Eaton Powerware 9395 Installation And Operation Manual
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Eaton Powerware 9395 Installation And Operation Manual

Eaton Powerware 9395 Installation And Operation Manual

650–825 kva
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Powerware 9395 UPS and Plus 1 UPS
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650–825 kVA
Installation and Operation Manual

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  • Page 1 Powerware 9395 UPS and Plus 1 UPS ® 650–825 kVA Installation and Operation Manual...

  • Page 2: Important Safety Instructions

    National Fire Protection Association, Inc. All other trademarks are property of their respective companies. ECopyright 2008 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any way without the express written approval of Eaton Corporation.

  • Page 3: Table Of Contents

    ................. . . 4−17 EATON Powerware 164201725 Rev 1 www.powerware.com ®...
  • Page 4 ............7−17 EATON Powerware 164201725 Rev 1 www.powerware.com ®...
  • Page 5 ................W−1 EATON Powerware 164201725 Rev 1 www.powerware.com ®...
  • Page 6 1−2 Figure 1-2. Powerware 9395 UPS 650–825 kVA Cabinet with the Field Installed UPM ........
  • Page 7 ..............9−5 EATON Powerware 164201725 Rev 1 www.powerware.com ®...
  • Page 8 TABLE OF CONTENTS This page intentionally left blank. EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 9: Introduction

    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 an Eaton service representative in advance (usually a two−week notice is required) to reserve a preferred startup date.

  • Page 10: Control Panel

    INTRODUCTION ISBM SECTION UPM SECTION Figure 1-1. Powerware 9395 UPS (650–825 kVA) Cabinets 1.1.2 Control Panel The control panel, located on the front of the UPS, contains an LCD and pushbutton switches to control the operation of the UPS and to display the status of the UPS system.

  • Page 11: Advanced Battery Management

    INTRODUCTION ISBM SECTION UPM SECTION FI−UPM Figure 1-2. Powerware 9395 UPS 650–825 kVA Cabinet with the Field Installed UPM 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.

  • Page 12: Sync Control

    1.2.2 Sync Control An optional Powerware 9395 Sync Control maintains the critical load outputs of two separate single module Powerware 9395 UPS systems in synchronization. This option facilitates the uninterrupted transfer of the load from one load bus to another by means of transfer switches.

  • Page 13: Basic System Configurations

    Remote Emergency Power−off (REPO) control, RMP II, or X−Slot communication cards. Using This Manual This manual describes how to install and operate the Powerware 9395 UPS (650–825 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 7.3.10 on page 7−17).

  • Page 14: Symbols, Controls, And Indicators

    Operation, including controls, functions of the standard and optional features, procedures for using with the UPS, and information about maintenance. Refer to the Powerware 9395 Field Installed UPM Mechanical Installation Manual for the following additional information: Mechanical installation instructions, including site preparation, planning for mechanical installation, and safety information.

  • Page 15: Getting Help

    Scheduling initial startup Regional locations and telephone numbers A question about any of the information in this manual A question this manual does not answer Please call the Eaton Help Desk for Powerware products at: 1−800−843−9433 1−919−870−3028 United States: 1−800−461−9166 ext 260...
  • Page 16 INTRODUCTION This page intentionally left blank. 1−8 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 17: Safety Warnings

    Keep the UPS door closed and front panels installed to ensure proper cooling airflow and to protect personnel from dangerous voltages inside the unit. Do not install or operate the UPS system close to gas or electric heat sources. 2−1 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 18 Une mise au rebut réglementaire des batteries est obligatoire. Consulter les règlements en vigueur dans votre localité. Ne jamais jeter les batteries au feu. L’exposition aux flammes risque de les faire exploser. 2−2 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 19: Section I - Installation

    Section I Installation 2−1 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 20 2−2 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 21: Ups Installation Plan And Unpacking

    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 an Eaton service representative in advance (usually a two−week notice is required) to reserve a preferred startup date.
  • Page 22 Figure 3-10. Dimensions are in millimeters (inches). Table 3-1. UPS Cabinet Weights Weight kg (lb) Model Section Shipping Installed ISBM 1498 (3302) 1390 (3064) Powerware 9395−825/650 1590 (3505) 1482 (3267) ISBM 1498 (3302) 1390 (3064) Powerware 9395−825/750 1590 (3505) 1482 (3267) ISBM 1498 (3302) 1390 (3064) Powerware 9395−825/825...

  • Page 23: Figure 3-1. Ups Cabinet Dimensions (Front View)

    Dimensions are in millimeters [inches]. Figure 3-1. UPS Cabinet Dimensions (Front View) Dimensions are in millimeters [inches]. Figure 3-2. UPS Cabinet Dimensions (Right Side View) 3−3 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 24 UPS INSTALLATION PLAN AND UNPACKING Figure 3-3. ISBM Section Dimensions (Front View) Figure 3-4. UPM Section Dimensions (Front View) 3−4 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 25 Dimensions are in millimeters [inches]. Figure 3-6. ISBM Section Dimensions (Bottom View) Front Dimensions are in millimeters [inches]. Figure 3-7. UPM Section Dimensions (Top View) 3−5 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 26 Dimensions are in millimeters [inches]. Figure 3-8. ISBM Section Center of Gravity Dimensions are in millimeters [inches]. Figure 3-9. UPM Section Center of Gravity 3−6 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 27: Figure 3-10. Remote Epo Switch Dimensions

    [0.40] Needed to remove key Front View 1/2" Knockout Pattern (Typical 5 Sides) Dimensions are in millimeters [inches]. Figure 3-10. Remote EPO Switch Dimensions 3−7 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 28: Ups System Power Wiring Preparation

    In a separate battery system, multiple UPMs are each powered from separate battery sources. A Field Installed UPM (FI−UPM) is always designated as UPM 4. 3−8 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 29 Table 3-4 for installations using a common battery system or Table 3-5 for installations using a separate battery system. Wire sizes listed are for copper wiring only. Table 3-4. Input/Output Ratings and External Wiring Requirements for the Powerware 9395−825/650, 9395−825/750, and 9395−825/825 – Common Battery Units Rating 50/60 Hz Basic Unit Rating...
  • Page 30 UPS INSTALLATION PLAN AND UNPACKING Table 3-5. Input/Output Ratings and External Wiring Requirements for the Powerware 9395−825/650, 9395−825/750, and 9395−825/825 – Separate Battery Units Rating 50/60 Hz Basic Unit Rating Input and Output Voltage Volts 480/480 480/480 480/480 AC Input to UPS Rectifier (0.98 Minimum pF)
  • Page 31 UPS INSTALLATION PLAN AND UNPACKING Table 3-6. UPS Intercabinet Power Cable Terminations for the Powerware 9395−825/650, 9395−825/750, and 9395−825/825 Tightening Torque Terminal Function Terminal Function Bus Landing Stud Nm (lb ft) E1A (UPM 1) E1A (UPM 2) Phase A 3 – stud mounting 12 (8.3)
  • Page 32 Figure 4-17 on page 4−19 and Figure 4-18 on page 4−20 show the location of the power cable terminals inside the UPS. Table 3-8. UPS External Power Cable Terminations for the Powerware 9395−825/650, 9395−825/750, and 9395−825/825 Bus Landings Tightening Torque...
  • Page 33 Rectifier Input, Bypass Input, Battery Input, Conical Washer 180500037−120 Output, and Neutral Rectifier Input, Bypass Input, Battery Input, 180200001−07 Output, and Neutral Table 3-10. Recommended Installation Parts and Tools (Not Supplied by Eaton Part Size Quantity Manufacturer Part Number Notes Thomas &...
  • Page 34 Table 3-5 on page 3−10, the DC terminations listed in Table 3-8 on page 3−12, type of battery installation, and requirements from NEC Table 4, Electrical Metallic Tubing (EMT). 3−14 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 35 Table 3-12 lists the recommended rating for input circuit breakers. Table 3-12. Recommended Input Circuit Breaker Ratings Input Rating UPS Model Load Rating 480V 80% Rated 1200A Powerware 9395−825/650 100% Rated 1000A 80% Rated 1600A Powerware 9395−825/750 100% Rated 1200A...

  • Page 36: Ups System Interface Wiring Preparation

    3 hours. For longer discharge times a larger disconnect may be required. Table 3-14. Recommended DC Input Battery Disconnect Ratings – Common Battery Input Rating UPS Model 480V Powerware 9395−825/650 1600A Powerware 9395−825/750 2000A Powerware 9395−825/825 2000A Table 3-15.
  • Page 37 Alarm relay contacts have a maximum current rating of 5A and a switched voltage rating of 30 Vac and 28 Vdc. Alarm relay wiring should be a minimum of 22 AWG. 3−17 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 38: Inspecting And Unpacking The Ups Cabinet

    Carefully inspect the outer packaging for evidence of damage during transit. C A U T I O N Do not install a damaged cabinet. Report any damage to the carrier and contact an Eaton service representative immediately. NOTE For the following step, verify that the forklift or pallet jack is rated to handle the weight of the cabinet (see Table 3-1 on page 3−2 for cabinet weight).

  • Page 39: Figure 3-11. Ups Cabinet As Shipped On Pallet (Isbm Section)

    Inspect the contents for any evidence of physical damage, and compare each item with the Bill of Lading. If damage has occurred or shortages are evident, contact an Eaton service representative immediately to determine the extent of the damage and its impact on further installation.

  • Page 40: Figure 3-12. Ups Cabinet As Shipped On Pallet (Upm Section)

    UPS INSTALLATION PLAN AND UNPACKING Figure 3-12. UPS Cabinet as Shipped on Pallet (UPM Section) 3−20 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 41: Preliminary Installation Information

    End forklift slots may be used for minor positioning if the forks are kept in a horizontal position with no upward angling. If these instructions are not followed, damage to the wiring channel and wiring will occur. 4−1 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 42: Figure 4-1. Removing The Isbm Section Left Side Shipping Bracket

    Remove the right side shipping bracket. Front Door Pallet Shipping Bracket Bolts Shipping Bracket Left Side Shipping Bolts Bracket Figure 4-1. Removing the ISBM Section Left Side Shipping Bracket 4−2 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 43: Figure 4-2. Removing The Isbm Section Right Side Shipping Bracket

    Carefully lower the cabinet until the cabinet base contacts the floor. Repeat Steps 2 through 6 for the remaining cabinet. Proceed to paragraph 4.3. 4−3 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 44: Figure 4-3. Removing The Upm Section Left Side Shipping Bracket

    Front Panels Pallet Shipping Bracket Bolts Wireway Panel Shipping Bracket Left Side Shipping Bolts Bracket Figure 4-3. Removing the UPM Section Left Side Shipping Bracket 4−4 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 45: Figure 4-4. Removing The Upm Section Right Side Shipping Bracket

    Retain the hardware for later use. Remove the screws securing the corner channel and remove the channel (see Figure 4-5). Retain the hardware for later use. 4−5 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 46: Figure 4-5. Cabinet Section Joining

    Reinstall the left front corner channel (see Figure 4-5) and secure using the retained hardware. Reinstall the left middle panel (see Figure 4-5) and secure using the retained hardware. 4−6 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 47 ISBM and UPM cabinet sections. Secure the bracket with the screws from the field kit (see Figure 4-7). 13. Proceed to paragraph 4.4. 4−7 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 48: Electrically Connecting The Cabinet Sections

    ISBM section to the AC Input to UPMs terminals. See Figure 4-8 on page 4−11 for terminal locations. 4−8 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 49 ISBM section to the ground bolt in the ISBM section. 14. Connect the ground braid to the ISBM section ground bolt and secure. 4−9 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 50: Field Installed Upm Installation

    National Electrical Code (NEC), Article 480. After the battery system is installed, return to paragraph 4.7 to complete the wiring of the UPS. 4−10 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 51 (See Figure 4-10 for detail.) DC Input to UPMs + (E4) (See Figure 4-10 for detail.) Figure 4-8. UPS ISBM Section Intercabinet Power Terminal Locations 4−11 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 52 Install the second lug with the raised barrel portion facing the front of the cabinet. Figure 4-9. UPS ISBM Section Input Power Terminal Detail 4−12 EATON Powerware 164201725 Rev 1 www.powerware.com ®...

  • Page 53: Figure 4-10. Ups Isbm Section Battery Input Power Terminal Detail

    Install the second lug with the raised barrel portion facing the front of the cabinet. Figure 4-11. UPS ISBM Section Output Power Terminal Detail 4−13 EATON Powerware 164201725 Rev 1 www.powerware.com ®...
  • Page 54 Pigtail Harnesses Location of RJ45 Coiled CAN Cable ISBM Section Right Side View UPM Section Left Side View Figure 4-12. UPS Intercabinet Interface Harness Locations 4−14 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 55 ISBM Section Right Side Inside View Figure 4-13. Pl1 Interface Board Location Pl1 Interface Board J39 Inverter CAN Connector Figure 4-14. J39 Location on Pl1 Interface Board 4−15 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 56: Installing Ups External And Battery Power Wiring

    Remove the screws securing the top and bottom internal safety shield panels and remove the panels to gain access to the input, output, and battery terminals. Retain the hardware for later use. 4−16 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 57 See paragraph 3.2.2 on page 3−8 for wiring and termination requirements. Proceed to paragraph 4.7.2. 4−17 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 58 Bottom Entry Conduit Landing for AC Input and Output, and DC Input (Remove panel to drill or punch conduit holes.) Figure 4-16. ISBM Section Conduit and Wire Entry Locations 4−18 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 59 DC Input from Battery – (E5) (See Figure 4-19 or Figure 4-20 for Detail BB.) Neutral (E12) ISBM Figure 4-17. UPS ISBM Section Power Terminal Locations 4−19 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 60 Phase A (E8) AC Input to Phase B (E7) UPS Bypass Phase C (E6) Section A–A Figure 4-18. UPS ISBM Section Power Terminal Detail AA 4−20 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 61 4.7.1, Step 2 on page 4−16. Secure with the retained hardware. Reinstall the left front panel removed in paragraph 4.7.1, Step 1 on page 4−16 and secure with the retained hardware. 4−21 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 62 DC Input from Battery + (E4) Front DC Input from Battery – (E5) Section B–B Figure 4-19. UPS ISBM Section Power Terminal Detail BB – Common Battery 4−22 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 63 (UPM 2) DC Input from Battery – (E5) (UPM 3) Section B–B Figure 4-20. UPS ISBM Section Power Terminal Detail CC – Separate Battery 4−23 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 64: Installing Interface Connections

    11. Reinstall the front door removed in Step 3 and secure with the retained hardware. 12. Close the door and secure the latch. 4−24 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 65 4−31 for detail.) for detail.) (See Figure 4-24 on page 4−28 for terminal assignments.) ISBM Figure 4-21. UPS ISBM Section Interface Terminal Locations 4−25 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 66 Building Alarm 5 Return NOTE Return indicates connection to electronics circuit ground. Common" indicates connection to common side of isolated relay contact. 4−26 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 67 Reinforced insulation to the mains is required. NOTE Alarm relay wiring should be a minimum of 22 AWG Figure 4-23. Typical Alarm Relay Connection 4−27 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 68 NOTE A jumper wire must be connected between pins 1 and 2 on TB1, if the normally−closed REPO contact is not used. Figure 4-24. Terminal Blocks TB1, TB2, and TB3 Connector Assignments 4−28 EATON Powerware 164201725 Rev 1 www.powerware.com ®...

  • Page 69: Tb1 Battery Interface Connections

    11. Reinstall the front door removed in Step 3 and secure with the retained hardware. 12. If wiring X−Slot connections, proceed to paragraph 4.8.3; otherwise, proceed to Step 13. 13. Close the door and secure the latch. 4−29 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 70: Figure 4-21. Typical Battery Interface Connection

    NOTE Battery aux and DC shunt trip wiring should be a minimum of 18 AWG. Figure 4-26. Typical Battery Interface Connection – Separate Battery System 4−30 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 71: X−Slot Connections

    NOTE When installing external wiring to X−Slot cards, conduit must be installed to the UPS cabinet. 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, contact an Eaton service representative (see page 1−7). To install wiring to connections: If not already installed, install the LAN and telephone drops.

  • Page 72: Installing A Repo Switch

    NOTE The REPO switch must be a normally−open or normally−closed latching-type switch not tied into any other circuits. NOTE This procedure is intended to be used for the installation of the Eaton Corporation−supplied REPO switch. If installing another manufacturer’s switch, use this procedure only as a guide.
  • Page 73 NOTE REPO normally−open and normally−closed return terminals are separated on the terminal board but are electrically in common. Figure 4-29. Normally−Open REPO Switch Wiring 4−33 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 74 NOTE REPO normally−open and normally−closed return terminals are separated on the terminal board but are electrically in common. Figure 4-30. Normally-Closed REPO Switch Wiring 4−34 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 75: Installing Options And Accessories

    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 an Eaton service representative in advance (usually a two−week notice is required) to reserve a preferred startup date.

  • Page 76: Installation Checklist

    - Accessories are mounted in installed locations and wiring is terminated inside the UPS cabinet. (OPTIONAL) - The debris shields covering the UPS cabinet ventilation grills are removed. - Startup and operational checks are performed by an authorized Eaton Customer Service Engineer. 4−36 EATON Powerware 164201725 Rev 1 www.powerware.com...
  • Page 77 UPS SYSTEM INSTALLATION Notes _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ _________________________________________________________________________ 4−37 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 78 UPS SYSTEM INSTALLATION This page intentionally left blank. 4−38 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 79: Installing An Optional Powerware Hot Sync Can Bridge Card

    UPS. See Figure 4-21 on page 4−25 and Figure 4-27 on page 4−31 for X−Slot communication bay locations. 5−1 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 80 SCM II (see paragraph 5.4) To locate the appropriate terminals on the Powerware Hot Sync CAN Bridge Card, see Figure 5-2 and Table 5-1. 5−2 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 81: Figure 5-2. Powerware Hot Sync Can Bridge Card Connections

    Normally-open contact closes when UPS is on bypass. RMP II, RIM II, and SCM II connections. CAN L Can H CAN Input for parallel operation. Shield 5−3 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 82: Installing An Optional Remote Monitor Panel Ii

    Figure 5-4, and Table 5-2 for the terminal location and wiring information. Close the front door and secure the latch. 10. Restart the UPS. See Chapter 7, UPS Operating Instructions," for startup instructions. 5−4 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 83: Figure 5-3. Remote Monitor Panel Ii And Relay Interface Module Ii Terminal Locations

    0.9 (8) Use twisted pair J3–7 (TX) TB1–4 (RDX) 0.9 (8) TB3 Line 0.9 (8) TB3 Neutral 0.9 (8) Ground Terminal 2.7 (24) Maximum 5−5 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 84: Installing An Optional Relay Interface Module Ii

    INSTALLING OPTIONS AND ACCESSORIES NOTE Setup of the Powerware Hot Sync CAN Bridge Card must be performed by an authorized Eaton Customer Service Engineer. Contact an Eaton service representative to schedule a date. 11. To check the operation of the RMP II, ensure that the UPS is supplying the load via inverter or bypass.

  • Page 85: Figure 5-5. J1, J2, J3, And J4 15−Pin D−Sub Connectors

    10. Restart the UPS. See Chapter 7, UPS Operating Instructions," for startup instructions. NOTE Setup of the Powerware Hot Sync CAN Bridge Card must be performed by an authorized Eaton Customer Service Engineer. Contact an Eaton service representative to schedule a date.

  • Page 86: Installing An Optional Supervisory Contact Module Ii

    120 Vac Power Ground Terminal Terminal TB2 Customer Supervisory Contact Interface Terminal TB1 Signal Connections from the UPS Figure 5-6. Supervisory Contact Module II Terminal Location 5−8 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 87: Figure 5-7. Supervisory Contact Module Ii Tb2

    INSTALLING OPTIONS AND ACCESSORIES NOTE Setup of the Powerware Hot Sync CAN Bridge Card must be performed by an authorized Eaton Customer Service Engineer. Contact an Eaton service representative to schedule a date. Install wiring between the SCM II terminal block TB2 and the monitoring equipment.

  • Page 88: Accessory Mounting Dimensions

    Surface Mount using #10 Pan Head Screws for Hanging. (Mount with vent holes facing up.) Dimensions are in millimeters [inches]. Figure 5-8. Remote Monitor Panel II Dimensions 5−10 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 89: Figure 5-9. Relay Interface Module Ii Dimensions

    Surface Mount using #10 Pan Head Screws for Hanging. (Mount with vent holes facing up.) Dimensions are in millimeters [inches]. Figure 5-9. Relay Interface Module II Dimensions 5−11 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 90: Figure 5-10. Supervisory Contact Module Ii Dimensions

    Surface Mount using #10 Pan Head Screws for Hanging. (Mount with vent holes facing up.) Dimensions are in millimeters [inches]. Figure 5-10. Supervisory Contact Module II Dimensions 5−12 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 91 Section II Operation 5−13 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 92 5−14 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 93: Understanding Ups Operation

    Understanding UPS Operation Figure 6Table 6 UPS System Overview The Powerware 9395 UPS is a continuous−duty, solid-state, transformerless (at 480 Vac), three−phase, true online system that provides conditioned and uninterruptible AC power to the UPS system’s output and critical load.

  • Page 94: Modes

    UNDERSTANDING UPS OPERATION Modes The Powerware 9395 UPS supports a critical load in three different modes of operation: In Normal mode, the critical load is supplied by the inverter, which derives its power from rectified utility AC power. In this mode, the battery charger also provides charging current for the battery, if needed.

  • Page 95: Bypass Mode

    CB4 is wired in parallel with this combination. Together they are wired in parallel with the rectifier and inverter. 6−3 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 96: Battery Mode

    DC power that the inverter converts to AC power. Figure 6-4 shows the path of electrical power through the UPS system when operating in Battery mode. 6−4 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 97: Figure 6-4. Path Of Current Through The Ups In Battery Mode

    6−5 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 98: Ups System Oneline Configurations

    UPM – Reverse Transfer Dual-Feed 9395−825/825 Separate Battery System 9395−825/650 Simplified Dual−Fed UPS with Maintenance Figure 6-9 on page 6−11 9395−825/750 Bypass Panel 9395−825/825 6−6 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 99: Figure 6-5. Ups System, Dual-Feed, Common Battery

    DO NOT install both a source neutral and a bonding jumper. Figure 6-5. UPS System, Dual-Feed, Common Battery System 6−7 EATON Powerware 164201725 Rev 1 www.powerware.com ®...

  • Page 100: Figure 6-6. Ups System, Dual-Feed, Separate Battery

    DO NOT install both a source neutral and a bonding jumper. Figure 6-6. UPS System, Dual-Feed, Separate Battery System 6−8 EATON Powerware 164201725 Rev 1 www.powerware.com ®...
  • Page 101 DO NOT install both a source neutral and a bonding jumper. Figure 6-7. Plus 1 UPS System, Dual-Feed, Common Battery System 6−9 EATON Powerware 164201725 Rev 1 www.powerware.com ®...
  • Page 102 DO NOT install both a source neutral and a bonding jumper. Figure 6-8. Plus 1 UPS System, Output Dual-Feed, Separate Battery System 6−10 EATON Powerware 164201725 Rev 1 www.powerware.com ®...

  • Page 103: Figure 6-9. Simplified Dual−Feed Ups With Maintenance Bypass Panel

    (BIB) is installed in the maintenance bypass and a single−feed UPS is being installed, a single feed to the maintenance bypass is acceptable for supplying both the UPS and the bypass. Figure 6-9. Simplified Dual−Feed UPS with Maintenance Bypass Panel 6−11 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 104 UNDERSTANDING UPS OPERATION This page intentionally left blank. 6−12 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 105: Ups Operating Instructions

    UPS operation. Figure 7-1 shows the UPS controls and indicators. Control Panel AC Input Breaker CB1 (optional) ISBM Figure 7-1. UPS Controls and Indicators – ISBM Section Shown 7−1 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 106: Circuit Breaker

    The following paragraphs describe using the UPS control panel to monitor the UPS. See paragraph 7.3 for use of the operational controls. When the unit powers up, the screen displays the Eaton | Powerware logo as shown in Figure 7-2. To advance to the Main Menu and Mimic screen, press any control panel pushbutton once.

  • Page 107: Status Indicators

    LCD in the UPS status area. This message is also written to the Active Events Log and may be added to the History Log. The messages are divided into four categories: alarms, notices, status, and commands. 7−3 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 108: Using The Lcd And Pushbuttons

    Control UPS operation (see paragraphs 7.2.7 and 7.2.8) After approximately 30 minutes, the display screen darkens. To restore the screen, press any pushbutton once. 7−4 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 109: Using The Menu

    06 / 25 / 2008 INPUT BATT STSW OUTPUT BYPASS CONTROLS LOAD OFF EVENTS METERS SETUP Figure 7-4. Main Menu and Mimic Screen (Normal Mode) 7−5 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 110: Display Menu Operation

    The Battery screen displays the battery voltage (Vdc), the battery current (Idc), the minutes of battery time remaining, and battery temperature. Battery temperature must be set up by an authorized Eaton Customer Service Engineer. When battery life decreases to less than 20%, Check Battery is displayed.
  • Page 111 YES. To complete the save function and return to the System Setup screen, select the return arrow pushbutton 7−7 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 112: System Status Screen And Controls

    For detailed information about using the System Controls, see paragraph 7.3. SYSTEM STATUS SHUTDOWN BYPASS AVAILABLE MAINTENANCE BYPASS CHARGER UPM: OFFLINE CONTROLS Figure 7-5. Typical System Status Screen 7−8 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 113 Turns the UPM on without transferring the load to Normal mode. The Load is on bypass. UPM Off Transfers the load to bypass and turns the UPM off. 7−9 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 114: Load Off Screen

    UPM status should indicate OFFLINE. Close the battery breaker. If the UPS contains input breaker CB1, close input breaker CB1. On the System Status screen, select the command. 7−10 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 115: Starting The Ups In Bypass Mode

    System Status menu bar. The Bypass CONTROLS Control Command screen is displayed. 10. On the Bypass Control Command screen, select GO TO BYPASS 7−11 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 116: Starting The Upms

    INVERTER SYNCING READY The UPM 2 rectifier and inverter turn on. 15. Repeat Steps 8 through 11 selecting to start UPM 3. UPM 3 7−12 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 117: Transfer From Normal To Bypass Mode

    UPM status indicates READY. The power module remains on. W A R N I N G Power is present inside the UPS cabinet sections. 7−13 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 118: Transfer From Bypass To Normal Mode

    If the UPS is a Plus 1 model, repeat Steps 2 through 6 selecting to shut UPM 4 down UPM 4. W A R N I N G Power is present inside the UPS cabinet sections. 7−14 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 119: Ups And Critical Load Shutdown

    UPS output by LOAD OFF powering down the UPS and de-energizing the critical load. The UPS (including Bypass) remains off until restarted. 7−15 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 120 When LOAD OFF is selected and held for three seconds, the input, output, battery, and bypass backfeed contactors open, and the power module is turned off. 7−16 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 121: Using The Remote Emergency Power−Off Switch

    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.

  • Page 122: Figure 7-7. Repo Operation

    UPS OPERATING INSTRUCTIONS Activated Deactivated Pushbutton locked into place Unlock pushbutton to release Figure 7-7. REPO Operation 7−18 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 123: Communication

    Chapter 8 Communication Figure 8Table 8 This chapter describes the communication features of the Powerware 9395 650–825 kVA UPS and provides information about connecting hardware and using Terminal mode. For terminal wiring information, see paragraph 3.2.3 on page 3−16 and paragraph 4.8 on page 4−24.

  • Page 124: Enotify Service

    Powerware 9395 UPS: Proactive monitoring, called Anomaly Detection, automatically analyzes the status of the Powerware 9395 UPS on a daily basis. All data gathered from the unit, current and historical, is analyzed at the Customer Reliability Center (CRC) for trending issues.

  • Page 125: Powerware Lansafe Power Management Software

    ConnectUPS Card. The eNotify Service runs on common protocols and transport mechanisms, making the connectivity between the Powerware 9395 UPS and the Powerware Remote Monitoring servers easy to set up. By using common e−mail transport mechanism, you do not have to open your network to proprietary or potentially unsecure protocols and transports.

  • Page 126: Terminal Mode

    See paragraph 7.2 on page 7−2, Using the Control Panel," for instructions on navigating the control panel. 8−4 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 127: Event History Log

    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. 8−5 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 128: Figure 8-2. Sample Event History Log

    COMMUNICATION MODEL: POWERWARE 9395 CTO: TF12710000000 SERIAL: MCU DSP: 70.81.14 MCU BOOTLOADER: 80.40 MCU PLD: 1.00 PMF 1 DSP: 80.81.14 PMF 1 BOOTLOADER: 80.40 PMF 1 PLD: 1.00 XSLOT CAN BRIDGE: 0.00 CSB DSP: 70.81.14 CSB BOOTLOADER: 1.12 DISPLAY: 1.06 TIME: 19:17:16 DATE: 03/23/2099 03/16/2099 21:25:20.355 S138: CONTROL POWER ON (PM1)

  • Page 129: Building Alarm Monitoring

    The RMP II can be flush-mounted or surface-mounted on a desktop, or secured to a wall. Figure 8-3 shows an RMP II front panel. Figure 8-3. Remote Monitor Panel II Front Panel 8−7 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 130 The UPS is preparing to shut down because the UPS is in Battery mode and the DC voltage is approaching its low limit. This indicator is accompanied by a horn. 8−8 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 131: Relay Interface Module Ii

    Contacts are closed when approximately two minutes of battery time is remaining before the critical load is lost. UTILITY FAILURE Pins 6 and 15 Contacts are closed when Utility Failure is detected. 8−9 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 132: Supervisory Contact Module Ii

    BYPASS NOT AVAILABLE TB2-10 through TB2-12 ON BATTERY TB2-13 through TB2-15 UPS ALARM TB2-16 through TB2-18 ON BYPASS TB2-19 through TB2-21 SHUTDOWN IMMINENT TB2-22 through TB2-24 8−10 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 133: Ups Maintenance

    Eaton service representative. If the string requires service, refer to the battery manufacturer’s operating manual for instructions on battery maintenance or contact an Eaton service representative. Observe these precautions when working on or around batteries: Remove watches, rings, or other metal objects.

  • Page 134: Performing Preventive Maintenance

    See Figure 9-1 and Figure 9-2 for filter locations. The ISBM section filter sizes are 12" 20" 0.25" and the UPM section filter sizes are 20" 44" 0.25". Contact an Eaton service representative for replacement filters. To remove the filters: a.

  • Page 135: Figure 9-1. Isbm Section Air Filter Locations

    Reinstall the UPM section front panels removed in Step a and secure with the retained hardware. Reinstall the ISBM section front panel removed in Step b and secure with the retained hardware. 9−3 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...

  • Page 136: Figure 9-2. Upm Section Air Filter Locations

    If the UPS is a Plus 1 model, check the Field Installed UPM (FI−UPM) air filter (located behind the front panel) and wash or replace as necessary. See Figure 9-3 for the filter location. The FI−UPM filter size is 20" 44" 0.25". Contact an Eaton service representative for replacement filter. To remove the filter: a.

  • Page 137: Periodic Maintenance

    Eaton service representative for more information about service offerings. 9.2.5 BATTERY Maintenance Contact an Eaton service representative for battery maintenance. Battery replacement and maintenance should be performed only by authorized service personnel. Installing Batteries NOTE There is no manual DC disconnect device within the UPS.

  • Page 138: Recycling The Used Battery Or Ups

    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. For more information about training and other services, contact the Eaton Help Desk for Powerware products (see page 1−7).

  • Page 139: Product Specifications

    The UPS is housed in a free-standing cabinet, divided into two sections with safety shields behind the door and front panels. The UPS is available in 50 or 60 Hz with various output power ratings. Models Power Rating Frequency Powerware 9395−825/650 650 kVA 50/60 Hz Powerware 9395−825/750 750 kVA 50/60 Hz Powerware 9395−825/825...

  • Page 140: Ups Output

    Meets IEC 801-2 specifications. Withstands up to 25 kV pulse Immunity without damage and with no disturbance or adverse effect to the critical load. 10−2 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 141 Powerware−built battery cabinets (individually and collectively, the "Warranted Items") are free from defects in material and workmanship. If, in the opinion of Eaton, a Warranted Item is defective and the defect is within the terms of this Warranty, Eaton’s sole obligation will be to repair or replace such defective item (including by providing service, parts, and labor, as applicable), at the option of Eaton.
  • Page 142 WARRANTY This page intentionally left blank. W−2 EATON Powerware 164201725 Rev 1 www.powerware.com ® 9395 UPS (650–825 kVA) Installation and Operation Manual...
  • Page 144 *1642017251* 164201725 1...

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