Eaton Power Xpert 9395, Installation Manual

Page 1: ...Power Xpert 9395 Integrated Battery Cabinet Model 1085 and 1085HR Installation Manual ...

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Page 3: ...Power Xpert 9395 Integrated Battery Cabinet Model 1085 and 1085HR Installation Manual ...

Page 4: ...ES CONSIGNES DE SÉCURITÉ IMPORTANTES Eaton Powerware LanSafe Powerware Hot Sync and X Slot are registered trademarks and ConnectUPS is a trademark of Eaton Corporation or its subsidiaries and affiliates AS 400 is a registered trademark of International Business Machines Corporation Modbus is a registered trademark of Schneider Automation All other trademarks are property of their respective compan...

Page 5: ...ing Preparation 5 3 2 3 Interface Wiring Preparation 9 3 3 Inspecting and Unpacking the Battery Cabinet 10 4 Installation 4 1 4 1 Preliminary Installation Information 4 1 4 2 Unloading the Battery Cabinet from the Pallet 4 1 4 3 Model 1085 or 1085HR Battery Cabinet Installation 4 3 4 3 1 Mechanical Installation 4 3 4 3 2 External Power Wiring Installation 4 7 4 3 3 External Interface Wiring Instal...

Page 6: ...r and Interface Terminal Locations 4 9 Figure 4 8 1085HR Battery Power and Interface Terminal Locations 4 10 Figure 4 9 Battery Breaker Interface Wiring 4 12 Figure 4 10 Terminal Block TB1 Connector Assignments First Cabinet 4 13 Figure 4 11 Terminal Block TB1 Connector Assignments Middle Cabinets 4 14 Figure 4 12 Terminal Block TB1 Connector Assignments Last Cabinet 4 14 Figure 4 13 1085 Battery ...

Page 7: ...dvance usually a two week notice is required to reserve a preferred startup date 1 1 Configuration and Installation Features The 9395 Model 1085 battery cabinet is designed to be installed in a standalone configuration using two to four battery cabinets Power wiring is installed externally between each battery cabinet and the UPS or battery disconnect using conduit Battery cabinets may be installe...

Page 8: ...can use the 1085 1085HR battery cabinets Figure 1 1 Typical Power Xpert 9395 Model 1085 or 1085HR Battery Cabinet 1 4 Using This Manual This manual describes how to install the Power Xpert 9395 battery cabinet Read and understand the procedures described in this manual to ensure trouble free installation Read through each procedure before beginning the procedure Perform only those procedures that ...

Page 9: ...installed adjacent to the UPS or in a separate location are wired with external customer supplied conduit and wiring and may use the battery cabinet breaker as the battery isolation device or a single overcurrent protection and disconnect device located near the batteries 1 6 Symbols Controls and Indicators The following are examples of symbols used on the battery cabinet to alert you to important...

Page 10: ... and optional accessories procedures for starting and stopping the UPS and information about maintenance and responding to system events S Communication capabilities of the UPS system Visit www eaton com powerquality or contact your service representative for information on how to obtain copies of these manuals 1 8 Getting Help If help is needed with any of the following S Scheduling initial start...

Page 11: ...ions should be observed 1 Remove watches rings or other metal objects 2 Use tools with insulated handles 3 Do not lay tools or metal parts on top of batteries 4 Wear rubber globes and boots S ELECTRIC ENERGY HAZARD Do not attempt to alter any battery wiring or connectors Attempting to alter wiring can cause injury S Do not open or mutilate batteries Released electrolyte is harmful to the skin and ...

Page 12: ...e found at www eaton com powerquality or contact your service representative for information on how to obtain copies S Keep surroundings uncluttered clean and free from excess moisture S Observe all DANGER CAUTION and WARNING notices affixed to the inside and outside of the equipment AVERTISSEMENT S Les batteries peuvent présenter un risque de décharge électrique ou de brûlure par des courts circu...

Page 13: ...he procedures and illustrations in paragraph 3 2 and Chapter 4 to create a logical plan for installing the system 3 2 Preparing the Site For the battery system to operate at peak efficiency the installation site should meet the environmental parameters outlined in this manual If the UPS is to be operated at an altitude higher than 1500m 5000 ft contact your service representative for important inf...

Page 14: ...y cabinet are shown in Table 3 2 Dimensions are in millimeters inches Table 3 2 UPS Cabinet Clearances From Top of Cabinet Minimum clearance over the UPS cabinet is 457 2 mm 18 for ventilation From Front of Cabinet 914 4 mm 36 working space From Back of Cabinet None Required From Right Side of Cabinet None Required From Left Side of Cabinet None Required The basic environmental requirements of bot...

Page 15: ...085HR Installation Manual S 164201687 Rev 4 www eaton com powerquality 3 3 DIMENSIONS ARE IN MILLIMETERS INCHES Figure 3 1 Model 1085 or 1085HR Battery Cabinet Dimensions Front View DIMENSIONS ARE IN MILLIMETERS INCHES Figure 3 2 Model 1085 or 1085HR Battery Cabinet Dimensions Right Side View ...

Page 16: ...HR Installation Manual S 164201687 Rev 4 www eaton com powerquality 3 4 DIMENSIONS ARE IN MILLIMETERS INCHES Front Figure 3 3 Model 1085 or 1085HR Battery Cabinet Dimensions Top View DIMENSIONS ARE IN MILLIMETERS INCHES Front Figure 3 4 Model 1085 or 1085HR Battery Cabinet Dimensions Bottom View ...

Page 17: ...eakers S Refer to NEC Article 250 and local codes for proper grounding practices S The battery cabinet frame is not referenced to the DC circuit S Battery voltage is computed at 2 volts per cell as defined by Article 480 of the NEC Rated battery current is computed at 2 volts per cell S The battery wiring used between the battery and the UPS should not allow a voltage drop of more than 2 VDC at ra...

Page 18: ... 7 500 1 500 8 1100 1100 7 500 1 500 9 All All Ground Refer to NEC Table 250 122 As Required Refer to NEC Table 250 122 As Required NOTE Replace with same type and number as original battery Mixing battery letter designation and or sizes will damage equipment and void warranty Table 3 4 External Power Wiring Requirements for the Power Xpert 9395 Model 1085 Battery Cabinet Separate Battery UPS Mode...

Page 19: ...e type and number as original battery Mixing battery letter designation and or sizes will damage equipment and void warranty Table 3 6 External Power Wiring Requirements for the Power Xpert 9395 Model 1085HR Battery Cabinet Separate Battery UPS Model Power Xpert 9395 Minimum Number of Cabinets per UPM Battery Terminal Each Battery Cabinet to UPS or Battery Disconnect Battery Disconnect 1 to UPS Ba...

Page 20: ...42 4 375 3 8 Hex Bolt 2 1 Bolt Mounting 22 6 200 M10 Hex Ground Ground Ground Pressure 2 14 1 0 5 6 50 7 16 Slot NOTE Customer ground sized in accordance with NEC Table 250 122 can be run in any conduit listed Refer to the appropriate UPS manual A battery disconnect switch is recommended and may be required by NEC or local codes when batteries are remotely located The battery disconnect switch sho...

Page 21: ...rip requires 48 Vdc to activate Use Class 2 wiring methods as defined by the NEC for interface wiring from 30 to 600V The wiring should be a minimum of 18 AWG rated at 48V 1A minimum S All interface wiring between the UPS and battery cabinet is to be provided by the customer S When installing external interface wiring for example battery breaker shunt trip to the battery cabinet interface terminal...

Page 22: ...se a forklift or pallet jack to move the packaged cabinet to the installation site or as close as possible before unpacking Insert the forklift or pallet jack s forks between the pallet supports on the bottom of the unit CAUTION Do not tilt the UPS cabinet more than 10 from vertical or the cabinet may tip over 3 Set the pallet on a firm level surface allowing a minimum clearance of 3m 10 ft on eac...

Page 23: ...CKING Power Xpert 9395 Integrated Battery Cabinet Model 1085 and 1085HR Installation Manual S 164201687 Rev 4 www eaton com powerquality 3 11 Figure 3 5 Power Xpert 9395 Model 1085 or 1085HR Battery Cabinet as Shipped on Pallet ...

Page 24: ...INSTALLATION PLAN AND UNPACKING Power Xpert 9395 Integrated Battery Cabinet Model 1085 and 1085HR Installation Manual S 164201687 Rev 4 www eaton com powerquality 3 12 This page intentionally left blank ...

Page 25: ...ipment weight wiring and terminal data and installation notes S Refer to the applicable Power Xpert 9395 UPS Installation and Operation Manual listed in paragraph 1 7 for UPS cabinet conduit and terminal specifications and locations S The conduit landing plates are to be removed to add conduit landing holes as required Plate material is 16 gauge steel 1 5 mm 0 06 thick S The recommended installati...

Page 26: ... Locate the field kit packed inside of the cabinet Locate the four 1 2 jacking bolts and install them in the threaded holes in the front and rear supports Place a floor protector underneath each jacking bolt and screw the bolts down against them The floor protectors protect the floor from being marred by the jacking bolts Retain the remaining parts of the field kit for later use Floor Protector St...

Page 27: ...ted by the jacking bolts 9 Remove the jacking bolts and discard or recycle them in a responsible manner 10 Remove the hardware holding the front rear and side supports to the cabinet base Discard or recycle the hardware and support brackets in a responsible manner 11 Roll the battery cabinet to its final location 12 Repeat Steps 3 through 11 for each cabinet you are preparing to install 4 3 Model ...

Page 28: ...casters and the cabinet is level NOTE When multiple battery cabinets are ordered for standalone installation the first battery cabinet is supplied with two cosmetic covers Additional battery cabinets are supplied without cosmetic covers 4 Remove the cosmetic cover and hanger brackets from the appropriate side or sides of the battery cabinets depending on the position of the cabinets Save covers sc...

Page 29: ...top door hinges of the battery cabinets 9 Locate the small flat bracket from the field kit Align the holes in the small flat bracket over the hinge screw holes Replace the screws in the hinges securing the bracket to the cabinets see Figure 4 3 10 Locate the large flat bracket from the field kit Place the bracket over the bolts on the bottom side of the adjacent lower hinges on the battery cabinet...

Page 30: ...t under the lower battery tray and through the cabinet to cabinet cable access area in the side of the cabinets and attach to the ground stud in the other battery cabinet see Figure 4 4 Hardware is provided on each ground stud 13 If installing additional battery cabinets repeat Steps 4 through 12 to join each additional battery cabinet otherwise proceed to Step 14 14 If not already installed mount...

Page 31: ...t place objects on the ventilation grill NOTE Remove the battery cabinet top or bottom conduit landing plate to drill or punch conduit holes see Figure 4 6 NOTE Wiring is installed externally between each battery cabinet and the UPS or battery disconnect using conduit see Figure 5 1 through Figure 5 4 NOTE All battery cabinets have to be directly connected to the UPS or battery disconnect not dais...

Page 32: ...Control Interface TB1 Connections Remove panel to drill or punch conduit holes Front Front Figure 4 6 Battery Cabinet Conduit and Wire Entry Locations 3 If wiring to a battery disconnect proceed to Step 6 otherwise proceed to Step 4 4 Follow the required battery cable routing instructions specified in Section 3 2 2 above Route and connect the other end of the battery cables to the UPS cabinet batt...

Page 33: ... Repeat Steps 1 through 7 for each battery cabinet and then proceed to paragraph 4 3 3 Cabinet to UPS Negative Terminals Cabinet to UPS Positive Terminals Interface Terminal Block TB1 and Connectors J3 And P3 see Figure 4 10 For details Battery Breaker Ground Terminal NOTE Use pressure and bus bar terminations as necessary for connecting cables between the UPS and battery cabinets Inter Cabinet Wi...

Page 34: ...ectors J3 And P3 see Figure 4 10 For details Battery Breaker Ground Terminal Inter Cabinet Wiring Access to Route Interface Wires Between Cabinets Inter Cabinet Wiring Access to Route Interface Wires Between Cabinets EMP Mounting Location if installed Ground Stud Ground Stud NOTE Use pressure and bus bar terminations as necessary for connecting cables between the UPS and battery cabinets Figure 4 ...

Page 35: ...nect to terminal 5 On the last battery cabinet TB1 terminal board verify the jumper is connected between terminals 4 and 10 See Figure 4 10 through Figure 4 12 and Figure 5 6 through Figure 5 8 5 If wiring a battery disconnect proceed to Step 9 otherwise proceed to Step 6 NOTE The 9395 system can trip a maximum of six battery cabinets total This applies to both the 1085 standard and High Rate seri...

Page 36: ... 9395 Installation and Operation manual listed in paragraph 1 7 for UPS cabinet terminal locations and assignments and termination requirements 13 Proceed to paragraph 4 3 4 Table 4 1 TB1 Interface Connections Terminal TB1 Name Description 1 CB1 Aux 1 Switch NC Auxiliary battery breaker dry contacts Not used 2 CB1 Aux 1 Switch Com 3 CB1 Aux 1 Switch NO 4 Jumper Tie Points Multi cabinet selection 5...

Page 37: ...om powerquality 4 13 1 2 3 4 5 6 7 8 9 11 10 12 P3 From UPS contractor supplied wiring To Next Battery Cabinet TB1 Jumper Position for First Cabinet in Multi Cabinet Installations Battery Aux Battery Aux Return 48 Vdc Battery Shunt Trip 48 Vdc Battery Shunt Trip Figure 4 10 Terminal Block TB1 Connector Assignments First Cabinet ...

Page 38: ...vious Battery Cabinet To Next Battery Cabinet TB1 Jumper Position for Middle Cabinets in Multi Cabinet Installations Figure 4 11 Terminal Block TB1 Connector Assignments Middle Cabinets 1 2 3 4 5 6 7 8 9 11 10 12 J3 P3 From Previous Battery Cabinet Not Used TB1 Jumper Position for Last Cabinet in Multi Cabinet Installations Figure 4 12 Terminal Block TB1 Connector Assignments Last Cabinet ...

Page 39: ...e the battery string connections see Figure 4 13 3 FOR 1085HR ONLY Connect the string of battery trays by mating the loose black connector with the blue locking mechanism from each tray to the fixed black connector mounted on the front edge of the tray below Connect the top and bottom tray connectors to the mating cabinet connectors to complete the battery string connections see Figure 4 14 4 Repe...

Page 40: ...installing the battery cabinet is to complete the Installation Checklist This checklist ensures all hardware cables and other equipment have been installed Completing all items on the checklist will ensure a smooth installation Make a copy of the Installation Checklist before filling it out and retain the original After completing your installation a service representative will be able to verify t...

Page 41: ...d E5 terminals in the UPS cabinet Internal battery cabinet connections such as cables and plugs have been completed Battery Shunt trip and Aux contact signal wiring is connected from the battery breaker to the UPS The EMP is installed and set up by an authorized Eaton Corporation Customer Service Engineer Air conditioning equipment is installed and operating correctly The area around the installed...

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Page 43: ...net Battery Cabinet NOTE See paragraph 3 2 2 for wiring installation notes and Table 3 3 for wiring requirements E4 E5 I O Figure 5 1 Battery Cabinet Oneline Common Battery 275 and 500 kVA RT and 275 kVA Plus 1 UPS UPS Cabinet Four Cabinets Maximum Battery Cabinet Battery Cabinet Battery Cabinet Battery Cabinet NOTE See paragraph 3 2 2 for wiring installation notes and Table 3 3 for wiring require...

Page 44: ...5 2 UPS Cabinet Three Cabinets Maximum Battery Cabinet Battery Cabinet Battery Cabinet NOTE See paragraph 3 2 2 for wiring installation notes and Table 3 3 for wiring requirements E4 E5 I O Three Cabinets Maximum Battery Cabinet Battery Cabinet Battery Cabinet E4 E5 UPM 1 UPM 2 Figure 5 3 Battery Cabinet Oneline Separate Battery 275 kVA Plus 1 and 500 kVA RT UPS ...

Page 45: ...ery Cabinet Battery Cabinet Battery Cabinet Battery Cabinet NOTE See paragraph 3 2 2 for wiring installation notes and Table 3 3 for wiring requirements Battery Disconnect E4 E5 I O E4 E5 UPM 1 UPM 2 Four Cabinets Maximum Battery Cabinet Battery Cabinet Battery Cabinet Battery Cabinet Battery Disconnect Figure 5 4 Battery Cabinet Oneline with Disconnect Separate Battery 275 kVA Plus 1 and 500 kVA ...

Page 46: ... Manual S 164201687 Rev 4 www eaton com powerquality 5 4 5 2 Schematics Figure 5 5 show the battery cabinet three pole internal power wiring Figure 5 6 through Figure 5 8 show the battery cabinet breaker CB1 control wiring Figure 5 5 1085 or 1085HR Battery Cabinet with Three Pole Breaker Power Wiring Schematic ...

Page 47: ...ion Manual S 164201687 Rev 4 www eaton com powerquality 5 5 First Cabinet in Multi Cabinet Installations Figure 5 6 Battery Cabinet Breaker CB1 Control Wiring Schematic First Cabinet Middle Cabinets in Multi Cabinet Installations Figure 5 7 Battery Cabinet Breaker CB1 Control Wiring Schematic Middle Cabinets ...

Page 48: ... 9395 Integrated Battery Cabinet Model 1085 and 1085HR Installation Manual S 164201687 Rev 4 www eaton com powerquality 5 6 Last Cabinet in Multi Cabinet Installations Figure 5 8 Battery Cabinet Breaker CB1 Control Wiring Schematic Last Cabinet ...

Page 49: ...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 wo...

Page 50: ... and maintenance should be performed only by authorized service personnel 6 3 Installing Batteries CAUTION The 1085 and 1085HR batteries CANNOT be intermixed Serious damage to equipment may result NOTE There is no manual DC disconnect device within the UPS Contact your service representative for battery maintenance Battery replacement and maintenance should be performed only by authorized service ...

Page 51: ...liser le même nombre et modéle des batteries S L élimination des batteries est règlementée Consulter les codes locaux à cet effet CAUTION Do not discard the batteries in the trash This product contains sealed lead acid batteries and must be disposed of properly For more information contact your local recycling reuse or hazardous waste center CAUTION Do not discard waste electrical or electronic eq...

Page 52: ...MAINTENANCE Power Xpert 9395 Integrated Battery Cabinet Model 1085 and 1085HR Installation Manual S 164201687 Rev 4 www eaton com powerquality 6 4 This page intentionally left blank ...

Page 53: ...startup and commissioning of the Product b if the Product is moved to a new location by someone other than an authorized Eaton Customer Service Engineer in the USA or Agent outside of the USA or c if the Product s serial numbers have been removed or are illegible Any Warranted Items repaired or replaced pursuant to this Warranty will be warranted for the remaining portion of the original Warranty ...

Page 54: ...WARRANTY Power Xpert 9395 Integrated Battery Cabinet Model 1085 and 1085HR Installation Manual S 164201687 Rev 4 www eaton com powerquality W 2 This page intentionally left blank ...

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