Eaton Powerware 9155, Upgrade Procedure

Page 1: ...p n Revision 1 9x55 8 15 kVA Battery Upgrade For use with the Eaton 9155 and 9355 8 15 kVA Powerware Series ...

Page 2: ...s manual contains important instructions that you should follow during installation and maintenance of the UPS and batteries Please read all instructions before operating the equipment and save this manual for future reference CONSIGNES DE SÉCURITÉ IMPORTANTES CONSERVER CES INSTRUCTIONS Ce manuel comporte des instructions importantes que vous êtes invité à suivre lors de toute procédure d installa...

Page 3: ... kVA Battery Upgrade 8 15 kVA Rev 1 iii T Ta ab blle e o of f C Co on nt te en nt ts s 1 1 I In nt tr ro od du uc ct tiio on n 1 1 2 2 B Ba at tt te er ry y U Up pg gr ra ad de e P Pr ro oc ce ed du ur re e 3 3 ...

Page 4: ...iv 9x55 8 15 kVA Battery Upgrade 8 15 kVA Rev 1 Table of Contents ...

Page 5: ... models require this battery upgrade Prior to the upgrade the two battery trays in a shelf are oriented in opposite directions The positive terminal of the left tray is to the front of the unit while the negative terminal of the right tray is in the front After this upgrade all trays will be oriented with the positive terminals to the front Installing the new adapter requires that you cut the exis...

Page 6: ...2 9x55 8 15 kVA Battery Upgrade 8 15 kVA Rev 1 Introduction ...

Page 7: ...rformed by qualified personnel IMPORTANT In the event of input power failure while performing this procedure battery backup will not be available 1 If possible remove power from the system Otherwise follow the instructions in the UPS Maintenance section of the User s Guide to place the 9x55 8 15kVA UPS in Maintenance bypass First put the UPS into bypass then move the switch to maintenance bypass H...

Page 8: ...he rear of the unit is open Follow applicable lockout tagout procedures Figure 2 CB1 Is Open Located at the rear of the unit NOTE If an external battery cabinet is attached it must be disconnected from the UPS Ensure that CB1 is open on each associated external battery cabinet Battery Upgrade Procedure ...

Page 9: ...9x55 8 15 kVA Battery Upgrade 8 15 kVA Rev 1 5 3 Remove the front dress panel of the battery compartment Figure 3 Remove Front Panel Battery Upgrade Procedure ...

Page 10: ...grade 8 15 kVA Rev 1 4 Using a 7mm nut driver remove the screws that secure the battery dead front and remove the dead front Figure 4 Remove Battery Dead Front Screws Figure 5 Battery Dead Front Removed Battery Upgrade Procedure ...

Page 11: ...ith all the positive red wires then all the negative black wires Ensure that the wires do not come into contact with any metal framing It is recommended to isolate the connectors by using a non conductive electrical tape to secure the end of each connector Figure 6 Disconnect the Cabinet Harnesses Battery Upgrade Procedure ...

Page 12: ...8 9x55 8 15 kVA Battery Upgrade 8 15 kVA Rev 1 Figure 7 Disconnected Cabinet Harnesses WARNING All battery trays must be disconnected prior to proceeding any further Battery Upgrade Procedure ...

Page 13: ...ive and negative disconnected harness from each shelf string to verify that there is no voltage Figure 8 Verify Zero Voltage WARNING After performing Step 6 there will still be full battery string voltage between the positive red and negative black terminals of the battery trays Battery Upgrade Procedure ...

Page 14: ... tray half way out and disengage the tray to tray jumper from the tray clips Figure 9 Disconnect Tray to Tray Jumper From Tray Clips 8 Disconnect the tray to tray jumper white terminal on a black wire Figure 10 Disconnected Tray to Tray Jumper Battery Upgrade Procedure ...

Page 15: ...9x55 8 15 kVA Battery Upgrade 8 15 kVA Rev 1 11 9 Slide both battery trays completely out of the unit Figure 11 Both Trays Slid Completely Out Battery Upgrade Procedure ...

Page 16: ...Rev 1 10 Remove and discard the tray to tray jumper Figure 12 Discard Tray to Tray Jumper 11 Repeat Steps 7 10 for the other battery shelves until all battery trays have been removed from the unit Figure 13 Empty Unit Battery Upgrade Procedure ...

Page 17: ...ch battery tray onto the shelf to get it started Figure 14 Insert New Battery Trays 13 Locate the remaining cabinet wiring that was previously disconnected from the old trays Use a wire cutter preferably the scissor action type as opposed to diagonal cutters to cut remove the existing female Faston terminal on the cabinet harness spade terminal off the ends of the red and black wires It is preferr...

Page 18: ...ev 1 14 Use a wire stripper preferably the no nick type so that no wire strands are cut off or nicked weakened to strip 1 4 inch of insulation from each of the red and black wires Figure 15 Strip 1 4 Inch of Insulation Battery Upgrade Procedure ...

Page 19: ...ool PN 59824 1 or equivalent is used in this step Ensure that the two pieces of black heat shrink highlighted in yellow in Figure 18 are on the adapter assembly Then insert the negative black wire into the crimp terminal on the black wire of the retrofit adapter see Figure 18 Figure 16 New Adapter Figure 17 Recommended Crimp Tool WARNING Ensure that no bare wire is exposed outside of the crimp ter...

Page 20: ... Adapter Harness to the Battery Cabinet Wires 16 Repeat the insertion and crimping steps for the positive red wire ensuring that no bare wires are hanging out of the crimp Figure 19 Inserting and Crimping the Red Wire to The Adapter Harness Battery Upgrade Procedure ...

Page 21: ...t back into the unit between the newly installed trays Figure 21 Push Wires Between Newly Installed Trays 19 Repeat Steps 15 18 for all battery shelves 20 Verify the correct polarity between the newly installed UPS harness adapter and the battery tray harness prior to making each connection CAUTION All the battery shelves must be modified to incorporate the new adaptor harness illustrated in Figur...

Page 22: ... to black and red to red 21 Push the new harness and connections back against the battery cases Secure the right side harness to the battery tray using a single tie wrap to prevent the connections from coming into contact with the dead front and its screws when reinstalled Battery Upgrade Procedure ...

Page 23: ...he previously removed 7 mm screws Ensure that the tray retainer clips on the back of the dead front do not pinch the battery cables Figure 23 Reinstall the Dead Front Figure 24 Reinstalled Dead Front 23 If an external battery cabinet is attached reconnect it to the UPS Battery Upgrade Procedure ...

Page 24: ...stall the front dress panel Figure 25 Battery Cabinet Front Dress Panel Reinstalled 25 Follow the instructions in the equipment s User s Guide shown in the Normal Mode Startup section to command the unit to normal mode of operation Battery Upgrade Procedure ...

Page 25: ...pgrade 8 15 kVA Rev 1 21 NOTE The figure below provides a schematic example of the end result as a reference for a two string two shelf configuration Figure 26 Schematic Example of New Configuration Battery Upgrade Procedure ...

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