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Summary of Contents for Eaton Powerware 9x55 series
- Page 1 Powerware Series 9x55 8–15 kVA Battery Upgrade For use with the Eaton ® 9155 and 9355 (8–15 kVA) p/n: Revision 1...
- Page 2 Eaton reserves the right to change specifications without prior notice. Eaton is a registered trademark of Eaton. All other trademarks are property of their respective companies. ©Copyright 2017 Eaton, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any way without the express written approval of Eaton.
- Page 3 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s 1 1 I I n n t t r r o o d d u u c c t t i i o o n n ........................................................... . 1 1 2 2 B B a a t t t t e e r r y y U U p p g g r r a a d d e e P P r r o o c c e e d d u u r r e e .
- Page 4 Table of Contents 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 5 C C h h a a p p t t e e r r 1 1 I I n n t t r r o o d d u u c c t t i i o o n n Eaton has designed a new harness (see...
- Page 6 Introduction 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 7 C C h h a a p p t t e e r r 2 2 B B a a t t t t e e r r y y U U p p g g r r a a d d e e P P r r o o c c e e d d u u r r e e WARNING This procedure involves interacting with components that may be energized.
- Page 8 Battery Upgrade Procedure Verify that the UPS battery circuit breaker CB1, at the rear of the unit, is open. Follow applicable lockout/ tagout procedures. Figure 2. CB1 Is Open (Located at the rear of the unit) NOTE If an external battery cabinet is attached, it must be disconnected from the UPS. Ensure that CB1 is open on each associated external battery cabinet.
- Page 9 Battery Upgrade Procedure Remove the front dress panel of the battery compartment. Figure 3. Remove Front Panel 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 10 Battery Upgrade Procedure Using a 7mm nut driver, remove the screws that secure the battery dead front and remove the dead front. Figure 4. Remove Battery Dead Front Screws Figure 5. Battery Dead Front Removed 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 11 Battery Upgrade Procedure Disconnect all the cabinet harnesses from all the battery trays, starting with all the positive (red) wires then all the negative (black) wires. Ensure that the wires do not come into contact with any metal framing. It is recommended to isolate the connectors by using a non-conductive electrical tape to secure the end of each connector.
- Page 12 Battery Upgrade Procedure Figure 7. Disconnected Cabinet Harnesses WARNING All battery trays must be disconnected prior to proceeding any further. 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 13 Battery Upgrade Procedure Using a voltmeter, measure the voltage between the positive (+) and negative (-) disconnected harness from each shelf/string to verify that there is no voltage. Figure 8. Verify Zero Voltage WARNING After performing Step 6, there will still be full battery string voltage between the positive (red) and negative (black) terminals of the battery trays.
- Page 14 Battery Upgrade Procedure Slide one battery tray half way out and disengage the tray to tray jumper from the tray clips. Figure 9. Disconnect Tray to Tray Jumper From Tray Clips Disconnect the tray to tray jumper (white terminal on a black wire). Figure 10.
- Page 15 Battery Upgrade Procedure Slide both battery trays completely out of the unit. Figure 11. Both Trays Slid Completely Out 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 16 Battery Upgrade Procedure 10. Remove and discard the tray to tray jumper. Figure 12. Discard Tray to Tray Jumper 11. Repeat Steps 7–10 for the other battery shelves until all battery trays have been removed from the unit. Figure 13. Empty Unit 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 17 Battery Upgrade Procedure 12. Slide the new battery trays into the unit. The positive (+) terminal of each tray should face the front of the unit and be on the right side of the tray (highlighted in yellow in Figure 14).
- Page 18 Battery Upgrade Procedure 14. Use a wire stripper (preferably the no-nick type so that no wire strands are cut off or nicked/weakened) to strip 1/4 inch of insulation from each of the red and black wires. Figure 15. Strip 1/4 Inch of Insulation 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 19 Battery Upgrade Procedure 15. Connect the newly provided adapter harness (see Figure 16) to the UPS battery tray wiring, using the crimp tool (or equivalent) illustrated in Figure 17. It is recommended that crimp tool PN 59824-1 equivalent is used in this step. Ensure that the two pieces of black heat shrink (highlighted in yellow in Figure 18) are on the adapter assembly.
- Page 20 Battery Upgrade Procedure Figure 18. Add New Adapter Harness to the Battery Cabinet Wires 16. Repeat the insertion and crimping steps for the positive (red wire), ensuring that no bare wires are hanging out of the crimp. Figure 19. Inserting and Crimping the Red Wire to The Adapter Harness 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 21 Battery Upgrade Procedure 17. Slide the black heat shrink tubing over each crimp terminal, one at a time. Either heat the heat shrink to get it to contract around the connections or use tie wraps to hold it in place (pull tightly, then cut the excess length).
- Page 22 Battery Upgrade Procedure Figure 22. Connecting the Anderson Connectors (black to black and red to red) 21. Push the new harness and connections back against the battery cases. Secure the right side harness to the battery tray using a single tie-wrap to prevent the connections from coming into contact with the dead front and its screws when reinstalled.
- Page 23 Battery Upgrade Procedure 22. Reinstall the dead front and secure with the previously removed 7 mm screws. Ensure that the tray retainer clips (on the back of the dead front) do not pinch the battery cables. Figure 23. Reinstall the Dead Front Figure 24.
- Page 24 Battery Upgrade Procedure 24. Reinstall the front dress panel. Figure 25. Battery Cabinet Front Dress Panel Reinstalled 25. Follow the instructions in the equipment’s User’s Guide (shown in the “Normal Mode Startup” section) to command the unit to normal mode of operation. 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
- Page 25 Battery Upgrade Procedure NOTE The figure below provides a schematic example of the end result as a reference for a two-string / two-shelf configuration: Figure 26. Schematic Example of New Configuration 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1...
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