Eaton 9395 UPS 400V 450-550 kVA (2x225 - 2x275 kVA) User’s and Installation Guide
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that you should follow during installation and maintenance of the UPS and batteries. Please read all instructions before operating the equipment and save this manual for future reference. This is a product for commercial and industrial application in the second environment. Installation restrictions or additional measures may be needed to prevent disturbances.
1 2 3 4 5 6 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 UPS standard features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.1 Installation features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 ii 6.4.1 Multiple UPS parallel system modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 6.4.2 Normal mode – distributed bypass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 6.4.3 Bypass mode – distributed bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 6.4.
8 9 10 11 12 7.4.20 Transfer from High Alert to Bypass mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.21 Transfer from Energy Saver System to High Alert mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.22 Transfer from High Alert to Energy Saver System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4.
List of Tables Table 3-1: UPS cabinet weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3-2: UPS cabinet clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3-3: Air conditioning or ventilation requirements during full load operation. . .
List of Figures Figure 1-1. Eaton 9395-550 (2*275) cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Figure 3-1. UPS cabinet dimensions (front view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Figure 3-2. UPS cabinet dimensions (right side view) . . . . . . . . . . . . . . . . . . . . . .
ii UPS 450-550 kVA (2x225 - 2x275 kVA) User’s and Installation Guide 1027574 Revision E
1 Introduction The Eaton® 9395 uninterruptible power supply (UPS) is a true online, continuous-duty, transformerless, double-conversion, solid-state, three-phase system, providing conditioned and uninterruptible AC power to protect the customer’s load from power failures.
Figure 1-1. Eaton 9395-550 (2*275) cabinet 1.1.3 Customer Interface • Building Alarm Monitoring – Up to five inputs in the UPS are available to connect the facility’s alarm system contacts. Some system configurations may limit the number of inputs available. The UPS uses these inputs to monitor the building alarms in addition to the UPS status. See Chapter 8: “Communication” for additional information.
• ConnectUPS -X Web/SNMP Card – This X-Slot card is provided as standard equipment and provides remote monitoring through a Web browser interface, e-mail, and a network management system (NMS) using SNMP. 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 ripple currents.
1.2.6 Separate rectifier input (factory-installed option) The Eaton 9395 450-550 kVA UPS can be supplied with separate rectifier inputs for each UPM. Separate inputs provide increased flexibility and reliability by allowing multiple input sources to supply the UPS. Input circuit breaker CB1 is not installed with this configuration. AC input control to the UPS and each UPM rectifier is to be provided by the customer. 1.2.
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 automatically transfer to Normal mode if a commercial electrical power brownout, blackout, overvoltage, undervoltage, or out-of-tolerance frequency condition occurs. In High Alert mode the unit transfers from Energy Saver mode to Normal mode (inverter online) or if in Normal mode remains in Normal mode for a default time period of one hour.
• Single UPS with two UPMs with separate batteries and a FI-UPM with a separate battery, and one standalone battery rack system per UPM • Distributed bypass system with two to five UPSs and a customer-supplied tie cabinet The UPS system configuration can be enhanced by adding optional accessories such as a Remote Emergency Power-off (REPO) control, RMP II, or X-Slot communication cards. 1.4 Using this manual This manual describes how to install and operate the Eaton 9395 UPS (450-550 kVA) cabinet.
RISK OF ELECTRIC SHOCK - Indicates that a risk of electric shock is present and the associated warning should be observed. CAUTION: REFER TO OPERATOR’S MANUAL - Refer to your operator’s manual for additional information, such as important operating and maintenance instructions. This symbol indicates that you should not discard the UPS or the UPS batteries in the trash. This product involves sealed, lead-acid batteries and must be disposed of properly.
2 Safety warnings IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the UPS and batteries. Please read all instructions before operating the equipment and save this manual for future reference. The UPS is designed for computer room applications, and contains safety shields behind the door and front panels. However, the UPS is a sophisticated power system and should be handled with appropriate care.
shock is less likely if you disconnect the grounding connection before you work on the batteries. • Proper disposal of batteries is required. Refer to local codes for disposal requirements. • Do not dispose of batteries in a fire. Batteries may explode when exposed to flame. • Keep the UPS door closed and front panels installed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit.
3 UPS installation plan and unpacking Use the following basic sequence of steps to install the UPS: 1. 2. 3. 4. 5. 6. Create an installation plan for the UPS system (Chapter 3). Prepare your site for the UPS system (Chapter 3). Inspect and unpack the UPS cabinet (Chapter 3). Unload and install the UPS cabinet, and wire the system (Chapter 4: “UPS system installation”). Complete the installation checklist at the end of this manual.
3.2.1 Environmental and installation considerations The UPS system installation must meet the following guidelines: • The system must be installed on a level floor suitable for computer or electronic equipment. • The system must be installed in a temperature and humidity controlled indoor area free of conductive contaminants. • The cabinet can be installed in line-up-and-match or standalone configurations. Failure to follow guidelines may void your warranty.
Rating/kVA Input/output voltage Heat rejection BTU/h x 1000 2*275 kVA 400/400 88.7 550 kVA 400/400 88.7 Table 3-3: Air conditioning or ventilation requirements during full load operation Ventilation required for cooling air exhaust: approximately 900 liter/sec/225-275kVA unit, + 280 liter/sec (ISBM). Figure 3-1. UPS cabinet dimensions (front view) Figure 3-2.
Figure 3-3. UPS cabinet dimensions (top view) Figure 3-4.
Figure 3-5. UPS cabinet center of gravity Figure 3-6.
3.2.2 UPS system power wiring preparation NOTE If installing, as part of the UPS system, a maintenance bypass without a rectifier input breaker, a minimum of two separate feeds with upstream feeder breakers, or one feed with two upstream feeder breakers, must be provided: one for the UPS and one for the maintenance bypass input. DO NOT use one feed or a single feeder breaker to supply both the UPS and the maintenance bypass.
Units Rating 50/60 Hz Basic UPM rating kVA kW 225 202 275 247 Input voltage Volts 400/400 400/400 AC input to each UPM rectifier (0.98 Min.
Terminal function Terminal Function Bus landing Tightening torque Nm Bolt size AC input to UPS rectifier E1 Phase L1 4-2 bolt mounting 76 M12 E2 Phase L2 4-2 bolt mounting 76 M12 E3 Phase L3 4-2 bolt mounting 76 M12 E6 Phase L1 4-2 bolt mounting 76 M12 E7 Phase L2 4-2 bolt mounting 76 M12 E8 Phase L3 4-2 bolt mounting 76 M12 E9 Phase L1 4-2 bolt mounting 76 M12 E10 Phase L2 4-2 bolt mounting 76 M12 E11 Phase L3 4-2 bolt mounting 76 M12 E4 Battery (+) 4-2
CAUTION To reduce the risk of fire, connect only to a circuit provided with maximum input circuit breaker current ratings from Table 3-8 in accordance with the national and local installation rules. The line-to-line unbalanced output capability of the UPS is limited only by the full load per phase current values for AC output to critical load shown in Table 3-4 on page 15. The recommended line-to-line load unbalance is 50% or less.
3.2.3 UPS system interface wiring preparation Control wiring for features and options should be connected at the customer interface terminal blocks located inside the UPS as described in Chapter 5: “Installing options and accessories”. WARNING Do not directly connect relay contacts to the mains related circuits. Reinforced insulation to the mains is required.
3.2.4 Distributed bypass power wiring preparation Read and understand the following notes while planning and performing the installation: • All distributed bypass UPS rectifier inputs must come from one source and all bypass input feeds must come from one source. • Distributed bypass UPS input wiring size requirements and output wiring size requirements from the UPSs to the tie cabinet or distribution panel are the same as listed in Table 3-4 on page 15.
3.3 Inspecting and unpacking the UPS cabinet The UPS cabinet is palleted separately for shipping. The cabinet is shipped bolted to a wooden pallet and protected with outer protective packaging material (see Figure 3-7). WARNING The UPS cabinet is heavy (see Table 3-1 on page 11). If unpacking instructions are not closely followed, the cabinet may tip and cause serious injury and equipment damage. Do not install a damaged cabinet.
NOTE While waiting for installation, protect the unpacked cabinet from moisture, dust, and other harmful contaminants. Failure to store and protect the UPS properly may void your warranty. Figure 3-7.
4 UPS system installation 4.1 Preliminary installation information WARNING Installation should be performed only by qualified personnel. Refer to the following while installing the UPS system: • Chapter 3: “UPS installation plan and unpacking” for cabinet dimensions, equipment weight, wiring and terminal data, and installation notes. • Do not tilt the cabinet more than ±10° during installation. • The landing plates can be removed to add cable entry holes as required.
• Insert the forks all the way through the base. DO NOT insert forks partially into the base to move the cabinet. • Fork may be partially inserted into the front or rear fork lift slots for minor positioning if the forks are kept in a horizontal position with no upward angling. • DO NOT use the forklift slots on the end of the cabinet to move the cabinet. If these instructions are not followed, damage to the wiring channel and wiring will occur.
Figure 4-1. Removing left side shipping bracket Figure 4-2.
4.3 Field installed UPM (FI-UPM) installation If installing a system with Field Upgrade UPM, install the FI-UPM using the instructions in the Eaton 9395 Field Installed UPM Mechanical Installation Manual, listed in section 1.8 on page 10. After the FIUPM is installed, proceed to Section 4.4 if installing a battery system; otherwise, proceed to Section 4.5. 4.4 Battery cabinet installation To install the battery cabinet, refer to the Eaton 9395 Integrated Battery Cabinet (Model IBC-L) installation manual.
Figure 4-3. Distributed bypass wire length NOTE Required parallel system wiring length must be equal to ensure approximately equal current sharing when in Bypass mode. For proper operation the following must be true: 1A = 2A = 3A = 4A 1B = 2B = 3B = 4B In order to save cabling costs, the following is also considered to be sufficient: 1A+1B=2A+2B=3A+3B=4A+4B Any difference in wire length will result in decreased capacity of the UPS system while on bypass.
4.6 Installing UPS external and battery power wiring NOTE The UPS cabinet is shipped with a debris shield covering the ventilation grill on top of the unit. Do not remove the debris shield until installation is complete. However, remove the shield before operating the UPS. Once the debris shield is removed, do not place objects on the ventilation grill. Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes (see Figure 4-4).
Figure 4-4.
Figure 4-5.
Figure 4-6. UPS power terminal locations - part b NOTE A unit with separate rectifier feeds has two sets of rectifier AC input connections.
B A A B 15704.0209 Figure 4-7.
Figure 4-8. Front view Figure 4-9. Side view.
4.6.2 Battery wiring CAUTION When sizing the battery system, do not exceed the internal battery charger capabilities. See Chapter 10: “Product specifications” for maximum battery charger current. To install wiring to connections: 1. If using an Eaton battery cabinet, proceed to Step 2; otherwise, proceed to Step 5. 2.
4.7 Installing interface connections WARNING Hazardous voltages are present near the user interface terminal area if the UPS is not totally disconnected. 4.7.1 TB1, TB2, and TB3 connections (other than TB1 battery interface connections) NOTE Interface wiring must be installed from the top of the UPS cabinet. To install wiring to connections: 1. Verify the UPS system is turned off and all power sources are disconnected. See Chapter 7: “UPS operating instructions” for shutdown instructions. 2.
Figure 4-10. Typical alarm relay connection NOTE Alarm relay contacts have a maximum current rating of 5A and a switched voltage rating of 30 Vac and 28 Vdc. Alarm relay normally-open and normally-closed return terminals are separated on the terminal board, but are connected together. Do not directly connect relay contacts to the mains related circuits. Reinforced insulation to the mains is required. Alarm relay wiring should be a minimum of .75 mm2. Figure 4-11.
NOTE For TB1, TB2 and TB3 connector assignments, see Figure 4-13 and for detail AA, see Figure 4-12. The X-Slot communication bays are illustrated in Figure 4-15. Figure 4-12. Interface terminal detail AA Figure 4-13.
NOTE All building alarm inputs require an isolated normally-open or normally-closed contact or switch (rated at 24 Vdc, 20 mA minimum) connected between the alarm input and common terminal as shown. Building alarm inputs can be programmed for use with either normally-open or normally-closed contacts. All control wiring and relay and switch contacts are customersupplied. The building alarms can be programmed to display the alarm functional name.
3 Building alarm 2 4 Building alarm 2 return 5 Building alarm 3 6 Building alarm 3 return 7 Building alarm 4 8 Building alarm 4 return 9 Building alarm 5 10 Building alarm 5 return Programmable UPS alarm. Activated by a remote dry contact closure. Programmable UPS alarm. Activated by a remote dry contact closure. Programmable UPS alarm. Activated by a remote dry contact closure. Programmable UPS alarm. Activated by a remote dry contact closure.
Figure 4-14. Typical battery interface connection NOTE Battery Aux and DC Shunt Trip wiring should be a minimum of 1.5 mm2. 4.7.3 X-Slot connections NOTE LAN and telephone drops for use with X-Slot cards must be provided by the customer. When installing internal wiring to X-Slot terminals, route the wiring through the internal opening in the X-Slot communication bay. For installation and setup of an X-Slot card, please contact Eaton Corporation. To install wiring to connections: 1.
Figure 4-15.
4.8 Installing a remote EPO switch NOTE This switch must be a dedicated switch not tied into any other circuits. This procedure is intended to be used for the installation of the Eaton remote EPO switch. If installing another manufacturer’s switch, only use this procedure as a guide. A remote EPO switch can be used in an emergency to shut down the UPS and remove power to the critical load from a location away from where the UPS is installed. Figure 4-16 shows a remote EPO switch. 1.
From remote EPO switch To customer interface Terminal board TB1 in UPS cabinet TB1-4 TB1-3 TB1-5 TB1-4 Remarks Twisted wires (2) 0.75mm2 2.5mm2 Table 4-2: Remote EPO wire terminations Figure 4-17. Normally-open remote EPO switch wiring NOTE Remote EPO switch rating is 24 Vdc, 1 A minimum. Remote EPO normally-open and normally-closed return terminals are separated on the terminal board, but are connected together. 10.
Figure 4-18. Normally-closed remote EPO switch wiring NOTE Remote EPO switch rating is 24 Vdc, 1 A minimum. Remote EPO normally-open and normally-closed return terminals are separated on the terminal board, but are connected together. Figure 4-19. Normally closed and normally open remote EPO switch wiring NOTE Remote EPO switch rating is 24 Vdc, 1 A minimum. Remote EPO normally-open and normally-closed return terminals are separated on the terminal board, but are connected together.
4.9 Installing options, accessories, and distributed bypass control wiring To install options, accessories, and distributed bypass control wiring, see Chapter 5: “Installing options and accessories”. 4.10 Initial startup Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer, or the warranty terms specified on page 128 become void. This service is offered as part of the sales contract for the UPS.
5 Installing options and accessories 5.1 Installing an optional HotSync CAN Bridge Card As an option, a HotSync Controller Area Network (CAN) Bridge Card, shown in Figure 5-1, can be installed to provide connectivity for operational mode control of a parallel system. In addition, this card can be used to connect optional system monitoring devices, such as a Remote Monitor Panel II, a Relay Interface Module II, or a Supervisory Contact Module II, to the UPS. Figure 5-1.
Figure 5-2. HotSync CAN Bridge Card connections J3 Terminal Name Description 1 Alarm 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 7 TX 8 CAN L 9 CAN H 10 Shield Programmable UPS alarm. Activate by a remote dry contact closure. RMP II, RIM II, and SCM II connections. CAN interface for parallel operation.
5.2 Installing distributed bypass control wiring NOTE When installing external wiring to the HotSync CAN Bridge Card terminals, route the wiring through the internal opening in the X-Slot communication bay. To install distributed bypass control wiring: 1. Verify the UPS system is turned off and all power sources are disconnected. See Chapter 7: “UPS operating instructions” for shutdown instructions. 2. Perform the procedure listed in Section 5.1. 3.
Figure 5-3. Distributed bypass system CAN and Pull-Chain simplified interface wiring NOTE This drawing is for distributed bypass wiring purposes and is not a floor layout plan. UPSs can be placed in any physical order. Figure 5-4. Distributed bypass system UPS CAN wiring without MOBs NOTE External CAN connections between UPSs require shielded twisted pair wire.
Figure 5-5. Distributed bypass Pull-Chain wiring without MOBs NOTE Use twisted pair wiring between the UPS and MOB AUX contacts.
Figure 5-6. Distributed bypass Pull-Chain wiring with MOBs NOTE NC and NO designations on MOB AUX contacts are defined with breaker in OFF (open) position. If MOB contacts have pigtail leads, use the same wire gauge to connect to the UPS and use the correct crimp connections for the wire gauge. External CAN connections between UPS cabinets require shielded twisted pair wire. Use twisted pair wiring between the UPS and MOB AUX contacts. Always confirm contact operation prior to wiring.
From To Function UPS 1 CAN Bridge Card J3-1 (Alarm) MOB 1 Aux 1 NC MOB Open Alarm UPS 1 CAN Bridge Card J3-2 (Alarm Return) MOB 1 Aux 1 Com UPS 1 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-
6 Understanding UPS operation 6.1 Looking inside the UPS system The Eaton 9395 UPS is a continuous-duty, solid-state, transformerless (at 400 Vac), three-phase, true online system that provides conditioned and uninterruptible AC power to the UPS system’s output and critical load. The basic system consists of a rectifier, battery converter, inverter, monitoring/operation control panel, integrated communication server, and digital signal processor (DSP) logic. Figure 6-1.
6.2 Single UPS A single UPS operates independently to support an applied load from the inverter, providing conditioned and uninterruptible AC power to the critical load from the output of the module. During an outage, the inverter continues to operate, supporting power to the load from the battery supply. If the unit requires service, applied loads are transferred to the internal bypass via the continuous-duty static switch either automatically or manually.
Figure 6-2. Path of current through the UPS in normal mode During normal UPS operation, power for the system is derived from a utility input source through the rectifier input contactor K1. The front panel displays Normal, indicating the incoming power is within voltage and frequency acceptance windows. Three-phase AC input power is converted to DC using IGBT devices to produce a regulated DC voltage to the inverter.
6.2.3 Bypass mode The UPS automatically switches to bypass mode if it detects an overload, load fault, or internal failure. The bypass source supplies the commercial AC power to the load directly. Figure 6-3 shows the path of electrical power through the UPS system when operating in Bypass mode. CAUTION The critical load is not protected while the UPS is in Bypass mode. Figure 6-3.
6.2.4 Variable Module Management System NOTE VMMS and ESS modes are mutually exclusive. If VMMS mode is enabled, ESS mode is disabled. In VMMS mode, the UPS operates as a traditional double-conversion UPS. However, the UPS will selectively shift the load to fewer UPMs based on the required load in order to force the remaining UPMs to carry a higher load. The efficiency rating for each UPM is highest when loads are greater than 50% of the UPM rating.
Figure 6-4. Path of current through the UPS in Energy Saver System If the bypass source falls outside of a predetermined voltage or frequency window, the system forward transfers to Battery mode and then to Normal mode with the inverter assuming the load. The transfer takes place with a 2 ms typical transfer time, to ensure loads being fed by the system output are not interrupted. All forward transfers transfer to Battery mode before returning to Normal mode.
Figure 6-5. Path of current through the UPS in battery mode During a utility power failure, the rectifier no longer has an AC utility source from which to supply the DC output current required to support the inverter. The input contactor K1 opens and the battery instantaneously supplies energy to the battery converter. The converter either bucks or boosts the voltage so that the inverter can support the customer’s load without interruption.
6.3 UPS system oneline configurations The system oneline drawings in this section show the simplified internal structure of the UPS, battery supply, and basic maintenance bypass.
Figure 6-6. UPS system – common rectifier feed, common battery, Dual-Feed configuration *) Static Switch line not present in IOM configuration systems.
Figure 6-7. UPS system – common rectifier feed, separate battery, Dual-Feed configuration *) Static Switch line not present in IOM configuration systems.
Figure 6-8.
Figure 6-9.
Figure 6-10. Simplified Dual-Feed UPS with maintenance bypass panel 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 provided: one for the UPS or rectifier input breaker (RIB) (if installed) 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.
6.4 Multiple UPS distributed bypass system Distributed bypass parallel operation extends the normal operation of Eaton 9395 UPSs by offering increased capacity and/or redundant capability. The output of the system is normally supplied by Uninterruptible Power Modules (UPMs) contained in each UPS. Multiple UPMs are connected with their outputs in parallel (tied together) to provide a load level greater than the rating of one UPM, for redundancy, or both.
The UPSs continually monitor themselves and the incoming utility power and automatically switch between these modes as required, without operator intervention, except when manually switching to Bypass mode. The sophisticated detection and switching logic inside the UPSs ensures that operating mode changes are automatic and transparent to the critical load, while internal monitoring systems indicate the current mode of operation.
6.4.3 Bypass mode – distributed bypass In Bypass mode, the output of the system is provided with three-phase AC power directly from the bypass input. While in this mode, the output of the system is not protected from fluctuations, spikes, or power outages from the source. No battery support is available to the output of the system in the Bypass mode of operation. The distributed bypass system automatically switches to Bypass mode if it detects a UPS system overload or load fault.
In the Parallel Redundant (N+1) arrangement, the bypass circuitry in each UPS operates to support the applied loads on bypass. If the UPSs are in NORMAL and one UPS trips offline, the remaining UPSs do not go to bypass as long as they have the capacity to support the load. In the Parallel Capacity (N+0) arrangement, if one UPS trips offline and goes to bypass, the remaining UPSs also go to bypass, if remaining UPSs can not support the load 6.4.
6.5 Multiple UPS distributed 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 6-6 through Figure 6-9 starting on page 61.
Figure 6-14.
Figure 6-15.
Figure 6-16.
7 UPS operating instructions This section describes how to operate the UPS. 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. Read this section of the manual and have thorough understanding of UPS operation before attempting to operate any of the controls.
7.1.1 Control panel The control panel is used to set up and control the UPS, and to monitor UPS operation. For a description of the UPS control panel functions, see Section 7.2. 7.1.2 Circuit breakers The optional circuit breaker (CB1) is used to control the AC input to the UPS rectifier. CB1 has three positions: ON, OFF and tripped. Before it can be set to ON from the tripped position, it needs to be set to OFF position. 7.
Indicator Status Descriptions On The UPS is operating normally and supplying power to the critical load. Off The UPS is turned off. On The UPS is in Battery mode. Because Battery mode is a normal condition of the UPS, the Normal indicator also remains illuminated. On The UPS is in Bypass mode. The critical load is supported by the bypass source. The Normal indicator is not illuminated when the system is in Bypass mode. On The UPS has an active alarm and requires immediate attention.
7.2.3 Using the LCD and pushbuttons The LCD on the control panel provides an operator interface with the UPS system. Figure 7-3 identifies the display areas discussed in the following sections. Figure 7-3. Parts of the LCD A - The UPS status area automatically scrolls between the Eaton Corporation model number, current date and time, active alarms, active notices, and load percent and battery runtime for the UPS. The top line of display blinks while scrolling when the system needs attention.
ESC ESC returns to Main Menu and Mimic screen from the Events, Meters, Controls, or Setup screens. Returns to the main System Setup Level screen from a setup submenu. Return arrow acknowledges or executes a command, or saves a setting. Up or down arrows scroll through screens and lists or highlight settings. Left or right arrows select or adjust settings displayed on the screen. Table 7-2: Display function menu map 7.2.5 Mimic screen Figure 7-4 shows the Main Menu and Mimic screen.
Function Subfunction Operation Service History The Service History Log is for service personnel and is password protected. If the customer needs access to the log, contact an Eaton service representative. Press the SERVICE pushbutton on the User History menu bar to display the Service History Log. The Service History Log lists up to 2048 events in chronological order, with the most recent event listed last (once 2048 is reached, the earliest event is overwritten).
Function 80 Subfunction Operation Contrast Adjust Select CONTRAST from the System Setup Level 0 menu to display the Contrast Adjust screen. Use the left or right arrow pushbutton to adjust the contrast for the LCD. When the contrast adjustment is complete, press the SAVE pushbutton. Once the setting is saved, the System Setup screen displays. To return to the System Setup screen without saving the setting, press the ESC pushbutton.
Function System Level 1 Setup 1027574 Revision E Subfunction Operation Advanced Power Management The Advanced Power Management Setup screen allows the selection of the Advanced Power Management function to be configured. Select ADVANCED POWER MANAGEMENT SETUP from the System Setup Level 0 menu to display the Advanced Power Management Setup screen. Use the up or down arrow pushbutton to highlight the desired function, then press the SELECT pushbutton.
Function 82 Subfunction Operation Change Password The Change Password screen allows the System Setup Level 1 password 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 the up or down arrow pushbutton to change the password character. Once the new password is entered, press the DONE pushbutton. The Change Password Save screen is displayed.
Function Subfunction Operation VMMS UPM Load Limit The VMMS Load Limit screen sets the maximum load that can be drawn from a UPM before additional UPMs are activated. Select APM LOAD LIMIT from the Module Management System Setup screen to display the VMMS Load Limit screen. Use the up or down arrow pushbutton to set the load limit. Press SAVE or ABORT. Once the action is completed, the Module Management System screen is displayed.
Function Message Maintenance Bypass Off; On Charger Charger Off; Charging UPM (during startup) DC Starting, Charger Off; DC Starting, Close Battery Breaker; Inverter Starting; Inverter Syncing; Ready; Online UPM 1 UPM 2 UPM 4 (only in systems with a Field Upgrade UPM) Offline; Shutdown, Charger Off; Ready; Ready, Charging; Online, Charger Off; Online, Charging Table 7-4: Typical system status messages Function Subfunction UPS Control Commands Use the up or down arrow pushbutton to highlight th
Function Subfunction Operation 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 Select the UPM, use the up or down arrow pushbutton to highlight the command function desired, then press the SELECT pushbutton to execute the command.
7.3 Single UPS operation 7.3.1 Starting the UPS in Normal mode To start the UPS system: 1. 2. 3. 4. 5. 6. 7. 8. 9. If the UPS contains input breaker CB1, verify that input breaker CB1 is open. Close the UPS input feeder circuit breaker. Close the UPS bypass input feeder circuit breaker. Observe the UPS control panel display becoming active, indicating logic power. Press the CONTROLS pushbutton on the main menu bar. The System Status screen appears.
7.3.3 Starting the UPMs To start the power module without transferring the critical load to Normal mode: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Unfasten the front door latch and swing the door open (see Figure 4-2 on page 25). If the UPS contains input breaker CB1, verify that input breaker CB1 is open. Close the UPS input feeder circuit breaker. Close the UPS Bypass input feeder circuit breaker. If the UPS contains input breaker CB1, close input breaker CB1.
7.3.4 Starting a single UPM To start a single UPM: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Unfasten the front door latch and swing the door open (see Figure 4-2 on page 25). If the UPS contains input breaker CB1, verify that input breaker CB1 is open. Close the UPS input feeder circuit breaker. Close the UPS Bypass input feeder circuit breaker. If the UPS contains input breaker CB1, close input breaker CB1. Close the door and secure the latch.
5. Press the SELECT pushbutton on the UPS Command menu bar. The UPS transfers to Variable Module Management System mode. In approximately twenty seconds 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.
5. Press the SELECT pushbutton on the UPS Command menu bar. 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. 7.3.
5. Press the SELECT pushbutton on the Bypass Command menu bar. If the UPS is online, the UPS transfers to Battery mode and then to Normal mode in approximately ten seconds. The Online status indicator is illuminated. The UPS status indicates ONLINE. The UPM status indicates ONLINE. 7.3.
WARNING Power is present inside the UPS cabinets. 7.3.12 Transfer from Bypass to Normal mode To transfer the critical load to Normal mode, perform the following procedure: 1. Press the CONTROLS pushbutton on the main menu bar. The System Status screen appears. 2. Press the NORMAL pushbutton on the System Status menu bar. The UPS transfers to Normal mode. If the power processor is not available, the system remains on bypass and an alarm sounds. 3.
3. Press the CONTROLS pushbutton on the System Status menu bar. The UPS Control Command screen is displayed. 4. On the UPS Control Command screen, select GO ONLINE. 5. Press the SELECT pushbutton on the UPS Command menu bar. The UPS transfers to Battery mode and then to Normal mode. If the power module is not available, the system remains on bypass and an alarm sounds. The NORMAL status indicator is illuminated. The UPS status indicates ONLINE. The UPM status indicates ONLINE. 7.3.
7.3.17 Transfer from Bypass to Energy Saver System To transfer the critical load to Energy Saver System: NOTE The Energy Saver System commands are displayed only if enabled at the factory or by an Eaton Customer Service Engineer. 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.
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 START HIGH ALERT. 5. Press the SELECT pushbutton on the Bypass Command menu bar. The UPS transfers to High Alert mode, but remains online.
5. Press the SELECT pushbutton on the UPS Command menu bar. The UPS transfers to Battery mode and then to High Alert mode. After one hour the UPS transfers to Energy Saver System and the critical load is immediately supplied by the bypass source. If the bypass source is not available, the power module remains on and an alarm sounds. The NORMAL status indicator is illuminated. The UPS status indicates HIGH ALERT. The UPM status indicates ONLINE. The power module is on. 7.3.
2. On the System Status screen, select the UPM Command. The UPS Control Command screen is displayed. 3. On the UPS Control Command screen, select 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 SELECT pushbutton on the UPM Command menu bar. The UPM status indicates READY. The output contactor opens. The power module remains on.
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 breakers. 7.3.27 Charger control To turn the battery charger on or off, perform the following procedure: 1. Press the CONTROLS pushbutton on the main menu bar. The System Status screen appears. 2. Scroll down to the charger. 3.
7.3.29 Using the Remote Emergency Power-off switch A UPS emergency power-off is initiated by the REPO pushbutton switch. In an emergency, you can use this switch to control the UPS output. The REPO switch de-energizes the critical load and powers down the UPS immediately, without asking for verification. The UPS, including Bypass, remains off until restarted. CAUTION All power to the critical load is lost when the REPO switch is activated in the following step.
Figure 7-7. The normal positions of the MBS switches and rectifier disconnect switch (must be located in the site wiring) Turn UPS from normal mode to mechanical bypass The procedure to turn the UPS to mechanical bypass switch is described below. 1. The normal start position should be following: 2. Perform transfer from normal mode to bypass mode as described in Section 7.3.11. Remember to verify the transfer before proceeding the next step. 3.
1. The normal start position should be the following: 2. 3. 4. 5. 6. Turn ON rectifier switch to connect rectifier input to UPS. Turn ON Static bypass switch to connect bypass input to UPS: Perform the UPS start-up procedure (bypass mode) in Section 7.3.2. Turn S10 switch from bypass position to UPS position to connect UPS output to load. Perform transfer from bypass to normal mode as described in Section 7.3.12. Remember to verify the transfer before proceeding to the next step.
7.4 Multiple UPS distributed bypass operation 7.4.1 Starting the distributed bypass system in normal mode To start the distributed bypass system: 1. Unfasten the front door latches and swing the doors open on all of the UPSs (see Figure 4-2 on page 25). 2. If the UPSs contain input breakers (CB1), verify that all input breakers are open. 3. Close all Module Output Breakers (MOBs). 4. Close all UPS input feeder circuit breakers. 5. If the UPSs contain input breakers (CB1), close all input breakers. 6.
1. Unfasten the front door latches and swing the doors open on all of the UPSs (see Figure 4-2 on page 25). 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. If the UPSs contain input breakers (CB1), close all input breakers. 6. Close all UPS Bypass input feeder circuit breakers. 7. Close the doors and secure the latches. 8. Observe the UPS control panel displays becoming active, indicating logic power.
7.4.8 Start Variable Module Management System High Alert mode from the bypass command menu For instructions, see Section 7.3.10 “Start Variable Module Management System High Alert mode from the bypass command menu” on page 91. 7.4.9 Starting the UPS UPMs To start the power modules without transferring the critical load to Normal mode: 1. Unfasten the front door latches and swing the doors open on all of the UPSs (see Figure 4-2 on page 25). 2.
NOTE To transfer to Normal mode after starting individual UPMs, follow the procedure in Section 7.4.12. 7.4.10 Starting a single UPM To start a single UPM: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Unfasten the front door latch and swing the door open (see Figure 4-2 on page 25). If the UPS contains input breaker CB1, verify that input breaker CB1 is open. Close the UPS input feeder circuit breaker. If the UPSs contain input breakers (CB1), close all input breakers.
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 GO TO BYPASS. 5. Press the SELECT pushbutton on the Bypass Command menu bar. All of the UPSs transfer to Bypass mode and the critical load is immediately supplied by the bypass source. If the bypass source is not available, the power module remains on and an alarm sounds. The BYPASS status indicator is illuminated. The Bypass status indicates ON.
7.4.14 Transfer from Energy Saver System to Normal mode To transfer the critical load to Normal mode: NOTE The Energy Saver System commands are displayed only if enabled at the factory or by an Eaton Customer Service Engineer. 1. On any UPS, press the CONTROLS pushbutton on the main menu bar. The System Status 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.
7.4.16 Transfer from High Alert to Normal mode To transfer the critical load to Normal mode: NOTE The High Alert mode commands are displayed only if enabled at the factory or by an Eaton Customer Service Engineer. 1. On any UPS, press the CONTROLS pushbutton on the main menu bar. The System Status 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.
1. On any UPS, 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 GO TO BYPASS. 5. Press the SELECT pushbutton on the Bypass Command menu bar. All the UPSs transfer to Battery mode and then to Bypass mode. The BYPASS status indicator is illuminated.
5. Press the SELECT pushbutton on the Bypass Command menu bar. All the UPSs transfer to Bypass mode and the critical load is immediately supplied by the bypass source. If the bypass source is not available, the power module remains on and an alarm sounds. The BYPASS status indicator is illuminated. The UPS status indicates BYPASS. The Bypass status indicates ON. The UPM status indicates READY. The power module remains on. 7.4.
7.4.23 Transfer from Normal to Bypass mode and shut down all 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 Figure 7.4.11 on page 105. 2. Press the CONTROLS pushbutton on the main menu bar. The System Status screen is displayed. 3. On the System Status screen, select the UPM command. The UPS Control Command screen is displayed. 4. On the UPS Control Command screen, select the UPM 1 command. 5.
7.4.25 Single UPM restart To restart a single UPM from a shutdown state: 1. Press the CONTROLS pushbutton on the main menu bar. The System Status screen is displayed. 2. On the System Status screen, select the UPM command. The UPS Control Command screen is displayed. 3. On the UPS Control Command screen, select the UPM to restart. 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 ON. 6.
7. Perform the LOAD OFF procedure in Section 7.4.31 on the UPS being shut down. The input, output, battery, and bypass backfeed contactors open, and the power module is turned off on the UPS being shut down. Logic power remains on. 8. Verify the battery breaker or disconnect for the UPS being shut down is open. If not, open the breaker. WARNING Power is present inside the UPS cabinet until the upstream input feeder circuit breaker is opened.
11. Press the SELECT pushbutton on the UPM 1 Command menu bar. The UPM status indicates SHUTDOWN. The input, output, and battery contactors open, and the power module is turned off. The remaining UPMs supply the critical load. If remaining UPMs can not support the load, selected UPM will not turn off. Logic power remains on. 12. If the UPS is a multimodule UPM model, repeat Steps 8 through 11 selecting UPMs 2, 3 and 4 to shut down UPMs 2, 3 and 4. 13.
NOTE If the UPS is starting on a bus with other online paralleled UPSs, the UPS will not go to bypass during startup. The UPS will start, sync to the other UPSs online, and go online. 16. Verify the following messages display sequentially on the UPS status line: DC STARTING, CHARGER OFF INVERTER STARTING INVERTER SYNCING ONLINE, CHARGER ON The rectifier and inverter turn on. The inverter continues to ramp to full voltage. Once the inverter reaches full voltage, the UPS output contactors (K3) close.
4. On the Charger Control Command screen, select CHARGER OFF. 5. Press the SELECT pushbutton on the Charger Command menu bar. 7.4.31 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 Load Off command on the Bypass Control Command screen. The UPS LOAD OFF controls the UPSs outputs by powering down the UPS and deenergizing the critical load.
Status screen is displayed. 2. On the System Status screen, select either the UPS or the BYPASS command. 3. Press the CONTROLS pushbutton 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.
NOTE The following instructions are for the Eaton-supplied REPO switch. If a customer-supplied REPO switch is used, 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 latches into the activated state.
8 Communication This chapter describes the communication features of the Eaton 9395 450–550 kVA UPS and provides information about connecting hardware and using Terminal mode. For location of the customer interface panels and terminals, see Figure 4-4 on page 29 and Figure 4-11 on page 36 through Figure 413 on page 37. 8.1 X-Slot cards The Eaton 9395 UPS has four X-Slot communication bays (see Figure 4-11 on page 36 for bay locations).
LanSafe software uses an RS-232 serial link to communicate with the UPS. The software provides upto-date graphics of UPS power and system data and power flow, a complete 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 useful view for their specific needs. LanSafe Power Management Software 8.
The Event History Log lists up to 500 system events in chronological order with the most recent event listed last. In this mode, system events are continually logged 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: MM DD YYYY HH:MM:SS.
03/16/2099 21:25:25.850 N011: OUTPUT UNDER OR OVER FREQ OK (PM1) ... 03/23/2099 18:59:20.450 A199: BATTERIES DISCONNECTED (PM1) ACTIVE ALARMS: 11 NOTICE: OUTPUT UNDER OR OVER FREQ (PM1) 12 ALARM: REMOTE EMERGENCY POWER OFF (MCU) 102 NOTICE: INVERTER L1 CURRENT LIMIT (PM1) 103 NOTICE: INVERTER L2 CURRENT LIMIT (PM1) 104 NOTICE: INVERTER L3 CURRENT LIMIT (PM1) 8.
9 UPS maintenance The components inside the UPS cabinet are secured to a sturdy metal frame. All repairable parts and assemblies are located for easy removal, with very little disassembly. This design allows authorized service personnel to perform routine maintenance and servicing quickly. You must schedule periodic performance checks of your UPS system to keep it running properly.
9.2 Performing preventive maintenance The UPS system requires very little preventive maintenance. However, the system should be inspected periodically to verify that the units are operating normally and that the batteries are in good condition. 9.2.1 DAILY maintenance Perform the following steps daily: 1. Check the area surrounding the UPS system. Ensure the area is not cluttered, allowing free access to the unit. 2.
9.3 Installing batteries NOTE There is no DC disconnect device within the UPS. Install batteries in accordance with the battery and battery cabinet or battery rack manufacturer’s instructions. 9.4 Recycling the used UPS or batteries Before scrapping UPS or its battery cabinet, the battery bank must be removed. Local requirements must be followed in battery recycling or discard. The removal of batteries is allowed only by authorised service personnel due to high energy and voltage.
10 Product specifications 10.1 Model numbers The UPS systems are housed in free-standing cabinets with safety shields behind the doors. The UPS systems are available in 50/60 Hz with various output power ratings. Models Power Rating Frequency Eaton 9395-550/450 450 kVA 50/60 Hz Eaton 9395-550/550 550 kVA 50/60 Hz The following sections detail the input, output, environmental, and battery specifications for the UPS. 10.2 Single module specifications 10.2.
Output Voltage Balance 3% for 100% maximum load imbalance (linear load) Output Voltage Phase Displacement 3° for 100% maximum load imbalance (linear load) Output Transients ±5% for 100% load step or removal Frequency Regulation ±0.1 Hz free running Synchronous to Bypass Bypass within voltage limits of +5%, –8% of output setting; bypass within ±3 Hz Frequency Slew Rate 0.
11 Warranty The product is warranted against defects in design, materials and workmanship for a period of twelve (12) months from its original date of purchase. The local office or distributor may grant a warranty period different to the above and refer to local terms of liability as defined in the supply contract.
12 Installation checklist All packing materials and restraints have been removed from each cabinet. Each cabinet in the UPS system is placed in its installed location. A cabinet grounding/mounting kit is installed between any cabinets that are bolted together. All conduits and cables are properly routed to the UPS and any ancillary cabinets. All power cables are properly sized and terminated. Neutral conductors are installed or bonded to ground as per requirements.
