Eaton Powerware 9395E User And Installation Manual
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Eaton Powerware 9395E User And Installation Manual

Eaton Powerware 9395E User And Installation Manual

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Powerware 9395E UPS
200 kVA
User's and Installation Guide

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  • Page 1 Powerware 9395E UPS 200 kVA User’s and Installation Guide...
  • Page 2 This is a product for commercial and industrial application in the second environment . Installation restrictions or additional measures may be needed to prevent disturbances. ©2010 Eaton Corporation All Rights Reserved The contents of this manual are the copyright of the publisher and may not be reproduced (even extracts) unless permission granted.

  • Page 3: Table Of Contents

    Powerware 9395E UPS 200 kVA User’s and Installation Guide 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...
  • Page 4 5.3 Operation .........................................58 5.3.1 Starting the UPS in normal mode ..............................58 5.3.2 Starting the UPS in bypass mode ..............................59 5.3.3 Starting the power module ................................60 5.3.4 Transfer from normal to bypass mode ............................60 5.3.5 Transfer from bypass to normal mode ............................61 5.3.6 Transfer from normal to bypass mode and shut down UPS ....................61 5.3.7 UPS and critical load shutdown ..............................61 5.3.8 Charger control ....................................62...

  • Page 5: Introduction

    1 Introduction The Eaton® Powerware® 9395E 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 all nine power failures. The Powerware 9395E UPS is available as a single module system.
  • Page 6 Figure 1-1.Powerware 9395E-200 cabinet UPS 200 kVA User’s and Installation Guide...

  • Page 7: Customer Interface

    1.1.2 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.

  • Page 8: Basic Systemcconfigurations

    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 9395E UPS (200 kVA) cabinet. Read and understand the procedures described in this manual to ensure trouble-free installation and operation.

  • Page 9: Symbols, Controls, And Indicators

    1.6 Symbols, controls, and indicators The following are examples of symbols used on the UPS or accessories to alert you to important information: 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.

  • Page 10: Ups Installation Plan And Unpacking

    Have authorized service personnel perform preliminary operational checks and startup. NOTE 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. This service is offered as part of the sales contract for the UPS. Contact service in advance (usually a two- week notice is required) to reserve a preferred startup date.
  • Page 11 Model Shipping Installed Powerware 9395E-200 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.
  • Page 12 Figure 2-1. UPS cabinet dimensions (front view) Figure 2-2. UPS cabinet dimensions (right side view) UPS 200 kVA User’s and Installation Guide...
  • Page 13 Figure 2-3. UPS cabinet dimensions (top view) Front Figure 2-4. UPS cabinet dimensions (bottom view) UPS 200kVA User’s and Installation Guide...

  • Page 14: Ups System Power Wiring Preparation

    Figure 2-5. UPS cabinet center of gravity Figure 2-6. 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.
  • Page 15 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 9395E-200 Read and understand the following notes while planning and performing the installation: •...
  • Page 16 Terminals E1 through E12 are 2-hole bus bar mountings for standard NEMA 2-hole barrel lugs. See Table 2-5 for power cable terminations and Table 2-6 for recommended installation parts and tools not supplied by Eaton Corporation. Figure 3-4 and Figure 3-5 show the location of the power cable terminals inside the UPS.

  • Page 17: Ups System Interface Wiring Preparation

    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 2-4. The recommended line-to- line load unbalance is 50% or less. Source protection for the AC input to bypass should be treated as if supplying a 200 kVA three- phase transformer, to allow for inrush current.
  • Page 18 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.

  • Page 19: Inspecting And Unpacking The Ups Cabinet

    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.
  • Page 20 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 9395E UPS (200 kVA) cabinet as shipped on pallet UPS 200 kVA...

  • Page 21: Ups System Installation

    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. •...
  • Page 22 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.
  • Page 23 Figure 3-1. Removing left side shipping bracket UPS 200 kVA User’s and Installation Guide...

  • Page 24: Battery Cabinet Installation

    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.

  • Page 25: Installing Ups External And Battery Power Wiring

    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.
  • Page 26 Figure 3-3. Conduit and wire entry locations UPS 400 kVA (2x200 kVA) User’s and Installation Guide...
  • Page 27 Front view Figure 3-4 a UPS power terminal locations Side view Figure 3-4. b UPS power terminal locations UPS 200 kVA User’s and Installation Guide...
  • Page 28 Figure 3-5 a, front view Figure 3-5 b, side view. UPS power terminal locations MBS version UPS 200 kVA User’s and Installation Guide...

  • Page 29: Battery Wiring

    3.4.2 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 currents. To install wiring to connections: 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.
  • Page 30 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).
  • Page 31 Figure 3-7. Interface terminal locations UPS 200 kVA User’s and Installation Guide...
  • Page 32 Terminal TB1 Name Description Remote EPO NC Remote EPO return Dry contact used to active remote EPO of UPS. 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...
  • Page 33 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.

  • Page 34: Tb1 Battery Interface Connections

    3.5.2 TB1 battery interface connections To install wiring to connections: Verify the UPS system is turned off and all power sources are removed. See Chapter 6, “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).

  • Page 35: X-Slot Connections

    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.

  • Page 36: Installing A Remote Epo Switch

    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.
  • Page 37 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”...
  • Page 38 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.

  • Page 39: Initial Startup

    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. This service is offered as part of the sales contract for the UPS.
  • Page 40 Accessories are mounted in installed locations and wiring is terminated inside the UPS cabinet. (OPTIONAL) r The debris shield covering the UPS cabinet ventilation grill is removed. r Startup and operational checks are performed by an authorized Eaton Customer Service Engineer. UPS 200 kVA...

  • Page 41: Understanding Ups Operation

    4 Understanding UPS operation 4.1 Looking inside the UPS system The Powerware 9395E 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.

  • Page 42: Modes

    4.2 Modes The Powerware 9395E 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.

  • Page 43: Bypass 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 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.

  • Page 44: Battery Mode

    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.

  • Page 45: Ups System Oneline Configurations

    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.
  • Page 46 DO NOT install both a source neutral and a bonding jumper. Figure 4-5. Powerware 9395E 200 kVA UPS system, 400 V input and 400 V output dual-feed UPS 200 kVA...
  • Page 47 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.

  • Page 48: Ups Operating Instructions

    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.

  • Page 49: Ups Controls And Indicators

    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 9395E 200 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.

  • Page 50: Using The Control Panel

    6.3 for use of the operational controls. When the unit powers up, the screen displays the Eaton | Powerware logo as shown in Figure 5-2. To advance to the main menu and mimic screen, press any control panel pushbutton once.

  • Page 51: Using The Lcd And Pushbuttons

    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.

  • Page 52: Using The Menu

    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.
  • Page 53 The Meter screens show the UPS meter readings for the unit. The default volt- age 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-phase (A-B, B-C, C-A). Press the METERS pushbutton on the main menu bar to display the Unit Meter screens.
  • Page 54 Function Subfunction Operation kW Demand Log 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.
  • Page 55 Function Subfunction Operation Maximum Current 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 interval, the total time over limit during the interval, and the number of times over during the interval.
  • Page 56 Function Subfunction Operation System Level 0 Function Selection This screen can be used to set the screen contrast, show the firmware versions Setup installed, identify the unit type and enter a password to access Level 1 functions. Press the SETUP pushbutton on the main menu bar to display the System Setup Level 0 Screen.

  • Page 57: System Controls Screen

    Function Subfunction Operation Set Date and Time The Set Date and Time DD/MM/YYYY screen allows the internal date and time DD/MM/YYYY of the UPS to be set in the day/month/year format. The date and time informa- tion is used for display on the screen and for logging events in the Event and History Logs.

  • Page 58: Load Off 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.

  • Page 59: Starting The Ups In Bypass Mode

    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.

  • Page 60: Starting The Power Module

    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.

  • Page 61: Transfer From Bypass To Normal Mode

    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.

  • Page 62: Charger Control

    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.

  • Page 63: Using The Remote Emergency Power-Off Switch

    You should use this feature only when you want to de-energize the critical load. NOTE The following instructions are for the Eaton Corporation-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.

  • Page 64: Using Mechanical Bypass Switch

    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.
  • Page 65 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.

  • Page 66: Responding To System Events

    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.

  • Page 67: Communication

    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 9395E 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): •...

  • Page 68: Powerware Lansafe Power Management Software

    7.2 Powerware LanSafe Power Management Software Each Powerware 9395E 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.
  • Page 69 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 9395E CTO: TF12710000000 SERIAL: MCU DSP: 70.81.14...

  • Page 70: Building Alarm Monitoring

    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.

  • Page 71: Ups Maintenance

    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.

  • Page 72: Performing Preventive Maintenance

    8.2.5 Maintenance training A basic training course, available from Eaton Corporation, gives you a competent working knowledge of the UPS system operation and teaches you how to perform first level corrective maintenance.

  • Page 73: Installing Batteries

    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.

  • Page 74: Product Specifications

    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 Powerware 9395E-200 200 kVA 50/60 Hz The following sections detail the input, output, environmental, and battery specifications for the UPS.

  • Page 75: Environmental

    10.2.3 Environmental 0 to 40°C without derating. The recommended operating Operating Temperature temperature is 25°C. Operating Altitude Maximum 1500m at 40°C without derating –25 to +60°C, excluding batteries (prolonged storage above Storage Temperature 40°C causes rapid battery self-discharge) Relative Humidity (operating and storage) 5% to 95% maximum noncondensing Acoustical Noise 75 dB at a 1m distance, c weighted...

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