must be from a common ground point 1 2 7 Distributed Bypass System There are two types of redundancy UPS based based on the number of...

Page 14: ...to bypass 1 2 10 Energy Saver and High Alert Modes Energy Saver mode allows the UPS to operate in Bypass mode In this mode the UPS is operating on bypass with the UPMs in standby ready to automatical...

Page 15: ...le UPMs are each powered from separate battery sources UPMs in distributed bypass and parallel systems must use a separate battery system A supplemental 48 Vdc shunt trip signal for the battery discon...

Page 16: ...each procedure before beginning the procedure Perform only those procedures that apply to the UPS system being installed or operated 1 6 Conventions Used in This Manual This manual uses these type con...

Page 17: ...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 U...

Page 18: ...tion and Operation Manual for the following additional information Installation instructions including site preparation planning for installation and wiring and safety information Detailed illustratio...

Page 19: ...urrent The following precautions should be observed 1 Remove watches rings or other metal objects 2 Use tools with insulated handles 3 Do not lay tools or metal parts on top of batteries 4 Wear rubber...

Page 20: ...nsert forks partially into the base to move the cabinet Forks may be partially inserted into the front or rear forklift slots for minor positioning if the forks are kept in a horizontal position with...

Page 21: ...Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 2 1 Section I Installation...

Page 22: ...Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 2 2...

Page 23: ...and understand how this manual applies to the system being installed Use the procedures and illustrations in paragraph 3 2 and Chapter 4 to create a logical plan for installing the system 3 2 Prepari...

Page 24: ...2 UPS Cabinet Clearances From Top of Cabinet 457 2 mm 18 minimum clearance for ventilation From Front of Cabinet 914 4 mm 36 working space From Back of Cabinet None Required From Right Side of Cabinet...

Page 25: ...ements During Full Load Operation Rating Input Output Voltage Heat Rejection BTU hr 1000 kg cal hr Ventilation Required for Cooling Air Exhaust 450 kVA 400 400 87 21886 Approximately 1652 liter sec 35...

Page 26: ...550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 3 4 Dimensions are in millimeters inches Figure 3 2 UPS Cabinet Dimensions Right Side View Front Dimensions are in...

Page 27: ...lation and Operation Manual 164201701 Rev 3 www eaton com powerquality 3 5 Front Dimensions are in millimeters inches Figure 3 4 UPS Cabinet Dimensions Bottom View Front Dimensions are in millimeters...

Page 28: ...3 8 1873 8 73 8 830 32 7 929 4 36 6 1140 2 44 9 435 2 17 1 CG CG Dimensions are in millimeters inches Figure 3 6 UPS Cabinet Center of Gravity Dimensions are in millimeters inches 115 8 4 56 114 3 4 5...

Page 29: ...r 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 If the load requires a neutral a bypass sou...

Page 30: ...ommon ground point On a UPS configured as an Input Output Module IOM requirements for bypass input wiring termination conduit and bypass breaker are not applicable A Field Installed UPM FI UPM is alwa...

Page 31: ...e AWG or kcmil each 350 3 4 0 3 350 3 4 0 3 350 3 350 3 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...

Page 32: ...3 250 3 500 3 300 3 500 3 300 4 DC Input from Each Battery Cabinet to Each UPS UPM or Each Battery Disconnect 1 Positive 1 Negative C Total Amps 902 902 1002 1002 1103 1103 Minimum Conductor Size Num...

Page 33: ...iring Requirements for the 9395 550 450 9395 550 500 and 9395 550 550 Separate Battery Basic UPM Rating Units Rating 50 60 Hz kVA kW 275 250 275 250 Input Voltage Volts 400 480 AC Input to each UPM Re...

Page 34: ...olt mounting 76 56 M12 E3 Phase C 4 2 bolt mounting 76 56 M12 AC Input to Bypass E6 Phase A 4 2 bolt mounting 76 56 M12 E7 Phase B 4 2 bolt mounting 76 56 M12 E8 Phase C 4 2 bolt mounting 76 56 M12 AC...

Page 35: ...80200001 07 NOTE Bypass terminations are not applicable to IOM configurations Table 3 10 Recommended Installation Parts and Tools Not Supplied by Eaton Part Size Quantity Manufacturer Part Number Note...

Page 36: ...ur Wire A B C Ground 4 2 1 2 3 AC Input to Bypass and Output Five Wire A B C Neutral Ground 5 2 1 2 3 DC Battery Positive Negative Ground See Note 1 Power Xpert 9395 550 500 480 Vac AC Input to UPS Re...

Page 37: ...700A Power Xpert 9395 550 550 80 Rated 1200A 1000A 100 Rated 1000A 800A Table 3 14 Separate Rectifier Input Recommended Input Circuit Breaker Ratings UPS Model Input Rating for Each UPM Load Rating 4...

Page 38: ...ould be installed between the battery and the UPS External DC input overcurrent protection and disconnect switch for the remote battery location is to be provided by the customer Table 3 16 lists the...

Page 39: ...t terminals route the wiring through the internal opening in the X Slot communication bay All building alarm inputs or remote features require an isolated normally open contact or switch rated at 24 V...

Page 40: ...T install both a source neutral and a bonding jumper See Table 3 7 for neutral bonding jumper wire sizes The bonding jumper must be copper wire Eaton UPS systems are designed to operate with two optio...

Page 41: ...s heavy see Table 3 1 on page 3 2 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 wiri...

Page 42: ...m vertical or the cabinet may tip over 3 Set the pallet on a firm level surface allowing a minimum clearance of 3m 10 ft on each side for removing the cabinet from the pallet NOTE The UPS cabinet is s...

Page 43: ...TION PLAN AND UNPACKING Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 3 21 Figure 3 8 Power Xpert 9395 UPS 450 550 kVA Cabinet as Shippe...

Page 44: ...UPS INSTALLATION PLAN AND UNPACKING Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 3 22 This page intentionally left blank...

Page 45: ...1 on page 3 2 If unpacking and unloading instructions are not closely followed the cabinet may tip and cause serious injury CAUTION Do not tilt cabinets more than 10 from vertical Lift the cabinet onl...

Page 46: ...Figure 4 2 Remove the right side shipping bracket If installing the cabinet permanently retain the shipping bracket and securing hardware for later use 4 Using the forklift raise the UPS cabinet secti...

Page 47: ...550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 4 3 Shipping Bracket Bolts Shipping Bracket Bolts Pallet Left Side Shipping Bracket UPM Removable Front Panels Fig...

Page 48: ...VA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 4 4 Shipping Bracket Bolts Shipping Bracket Bolts Front Door Removable Left Front Panel Pallet Right Side Shipping Brack...

Page 49: ...an be bypassed while the remaining UPMs support the load as long as the remaining UPMs have the capacity to do so If installing a distributed bypass system install the customer supplied tie cabinet or...

Page 50: ...cal 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 washer or large terminal Hex Nut Conical Washer Lug Bus Bar...

Page 51: ...rea Bottom Access Wiring Remove the bottom conduit plate from the inside bottom of the UPS Identify all conduit requirements and mark their location Drill and punch all conduit holes in the bottom con...

Page 52: ...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 Ventilation Grill Debris Shield...

Page 53: ...UPS cabinet See paragraph 3 2 2 on page 3 7 for wiring and termination requirements 11 If wiring a distributed bypass system proceed to Step 12 otherwise proceed to Step 14 CAUTION Distributed bypass...

Page 54: ...proper operation the following must be true 1A 2A 3A 4A 1B 2B 3B 4B NOTE Any difference in wire length will result in decreased capacity of the UPS system while on bypass For example a 10 difference...

Page 55: ...t from Battery E4 E5 DC Input from Battery E12 Neutral AC Input to UPS Rectifier A B C AC Output to Critical Load A B C See Figure 4 7 for detail AA AC Input to UPS Bypass A B C See Figure 4 7 for det...

Page 56: ...d Terminals AC Output to Critical Load Phase C E8 Phase A E6 Phase B E7 E12 Neutral AC Input to UPS Rectifier Phase A E1 Phase C E3 Phase B E2 Phase C E11 Phase A E9 Phase B E10 AC Input to UPS Bypass...

Page 57: ...from Battery E4 E5 DC Input from Battery E12 Neutral AC Input to UPM Rectifiers A B C AC Output to Critical Load A B C See Figure 4 9 for detail AA AC Input to UPS Bypass A B C See Figure 4 9 for deta...

Page 58: ...UPM Rectifier Input Terminal Block Phase C E11 Phase A E9 Phase B E10 AC Input to UPS Bypass Ground terminal bus can be relocated below Alternate Ground Terminal Bus Location See Figure 4 10 for detai...

Page 59: ...terminal locations 5 If wiring the UPS for a common battery proceed to Step 6 if wiring for a separate battery proceed to Step 8 6 Connect the positive negative and ground DC power wiring from the bat...

Page 60: ...N Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 4 16 DC Input from Battery E4 E5 DC Input from Battery Figure 4 11 UPS Power Terminal De...

Page 61: ...nal area if the UPS is not totally disconnected Use the procedures in the following paragraphs to connect the TB1 TB1 Battery TB2 and TB3 interface connections 4 7 1 TB1 TB2 and TB3 Connections Other...

Page 62: ...remove the panel This panel is to the right of the X Slot communication bay see Figure 4 13 on page 4 19 8 Remove the UPS cabinet top interface entry conduit landing plates to drill or punch holes se...

Page 63: ...nd Operation Manual 164201701 Rev 3 www eaton com powerquality 4 19 X Slot Communication Bays TB3 TB1 and TB2 See Figure 4 14 for detail See Figure 4 16 on page 4 22 for terminal assignments See Figur...

Page 64: ...l 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...

Page 65: ...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 N...

Page 66: ...r 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 mus...

Page 67: ...and remove the panel This panel is to the right of the X Slot communication bays see Figure 4 13 on page 4 19 8 To locate the appropriate terminals and review the wiring and termination requirements s...

Page 68: ...h the retained hardware 22 If removed reinstall the left front panel removed in Step 5 and secure with the retained hardware Battery Disconnect TB1 Battery Aux Battery Aux Common 48 Vdc Battery Shunt...

Page 69: ...ll wiring to connections 1 If not already installed install the LAN and telephone drops 2 Unfasten the front door latch and swing the door open see Figure 4 2 on page 4 4 3 Remove the UPS cabinet inte...

Page 70: ...ther circuits NOTE This procedure is intended for installing the Eaton Corporation supplied REPO switch If installing another manufacturer s switch use this procedure only as a guide NOTE The REPO swi...

Page 71: ...re 4 13 on page 4 19 9 Remove the UPS cabinet interface entry conduit landing plates to drill or punch holes see Figure 4 4 on page 4 8 10 Reinstall the interface entry plates and install conduit 11 T...

Page 72: ...devices A second contact block is provided on the REPO switch for this function see Figure 4 20 The REPO switch wiring must be in accordance with NEC Article 725 Class 2 requirements 16 Reinstall the...

Page 73: ...and normally closed return terminals are separated on the terminal board but are electrically in common 1 2 Figure 4 22 Normally Closed REPO Switch Wiring 3 NO UPS TB1 REPO Switch NO Twisted Wires 1 N...

Page 74: ...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...

Page 75: ...equipment is installed and operating correctly The area around the installed UPS system is clean and dust free Eaton recommends that the UPS be installed on a level floor suitable for computer or elec...

Page 76: ...erly routed to the UPS cabinets and to the tie cabinet or distribution panel All power cables are properly sized and terminated A ground conductor is properly installed Controller Area Network CAN wir...

Page 77: ...________________________ _________________________________________________________________________ _________________________________________________________________________ ___________________________...

Page 78: ...UPS SYSTEM INSTALLATION Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 4 34 This page intentionally left blank...

Page 79: ...rds are not supported and will cause system conflicts 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...

Page 80: ...by the NEC for interface and power wiring up to 30V The wire should be rated at 24V 1A minimum Use Class 2 wiring methods as defined by the NEC for interface and power wiring from 30 to 600V Signal w...

Page 81: ...c CAN Bridge Card Connections Table 5 1 Powerware Hot Sync CAN Bridge Card Interface Connections J3 Terminal Name Description 1 Alarm Programmable UPS alarm Activated by a remote dry contact closure 2...

Page 82: ...4 on page 4 8 5 Reinstall the interface entry plates and install the conduit 6 To locate the appropriate terminals and review the wiring and termination requirements see paragraph 3 2 3 on page 3 17...

Page 83: ...Wiring 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 N...

Page 84: ...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 TB1 TB1 TB2 TB2 TB2 TB2 NOTE Use twisted pair wiring between the UPS and MOB...

Page 85: ...OTE Always confirm contact operation prior to wiring 1 2 3 4 5 6 7 8 9 10 UPS 1 UPS 2 TB2 TB2 TB2 TB2 TB1 TB1 TB1 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...

Page 86: ...rm UPS 3 CAN Bridge Card J3 2 Alarm Return MOB 3 Aux 1 Com UPS 3 TB2 1 Pull Chain MOB 3 Aux 2 NO Pull Chain UPS 3 TB2 2 Pull Chain Common UPS 4 TB2 2 Pull Chain Common Pull Chain Common UPS 4 CAN Brid...

Page 87: ...mation and Figure 5 7 Figure 5 8 and Table 5 5 for the RMP II terminal location and wiring information NOTE 120 Vac for the RMP II should be supplied from the critical bus by facility planners or the...

Page 88: ...an Eaton service representative to schedule a date 13 To check the operation of the RMP II ensure that the UPS is supplying the load via inverter or bypass If the indicators on the RMP II show the ap...

Page 89: ...and RIM 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 7 Figure 5 8 and Table 5 5 for the RIM II terminal location and...

Page 90: ...d J4 15 Pin D Sub Connectors 5 5 Installing an Optional Supervisory Contact Module II To install SCM II wiring 1 Verify the UPS system is turned off and all power sources are removed See Chapter 7 UPS...

Page 91: ...inal TB1 Signal Connections from the UPS Terminal TB3 120 Vac Power Terminal TB2 Customer Supervisory Contact Interface Figure 5 10 Supervisory Contact Module II Terminal Location NOTE Setup of the Po...

Page 92: ...Normal No Redundancy On Generator Bypass Not Available On Battery UPS Alarm On Bypass Shutdown Imminent Figure 5 11 Supervisory Contact Module II TB2 NOTE Supervisory contacts are rated at 2 0A at 28...

Page 93: ...imensions Figure 5 12 through Figure 5 14 show the dimensions of the RMP II the RIM II and the SCM II Flush Mount using 10 Pan Head Screws Mount with vent holes facing up Surface Mount using 10 Pan He...

Page 94: ...Rev 3 www eaton com powerquality 5 16 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...

Page 95: ...v 3 www eaton com powerquality 5 17 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 wi...

Page 96: ...INSTALLING OPTIONS AND ACCESSORIES Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 5 18 This page intentionally left blank...

Page 97: ...Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 5 19 Section II Operation...

Page 98: ...Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 5 20...

Page 99: ...erter Input Contactor K1 AC Input to Rectifier Charger AC Input to Bypass Backfeed Protection Contactor K5 Power Module Inverter Rectifier Digital Metering Static Switch AC Output to Critical Load UPS...

Page 100: ...y the inverter which derives its power from rectified utility AC power In this mode the battery charger also provides charging current for the battery if needed In Energy Saver mode commercial AC powe...

Page 101: ...CB1 Figure 6 2 Path of Current Through the UPS in Online Mode The inverter produces a three phase AC output to a customer s load without the use of a transformer The inverter derives regulated DC from...

Page 102: ...hen operating in Energy Saver mode Static Switch K5 Rectifier Inverter K1 K3 Main Power Flow Trickle Current Energized De Energized Closed Open Breakers Contactors K2 Bypass Input Rectifier Input Outp...

Page 103: ...low the UPM to immediately return to active mode in the event of a disturbance or load step on the critical bus VMMS limits the maximum power available from a UPM when in VMMS mode The default setting...

Page 104: ...f the system is provided with three phase AC power directly from the system input While in this mode the output of the system is not protected from voltage or frequency fluctuations or power outages f...

Page 105: ...ource from which to supply the DC output current required to support the inverter The input contactor K1 opens and the battery instantaneously supplies energy to the battery converter The converter ei...

Page 106: ...ngle Reverse Transfer UPS Three UPM Common Rectifier Feed Separate Battery Dual Feed Configuration Figure 6 10 on page 6 13 9395 550 450 9395 550 500 9395 550 550 480 480 Single Reverse Transfer UPS T...

Page 107: ...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...

Page 108: ...atic 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 Bat...

Page 109: ...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 Contact...

Page 110: ...r 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 Contacto...

Page 111: ...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 Conne...

Page 112: ...utput 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 O...

Page 113: ...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...

Page 114: ...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 Br...

Page 115: ...o 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 Con...

Page 116: ...3 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 Conta...

Page 117: ...ut to UPS Rectifiers 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 1 Battery Breaker...

Page 118: ...r 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 Contact...

Page 119: ...Input RIB BIB To UPS Bypass Input NOTE If installing a maintenance bypass a minimum of two separate feeds with upstream feeder breakers or a single feed with two upstream feeder breakers must be prov...

Page 120: ...alleled UPMs transfer the load to bypass using the UPS static switches Communication is required between the UPSs for system metering and mode control System level communication and control are accomp...

Page 121: ...ction A notice is a minor system event that may or may not require attention An alarm is a system event that requires immediate intervention The following paragraphs describe the differences in the th...

Page 122: ...ypass input While in this mode the output of the system is not protected from fluctuations spikes or power outages from the source No battery support is available to the output of the system in the By...

Page 123: ...if the distributed bypass system is unable to return to Normal 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 s...

Page 124: ...sual alarms that indicate a two minute SHUTDOWN IMMINENT warning Unless the system has a valid AC input soon redundant UPMs begin shutting down until there are no longer enough UPMs online to support...

Page 125: ...ach UPM in the UPSs but represent each UPS in the distributed bypass system The internal structure of each UPS is shown in Figure 6 6 through Figure 6 9 starting on page 6 9 Oneline Drawing UPS Model...

Page 126: ...E2 E3 CB1 optional UPS 2 A B E4 E5 BATTERY SYSTEM Not supplied with the UPS C E9 E10 E11 E12 D NOTE This oneline does not show each UPM in the UPSs but represents each UPS in the distributed bypass s...

Page 127: ...reaker 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...

Page 128: ...use 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...

Page 129: ...operly NOTE Read this section of the manual and have thorough knowledge of UPS operation before attempting to operate any of the controls NOTE The UPS displays 2 minutes of battery runtime at the init...

Page 130: ...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 3 1...

Page 131: ...control panel pushbutton once 7 2 2 System Events When the UPS system is running in Online mode it continually monitors itself and the incoming utility power In Battery or Bypass modes the UPS may iss...

Page 132: ...system needs attention Some notices and alarms may be accompanied by an audible horn To silence the horn press any control panel pushbutton once Shown is a typical alarm message For more information a...

Page 133: ...n numbers LOAD OFF De energizes the critical load and powers down the UPS ESC Returns to Main Menu and Mimic screen from the Events Meters Controls or Setup screens Returns to the main System Setup Le...

Page 134: ...readings for the unit The default voltage displayed on these screens is phase to neutral However an authorized Eaton Customer Service Engineer can change the screens to display the voltage phase to p...

Page 135: ...ord to be changed Select CHANGE PASSWORD from the System Setup Level 1 menu to display the Change Password screen Use the left or right arrow pushbutton to select the password character position Use t...

Page 136: ...to make the change Press SAVE or ABORT Once the action is completed the COM Port Setup screen is displayed Controls See paragraph 7 2 7 for details 7 2 7 System Status Screen and Controls Press the CO...

Page 137: ...raph 7 2 8 Bypass 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 G...

Page 138: ...L Figure 7 6 Load Off Screen 7 3 Single UPS Operation NOTE A Field Installed UPM FI UPM is always designated as UPM 4 7 3 1 Starting the UPS in Online Mode To start the UPS system 1 Unfasten the front...

Page 139: ...STARTING INVERTER SYNCING ONLINE CHARGING The rectifier and inverter turn on The inverter continues to ramp up to full voltage Once the inverter reaches full voltage the UPS output contactor K3 closes...

Page 140: ...critical load to Online mode 1 Unfasten the front door latch and swing the door open see Figure 4 2 on page 4 4 2 If the UPS contains input breaker CB1 verify that input breaker CB1 is open 3 Close th...

Page 141: ...model repeat Steps 12 through 15 selecting UPM 4 to start UPM 4 20 Verify the following messages display sequentially on the UPM status line DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING...

Page 142: ...DC STARTING CHARGER OFF INVERTER STARTING INVERTER SYNCING READY The UPM rectifier and inverter turn on 17 To transfer the UPM to Online mode press the CONTROLS pushbutton on the UPS Control Command...

Page 143: ...tatus screen select the UPS command 4 Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed 5 On the UPS Control Command screen select GO TO ONLINE 6...

Page 144: ...tus screen is displayed 2 On the System Status screen select the UPS command 3 Press the CONTROLS pushbutton on the System Status menu bar The UPS Control Command screen is displayed 4 On the UPS Cont...

Page 145: ...The UPS Control Command screen is displayed 4 On the UPS Control Command screen select GO TO ONLINE 5 Press the SELECT pushbutton on the UPS Command menu bar The UPS transfers to Online mode The ONLIN...

Page 146: ...ss status indicates ON The UPM status indicates READY The power module remains on 7 3 13 Transfer from Bypass to High Alert Mode To transfer the critical load to High Alert mode NOTE The High Alert mo...

Page 147: ...s illuminated The UPS status indicates BYPASS The Bypass status indicates ON The UPM status indicates READY The power module remains on 7 3 15 Transfer from Energy Saver to High Alert Mode To transfer...

Page 148: ...is illuminated The UPS status indicates ENERGY SAVER The Bypass status indicates ON The UPM status indicates ONLINE If the battery is not charging the power module is off 7 3 17 Transfer from Online t...

Page 149: ...ol Command menu bar The UPM Control Command screen is displayed 5 On the UPM Control Command screen select UPM OFF 6 Press the SELECT pushbutton on the UPM Command menu bar The UPM status indicates RE...

Page 150: ...ne mode The UPM status indicates ONLINE 7 3 20 UPS and Critical Load Shutdown To perform maintenance or service on the critical load shut down power to the load 1 Turn off all equipment that is being...

Page 151: ...e the LOAD OFF pushbutton 1 Press the LOAD OFF pushbutton 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 L...

Page 152: ...wing step You should use this feature only when you want to de energize the critical load 6 To shut down the UPS press LOAD OFF from the Load Off menu bar and hold for three seconds To abort the shutd...

Page 153: ...r to the operating instructions provided with the switch To use the REPO switch 1 Firmly push the red pushbutton until it locks into place The switch latches into the activated state see Figure 7 7 Th...

Page 154: ...akers 7 Close the doors and secure the latches 8 Observe the UPS control panel displays becoming active indicating logic power 9 On any UPS press the CONTROLS pushbutton on the main menu bar The Syste...

Page 155: ...ed bypass system 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...

Page 156: ...input breakers CB1 close all input breakers 6 Close the doors and secure the latches 7 Observe the UPS control panel displays becoming active indicating logic power 8 On any UPS press the CONTROLS pu...

Page 157: ...in the distributed bypass system NOTE To transfer to Online mode after starting individual UPMs follow the procedure in paragraph 7 4 6 7 4 4 Starting a Single UPM To start a single UPM 1 Unfasten the...

Page 158: ...PM transfers to Online mode The UPM status indicates ONLINE 7 4 5 Transfer from Online to Bypass Mode To transfer the critical load to Bypass mode CAUTION In Bypass mode the critical load is not prote...

Page 159: ...ates ONLINE The UPM status indicates ONLINE 7 4 7 Transfer from Online to Energy Saver Mode To transfer the critical load to Energy Saver mode NOTE The Energy Saver mode commands are displayed only if...

Page 160: ...status indicator is illuminated The UPS status indicates ONLINE The UPM status indicates ONLINE 7 4 9 Transfer from Online to High Alert Mode To transfer the critical load to High Alert mode NOTE The...

Page 161: ...inated The UPS status indicates ONLINE The UPM status indicates ONLINE 7 4 11 Transfer from Bypass to Energy Saver Mode To transfer the critical load to Energy Saver mode NOTE The Energy Saver mode co...

Page 162: ...ss status indicates ON The UPM status indicates READY The power module remains on 7 4 13 Transfer from Bypass to High Alert Mode To transfer the critical load to High Alert mode NOTE The High Alert mo...

Page 163: ...s illuminated The UPS status indicates BYPASS The Bypass status indicates ON The UPM status indicates READY The power module remains on 7 4 15 Transfer from Energy Saver to High Alert Mode To transfer...

Page 164: ...icator is illuminated The UPS status indicates ENERGY SAVER The Bypass status indicates ON The UPM status indicates ONLINE If the battery is not charging the power module is off 7 4 17 Transfer from O...

Page 165: ...the UPM to shutdown 4 Press the CONTROLS pushbutton on the UPS Control Command menu bar The UPM Control Command screen is displayed 5 On the UPM Control Command screen select UPM OFF 6 Press the SELE...

Page 166: ...mmand menu bar The UPM transfers to Online mode The UPM status indicates ONLINE 7 4 20 Single UPS Shutdown using Load Off NOTE To shut down a single UPS MOBs with dual auxiliary contacts must be insta...

Page 167: ...rt 7 4 21 Single UPS Shutdown using UPM Shutdown NOTE To shut down a single UPS MOBs with dual auxiliary contacts must be installed and connected according to the procedure in paragraph 5 2 on page 5...

Page 168: ...ass feeder circuit breakers for the UPS being shut down The UPS is now completely shut down External Communications Failure alarm is active on remaining online UPSs This is an expected event and will...

Page 169: ...nverter turn on The inverter continues to ramp to full voltage Once the inverter reaches full voltage the UPS output contactor K3 closes Power is now supplied to the critical load in Online mode along...

Page 170: ...and 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 Load Off command on the Bypass Control Command screen The UP...

Page 171: ...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 CA...

Page 172: ...sed it may not activate in the same manner refer to the operating instructions provided with the switch To use the REPO switch 1 Firmly push the red pushbutton until it locks into place The switch lat...

Page 173: ...ides out of band remote notification and monitoring using modem communication directly to cell phones and pagers Relay Interface Card AS 400 has isolated dry contact Form C relay outputs for UPS statu...

Page 174: ...atus of the Power Xpert 9395 UPS on a daily basis All data gathered from the unit current and historical is analyzed at the Customer Reliability Center CRC for trending issues A set of factors or rule...

Page 175: ...mplete record of critical power events and notification of important UPS or power information With custom views for monitoring status and metering information various user groups can select the most u...

Page 176: ...tween the UPS and modem 8 5 Terminal Mode In Terminal mode the user can request the following NOTE The brackets in the following bullets indicate standard keyboard characters To use a key combination...

Page 177: ...d through the serial port to the device connected to the port The printed log entries contain a time and date stamp and the alarm text message Terminal mode uses this format for printing alarm entries...

Page 178: ...2099 21 25 20 515 N011 OUTPUT UNDER OR OVER FREQ PM1 03 16 2099 21 25 20 675 S302 EEPS CONFIGURING PM1 03 16 2099 21 25 23 475 N267 POWER MODULE CABLE FAIL 15 PM1 03 16 2099 21 25 25 180 N271 DC HW AM...

Page 179: ...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 equip...

Page 180: ...N 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...

Page 181: ...pin connectors labeled J1 through J4 Figure 8 4 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 thro...

Page 182: ...be flush mounted or surface mounted on a desktop or secured to a wall Figure 8 5 shows the SCM II Figure 8 5 Supervisory Contact Module II The SCM II provides signals for the indications shown in Tab...

Page 183: ...PRESENT This unit should not be operated with the cabinet doors open or protective panels removed Do not make any assumptions about the electrical state of any cabinet in the UPS system Because each b...

Page 184: ...ment is within the parameters specified in paragraph 3 2 1 on page 3 1 and Chapter 10 Product Specifications 4 Ensure the UPS is in Normal mode Normal status indicator is illuminated If an alarm lamp...

Page 185: ...ure the latch 3 If the UPS is a Plus 1 model check the Field Installed UPM FI UPM air filter located behind the front panel and wash or replace as necessary See Figure 9 2 for the filter location The...

Page 186: ...ions in a suitable log FI UPM Air Filter Figure 9 2 FI UPM Air Filter Location 9 2 3 PERIODIC Maintenance Periodic inspections of the UPS should be made to determine if components wiring and connectio...

Page 187: ...to the skin and eyes It may be toxic A battery can cause electrical shock burn from high short circuit current or fire Observe proper precautions ATTENTION Une batterie peut pr senter un risque de cho...

Page 188: ...UPS MAINTENANCE Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality 9 6 This page intentionally left blank...

Page 189: ...50 60 Hz 10 2 Specifications The following sections detail the input output battery and environmental specifications for the UPS 10 2 1 UPS Input Operating Input Voltage 480 Vac Operating Input Frequ...

Page 190: ...running Synchronous to Bypass 10 to 10 3 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...

Page 191: ...s startup and commissioning of the Product b if the Product is moved to a new location by someone other than an authorized Eaton Customer Service Engineer in the USA or Agent outside of the USA or c i...

Page 192: ...WARRANTY Power Xpert 9395 UPS 450 550 kVA Installation and Operation Manual 164201701 Rev 3 www eaton com powerquality W 2 This page intentionally left blank...

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