Eaton 93PM IBC-LW, Installation Manual

Page 1: ...p n P 164000541 Revision 04 IBC LW Large 432V and 480V IBC LHW Large High Rate 432V and 480V Installation Manual Eaton 93PM Universal Integrated Battery Cabinet...

Page 2: ...e reproduced in any way without the express written approval of Eaton IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during i...

Page 3: ...id or unenforceable the remaining provisions of this Agreement will remain in full force 5 5 Waiver The waiver by either party of any default or breach of this Agreement will not constitute a waiver o...

Page 4: ......

Page 5: ...rations 11 3 2 2 IBC Power Wiring Preparation 19 3 2 3 IBC Interface Wiring Preparation 25 3 3 Inspecting and Unpacking the IBC 26 3 4 Battery Breaker Location 27 4 4 I In ns st ta alllla at tiio on n...

Page 6: ...aintenance 63 6 2 2 PERIODIC Maintenance 63 6 2 3 ANNUAL Maintenance 63 6 2 4 BATTERY Maintenance 63 6 2 5 BATTERY Shelf Life 64 6 3 Recycling the Used Batteries 64 6 4 Maintenance Training 64 7 7 P P...

Page 7: ...M IBC LHW 38 Figure 15 DC Power Terminal Bottom Wiring Entry Terminal Installation 39 Figure 16 DC Power Terminal Detail Eaton 93PM IBC LW or Eaton 93PM IBC LHW 40 Figure 17 DC Power Terminal Top Wiri...

Page 8: ...viii Eaton 93PM Universal Integrated Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 List of Figures...

Page 9: ...aton 93PM IBC LW and Eaton 93PM IBC LHW 20 Table 7 Standalone External Power Wiring Recommendation Eaton 93PM IBC LW 300A Breaker 21 Table 8 Standalone External Power Wiring Recommendations Eaton 93PM...

Page 10: ...x Eaton 93PM Universal Integrated Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 List of Tables...

Page 11: ...us voltage protection UPS systems 200 kW and below can utilize up to four IBC LWs per UPS or two IBC LHWs per UPS to meet application runtime needs 400 kW UPS systems can utilize up to eight IBC LWs p...

Page 12: ...ccessible mechanical terminals located at the bottom front of the cabinet reduce installation time Interface wiring can be routed through the top left or right sides of the IBCs in line up and match c...

Page 13: ...UPS Use with a Eaton 93PM 20 50 kW UPS Eaton 93PM 20 100 kW UPS Eaton 93PM 20 150 kW UPS or Eaton 93PM 20 200 kW UPS Up to eight IBC LWs can be paralleled to extend the run time Use with a Eaton 93PM...

Page 14: ...erator s manual for additional information such as important operating and maintenance instructions This symbol indicates that you should not discard the UPS or the UPS batteries in the trash This pro...

Page 15: ...eration Manual Eaton 93PM UPS 480V Three Wire 400 kW Frame Installation and Operation Manual 1 UPS optional components and accessory installation instructions including site preparation planning for i...

Page 16: ...LW and IBC LHW Installation Manual P 164000541 Rev 04 1 1 9 9 E Eq qu uiip pm me en nt t R Re eg giis st tr ra at tiio on n Please visit www eaton com pq register to register your new Eaton UPS Eaton...

Page 17: ...output terminals may carry live voltage even when the UPS is not connected to an AC source To reduce the risk of fire or electric shock install this UPS system in a temperature and humidity controlle...

Page 18: ...nside the unit Do not install or operate the UPS system close to gas or electric heat sources Lead acid batteries can present a risk of fire because they generate hydrogen gas Do not smoke when near b...

Page 19: ...ais jeter les batteries au feu L exposition aux flammes risque de les faire exploser Les accumulateurs au plomb acide peuvent repr senter un risque d incendie car ils g n rent de l hydrog ne gazeux Ne...

Page 20: ...10 Eaton 93PM Universal Integrated Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 Safety Warnings...

Page 21: ...ocedures and illustrations in this section to create a logical plan for installing the IBC This section contains the following information Physical features and requirements including dimensions Power...

Page 22: ...tact your service representative for information on how to obtain copies The IBC operating environment must meet the weight requirements shown in Table 1 Table 2 Table 3 or Table 4 and the size requir...

Page 23: ...egrated Battery Cabinet Large with E39 Batteries 1881 4148 1836 4048 6 at 306 675 Eaton 93PM Universal Integrated Battery Cabinet Large with E28 Batteries 1545 3408 1500 3308 6 at 250 551 Eaton 93PM U...

Page 24: ...t of Cabinet 914 4 mm 36 working space From Back of Cabinet with Top Exhaust Option None Required From Back of Cabinet with Rear Exhaust Option 254 mm 10 minimum clearance for ventilation From Back of...

Page 25: ...Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 15 Figure 3 Eaton 93PM IBC LW or Eaton 93PM IBC LHW Dimensions Front and Right Side Views Dimensions are in millimeters inches...

Page 26: ...ual P 164000541 Rev 04 Figure 4 Eaton 93PM IBC LW or Eaton 93PM IBC LHW Dimensions Rear Views Dimensions are in millimeters inches NOTE The IBC Front Floor Mounting Bracket s mounting dimensions are i...

Page 27: ...Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 17 Figure 5 Eaton 93PM IBC LW or Eaton 93PM IBC LHW Dimensions Top and Bottom Views Dimensions are in millimeters inches TopView Bott...

Page 28: ...l Integrated Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 Figure 6 Eaton 93PM IBC LW or Eaton 93PM IBC LHW Center of Gravity Dimensions are in millimeters inches Installat...

Page 29: ...7 1 1836 4048 with 135Ah Batteries E54 982 38 7 505 19 9 434 17 1 2179 4803 with 103Ah Batteries B37 975 38 4 507 20 0 434 17 1 1876 4136 with 95Ah Batteries H41 957 38 4 507 20 0 434 17 1 1829 4032 w...

Page 30: ...battery strings are to be connected by an authorized Eaton Customer Service Engineer Refer to the appropriate Eaton 93PM UPS installation and operation manual listed in paragraph 1 7 For More Informa...

Page 31: ...r Pole 93PM IBC LW 50 kW 100 kW 150 kW 200 kW 1 or 2 Battery 3 0 2 Not Required Battery 3 0 2 Not Required 3 or 4 Battery 3 0 2 3 0 2 Battery 3 0 2 3 0 2 Ground 4 one per cabinet 4 one per cabinet 93P...

Page 32: ...M IBC LW 400A Breaker Battery Cabinet to UPS or External Customer Supplied Tie Point and Breaker or Disconnect Tie Point and Breaker or Disconnect to UPS Model UPS Model Num ber of Cabi nets Termi nal...

Page 33: ...W 400 5 400 6 400 7 400 8 1 2 3 4 5 6 7 or 8 Battery 300 2 500 4 Battery 300 2 500 4 Ground 1 one per cabinet 1 one per cabinet Table 9 Standalone External Power Wiring Recommendations Eaton 93PM IBC...

Page 34: ...300 2 Not Required 400 3 400 4 5 6 7 or 8 Battery 300 2 300 2 Battery 300 2 300 2 Ground 1 one per cabinet 1 one per cabinet 93PM IBC LHW 400 5 400 6 400 7 400 8 1 2 3 4 5 6 7 or 8 Battery 300 2 500...

Page 35: ...Recommended DC Circuit Breaker or Disconnect Ratings Three or Four IBC LWs or Two IBC LHWs Model UPS Model Input Rating Eaton 93PM IBC LW 50 kW 100 kW 150 kW 200 kW 400 kW 300A Eaton 93PM IBC LW 50 kW...

Page 36: ...art of the sales contract for the UPS Contact an Eaton service representative in advance a minimum two week notice is required to reserve a preferred startup date WARNING The IBC is heavy see Table 1...

Page 37: ...impact on further installation NOTE While waiting for installation protect the unpacked cabinet from moisture dust and other harmful contaminants Failure to store and protect the IBC properly may voi...

Page 38: ...d Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 Figure 8 Eaton 93PM IBC LW or Eaton 93PM IBC LHW Battery Breaker Location Front View with Front Door Removed Battery Breaker...

Page 39: ...osely followed the cabinet may tip and cause serious injury RISK OF INSTABILITY Do not remove any internal panels until the cabinet is removed from and lowered from the pallet Do not tilt cabinet more...

Page 40: ...bolts holding the left right front and rear to the pallet skids see Figure 9 DO NOT loosen or remove the cabinet mounting bolts or the cabinet support bolts WARNING RISK OF INSTABILITY Turning the jac...

Page 41: ...oor Mounting Bolts 4 places top 2 places bottom CAUTION CABINET MAY FALL Do not loosen the hardware attaching the front supports to the cabinet base The cabinet must be lowered by the jacking bolts be...

Page 42: ...see Figure 12 CAUTION To prevent tipping when rolling the cabinet push the cabinet from the rear whenever possible 15 Roll the IBC to the line up and match installation location on the right side of t...

Page 43: ...4000541 Rev 04 33 Figure 10 Line Up and Match Wiring Access Locations Inter cabinet wiring access to route interface wiring between cabinets Inter cabinet wiring access knockouts Remove knockouts as r...

Page 44: ...34 Eaton 93PM Universal Integrated Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 Figure 11 Rear Ventilation Figure 12 Top Ventilation Installation...

Page 45: ...ed to wire IBC 3 and IBC 4 NOTE 4 See paragraph 3 2 2 IBC Power Wiring Preparation Table 6 and Table 10 for wiring and termination requirements NOTE 5 Refer to the applicable Eaton 93PM UPS Installati...

Page 46: ...00 kW Frame UPS models Do not shorten or cut factory supplied wiring 6 Route the battery wiring positive negative and ground through the bottom side inter cabinet access pass through see Figure 10 of...

Page 47: ...he ground positive and negative power wiring to the UPS cabinet external battery ground and input terminals NOTE Route the battery wiring between the UPS and subsequent IBCs through the bottom of the...

Page 48: ...sal Integrated Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 Figure 14 DC Power Terminal Locations Eaton 93PM IBC LW or Eaton 93PM IBC LHW DC OutputTerminals and Ground Ter...

Page 49: ...BC LW and IBC LHW Installation Manual P 164000541 Rev 04 39 Figure 15 DC Power Terminal Bottom Wiring Entry Terminal Installation Bottom EntryWiring Line Match or Remote Installation DC Output PowerTe...

Page 50: ...Figure 16 DC Power Terminal Detail Eaton 93PM IBC LW or Eaton 93PM IBC LHW IBC DC Output to UPS NegativeTerminals IBC DC Output to UPS PositiveTerminals GroundTerminals Terminal blocks are shipped un...

Page 51: ...5 Install battery terminal compression lugs to the DC bus bars Position the open terminal ends pointing down for bottom entry wiring and up for top entry wiring see Figure 14 Figure 15 Figure 17 and...

Page 52: ...y Breaker assembly which is mounted on a sliding bracket To move the assembly loosen the screw located beneath the breaker and then press the lever on top of the bracket see Figure 18 and slide the br...

Page 53: ...abinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 43 Figure 18 Battery Breaker Mount Screw Location and Mount Lever Location Eaton 93PM IBC Battery Breaker Mount Screw Location Battery...

Page 54: ...ing to the ground terminal on the IBC Connect the positive and negative power wiring to the IBC DC and DC output terminals on the IBC For a detailed view of the IBC terminal block see Figure 16 17 Con...

Page 55: ...d to paragraph 4 4 Battery Breaker Instantaneous Trip Setting otherwise skip to paragraph 4 4 Battery Breaker Instantaneous Trip Setting NOTE Internal battery strings are to be connected by an authori...

Page 56: ...rip setting provides the maximum protection for the batteries Failure to adhere to 5x instantaneous trip setting voids the battery warranty To verify the trip setting 1 Verify the UPS system is not in...

Page 57: ...NOTE 3 See paragraph 3 2 3 IBC Interface Wiring Preparation Table 12 and Figure 24 for wiring and termination requirements NOTE 4 Refer to the applicable Eaton 93PM UPS Installation and Operation manu...

Page 58: ...Drill and punch all conduit holes in the bottom conduit plate prior to mounting on the IBC Install the conduit plate and install all conduit runs into the plate Pull the wiring through the conduit in...

Page 59: ...ns Terminal TB2 Name Description 10 Thermal Sensor Optional Contacts used to signal a battery temperature out of specification and to turn off the battery charger to prevent thermal runaway 9 Thermal...

Page 60: ...iring UPS Shunt Trip TB 1 2 3 4 IBC1 1 2 3 4 5 6 7 8 9 10 IBC2 TB2 1 2 3 4 5 6 7 8 9 10 IBC3 1 2 3 4 5 6 7 8 9 10 IBC4 1 2 3 4 5 6 7 8 9 10 UPS Building Alarm TB 5 6 7 8 1 2 3 4 9 10 Shunt Trip Batter...

Page 61: ...wires for each input and return or common Strip wire insulation back 10 millimeters to wire terminal blocks Thermal Sensor 26 16 0 4 3 5 0 8 7 1 Slotted Use twisted pair wires for each input and retu...

Page 62: ...ery shunt trip interface wiring from the UPS battery shunt trip interface terminals through the bottom inter cabinet access pass through see Figure 10 of the UPS cabinet and IBC to the IBC battery int...

Page 63: ...t tiio on ns s NOTE 1 The UPS thermal sensor signal uses an UPS building alarm input to indicate a thermal trip condition and to turn off the battery charger NOTE 2 Any pair of unused building alarm t...

Page 64: ...BC Identify all conduit requirements and mark their location Drill and punch all conduit holes in the bottom conduit plate prior to mounting on the IBC Install the conduit plate and install all condui...

Page 65: ...completed Installation Checklist to verify all applicable equipment installations have been completed NOTE The Installation Checklist MUST be completed prior to starting the UPS system for the first t...

Page 66: ..._______________________________________ _________________________________________________________________________ _________________________________________________________________________ ____________...

Page 67: ...w the UPS and Eaton 93PM Universal Integrated Battery Cabinet Large High Rate IBC LHW intercabinet power connection onelines See paragraph 3 2 2 IBC Power Wiring Preparation for wiring installation no...

Page 68: ...by the customer Figure 28 Eaton 93PM IBC LW Standalone Power Online Four Cabinets ExternalTie Point and Battery Breaker or Disconnect UPS Cabinet Battery Cabinet 1 Battery Cabinet 2 Battery Cabinet 3...

Page 69: ...abinet Battery Cabinet 1 Battery Cabinet 2 Internal Internal Battery Battery Breaker Breaker NOTE Battery cabinet wiring assumes using factory supplied wiring and two wires per pole Figure 30 Eaton 93...

Page 70: ...1 Battery Cabinet 2 Two Battery Cabinets Maximum ExternalTie Point and Battery Breaker or Disconnect NOTE 1 External tie point battery breaker or disconnect and wiring to be supplied by the customer N...

Page 71: ...ry Shunt Trip 48 Vdc Battery Shunt Trip 1 2 48 Vdc TB2 or TB3 TB2 or TB3 TB2 or TB3 TB2 or TB3 UPS Building Alarm TB 1 2 TB2 or TB3 UPS Shunt Trip TB Battery Detect Battery Detect Common 48 Vdc Batter...

Page 72: ...62 Eaton 93PM Universal Integrated Battery Cabinet IBC LW and IBC LHW Installation Manual P 164000541 Rev 04 Figure 33 Eaton 93PM Universal Integrated Battery Cabinet Schematic Onelines and Schematics...

Page 73: ...However the system should be inspected periodically to verify that the units are operating normally Record maintenance results and any corrective actions in a suitable log 6 6 2 2 1 1 D DA AI IL LY Y...

Page 74: ...act your local recycling reuse or hazardous waste center Special Symbols The following are examples of symbols used on the UPS or accessories to alert you to important information RISK OF ELECTRIC SHO...

Page 75: ...nd the environmental and safety specifications for the UPS 7 7 2 2 1 1 B Ba at tt te er ry y S Sp pe ec ciif fiic ca at tiio on ns s IBC Battery Types IBC LW E28 280 W cell battery valve regulated lea...

Page 76: ...operation in a 20 30 C 68 86 F temperature environment The batteries are rated for a 25 C 77 F ambient temperature to extend their useful life Transit Temperature 15 C to 40 C 5 F to 104 F Storage Tem...

Page 77: ...1 Rev 04 67 C Ch ha ap pt te er r 8 8 W Wa ar rr ra an nt ty y For warranty information please refer to the Resources link on our website www eaton com 93PM EQUIPMENT REGISTRATION Please visit www eat...

Page 78: ...P 16400054104 P 164000541 04...