Powerware 9395 UPS 225–275 kVA User’s and Installation Guide 1027212 Revision B Contents Introduction ...5 1.1 UPS standard features ...5 1.1.1 Control panel ...5 1.1.2 Customer Interface ...7 1.1.3 Advanced Battery Management ...7 1.1.4 Power Management Software ...7 1.1.5 Installation features ...7 1.2 Options and accessories ...7 1.2.1 Integrated battery cabinet ...7...
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5.3 Operation ...57 5.3.1 Starting the UPS in normal mode ...57 5.3.2 Starting the UPS in bypass mode ...58 5.3.3 Starting the power module ...59 5.3.4 Transfer from normal to bypass mode ...59 5.3.5 Transfer from bypass to normal mode ...60 5.3.6 Transfer from normal to bypass mode and shut down UPS ...60 5.3.7 UPS and critical load shutdown ...60 5.3.8 Charger control ...61...
The cabinet matches the battery and distribution cabinets in style and color and can be installed in line-up-and-match or standalone configurations. Figure 1-1 shows the Powerware 9395 UPS (225–275 kVA) and Figure 1-2 shows a typical single module system.
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Figure 1-1. Powerware 9395 UPS (225–275 kVA) cabinet Figure 1-2. Powerware 9395 UPS (225–275 kVA) typical single module system 1027212 UPS 225 - 275 kVA Revision B User’s and Installation Guide...
Battery backup protection can be enhanced by equipping the UPS system with up to four Powerware 9395 battery cabinets containing sealed lead-acid, maintenance-free batteries. The battery cabinet is available in one size, with a 240-cell configuration. The cabinets are designed for line-up-and-match installation, but may be installed separate from the UPS cabinet.
Remote Emergency Power-off (REPO) control, or X-Slot® communication cards. 1.4 Using this manual This manual describes how to install and operate the Powerware 9395 UPS (225–275 kVA) cabinet. Read and understand the procedures described in this manual to ensure trouble-free installation and operation. In particular, be thoroughly familiar with the REPO procedure (see paragraph 5.3.10 on page 62).
(WEEE) in the trash. For proper disposal, contact your local recycling/reuse or hazardous waste center. 1.7 For more information Refer to the Powerware 9395 Integrated Battery Cabinet (Model IBC-L) installation manual (164201687) for the following additional information: • Integrated Battery Cabinet (IBC) installation instructions, including site preparation, planning for installation, wiring, and safety information.
2 UPS installation plan and unpacking Use the following basic sequence of steps to install the UPS: Create an installation plan for the UPS system (Chapter 2). Prepare your site for the UPS system (Chapter 2). Inspect and unpack the UPS cabinet (Chapter 2). Unload and install the UPS cabinet, and wire the system (Chapter 3). Complete the Installation Checklist (Chapter 3).
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Dimensions are in millimeters. Model Powerware 9395-275/225 Powerware 9395-275/275 Table 2-1. UPS cabinet weights The UPS cabinets use forced air cooling to regulate internal component temperature. Air inlets are in the front of the cabinet and outlets are in the top. You must allow clearance in front of and above each cabinet for proper air circulation.
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Figure 2-1. UPS cabinet dimensions (front view) Figure 2-2. UPS cabinet dimensions (right side view) 1027212 UPS 225 - 275 kVA Revision B User’s and Installation Guide...
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Figure 2-3. UPS cabinet dimensions (top view) Figure 2-4. UPS cabinet dimensions (bottom view) Figure 2-5. UPS Cabinet dimensions (bottom view with mounting brackets) 1027212 Revision B UPS 225 - 275 kVA User’s and Installation Guide...
Figure 2-6. UPS cabinet center of gravity Figure 2-7. Remote EPO switch dimensions 2.2.2 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. User’s and Installation Guide UPS 225 - 275 kVA 1027212 Revision B...
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NOTE callout letters A, B, C, and D map to figure 6-5 on page 6-6. Table 2-4. Input/output ratings and external wiring requirements for the Powerware 9395-275/225 and 9395-275/275 Read and understand the following notes while planning and performing the installation: •...
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DC input from battery to UPS Input and output neutral Customer ground NOTE Customer ground, size1/0, can be run in any conduit. Table 2-5. UPS cabinet power cable terminations for the Powerware 9395-275/225 and 9395-275/275 Part Long barrel 2 hole lug 500 MCM...
Table 2-8 lists the recommended rating for bypass and output circuit breakers satisfying the criteria for both. UPS model 9395-275/225 9395-275/275 Table 2-8. Recommended bypass and output circuit breaker ratings There is no DC disconnect device within the UPS. A battery disconnect switch is recommended, and may be required by local codes when batteries are remotely located.
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Read and understand the following notes while planning and performing the installation: • Install the interface wiring (for example, building alarm, relay output, battery breaker trip, and X-Slot) separate from the power wiring. The wiring should have double insulation and rated at Uo/U = 300/500 Volts.
2.3 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 3-8). CAUTION The UPS cabinet is heavy (see Table 2-1 on page 11). If unpacking instructions are not closely followed, the cabinet may tip and cause serious injury. Carefully inspect the outer packaging for evidence of damage during transit. CAUTION Do not install a damaged cabinet. Report any damage to the carrier and contact your service representative immediately.
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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 2-8. Powerware 9395 UPS (225–275 kVA) cabinet as shipped on pallet User’s and Installation Guide UPS 225 - 275 kVA 1027212 Revision B...
3 UPS system installation 3.1 Preliminary installation information WARNING Installation should be performed only by qualified personnel. Refer to the following while installing the UPS system: • Chapter 2 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 are to be removed to add holes as required.
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CAUTION • Do not tilt cabinets more than 10° from vertical. • Lift the cabinet only with a forklift or damage may occur. NOTE For the following steps, verify that the forklift or pallet jack is rated to handle the weight of the cabinet (see Table 2-1 on page 11 for cabinet weight). If not already accomplished, use a forklift or pallet jack to move the cabinet to the installation area, or as close as possible, before unloading from the pallet. Insert the forklift or pallet jack forks from the right side of the cabinet, between the supports on the bottom of the pallet (see Figure 2-6 on page 13 for the UPS cabinet center of gravity measurements).
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Figure 3-1. Removing left side shipping bracket 1027212 UPS 225 - 275 kVA Revision B User’s and Installation Guide...
Figure 3-2. Removing right side shipping bracket 3.3 Battery cabinet installation To install the battery cabinet, refer to the Powerware 9395 Integrated Battery Cabinet (Model IBC-L) installation manual. After the battery cabinet is installed, return to paragraph 3.4 to wire the UPS and battery cabinet.
3.4 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. NOTE Remove the UPS cabinet top or bottom conduit landing plate to drill or punch conduit holes (see Figure 3-3). NOTE If the load requires a neutral, a bypass source neutral must be provided. If the load does not require a neutral and there is no neutral conductor connected at the bypass input, a neutral to ground bonding jumper must be installed. DO NOT install both a source neutral and a bonding jumper. See Table 2-4 on page 15 for neutral bonding jumper wire sizes. Bonding jumper must be copper wire. Use the procedures in the following paragraphs to connect the external and battery power wiring. 3.4.1 External power wiring installation To install wiring to connections: Remove one top screw and two bottom screws securing the UPS left front panel (see Figure 3-1).
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Figure 3-3. Conduit and wire entry locations 1027212 UPS 225 - 275 kVA Revision B User’s and Installation Guide...
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Figure 3-4. UPS power terminal locations Figure 3-5. UPS power terminal detail AA 1027212 Revision B UPS 225 - 275 kVA User’s and Installation Guide...
If using a Powerware battery cabinet, proceed to Step 2; otherwise, proceed to Step 5. Route and connect the battery cables between the UPS and battery cabinets in accordance with the instructions in the Powerware 9395 Integrated Battery Cabinet (Model IBC-L) installation manual. See Figure 3-3 through Figure 3-5 for wiring access information and terminal locations.
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To install wiring to connections: Verify the UPS system is turned off and all power sources are removed. See Chapter 5, “UPS Operating Instructions, ” for shutdown instructions. If not already accomplished, remove one top screw and two bottom screws securing the UPS left front panel (see Figure 3-1).
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Figure 3-7. Interface terminal locations 1027212 UPS 225 - 275 kVA Revision B User’s and Installation Guide...
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Terminal TB1 Name Remote EPO NC Remote EPO return Remote EPO NO Remote EPO return Battery aux Battery aux return 48 Vdc battery shunt trip + 48 Vdc battery shunt trip - Not used Not used Terminal TB2 Name Pull chain Pull chain return Alarm relay NC Alarm relay return...
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Figure 3-8. Interface terminal detail AA 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.
Step 10. Route the Shunt trip and Aux wiring harness supplied with the battery cabinet from the battery cabinet to the UPS cabinet. Refer to the Powerware 9395 Integrated Battery Cabinet (Model IBC-L) installation manual for battery cabinet wiring access information.
NOTE Battery Aux and DC Shunt Trip wiring should be a minimum of 1.5 mm Figure 3-10. Typical battery interface connection 3.5.3 X-Slot connections NOTE LAN and telephone drops for use with X-Slot cards must be provided by the customer. NOTE 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: If not already installed, install the LAN and telephone drops.
Figure 3-11. X-Slot communication bays 3.6 Installing a remote EPO switch NOTE Remove the UPS cabinet interface entry plates to punch holes (see Figure 3-3). NOTE This switch must be a dedicated switch not tied into any other circuits. NOTE This procedure is intended to be used for the installation of the Powerware 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 3-12 shows a remote EPO switch.
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Securely mount the remote EPO switch. Recommended locations include operator’s consoles or near exit doors. See Figure 2-7 for enclosure dimensions and wiring knockouts. Verify the UPS system is turned off and all power sources are removed. See Chapter 5, “UPS operating instructions”...
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Note Remote EPO switch rating is 24 Vdc, 1 A minimum. Note Remote EPO normally-open and normally-closed return terminals are separated on the terminal board, but are electrically in common. Figure 3-13. Normally-Open remote EPO switch wiring 10. If you are installing multiple remote EPO switches, wire additional switches in parallel with the first remote EPO.
Note Remote EPO switch rating is 24 Vdc, 1 A minimum. Note Remote EPO normally-open and normally-closed return terminals are separated on the terminal board, but are electrically in common. Figure 3-15. Normally closed and normally open remote EPO switch wiring 3.7 Initial startup Startup and operational checks must be performed by an authorized Eaton Customer Service Engineer, or the warranty terms specified on page W-1 become void.
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Installation checklist r All packing materials and restraints have been removed from each cabinet. r Each cabinet in the UPS system is placed in its installed location. r A cabinet grounding/mounting kit is installed between any cabinets that are bolted together. r All conduits and cables are properly routed to the UPS and any ancillary cabinets.
4 Understanding UPS operation 4.1 Looking inside the UPS system The Powerware 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.
4.2 Modes The Powerware 9395 UPS supports a critical load in three different modes of operation. The UPS can automatically use all three modes, as required. The standard operation modes are: • In Normal mode, the critical load is supplied by the inverter, which derives its power from rectified utility AC power.
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 the rectifier and uses IGBT devices and pulse-width modulation (PWM) to produce a regulated and filtered AC output. The AC output of the inverter is delivered to the system output through the output contactor K3.
In bypass mode, the output of 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 from the source. Some power line filtering and spike protection is provided to the load but no active power conditioning or battery support is available to the output of the system in the bypass mode of operation.
4.3 UPS system one line configurations One line drawing UPS model Figure 4-5 9395-275/225 Figure 4-6 9395-275/275 User’s and Installation Guide Voltage Input...
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DO NOT install both a source neutral and a bonding jumper. Figure 4-5. Powerware 9395 225–275 kVA UPS system, 400 V input and 400 V output dual-feed 1027212...
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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.
5 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. 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 two minutes of battery runtime at the initial startup. After a 24-hour charging period, the UPS automatically runs a battery test and the correct battery runtime displays. 1027212 Revision B UPS 225 - 275 kVA User’s and Installation Guide...
The controls and indicators identified and described in this section are used to control and monitor UPS operation. Figure 6-1 shows the UPS controls and indicators. Figure 5-1. Powerware 9395 225–275 kVA UPS controls and indicators 5.1.1 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 paragraph 5.2.
5.2 Using the control panel The following paragraphs describe the UPS control panel, including controls and indicators, and how to monitor UPS operation. The control panel (see Figure 5-2) is located on the front door of the UPS. Figure 5-2. UPS control panel The control panel consists of the following: •...
5.2.2 Using the LCD and pushbuttons The LCD on the control panel provides an operator interface with the UPS system. Figure 5-3 identifies the display areas discussed in the following sections. Figure 5-3. Parts of the LCD 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.
5.2.3 Using the menu The UPS menu bar allows you to display data in the information area to help you monitor and control UPS operation. Table 5-2 shows the basic menu structure. Menu option Description Displays the list of active system events and a historical log of system events. EVENTS METERS Displays performance meters for the system or critical load.
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Function Subfunction History Meters Output Input Bypass Battery Output Current Battery Discharge Log Summary Battery Discharge kW Demand Log Summary User’s and Installation Guide Operation Press the HISTORY pushbutton on the Active Events menu bar to display the His- tory Log. The History Log lists up to the 500 system events in chronological order, with the most recent event listed last (once 500 is reached, the earliest event is overwritten).
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Function Subfunction kW Demand Log kW Demand Log Screen 1 Setup Screen 2 Time Interval Moni- tored Setup Time Interval Moni- tored Save Maximum Level (kW) Setup Maximum Level (kW) Save Maximum Current Log Summary 1027212 Revision B Operation The kW Demand Log screen displays the individual log entries, including the interval date and time frame, the maximum reading during the interval, the total time over limit during the interval, an estimated number of total kWh used during the interval, and the number of times over limit during the interval.
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Function Subfunction Maximum Current Maximum Current Screen 1 Log Setup Screen 2 Time Interval Moni- tored Setup Time Interval Moni- tored Save Maximum % of Full Load Setup Maximum % of Full Load Save Calculation Method Setup User’s and Installation Guide Operation The Maximum Current Log screen displays the individual log entries, including the interval date and time frame, the maximum percent of full load during the...
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Function Subfunction System Level 0 Function Selection Setup Contrast Adjust Firmware Versions Identification System Level 1 Password Setup Function Selection Change Password Change Password Save Time Format Set Date and Time MM/DD/YYYY 1027212 Revision B Operation This screen can be used to set the screen contrast, show the firmware versions installed, identify the unit type and enter a password to access Level 1 functions.
Set Date and Time DD/MM/YYYY Com Port Selection Com Port Setup Control Table 5-3. Display menu operation 5.2.6 System controls screen Press the CONTROLS pushbutton on the main menu bar to display the System Controls screen. LOAD OFF , normal operation, transfer to bypass, charger control, and power module startup and shutdown functions are controlled from this screen.
Figure 5-6. System controls screen 2 5.2.7 Load off screen The load off screen appears when the LOAD OFF pushbutton is selected from the main menu bar or System Controls menu bar. This screen allows the LOAD OFF process to be aborted if the LOAD OFF pushbutton was pressed accidentally.
On the System Controls screen, the power module (PM) status should indicate SHUTDOWN. Close the battery breaker. If the UPS contains input breaker CB1, close input breaker CB1. Press the NORMAL pushbutton on the system controls menu bar. If Auto Bypass is enabled (factory default), the critical load is immediately supplied by the bypass source, in Bypass mode, until the inverter turns on and the UPS transfers to Normal mode.
5.3.3 Starting the power module To start the power module without transferring the critical load to normal, perform the following procedure: 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 becoming active, indicating logic power.
5.3.5 Transfer from bypass to normal mode To transfer the critical load to Normal mode, perform the following procedure: Press the CONTROLS pushbutton on the main menu bar. The System Controls screen appears. Press the NORMAL pushbutton on the System Controls menu bar. The UPS transfers to Normal mode.
5.3.8 Charger control To turn the battery charger on or off, perform the following procedure: Press the CONTROLS pushbutton on the main menu bar. The System Control screen appears. Press the pushbutton to display System Controls Screen 2. Press the CHGR ON or CHGR OFF pushbutton on the System Controls menu bar to toggle the charger on or off.
5.3.10 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.
5.3.11 Using Mechanical Bypass Switch The operation of the integral MBS is allowed for a trained person only who is familiar with the UPS behaviour and functions. The full UPS wiring diagram with a MBS switch is presented in the installation part of the manual. NOTE! The integral MBS and Static Bypass need to supplied by the same source.
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Turn UPS from mechanical bypass to normal mode The procedure to turn the UPS back to normal mode is described below. The normal start position should be following: Turn ON rectifier switch to connect rectifier input to UPS. Turn ON Static bypass switch to connect bypass input to UPS: Perform UPS start-up procedure (bypass mode) contained in paragraph 5.3.2.
6 Responding to system events 6.1 General When the UPS system is running in Normal mode, it continually monitors itself and the incoming utility power. In Battery or Bypass modes, the UPS may issue alarms to let you know exactly what event caused the change from Normal mode. System events on the UPS can be indicated by horns, lights, messages, or all three.
Figure 3-3 on page 26 and Figure 3-7 through Figure 3-9 starting on page 30. 7.1 X-Slot cards The Powerware 9395 UPS four X-Slot communication bays (see Figure 3-7 on page 30 for). The UPS is compatible with the following X-Slot cards (see Figure 7-1): •...
7.2 Powerware LanSafe Power Management Software Each Powerware 9395 UPS ships with LanSafe Power Management Software. To begin installing Powerware LanSafe software, see the instructions accompanying the Software Suite CD. Powerware LanSafe software uses an RS-232 serial link to communicate with the UPS. The software provides up-to-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.
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If a port is operating in Terminal mode and is connected to a computer, you can press [Esc] [H] to print the entire log with a firmware version header. The log in terminal mode is always in english. MODEL: POWERWARE 9395 CTO: TF12710000000 SERIAL: MCU DSP: 70.81.14...
7.4 Building alarm monitoring This standard feature lets you connect the UPS to your building alarms, such as smoke detectors or overtemperature alarms. The customer interface terminals for external connections are located inside the UPS. You should use twisted-pair wires for each alarm input and common. The building alarms can be programmed to display the alarm functional name.
8 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.
8.2 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. 8.2.1 DAILY maintenance Perform the following steps daily: Check the area surrounding the UPS system. Ensure the area is not cluttered, allowing free access to the unit.
8.3 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 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.
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 Powerware 9395-275/225 Powerware 9395-275/275 The following sections detail the input, output, environmental, and battery specifications for the UPS.
10.2.3 Environmental Operating Temperature Operating Altitude Storage Temperature Relative Humidity (operating and storage) Acoustical Noise EMI Suppression Electrostatic Discharge (ESD) Immunity 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.
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