Eaton 93E, 93P, 93PM, 93E40KMBSB Manual

Installation

The battery system provides emergency short-term backup power to safeguard operation during brownouts, blackouts, and other power interruptions. By default, 93PM and 93E UPSs are configured to use valve-regulated lead-acid (VRLA) batteries. For the battery specification, see UPS User's and Installation Guide. Should there be a need to connect other type of batteries or other energy storage means, a certified service technician should be consulted prior to proceeding with installation.

For the 93PM and 93E product lines, there are two different battery cabinets: Small and Large Battery Cabinet. The battery block configuration in the chosen battery cabinet must always match the UPS requirement. Used battery configuration must be inserted into UPS settings during commissioning or start-up. Refer to UPS installation and operation manual for UPS configuration. The allowed battery block configurations for 93PM and 93E UPSs are presented in table 2-1.

Table 2-1. Battery block configuration for 93PM and 93E UPSs.

Battery strings with different battery quantity and voltage may not be connected in parallel.

Make sure that 93PM 30-50kW UPS with internal batteries always uses 36 battery blocks per string. External battery strings must also contain 36 battery blocks per string.

Battery cabinet internal power wiring, Battery-to-UPS power wiring and control wiring for integral line-up and match battery cabinets are supplied with the Small Battery Cabinet. Large Battery Cabinet is provided only with battery cabinet internal power wiring and control wiring.

There are several cable entries in the battery cabinets. The cabinets can be wired in the following ways:

• through the left side panel
• through the right side panel
• through the back wall
• through the roof
• through the bottom (only Large Battery Cabinet)

Cable entry to the 93PM UPS is always on the rear or the bottom of the cabinet. In 30-150 kW UPS models the entry is also located on the bottom of the right side panel.

Cable entry to the 93E UPS is on the rear or the bottom of the UPS cabinet. For the 80-120 kVA models the bottom cable entry is in the front section of the bottom plate and for the 160-200 kVA models the entry is in the rear section of the bottom plate.

NOTE
Installation instructions are given in 93PM UPS User's and Installation Guide Chapter UPS system power wiring preparation for Eaton 93PM and in 93E UPS Installation & Operation Manual Chapter Installing UPS external battery cabinet and battery power wiring for Eaton 93E.

Figure 2 -1: 93P/E battery cabinet (Small Battery Cabinet)

Figure 2 -2: 93P/E battery cabinet (Large Battery Cabinet)

A DC-rated circuit breaker within each cabinet provides protection and service isolation.

The battery cabinets use convection cooling to regulate internal component temperature. Air inlets are at the bottom and in Large Battery Cabinet also in the front of the cabinet and outlets are on the rear of the cabinet. Clearance must be allowed in front and rear of each cabinet for proper air circulation.

• 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.

Preparing the Small Battery Cabinet installation

NOTE
The battery cabinet is heavy. If unpacking instructions are not closely followed, the cabinet may tip and cause serious injury.

1. If not already accomplished, use a forklift or other material handling equipment to move the cabinet to the installation area, or as close as possible, before unloading from the pallet. Insert the forklift jacks between the skids on the bottom of the unit.
2. Open the package, remove the front and rear mounting brackets, and attach the ramp to a front edge of the pallet.
3. Carefully slide the battery cabinet off the pallet. Now the battery cabinet is ready to be placed aside the UPS.

Notes of installation location with 93PM UPS:

• Both sides can be used for battery cabinet placement but for easier service access to UPS, on the 93PM 30-150 kW UPS right side is preferred, and on the 93PM 160-200 kW left side is preferred.
• The battery cabinet must be located on the right side of 93PM 30-50 kW UPS cabinet if wiring through cabinet side panels. The 93PM 160-200 kW UPS does not enable wiring through its side panel.

Notes of installation location with 93E UPS:

• Both sides can be used for battery cabinet placement with the 93E UPS but on the left side is preferred with the 80-120 kVA UPS, and on the right side is preferred with the 160-200 kVA UPS to more easily access the battery input terminals through the bottom or the rear entry.

4. Open the battery cabinet and locate the external power wiring shipped along the cabinet.
5. Cables with single insulation are provided with the battery cabinet. These cables can be used for internal wiring, i.e. when the UPS cabinet and the battery cabinet are mounted side by side with no gap in between, and cables are routed directly from cabinet to cabinet. If any length of the cables is routed outside the cabinets then they need to be replaced by double insulated cables or a supplementary insulation needs to be used with cables provided.
6. Apply cable glands and/or plastic pass-through collars accordingly.

Make sure all power sources are disconnected before next steps.

7. Connect the power cables and signal wires to the UPS. No signal wires are connected to 93E UPS.
8. If multiple cabinets are to be used, repeat the steps to the rest of the cabinets and be sure to daisy chain the signal wire harnesses in the next cabinet. Signal wires are daisy chained by cutting the multiple connector and extra length of the cables and connecting them to TB2 terminals 5-8. Look at the Figure 2-6.

Preparing the Large Battery Cabinet installation

NOTE
The battery cabinet is heavy. If unpacking instructions are not closely followed, the cabinet may tip and cause serious injury.

1. If not already accomplished, use a forklift or other material handling equipment to move the cabinet to the installation area, or as close as possible, before unloading from the pallet. Insert the forklift jacks between the skids on the bottom of the unit.
2. Open the package and remove the two front mounting brackets on the side feet and two rear mounting bolts inside the middle foot.
3. Carefully lift the battery cabinet off the pallet. Now the battery cabinet is ready to be placed aside the UPS.

Notes of installation location with 93PM UPS:

• Both sides can be used for battery cabinet placement but for easier service access to UPS, on the 93PM 30-150 kW UPS right side is preferred, and on the 93PM 160-200 kW left side is preferred.
• The battery cabinet must be located on the right side of 93PM 30-50 kW UPS cabinet if wiring through cabinet side panels. The 93PM 160-200 kW UPS does not enable wiring through its side panel.

Notes of installation location with 93E UPS:

• Both sides can be used for battery cabinet placement with the 93E UPS but on the left side is preferred with the 80-120 kVA UPS, and on the right side is preferred with the 160-200 kVA UPS to more easily access the battery input terminals through the bottom or the rear entry.

4. Open the battery cabinet and locate the signal wiring shipped along the cabinet. The power cable must be made according to installation requirements. Minimum crosssection area for copper cable is stated on the next table:

Table 2-2: Cable cross-section minimum areas

5. Select the cable routing out of different options and route the cables to the dedicated connectors inside UPS cabinet. Terminals are located under the circuit breaker and are marked with +, - and a protecting earth designators.
6. Apply cable glands and/or plastic pass-through collars accordingly.

Make sure all power sources are disconnected before next steps.

7. Connect the power cables and signal wires to the UPS. No signal wires are connected to 93E UPS.
8. Battery installation is to be done on-site by authorized and trained service personnel. Batteries are to be installed on the shelves according to the following picture. Ensure you find a correct wiring instruction included into the cabinet and follow it.

Cable connection to battery poles is to be done as follows:

Figure 2 -5: Cable connection on battery poles

9. If multiple cabinets are to be used, repeat the steps for the rest of the cabinets and in 93PM system be sure to daisy chain the signal wire harnesses in the next cabinet. 93E system does not use signal wiring. Signal wires are daisy chained by cutting the multiple connector and extra length of the cables and connecting them to TB2 terminals 5-8. Look at the Figure 2-6.
   
   Figure 2 -6: Signal wiring of Large and Small Battery Cabinet

Installation with other than 93PM or 93E UPS

Other UPSs may not be fully compatible with 93P/E External Battery Cabinet. Check UPS manual for the requirements for the external battery supply.

Maintenance

The components inside the 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. Regular routine checks of operation and system parameters enable your system to function efficiently for many trouble-free years.

Important safety instructions

Remember that your UPS system is designed to supply power EVEN WHEN DISCONNECTED FROM THE UTILITY POWER. The UPS module interiors are unsafe until the DC power source is disconnected and the electrolytic capacitors are discharged. After disconnecting the utility power and the DC power, authorized service personnel should wait at least five minutes for capacitor bleed-off before attempting internal access to the UPS module.

• Servicing and maintenance should be performed by qualified service personnel only.
• LETHAL VOLTAGE PRESENT. This unit should not be operated with the cabinet doors open or protective panels removed. Do not make any assumptions about the electrical state of any cabinet in the UPS system.

Since each battery string is an energy source in itself, opening the battery circuit breaker does not de- energize the voltage within the battery string. DO NOT ATTEMPT TO ACCESS ANY INTERNAL AREA OF THE BATTERY STRING YOURSELF. VOLTAGES ARE ALWAYS PRESENT IN THE BATTERY STRING. If you suspect that a battery string needs service, you should contact your service representative.

If the string requires service, refer to the battery manufacturer's operating manual for instructions on battery maintenance or contact your service representative.

Observe these precautions when working on or around batteries:

• Remove watches, rings, or other metal objects.
• Use tools with insulated handles.
• Wear rubber gloves and boots.
• Do not lay tools or metal parts on top of batteries or battery cabinets.
• Disconnect the charging source prior to connecting or disconnecting terminals.
• Determine if the battery is inadvertently grounded. If it is, remove the source of the ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock is reduced if such grounds are removed during installation and maintenance.
• When replacing batteries, use the same number of sealed, lead-acid batteries.
• Proper disposal of batteries is required. Refer to your local codes for disposal requirements.

Performing preventive maintenance

The battery cabinets require very little preventive maintenance. However, the UPS system should be inspected periodically to verify that the units are operating normally and that the batteries are in good condition

NOTE
Work on energized circuit must be performed only by authorized personnel.

PERIODIC maintenance

Periodic inspections of the UPS should be made to determine if components, wiring, and connections exhibit evidence of overheating. Particular attention should be given to bolted connections. Maintenance procedures should specify that the bolted connections be re-torqued.

ANNUAL maintenance

Annual preventive maintenance should be performed only by authorized service personnel familiar with maintenance and servicing of the UPS system. Contact your service representative for more information about service offerings.

BATTERY maintenance

Contact your service representative for battery maintenance. Battery replacement and maintenance should be performed only by authorized service personnel.

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 authorized service personnel due to high energy and voltage.

Do not discard waste electrical or electronic equipment in the trash. For proper disposal, contact your local collecting/recycling/reuse or hazardous waste center and follow the local legislation.

These symbols indicate on a product

Figure 3 -1: WEEE symbol

Use proper local collecting centers meeting local legislation when handling waste of electrical and electronic equipment.

HAZARDOUS MATERIALS. Batteries may contain HIGH VOLTAGES, and CAUSTIC, TOXIC and FLAMMABLE substances. Batteries can injure or kill people and damage equipment if used improperly. DO NOT DISCARD unwanted batteries or battery material in the public waste disposal system. Follow ALL applicable, local regulations for storage, handling and disposal of batteries and battery materials.

Figure 3 -2: Recycling batteries symbol

Maintenance training

For more information about training and other services, contact your Eaton representative.

Technical data

For complete technical specification, contact your Eaton representative. Due to continuous product improvement programs, specifications are subject to change without notice.

Standards and regulations

Table 4 -1: Standards and regulations

Battery specification

Table 4 -2: Battery specification

Environmental specifications

Table 4 -3: Environmental specifications

Warranty
The product is warranted against defects in 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. Please refer to local terms of liability as defined in the supply contract.

Installation checklist

• All packing materials and restraints have been removed from each cabinet.
• Each cabinet in the UPS system is placed in its installation 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 as per requirements.
• A ground conductor is properly installed.
• Battery cables are terminated and connected to battery connectors.
• Battery Shunt trip and Aux contact signal wiring is connected from the UPS to the battery cabinet. Note: 93PM only
• Room ventilation and air conditioning equipment are installed and operating correctly.
• The area around the installed UPS system is clean and dust-free. (It is recommended that the UPS be installed on a level floor suitable for computer or electronic equipment.)
• Adequate workspace exists around the UPS and other cabinets.
• Adequate lighting is provided around all UPS equipment.
• A 230 VAC service outlet is located within 7.5 meters of the UPS equipment.
• Alarm relays and signal inputs are wired appropriately. (OPTIONAL)
• A remote battery disconnect control is mounted in its installation location and its wiring is terminated inside the UPS and battery cabinet. (OPTIONAL)
• Accessories are mounted in installation locations and wiring is terminated inside the UPS cabinet. (OPTIONAL)
• Startup and operational checks are performed by an authorized Eaton Customer Service Engineer