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TABLE OF CONTENT
Parts lists
El module (8 – 10kVA) “N” model 10 22 593
El module (8 – 10kVA) “S” model 10 22 595
El module (10 – 15kVA) “N” model 10 22 594
Chokes (8 – 10kVA) 10 22 592
Chokes (12 – 15kVA) 10 22 982
Fan module 10 22 818
SET Mechanics (8 – 10kVA) 10 22 205
SET Mechanics (12 – 15kVA) 10 22 983
Stands and wheels 10 22 599
Cable set 10 21 790
5. POWER BOARD
7. I / O - BOARD
Layout
9155 / 8 – 15kVA 10 21 596
9355 / 8 – 15kVA 10 21 718
Circuit diagram
All models 10 21 595
Parts list
9155 / 8 – 15kVA 10 23 727
9355 / 8 – 15kVA 10 23 728
Layout 10 21 281
Circuit diagram 10 21 280
Parts list 10 21 278
9. DISPLAY MODULE
Display board
Layout 10 21 650
Circuit diagram 10 21 649
Parts list 10 21 647
10. OPTIONS
Communications
ConnectUPS – X web SNMP adapter user’s guide *
Modbus user’s guide *
Modem Installation instructions 10 19 019
Functional description 10 19 139
Layout 10 18 687
Multi server card user’s guide *
Relay card Description 10 18 947
Circuit diagram 10 18 345
Connection cable 10 02 001
RS 232 single port user’s guide
Communication port connections
Power options
Battery module (BM) and cabinet assemblies, diagrams
Single battery cabinet for EM 10 22 569
Double battery cabinet for EM 10 22 571
Double battery cabinet stand alone 10 22 573
Triple battery cabinet stand alone 10 22 576
2 stand alone BM + cover assembly 10 22 574
3 stand alone BM + cover assembly 10 22 577
Single battery cabinet + EM assembly 10 22 579
Double battery cabinet + EM assembly 10 22 580
1 BM + EM and cover assembly 10 22 581
2 BM + EM and cover assembly 10 22 582
Stand alone BM circuit breaker assembly 10 22 223
Stand alone BM circuit breaker connection diagram 10 22 583
Warning!
Operations inside the UPS must be performed by a service engineer from the
manufacturer or from an agent authorised by the manufacturer.
Do not ever service inside the UPS when mains power is applied or the UPS is in battery mode.
Use the optional mechanical bypass if installed to the system. Remember to open battery
breaker. Always ensure by measuring with a multi-meter that no dangerous voltages are
present.
Audience
The intended audiences of this manual are people who plan the installation, install,
commission, and use or service the UPS. The manual provides guidelines to check delivery,
installing and commissioning of the UPS.
The reader is expected to know the fundamentals of electricity, wiring, electrical components
and electrical schematic symbols. This manual is written for a global reader.
Note!
Read the manual before operating or working on the UPS.
CE marking
The product has the CE marking in compliance with the following European directives:
• LV Directive (Safety) 72/23/CEE and 93/68/CEE
• EMC Directive 89/336/EEC and 93/68/EEC
Declaration of conformity with UPS harmonised standards and directives EN 62040-1-1
(Safety) and EN 50091-2 (EMC) are available on the web site (http://www.powerware.com).
User precautions
The only user operations permitted are:
• Start up and shut down of the UPS, excluding the commissioning start-up.
• Use of the LCD control panel and Maintenance Bypass Switch (MBS)
• Use of optional connectivity modules and their software
The user must follow the precautions and only perform the described operations. Any deviations
from the instructions could be dangerous to the user or cause accidental load loss.
Environment
The UPS must be installed according to the recommendations in this manual. Under no
circumstances the UPS should be installed in an airtight room, in the presence of flammable
gases, or in an environment exceeding the specification.
Excessive amount of dust in the operating environment of UPS may cause damage or lead to
malfunction. The UPS should be always protected from the outside weather and sunshine. The
recommended operating temperature is from +15 to +25 Celsius degrees.
Inquiries
Address any inquiries about the UPS and battery cabinet to the local office or agent authorised
by the manufacturer. Please quote the type code and the serial number of the equipment.
Delivery check
The UPS is delivered with the following items:
• Plastic bag containing:
Quick Installation Guide, paper format, multilingual (coming later)
User’s Guide, paper format, multilingual
User’s Guide, CD-ROM format, multilingual (coming later)
Residual voltage warning stickers
Software Suite, CD-ROM format, English language
RS-232 serial cable for the Software Suite
• Delivery documents
Note!
A claim for shipping damage must be filed immediately and the carrier must be
informed within 7 days of receipt of the equipment. The packing materials should be
stored for further investigation.
Unpack the equipment by removing the packing and shipping materials. Make a visual
inspection and check that the inside ‘Drop&Tell’ indicator is intact. Make sure that the floor
surface is solid and suitable for the wheeling and heavy weight, twist the levelling feets of the
unit to up position and remove the equipment from the pallet.
It is required to arrange ventilation of the UPS room. Sufficient amount of air cooling is needed
to keep the max. room temperature rise at desired level:
• Temperature rise of max. +5°C requires the airflow of 600 m3 per 1 kW of losses.
• Temperature rise of max. +10°C requires the airflow of 300 m3 per 1 kW of losses.
An ambient temperature of 15 to 25 Celsius degrees is recommended to achieve a long life of
the UPS and batteries. The cooling air entering the UPS must not exceed +40 °C. Avoid high
ambient temperature, moisture and humidity.
The floor material should be non-flammable and strong enough to support the heavy load. The
UPS has (4) leveling feet that should be used when finalising the installation. The diameter of a
single leveling foot is 1 inch (25.4 mm).
The UPS family has several alternative battery cabinets and configurations depending on the
selected back-up time and quality of batteries.
Please fix the mechanical bypass switch (MBS) to the wall (din rail) or to the back of the UPS
as shown below.
The overtemperature sensor cable is connected to the control input (X45 or X44) of the UPS,
see the next drawing. In the factory installed systems this cable is ready-made for use.
Figure 10. Wiring diagram of the UPS and the external transformer option.
Warning!
The UPS contains high DC voltages. A qualified person must do the connections between
the UPS and the external battery cabinet(s). The battery cabinet is connected electrically
in parallel with the internal batteries of the UPS.
Battery racks
External battery racks shall be sized to take the voltage drop in the cable into account. To
obtain support and help contact the local office or agent authorised by the manufacturer.
Warning!
Physical injury or death may follow, or damage may occur to the UPS, or the load
equipment if these instructions are ignored.
Note!
The rectifier requires a Neutral to operate. It’s connected internally from the bypass
terminal to the rectifier, see wiring diagram.
Table 14. Cable and fuse ratings for the different UPS ratings
(*With optional limited charging feature at low input and high kW load, see User Settings)
Wiring procedure
The power cable terminals are located in the back of the UPS unit. The service personnel is
responsible for the correct electrical installation. They must be authorised by the manufacturer.
The installation procedure:
1. Remove the cover(s) of the terminal box of the power cables with a screwdriver.
Refer to the dimensional drawing for the correct location at the back of the unit.
2. Slide the cables through the grommets of the connection box.
3. Connect the conductors of the rectifier and bypass input cables to the proper terminals.
With single phase unit it is recommended to use the same phases for rectifier and bypass
inputs.
4. Connect the conductors of the load cable to the proper terminals.
5. Connect the conductors of an external battery cabinet cable to the external battery +, -
and PE terminals. Check for the correct polarity.
See External Battery Cabinet (EBC) installation procedure.
Warning!
If available, the internal battery has to be disconnected first because the external battery
terminals are hazardous due to the parallel battery string.
Figure 21. Wiring diagram of UPS S-model (1-ph rectifier) with integral MBS, (Norway)
Note!
Site wiring fault must be
disabled from LCD
User Settings menu.
Note!
Do not place EBC on the UPS unit.
2. The required minimum distance for UPS unit and EBC is ten millimeters, which is also
required distance between two EBCs.
3. Turn F1 battery breaker from the UPS unit in OFF position.
4. Check that the circuit breaker F3 of the EBC is in the OFF position. To minimise safety risk
remove one of the cable (+ or -) from battery string to break a battery circuit.
Battery cables can be accessed by removing a plastic front cover and a metal hatch behind
the plastic cover. Do not remove the safety wire of the circuit breaker before all the wires
are connected and the installation of the whole system is ready. Remove plate A on the
rear side of the EBC to connect cables to EBC’s terminal block X6. Bring cables outside
from the EBC by removing the cover plate B. Place the plate A back to the original position
and connect the cable clamp to the place of the cover plate B.
5. If the system consists two or more EBC connect first the EBCs parallel as follows:
a) Connect the cables to second EBC in the same way as guided in point four (4)
of this installation procedure.
b) Remove the cover plate C of the first EBC and connect cables to terminal block X6.
Connect the cable clamp to the place of the cover plate C.
6. When all the EBCs are connected parallel, disconnect one of the cables (+ or -) from UPS
cabinets internal battery string in the same way as guided with EBC in point four (4) of
this installation procedure before connecting cables to terminal block X3 of the UPS unit.
Otherwise the terminal block X3 is live.
7. After installation connect disconnected battery cables to strings, check that the removed
plates on right positions remove safety wires from circuit breakers and turn breakers of
EBCs and the UPS on.
8. Finally change the Number of 32 pcs. battery strings from User Settings. SETTINGS ->
USER SETTINGS -> NUMBER OF BATTERY STRINGS.
Note!
It is not allowed to feed the load simultaneously from mains (bypass) and inverter(s) of
the UPS unit(s). While turning the switch, where the bypass is connected, ON/OFF, UPS
should be on static bypass mode or shut down.
Note!
The maximum load supported by the system is limited to size of one UPS if there are
two UPSs and bypass connected to SPM.
Terminals of the SPM have two-wire connection (L1 and N) and ground terminals. The upper
ground terminal is for a load cable and the lower ground terminal is for UPSs. The wiring shall
be done according to the following wiring diagrams. The terminals and cable routing is shown
in Figure Cable routing of the SPM. See also Table 14 for cable and fuse ratings for the different
UPS ratings.
Figure 29. SPM9155 wiring diagram with two UPSs and bypass connected
Communication cables
It is recommended that the control cables and power cables be installed on separate trays.
Where control cables will cross power cables make sure they are arranged at an angle as near to
90 degrees as possible.
All control cables shall preferably be shielded. If the shield is grounded, this shall take place on
only one end of the cable.
The procedure for connecting the control cables is the following:
1. Remove the front cover by lifting the cover from the bottom outwards by releasing the
retaining clip. It’s located in the bottom part of the bezel.
2. Locate the control terminal or X-slot module where you want to install the
communications cable.
LanSafe software
The LanSafe software shuts down computers and whole networks in case of an extended power
failure. It provides basic monitoring, data logging, notification and event actions for a single
UPS solution. The software is bundled free of charge in Software Suite CD.
The connection procedure for the RS-232 interface port is following:
1. Connect the RS-232 communication cable to the computer.
2. Connect the RS-232 communication cable to the serial interface on the UPS.
3. Run the UPS software installation disk (Software Suite CD) on the computer.
Note!
If communication does not work choose the correct baud rate from the LCD display
Please refer to the optional software manuals for appropriate baud rate settings.
Note!
Pay attention to proper polarity if one is using a semiconductor switch type. A relay or
other mechanical control is a preferred method.
Note!
EPO does not necessarily disconnect supply to load when unit is on internal or external
bypass. Quaranteed disconnection of bypass supply has to be through a separate
disconnect switch located in the supplying switchgear cabinet.
In order to have the UPS running again pins 1 and 2 of connector X52 have to be reconnected
and the UPS started manually. The pins must be shorted in order to keep the UPS running.
Maximum resistance is 10 ohm. The EPO shall not be galvanically connected to any mains
connected circuits. Reinforced insulation to the mains is required.
If the use of normally open EPO operation is desired, the loop on X52 has to be retained and
the normally open EPO switch connected to X12. Operation is as above.
Warning!
The relay contacts must not be directly connected to mains related circuits. Reinforced
insulation to the mains is required.
Note!
Please note the polarity of the inputs as indicated in the external control connections if
used with a polarity control.
The default and programmable settings for the signal inputs are
a) Disable Bypass Operation
If active the automatic transfer to the static bypass is prevented.
b) Charger off
If active the batteries charging is disabled. In case of mains power outage the discharge of
batteries is supported.
c) Remote ON/OFF
If active the UPS output turns off regardless of mode of operation. Auxiliary power, fan,
communications and rectifier/battery charger shall remain functional. Restart initiated
immediately when inactive.
d) Request Bypass
If active the UPS transfers to bypass if bypass voltage, frequency and synchronisation are ok.
e) Request Normal
If active the UPS transfers to inverter operation if not prohibited by EPO or alarm condition.
f) Force Bypass
If active the UPS is forced to static bypass operation regardless of the bypass status.
g) External Battery Breaker Status
If active the UPS knows that the batteries are disconnected.
h) Building alarm 1-6
These can be activated separately or at the same time with other building alarms.
i) Not in use (default)
j) Shutdown
If active the UPS will shutdown immediately.
k) Delayed Shutdown
If active the UPS will shutdown after user configurable delay time. Restart initiated
immediately when inactive.
l) Normal/Bypass
If active the UPS transfers to bypass if ok. If inactive the UPS transfers to inverter when
possible.
The UPS supports two serial communication devices according to the table below.
Independent Multiplexed
Configuration X-slot #1 X-slot #2 Std. RS-232 port
Default #1 Any X-slot Module Any X-slot Module Not in use
Default #2 Any X-slot Module Relay Module Available
Default #3 Any X-slot Module Not in use Available
Table 34. Typical X-slot configurations for UPS communication.
Display functions
As default and after 15 minutes of inactivity the UPS is showing the selectable start screen:
1. Logo screen
2. Mimic screen (See User Settings on LCD screen)
The screen backlit has automatic shutdown after long period of inactivity. It will light up once a
button is pushed. The right side button will initiate the text to the screen. The scrolling
through the menu structure is done with buttons indicated by the ↑ ↓images of the LCD
screen. The menu structure is shown in the table below.
Changing language
Pressing and holding down the first button on the left for about 5 seconds selects the language
menu. This action is possible from any LCD menu screen.
The default firmware has four main languages: English, Spanish, French and German. Other
local language packages including Chinese, Greek and Russian can be requested from the local
service representative.
Select Maximum charging current from User Settings menu. Default setting is 3.0 Amps and it
is changeable up to 20 Amps. Minimum step is 0.1 A.
Note!
Maximum charging current is dependent on output load and power rate of the UPS. If the
UPS is supporting maximum output load the highest level of Maximum charging current is
3.0 A, which is also the default setting. As a thumb rule, 1 kW decrease in the load provides
extra 2.0 A charging capacity. For example, the charging capacity is 5 Amps at 8 kW load,
and 7 A at 7 kW load.
Battery start-up
UPS will start on battery if mains is not available. Note that the UPS behavior may be slightly
different from the normal start-ups.
Shutdown
The procedure to shutdown from LCD is following:
1. Push any key of the control panel to enable the functions of the LCD screen
2. Select “TURN UPS OFF” from the LCD menu (see: Display Functions)
3. Press and hold ↵ button for 5 sec. There shall be an indication sound during the hold.
4. UPS shall do a shutdown routine.
5. Turn the battery and input circuit breakers to OFF position to finalise the shutdown procedure.
Note!
The behaviour is different if UPS is turned off from the programmable input or through
communication cards. If battery and input circuit breakers are left ON, UPS will enter a
stand-by mode and starts to charge batteries with a cooling fan operational. Output is
without the voltage in the stand-by mode.
Scrapping
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 authorised service personnel due to high energy and voltage.
Regular service/intervals
The UPS requires very little maintenance if installed in an appropriate environment.
Maintentenance Interval
Batteries change ~ 3-5 years / service
Batteries test ~ 18 months / service
Cooling fan change ~ 5 years / service
Table 42. Routine maintenance intervals recommended by the manufacturer.
Batteries
The condition of the batteries is crucial for operation. The UPS will indicate by audible and
visual alarms if the capacity of the battery bank has decreased. The UPS units are provided with
the automatic battery test and ABM management function to continuously monitor the
condition of the battery bank.
Note!
Do not dispose of batteries in a fire. The batteries may explode.
Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes. It
may be toxic.
Cooling fan
The cooling fan lifespan of the UPS unit is about 60 000 operating hours. The actual lifespan
depends on the environment and ambient temperature.
Fan failure can be predicted by increasing noise from the fan bearings. The fan replacement is
recommended once this symptom starts appearing.
Do not use other than manufacturer’s specified spare parts.
LED Indicators
The UPS unit has (4) LEDs to indicate the status.
Note!
The MBS consist of three switches and failure to understand the correct sequence may
drop the critical load.
Figure 42. The normal (UPS supplying the load) positions of the three MBS switches.
OFF ON ON
2. Use LCD to turn the UPS on internal static bypass mode. Remember to verify the transfer
before proceeding the next step.
ON
ON ON
ON OFF
ON
ON OFF OFF
9. Remount the locking plate of the S1-3 switches to the position to prevent the use of them.
Figure 46. The service (bypass supplying the load) positions of the three MBS switches.
ON OFF OFF
ON OFF
ON
5. Use LCD to “Turn UPS on” and wait until fully started.
- Make sure the UPS is not displaying alarms or notices alarm with the green LED lit.
- You may verify the output voltage from the meters screen of the LCD.
6. Use LCD to transfer the UPS to internal static bypass. Remember to verify the transfer
before proceeding the next step.
ON
ON ON
OFF ON ON
10. Remount the locking plate of the S1-3 swiches to the position to prevent the use of them.
Figure 48. UPS models with (1) and (2) battery bottom sections.
Figure 49. UPS models with (1) and (2) battery bottom sections plus integrated MBS.
Figure 51. UPS models with middle battery and bottom transformer sections.
Environment
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Amb. temperature 0 to +40°C (electronics), 15 to +25°C (batteries)
Relative humidity 0 to 95%, no condensation allowed
Altitude <1000 m above sea level at +40°C
Vibration IEC 68-2-6; max. 0.3 mm (2 to 9 Hz), max. 1 m/s2 (9 to 200 Hz) sinusoidal
Mechanical configuration
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Dimensions
- Width 305 mm
- Depth 702 mm
- Height 817 mm (32 bat) or 1214 mm (2x32 bat)
Weight
- no battery 65 kg 70 kg
- 32 battery 155 kg 160 kg
- 64 battery 265 kg 270 kg
- 32 battery and transformer 270 kg 275 kg
- MBS +15 kg
Colour RAL 9011 black
Characteristics
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Efficiency
Up to 92% Up to 93% Up to 92% Up to 93%
- nominal load
Heat losses <580 W <720 W <870 W <1050 W
Backup time 10 min (32 bat 7 Ah) 6 min (32 bat 7 Ah)
15 min (32 bat 9 Ah) 10 min (32 bat 9 Ah) 8 min (32 bat 9 Ah) 5 min (32 bat 9 Ah)
- load pf 0.7
28 min (64 bat 7 Ah) 20 min (64 bat 7 Ah) 15 min (64 bat 7 Ah) 10 min (64 bat 7 Ah)
(+25°C amb.) 33 min (64 bat 9 Ah) 25 min (64 bat 9 Ah) 20 min (64 bat 9 Ah) 15 min (64 bat 9 Ah)
Noise (ISO 7779) 50 - 53 dB(A) depending on the load
DC circuit
AC output
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Active power 7,2 kW 9 kW 10,8 kW 13.5 kW
Nro. of phases 1-phase
Frequency 50 Hz or 60 Hz, user selectable
Voltage 220, 230 or 240 Volts, user selectable
Short circuit
100 A, < 300 ms 144 A, < 300 ms
capability
10 min >100-110% load
1 min > 110-125% load
Overload capability
5 sec >125-150% load
300 ms >150% load
Contents
1. Safety instructions ................................................................................................................ 4
Audience ..................................................................................................................................................... 4
CE marking ................................................................................................................................................ 4
User precautions ......................................................................................................................................... 4
Environment ............................................................................................................................................... 5
Inquiries ..................................................................................................................................................... 5
2. Mechanical installation ......................................................................................................... 6
Delivery check ............................................................................................................................................ 6
Unpacking and visual inspection ................................................................................................................ 6
3. Planning before installation .................................................................................................. 8
4. Cabinet installation ............................................................................................................... 9
Mechanical bypass switch ........................................................................................................................... 9
Transformer option ................................................................................................................................... 11
External battery cabinet option ................................................................................................................ 12
Battery racks ............................................................................................................................................. 12
5. Electrical installation .......................................................................................................... 13
Power cables and protective fuses ............................................................................................................ 14
Wiring procedure ...................................................................................................................................... 15
External battery cabinet (EBC) installation procedure ............................................................................. 18
SPM tie cabinet ......................................................................................................................................... 20
6. Software and connectivity ................................................................................................... 23
Communication cables ............................................................................................................................. 23
Connection to the standard RS-232 port (X53) ....................................................................................... 23
LanSafe software ................................................................................................................................... 24
External control connections ................................................................................................................... 24
Emergency Power Off (EPO) ................................................................................................................ 25
Relay outputs ........................................................................................................................................ 26
Programmable signal inputs ................................................................................................................. 26
X-slot communication (option) ................................................................................................................ 27
SNMP/Web Module (optional) ............................................................................................................. 27
AS400 Relay Module (optional) ........................................................................................................... 28
Single Serial Port Module (optional) .................................................................................................... 28
Modus/Jbus Module (optional) ............................................................................................................ 28
7. User operations ................................................................................................................... 29
Display functions ...................................................................................................................................... 29
User Settings ............................................................................................................................................. 30
Configuring user settings ...................................................................................................................... 31
Changing language ............................................................................................................................... 31
Changing charging current ................................................................................................................... 31
Using relay outputs ............................................................................................................................... 31
Normal start-up ........................................................................................................................................ 32
Battery start-up ......................................................................................................................................... 32
Shutdown ................................................................................................................................................. 32
8. Maintenance ........................................................................................................................ 33
Scrapping .............................................................................................................................................. 33
Regular service/intervals ........................................................................................................................... 33
Batteries ................................................................................................................................................ 33
Cooling fan ........................................................................................................................................... 34
LED Indicators ......................................................................................................................................... 34
Maintenance bypass switch (MBS) operation ........................................................................................... 34
Turn UPS from normal mode to mechanical bypass ............................................................................. 35
Turn UPS from mechanical bypass to normal mode ............................................................................. 36
9. Dimensional drawings ........................................................................................................ 38
10. Technical data .................................................................................................................... 40
Standards .................................................................................................................................................. 40
Environment ............................................................................................................................................. 40
Mechanical configuration ......................................................................................................................... 40
Characteristics .......................................................................................................................................... 40
AC input ................................................................................................................................................... 41
DC circuit ................................................................................................................................................ 41
AC output ................................................................................................................................................. 41
11. Warranty ............................................................................................................................. 42
1. Safety instructions
The UPS operates with mains, battery or bypass power. It contains components that carry high
currents and voltages. The properly installed enclosure is earthed and IP20 rated against
electrical shock and foreign objects. However, only qualified personal is allowed to install and
service the UPS.
Warning!
Operations inside the UPS must be performed by a service engineer from the
manufacturer or from an agent authorised by the manufacturer.
Do not ever service inside the UPS when mains power is applied or the UPS is in battery mode.
Use the optional mechanical bypass if installed to the system. Remember to open battery
breaker. Always ensure by measuring with a multi-meter that no dangerous voltages are
present.
Audience
The intended audiences of this manual are people who plan the installation, install,
commission, and use or service the UPS. The manual provides guidelines to check delivery,
installing and commissioning of the UPS.
The reader is expected to know the fundamentals of electricity, wiring, electrical components
and electrical schematic symbols. This manual is written for a global reader.
Note!
Read the manual before operating or working on the UPS.
CE marking
The product has the CE marking in compliance with the following European directives:
• LV Directive (Safety) 72/23/CEE and 93/68/CEE
• EMC Directive 89/336/EEC and 93/68/EEC
Declaration of conformity with UPS harmonised standards and directives EN 62040-1-1
(Safety) and EN 50091-2 (EMC) are available on the web site (http://www.powerware.com).
User precautions
The only user operations permitted are:
• Start up and shut down of the UPS, excluding the commissioning start-up.
• Use of the LCD control panel and Maintenance Bypass Switch (MBS)
• Use of optional connectivity modules and their software
The user must follow the precautions and only perform the described operations. Any deviations
from the instructions could be dangerous to the user or cause accidental load loss.
Environment
The UPS must be installed according to the recommendations in this manual. Under no
circumstances the UPS should be installed in an airtight room, in the presence of flammable
gases, or in an environment exceeding the specification.
Excessive amount of dust in the operating environment of UPS may cause damage or lead to
malfunction. The UPS should be always protected from the outside weather and sunshine. The
recommended operating temperature is from +15 to +25 Celsius degrees.
Inquiries
Address any inquiries about the UPS and battery cabinet to the local office or agent authorised
by the manufacturer. Please quote the type code and the serial number of the equipment.
Delivery check
The UPS is delivered with the following items:
• Plastic bag containing:
Quick Installation Guide, paper format, multilingual (coming later)
User’s Guide, paper format, multilingual
User’s Guide, CD-ROM format, multilingual (coming later)
Residual voltage warning stickers
Software Suite, CD-ROM format, English language
RS-232 serial cable for the Software Suite
• Delivery documents
Note!
A claim for shipping damage must be filed immediately and the carrier must be
informed within 7 days of receipt of the equipment. The packing materials should be
stored for further investigation.
Unpack the equipment by removing the packing and shipping materials. Make a visual
inspection and check that the inside ‘Drop&Tell’ indicator is intact. Make sure that the floor
surface is solid and suitable for the wheeling and heavy weight, twist the levelling feets of the
unit to up position and remove the equipment from the pallet.
It is required to arrange ventilation of the UPS room. Sufficient amount of air cooling is needed
to keep the max. room temperature rise at desired level:
• Temperature rise of max. +5°C requires the airflow of 600 m3 per 1 kW of losses.
• Temperature rise of max. +10°C requires the airflow of 300 m3 per 1 kW of losses.
An ambient temperature of 15 to 25 Celsius degrees is recommended to achieve a long life of
the UPS and batteries. The cooling air entering the UPS must not exceed +40 °C. Avoid high
ambient temperature, moisture and humidity.
The floor material should be non-flammable and strong enough to support the heavy load. The
UPS has (4) leveling feet that should be used when finalising the installation. The diameter of a
single leveling foot is 1 inch (25.4 mm).
The UPS family has several alternative battery cabinets and configurations depending on the
selected back-up time and quality of batteries.
Please fix the mechanical bypass switch (MBS) to the wall (din rail) or to the back of the UPS
as shown below.
The overtemperature sensor cable is connected to the control input (X45 or X44) of the UPS,
see the next drawing. In the factory installed systems this cable is ready-made for use.
Warning!
The UPS contains high DC voltages. A qualified person must do the connections between
the UPS and the external battery cabinet(s). The battery cabinet is connected electrically
in parallel with the internal batteries of the UPS.
Battery racks
External battery racks shall be sized to take the voltage drop in the cable into account. To
obtain support and help contact the local office or agent authorised by the manufacturer.
Warning!
Physical injury or death may follow, or damage may occur to the UPS, or the load
equipment if these instructions are ignored.
Note!
The rectifier requires a Neutral to operate. It’s connected internally from the bypass
terminal to the rectifier, see wiring diagram.
Table 13. Cable and fuse ratings for the different UPS ratings
(*With optional limited charging feature at low input and high kW load, see User Settings)
Wiring procedure
The power cable terminals are located in the back of the UPS unit. The service personnel is
responsible for the correct electrical installation. They must be authorised by the manufacturer.
The installation procedure:
1. Remove the cover(s) of the terminal box of the power cables with a screwdriver.
Refer to the dimensional drawing for the correct location at the back of the unit.
2. Slide the cables through the grommets of the connection box.
3. Connect the conductors of the rectifier and bypass input cables to the proper terminals.
4. Connect the conductors of the load cable to the proper terminals.
5. Connect the conductors of an external battery cabinet cable to the external battery +, -
and PE terminals. Check for the correct polarity.
See External Battery Cabinet (EBC) installation procedure.
Warning!
If available, the internal battery has to be disconnected first because the external battery
terminals are hazardous due to the parallel battery string.
Note!
Do not place EBC on the UPS unit.
2. The required minimum distance for UPS unit and EBC is ten millimeters, which is also
required distance between two EBCs.
3. Turn F1 battery breaker from the UPS unit in OFF position.
4. Check that the circuit breaker F3 of the EBC is in the OFF position. To minimise safety risk
remove one of the cable (+ or -) from battery string to break a battery circuit.
Battery cables can be accessed by removing a plastic front cover and a metal hatch behind
the plastic cover. Do not remove the safety wire of the circuit breaker before all the wires
are connected and the installation of the whole system is ready. Remove plate A on the
rear side of the EBC to connect cables to EBC’s terminal block X6. Bring cables outside
from the EBC by removing the cover plate B. Place the plate A back to the original position
and connect the cable clamp to the place of the cover plate B.
Warning!
If there is already connected battery string to terminal block there is a danger of a lethal
electric shock. Thus it is recommended break a battery circuit by disconnecting one of the
cables from battery string before connecting new cables to terminal circuit.
5. If the system consists two or more EBC connect first the EBCs parallel as follows:
a) Connect the cables to second EBC in the same way as guided in point four (4)
of this installation procedure.
b) Remove the cover plate C of the first EBC and connect cables to terminal block X6.
Connect the cable clamp to the place of the cover plate C.
6. When all the EBCs are connected parallel, disconnect one of the cables (+ or -) from UPS
cabinets internal battery string in the same way as guided with EBC in point four (4) of
this installation procedure before connecting cables to terminal block X3 of the UPS unit.
Otherwise the terminal block X3 is live.
7. After installation connect disconnected battery cables to strings, check that the removed
plates on right positions remove safety wires from circuit breakers and turn breakers of
EBCs and the UPS on.
8. Finally change the Number of 32 pcs. battery strings from User Settings. SETTINGS ->
USER SETTINGS -> NUMBER OF BATTERY STRINGS.
Figure 18. To minimise safety risk remove + or - cable from battery string before connecting
UPS and EBCs.
Note!
It is not allowed to feed the load simultaneously from mains (bypass) and inverter(s) of
the UPS unit(s). While turning the switch, where the bypass is connected, ON/OFF, UPS
should be on static bypass mode or shut down.
Note!
The maximum load supported by the system is limited to size of one UPS if there are
two UPSs and bypass connected to SPM.
Terminals of the SPM have four-wire connection (L1, L2, L3 and N) and ground terminals. The
upper ground terminal is for a load cable and the lower ground terminal is for UPSs. The
wiring shall be done according to the following wiring diagrams. The terminals and cable
routing is shown in Figure Cable routing of the SPM.
Figure 22. SPM9355 wiring diagram with two UPSs and bypass connected
Communication cables
It is recommended that the control cables and power cables be installed on separate trays.
Where control cables will cross power cables make sure they are arranged at an angle as near to
90 degrees as possible.
All control cables shall preferably be shielded. If the shield is grounded, this shall take place on
only one end of the cable.
The procedure for connecting the control cables is the following:
1. Remove the front cover by lifting the cover from the bottom outwards by releasing the
retaining clip. It’s located in the bottom part of the bezel.
2. Locate the control terminal or X-slot module where you want to install the
communications cable.
LanSafe software
The LanSafe software shuts down computers and whole networks in case of an extended power
failure. It provides basic monitoring, data logging, notification and event actions for a single
UPS solution. The software is bundled free of charge in Software Suite CD.
The connection procedure for the RS-232 interface port is following:
1. Connect the RS-232 communication cable to the computer.
2. Connect the RS-232 communication cable to the serial interface on the UPS.
3. Run the UPS software installation disk (Software Suite CD) on the computer.
Note!
If communication does not work choose the correct baud rate from the LCD display
Please refer to the optional software manuals for appropriate baud rate settings.
Note!
Pay attention to proper polarity if one is using a semiconductor switch type. A relay or
other mechanical control is a preferred method.
Note!
EPO does not necessarily disconnect supply to load when unit is on internal or external
bypass. Quaranteed disconnection of bypass supply has to be through a separate
disconnect switch located in the supplying switchgear cabinet.
In order to have the UPS running again pins 1 and 2 of connector X52 have to be reconnected
and the UPS started manually. The pins must be shorted in order to keep the UPS running.
Maximum resistance is 10 ohm. The EPO shall not be galvanically connected to any mains
connected circuits. Reinforced insulation to the mains is required.
If the use of normally open EPO operation is desired, the loop on X52 has to be retained and
the normally open EPO switch connected to X12. Operation is as above.
Warning!
The relay contacts must not be directly connected to mains related circuits. Reinforced
insulation to the mains is required.
Note!
Please note the polarity of the inputs as indicated in the external control connections if
used with a polarity control.
The default and programmable settings for the signal inputs are
a) Disable Bypass Operation
If active the automatic transfer to the static bypass is prevented.
b) Charger off
If active the batteries charging is disabled. In case of mains power outage the discharge of
batteries is supported.
c) Remote ON/OFF
If active the UPS output turns off regardless of mode of operation. Auxiliary power, fan,
communications and rectifier/battery charger shall remain functional. Restart initiated
immediately when inactive.
d) Request Bypass
If active the UPS transfers to bypass if bypass voltage, frequency and synchronisation are ok.
e) Request Normal
If active the UPS transfers to inverter operation if not prohibited by EPO or alarm condition.
f) Force Bypass
If active the UPS is forced to static bypass operation regardless of the bypass status.
g) External Battery Breaker Status
If active the UPS knows that the batteries are disconnected.
h) Building alarm 1-6
These can be activated separately or at the same time with other building alarms.
i) Not in use (default)
j) Shutdown
If active the UPS will shutdown immediately.
k) Delayed Shutdown
If active the UPS will shutdown after user configurable delay time. Restart initiated
immediately when inactive.
l) Normal/Bypass
If active the UPS transfers to bypass if ok. If inactive the UPS transfers to inverter when
possible.
The UPS supports two serial communication devices according to the table below.
Independent Multiplexed
Configuration X-slot #1 X-slot #2 Std. RS-232 port
Default #1 Any X-slot Module Any X-slot Module Not in use
Default #2 Any X-slot Module Relay Module Available
Default #3 Any X-slot Module Not in use Available
Table 27. Typical X-slot configurations for UPS communication.
Display functions
As default and after 15 minutes of inactivity the UPS is showing the selectable start screen:
1. Logo screen
2. Mimic screen (See User Settings on LCD screen)
The screen backlit has automatic shutdown after long period of inactivity. It will light up once a
button is pushed. The right side button will initiate the text to the screen. The scrolling
through the menu structure is done with buttons indicated by the ↑ ↓images of the LCD
screen. The menu structure is shown in the table below.
Changing language
Pressing and holding down the first button on the left for about 5 seconds selects the language
menu. This action is possible from any LCD menu screen.
The default firmware has four main languages: English, Spanish, French and German. Other
local language packages including Chinese, Greek and Russian can be requested from the local
service representative.
Select Maximum charging current from User Settings menu. Default setting is 3.0 Amps and it
is changeable up to 20 Amps. Minimum step is 0.1 A.
Note!
Maximum charging current is dependent on output load and power rate of the UPS. If the
UPS is supporting maximum output load the highest level of Maximum charging current is
3.0 A, which is also the default setting. As a thumb rule, 1 kW decrease in the load provides
extra 2.0 A charging capacity. For example, the charging capacity is 5 Amps at 8 kW load,
and 7 A at 7 kW load.
Battery start-up
UPS will start on battery if mains is not available. Note that the UPS behavior may be slightly
different from the normal start-ups.
Shutdown
The procedure to shutdown from LCD is following:
1. Push any key of the control panel to enable the functions of the LCD screen
2. Select “TURN UPS OFF” from the LCD menu (see: Display Functions)
3. Press and hold ↵ button for 5 sec. There shall be an indication sound during the hold.
4. UPS shall do a shutdown routine.
5. Turn the battery and input circuit breakers to OFF position to finalise the shutdown procedure.
Note!
The behaviour is different if UPS is turned off from the programmable input or through
communication cards. If battery and input circuit breakers are left ON, UPS will enter a
stand-by mode and starts to charge batteries with a cooling fan operational. Output is
without the voltage in the stand-by mode.
Scrapping
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 authorised service personnel due to high energy and voltage.
Regular service/intervals
The UPS requires very little maintenance if installed in an appropriate environment.
Maintentenance Interval
Batteries change ~ 3-5 years / service
Batteries test ~ 18 months / service
Cooling fan change ~ 5 years / service
Table 35. Routine maintenance intervals recommended by the manufacturer.
Batteries
The condition of the batteries is crucial for operation. The UPS will indicate by audible and
visual alarms if the capacity of the battery bank has decreased. The UPS units are provided with
the automatic battery test and ABM management function to continuously monitor the
condition of the battery bank.
Note!
Do not dispose of batteries in a fire. The batteries may explode.
Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes. It
may be toxic.
Cooling fan
The cooling fan lifespan of the UPS unit is about 60 000 operating hours. The actual lifespan
depends on the environment and ambient temperature.
Fan failure can be predicted by increasing noise from the fan bearings. The fan replacement is
recommended once this symptom starts appearing.
Do not use other than manufacturer’s specified spare parts.
LED Indicators
The UPS unit has (4) LEDs to indicate the status.
Note!
The MBS consist of three switches and failure to understand the correct sequence may
drop the critical load.
Figure 38. The normal (UPS supplying the load) positions of the three MBS switches.
OFF ON ON
2. Use LCD to turn the UPS on internal static bypass mode. Remember to verify the transfer
before proceeding the next step.
ON
ON ON
ON OFF
ON
ON OFF OFF
9. Remount the locking plate of the S1-3 switches to the position to prevent the use of them.
Figure 39. The service (bypass supplying the load) positions of the three MBS switches.
ON OFF OFF
ON OFF
ON
5. Use LCD to “Turn UPS on” and wait until fully started.
- Make sure the UPS is not displaying alarms or notices alarm with the green LED lit.
- You may verify the output voltage from the meters screen of the LCD.
6. Use LCD to transfer the UPS to internal static bypass. Remember to verify the transfer
before proceeding the next step.
ON
ON ON
OFF ON ON
10. Remount the locking plate of the S1-3 swiches to the position to prevent the use of them.
Figure 41. UPS models with (1) and (2) battery bottom sections.
Figure 42. UPS models with (1) and (2) battery bottom sections plus integrated MBS.
Figure 44. UPS models with middle battery and bottom transformer sections.
Environment
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Amb. temperature 0 to +40°C (electronics), 15 to +25°C (batteries)
Relative humidity 0 to 95%, no condensation allowed
Altitude <1000 m above sea level at +40°C
Vibration IEC 68-2-6; max. 0.3 mm (2 to 9 Hz), max. 1 m/s2 (9 to 200 Hz) sinusoidal
Mechanical configuration
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Dimensions
- Width 305 mm
- Depth 702 mm
- Height 817 mm (32 bat) or 1214 mm (64 bat)
Weight
- no battery 75 kg
- 32 battery 165 kg
- 64 battery 275 kg
- 32 battery and transformer 280 kg
- MBS +17 kg
Colour RAL 9005 black
Characteristics
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Efficiency
Up to 92% Up to 92% Up to 92% Up to 93%
- nominal load
Heat losses <580 W <720 W <870 W <1050 W
10 min (32 bat 7 Ah) 6 min (32 bat 7 Ah)
Backup time
15 min (32 bat 9 Ah) 10 min (32 bat 9 Ah) 8 min (32 bat 9 Ah) 5 min (32 bat 9 Ah)
- load pf 0.7
28 min (64 bat 7 Ah) 20 min (64 bat 7 Ah) 15 min (64 bat 7 Ah) 10 min (64 bat 7 Ah)
- temperature +25°C
33 min (64 bat 9 Ah) 28 min (64 bat 9 Ah) 20 min (64 bat 9 Ah) 15 min (64 bat 9 Ah)
Noise (ISO 7779) 50 - 53 dB(A) depending on the load
DC circuit
AC output
Technical Specifications
General Rating 8-15 kVA 0.9 p.f.
Efficiency 92% at nominal load
Audible noise <50 dB (A) Environmental Monitoring Probe
Powerware®, Advanced Battery Management, LanSafe, PowerVision and FORESEER are trademark(s) of Powerware Corporation. © 2004 Powerware Corporation
GERMANY RUSSIA
Tel: +49 7841 6660 Tel: +7 095 787 2890
info.germany@powerware.com russia.sales@powerware.com
9X55 HV CAA Code Chart
CAA = Configuration After Assembly
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
No. of Batt. HW Options HW Options
Product Hardware kVA Rating Application Input Output Batt. Type Future Use Future Use Future Use Generation
Strings 1 (Future) 2 (Future)
K = 9X55 1 = 1in/1out 08 = 8kVA 1 = RT & HS 1 = 230V 1 = 230V 0 = None 0 = None 0 = None 0 = None 0 = None 0 = None 0 = None P=
10kVA Prototype
2 = 3in/1out 10 = 10kVA 2 = 400V 2 = 400V 1 = 1 * 32 1 = 7 Ah 1 = Released
10 kVA
3 = 3in/1out 12 = 12kVA 2 = 2 * 32 2 = 7 Ah
15kVA LongLife
A = 3in/3out 15 = 15kVA 4 = Freq. A = 1 * 36 3 = 9 Ah
15kVA Converter
B = 3in/3out 20 = 20kVA B = 2 * 36
30&40kVA
30 = 30kVA C = 3 * 36
40 = 40kVA D = 4 * 36
Revision changes: A: first release; B: 3 phase output models (9355) added; C: Added support for 30k 9355, removed HS (2) from digit 5 since it's not needed. D: Added support for 40k 9355
Digit 1: Product indentification, always K for 9X55. (OEM PRODUCTS MAY VARY)
Digit 2: Hardware indentification, single or three phase input/output, power range
Digit 3: First digit of kVA rating
Digit 4: Second digit of kVA rating
Digit 5: Application such as single or parallel, frequency converter, stand-by etc.
Digit 6: Input voltage selection, 400V for three phase, 230V for single phase input. May have other options in future.
Digit 7: Output voltage selection. 400V for three phase, 230V for single phase output. May have other options in future.
Digit 8: Number of battery strings ( battery compartments ) in a UPS.
Digit 9: Type of installed batteries in a UPS.
Digit 10: Hardware Options 1 for future use.
Digit 11: Hardware Options 2 for future use.
Digit 12: For possible future use.
Digit 13: For possible future use.
Digit 14: For possible future use.
Digit 15: Generation, 1 = First release.
POWERWARE 9155
8-10 kVA 230 / 230 VAC
1-phase input: 220-230-240 Volt, 50/60 Hz
Transformer models with standard batteries, without MBS ( * empty batt. cabinet )
1022543 PW9155-8I-ST-0-32x0Ah PW9155-8I-ST-0 * K10811110000001
1022544 PW9155-8I-ST-14-32x9Ah PW9155-8I-ST-14 K10811113000001
1022545 PW9155-10I-ST-0-32x0Ah PW9155-10I-ST-0 * K11011110000001
1022546 PW9155-10I-ST-10-32x9Ah PW9155-10I-ST-10 K11011113000001
Hot sync models without batteries, without MBS ( empty battery cabinets )
1024185 PW 9155-1x8-SHS-0-32x0Ah K10811110000001
1024186 PW9155-2x8-SHS-0-32x0Ah SYSTEM PW9155-2x8-SHS-0 K10811110000001
1024187 PW9155-3x8-SHS-0-32x0Ah SYSTEM PW9155-3x8-SHS-0 K10811110000001
1024188 PW9155-4x8-SHS-0-32x0Ah SYSTEM PW9155-4x8-SHS-0 K10811110000001
1024189 PW9155-1x8-SHS-0-64x0Ah K10811120000001
1024190 PW9155-2x8-SHS-0-64x0Ah SYSTEM PW9155-2x8-SHS-0 K10811120000001
1024191 PW9155-3x8-SHS-0-64x0Ah SYSTEM PW9155-3x8-SHS-0 K10811120000001
1024192 PW9155-4x8-SHS-0-64x0Ah SYSTEM PW9155-4x8-SHS-0 K10811120000001
1024193 PW9155-1x10-SHS-0-32x0Ah K11011110000001
1024194 PW9155-2x10-SHS-0-32x0Ah SYSTEM PW9155-2x10-SHS-0 K11011110000001
1024195 PW9155-3x10-SHS-0-32x0Ah SYSTEM PW9155-3x10-SHS-0 K11011110000001
1024196 PW9155-4x10-SHS-0-32x0Ah SYSTEM PW9155-4x10-SHS-0 K11011110000001
1024197 PW9155-1x10-SHS-0-64x0Ah K11011120000001
1024198 PW9155-2x10-SHS-0-64x0Ah SYSTEM PW9155-2x10-SHS-0 K11011120000001
1024199 PW9155-3x10-SHS-0-64x0Ah SYSTEM PW9155-3x10-SHS-0 K11011120000001
1024200 PW9155-4x10-SHS-0-64x0Ah SYSTEM PW9155-4x10-SHS-0 K11011120000001
POWERWARE 9155
8-10-12-15 kVA 400 / 230 VAC
3-phase input: 220/380-230/400-240/415 Volt, 50/60 Hz;
Transformer models with standard batteries, without MBS ( * empty batt. cabinet )
1022499 PW9155-8I-NT-0-32x0Ah * PW9155-8I-NT-0 K20812110000001
1022500 PW9155-8I-NT-14-32x9Ah PW9155-8I-NT-14 K20812113000001
1022501 PW9155-10I-NT-0-32x0Ah * PW9155-10I-NT-0 K21012110000001
1022502 PW9155-10I-NT-10-32x9Ah PW9155-10I-NT-10 K21012113000001
1022503 PW9155-12I-NT-0-32x0Ah * PW9155-12I-NT-0 K21212110000001
1022504 PW9155-12I-NT-8-32x9Ah PW9155-12I-NT-8 K21212113000001
1022505 PW9155-15I-NT-0-32x0Ah * PW9155-15I-NT-0 K21512110000001
1022506 PW9155-15I-NT-5-32x9Ah PW9155-15I-NT-5 K21512113000001
ORDER
CODES DESCRIPTION TYPE STRING TO EEP CAA (CTO) NUMBER
Hot sync models with long life batteries, without MBS ( continues )
1024253 PW9155-1x10-NLHS-20-64x7Ah K11012122000001
1024254 PW9155-2x10-NLHS-20-64x7Ah SYSTEM PW9155-2x10-NLHS-20 K11012122000001
1024255 PW9155-3x10-NLHS-20-64x7Ah SYSTEM PW9155-3x10-NLHS-20 K11012122000001
1024256 PW9155-4x10-NLHS-20-64x7Ah SYSTEM PW9155-4x10-NLHS-20 K11012122000001
1024257 PW9155-1x12-NLHS-15-64x7Ah K11212122000001
1024258 PW9155-2x12-NLHS-15-64x7Ah SYSTEM PW9155-2x12-NLHS-15 K11212122000001
1024259 PW9155-3x12-NLHS-15-64x7Ah SYSTEM PW9155-3x12-NLHS-15 K11212122000001
1024260 PW9155-4x12-NLHS-15-64x7Ah SYSTEM PW9155-4x12-NLHS-15 K11212122000001
1024261 PW9155-1x15-NLHS-10-64x7Ah K11512122000001
1024262 PW9155-2x15-NLHS-10-64x7Ah SYSTEM PW9155-2x15-NLHS-10 K11512122000001
1024263 PW9155-3x15-NLHS-10-64x7Ah SYSTEM PW9155-3x15-NLHS-10 K11512122000001
1024264 PW9155-4x15-NLHS-10-64x7Ah SYSTEM PW9155-4x15-NLHS-10 K11512122000001
ORDER
CODES DESCRIPTION TYPE STRING TO EEP CAA (CTO) NUMBER
Hot sync models without batteries, without MBS ( empty battery cabinets )
1024265 PW9155-1x8-NHS-0-32x0Ah K10812110000001
1024266 PW9155-2x8-NHS-0-32x0Ah SYSTEM PW9155-2x8-NHS-0 K10812110000001
1024267 PW9155-3x8-NHS-0-32x0Ah SYSTEM PW9155-3x8-NHS-0 K10812110000001
1024268 PW9155-4x8-NHS-0-32x0Ah SYSTEM PW9155-4x8-NHS-0 K10812110000001
1024269 PW9155-1x8-NHS-0-64x0Ah K10812120000001
1024270 PW9155-2x8-NHS-0-64x0Ah SYSTEM PW9155-2x8-NHS-0 K10812120000001
1024271 PW9155-3x8-NHS-0-64x0Ah SYSTEM PW9155-3x8-NHS-0 K10812120000001
1024272 PW9155-4x8-NHS-0-64x0Ah SYSTEM PW9155-4x8-NHS-0 K10812120000001
1024273 PW9155-1x10-NHS-0-32x0Ah K11012110000001
1024274 PW9155-2x10-NHS-0-32x0Ah SYSTEM PW9155-2x10-NHS-0 K11012110000001
1024275 PW9155-3x10-NHS-0-32x0Ah SYSTEM PW9155-3x10-NHS-0 K11012110000001
1024276 PW9155-4x10-NHS-0-32x0Ah SYSTEM PW9155-4x10-NHS-0 K11012110000001
1024277 PW9155-1x10-NHS-0-64x0Ah K11012120000001
1024278 PW9155-2x10-NHS-0-64x0Ah SYSTEM PW9155-2x10-NHS-0 K11012120000001
1024279 PW9155-3x10-NHS-0-64x0Ah SYSTEM PW9155-3x10-NHS-0 K11012120000001
1024280 PW9155-4x10-NHS-0-64x0Ah SYSTEM PW9155-4x10-NHS-0 K11012120000001
1024281 PW9155-1x12-NHS-0-32x0Ah K11212110000001
1024282 PW9155-2x12-NHS-0-32x0Ah SYSTEM PW9155-2x12-NHS-0 K11212110000001
1024283 PW9155-3x12-NHS-0-32x0Ah SYSTEM PW9155-3x12-NHS-0 K11212110000001
1024284 PW9155-4x12-NHS-0-32x0Ah SYSTEM PW9155-4x12-NHS-0 K11212110000001
1024285 PW9155-1x12-NHS-0-64x0Ah K11212120000001
1024286 PW9155-2x12-NHS-0-64x0Ah SYSTEM PW9155-2x12-NHS-0 K11212120000001
1024287 PW9155-3x12-NHS-0-64x0Ah SYSTEM PW9155-3x12-NHS-0 K11212120000001
1024288 PW9155-4x12-NHS-0-64x0Ah SYSTEM PW9155-4x12-NHS-0 K11212120000001
1024289 PW9155-1x15-NHS-0-32x0Ah K11512110000001
1024290 PW9155-2x15-NHS-0-32x0Ah SYSTEM PW9155-2x15-NHS-0 K11512110000001
1024291 PW9155-3x15-NHS-0-32x0Ah SYSTEM PW9155-3x15-NHS-0 K11512110000001
1024292 PW9155-4x15-NHS-0-32x0Ah SYSTEM PW9155-4x15-NHS-0 K11512110000001
1024293 PW9155-1x15-NHS-0-64x0Ah K11512120000001
1024294 PW9155-2x15-NHS-0-64x0Ah SYSTEM PW9155-2x15-NHS-0 K11512120000001
1024295 PW9155-3x15-NHS-0-64x0Ah SYSTEM PW9155-3x15-NHS-0 K11512120000001
1024296 PW9155-4x15-NHS-0-64x0Ah SYSTEM PW9155-4x15-NHS-0 K11512120000001
POWERWARE 9355
8-10-12-15 kVA 400 / 400 VAC
3-phase input & output 380, 400, 415 Volt, 50/60 Hz;
ORDER
CODES DESCRIPTION TYPE STRING TO EEP CAA (CTO) NUMBER
Hot sync models with long life batteries, without MBS ( continues )
1024357 PW9355-1x10-NLHS-20-64x7Ah KA1012222000001
1024358 PW9355-2x10-NLHS-20-64x7Ah SYSTEM PW9355-2x10-NLHS-20 KA1012222000001
1024359 PW9355-3x10-NLHS-20-64x7Ah SYSTEM PW9355-3x10-NLHS-20 KA1012222000001
1024360 PW9355-4x10-NLHS-20-64x7Ah SYSTEM PW9355-4x10-NLHS-20 KA1012222000001
1024361 PW9355-1x12-NLHS-15-64x7Ah KA1212222000001
1024362 PW9355-2x12-NLHS-15-64x7Ah SYSTEM PW9355-2x12-NLHS-15 KA1212222000001
1024363 PW9355-3x12-NLHS-15-64x7Ah SYSTEM PW9355-3x12-NLHS-15 KA1212222000001
1024364 PW9355-4x12-NLHS-15-64x7Ah SYSTEM PW9355-4x12-NLHS-15 KA1212222000001
1024365 PW9355-1x15-NLHS-10-64x7Ah KA1512222000001
1024366 PW9355-2x15-NLHS-10-64x7Ah SYSTEM PW9355-2x15-NLHS-10 KA1512222000001
1024367 PW9355-3x15-NLHS-10-64x7Ah SYSTEM PW9355-3x15-NLHS-10 KA1512222000001
1024368 PW9355-4x15-NLHS-10-64x7Ah SYSTEM PW9355-4x15-NLHS-10 KA1512222000001
Hot sync models without batteries, without MBS ( empty battery cabinets )
1024369 PW9355-1x8-NHS-0-32x0Ah KA0812210000001
1024370 PW9355-2x8-NHS-0-32x0Ah SYSTEM PW9355-2x8-NHS-0 KA0812210000001
1024371 PW9355-3x8-NHS-0-32x0Ah SYSTEM PW9355-3x8-NHS-0 KA0812210000001
1024372 PW9355-4x8-NHS-0-32x0Ah SYSTEM PW9355-4x8-NHS-0 KA0812210000001
1024373 PW9355-1x8-NHS-0-64x0Ah KA0812220000001
1024374 PW9355-2x8-NHS-0-64x0Ah SYSTEM PW9355-2x8-NHS-0 KA0812220000001
1024375 PW9355-3x8-NHS-0-64x0Ah SYSTEM PW9355-3x8-NHS-0 KA0812220000001
1024376 PW9355-4x8-NHS-0-64x0Ah SYSTEM PW9355-4x8-NHS-0 KA0812220000001
1024377 PW9355-1x10-NHS-0-32x0Ah KA1012210000001
1024378 PW9355-2x10-NHS-0-32x0Ah SYSTEM PW9355-2x10-NHS-0 KA1012210000001
1024379 PW9355-3x10-NHS-0-32x0Ah SYSTEM PW9355-3x10-NHS-0 KA1012210000001
1024380 PW9355-4x10-NHS-0-32x0Ah SYSTEM PW9355-4x10-NHS-0 KA1012210000001
1024381 PW9355-1x10-NHS-0-64x0Ah KA1012220000001
1024382 PW9355-2x10-NHS-0-64x0Ah SYSTEM PW9355-2x10-NHS-0 KA1012220000001
1024383 PW9355-3x10-NHS-0-64x0Ah SYSTEM PW9355-3x10-NHS-0 KA1012220000001
1024384 PW9355-4x10-NHS-0-64x0Ah SYSTEM PW9355-4x10-NHS-0 KA1012220000001
1024385 PW9355-1x12-NHS-0-32x0Ah KA1212210000001
1024386 PW9355-2x12-NHS-0-32x0Ah SYSTEM PW9355-2x12-NHS-0 KA1212210000001
1024387 PW9355-3x12-NHS-0-32x0Ah SYSTEM PW9355-3x12-NHS-0 KA1212210000001
1024388 PW9355-4x12-NHS-0-32x0Ah SYSTEM PW9355-4x12-NHS-0 KA1212210000001
1024389 PW9355-1x12-NHS-0-64x0Ah KA1212220000001
1024390 PW9355-2x12-NHS-0-64x0Ah SYSTEM PW9355-2x12-NHS-0 KA1212220000001
1024391 PW9355-3x12-NHS-0-64x0Ah SYSTEM PW9355-3x12-NHS-0 KA1212220000001
1024392 PW9355-4x12-NHS-0-64x0Ah SYSTEM PW9355-4x12-NHS-0 KA1212220000001
1024393 PW9355-1x15-NHS-0-32x0Ah KA1512210000001
1024394 PW9355-2x15-NHS-0-32x0Ah SYSTEM PW9355-2x15-NHS-0 KA1512210000001
1024395 PW9355-3x15-NHS-0-32x0Ah SYSTEM PW9355-3x15-NHS-0 KA1512210000001
1024396 PW9355-4x15-NHS-0-32x0Ah SYSTEM PW9355-4x15-NHS-0 KA1512210000001
1024397 PW9355-1x15-NHS-0-64x0Ah KA1512220000001
1024398 PW9355-2x15-NHS-0-64x0Ah SYSTEM PW9355-2x15-NHS-0 KA1512220000001
1024399 PW9355-3x15-NHS-0-64x0Ah SYSTEM PW9355-3x15-NHS-0 KA1512220000001
1024400 PW9355-4x15-NHS-0-64x0Ah SYSTEM PW9355-4x15-NHS-0 KA1512220000001
The UPS must be installed and serviced only by a service personnel from the manufacturer or
from an agent authorised by the manufacturer.
The UPS must be used as intended. Follow the instructions given in the User’s and Installation
manual.
Installation and use of the UPS must comply with all national and local safety regulations and
procedures.
To prevent overheating do not obstruct the flow of air for ventilation opening to the unit.
The UPS contains Lead-Acid batteries, which must be disposed of correctly in compliance with the
local regulations.
High leakage current; connect protective earth before power supply cables.
All primary power switches installed downstream of the UPS must be labelled as follows:
ISOLATE UPS ( Uninterrupted Power Supply ) before working on this circuit.
There is dangerous voltage inside the unit due to the internal batteries. Turn the battery breaker
off in order to isolate the batteries during service work.
Note: This trouble-shooting guide is a preliminary issue, based on information of R&D. Eaton Power
Quality Oy updates this document periodically and distributes it to service engineers attending the
Powerware 9155/9355 training. You can find this document also on the service web.
Note: Display, fan module and batteries can be exchanged while the unit remains in normal operation
(Refer to document 1022755).
1. Save the alarm log and label the file with the serial number of the unit (refer to service bulletin
SB9x55:7).
2. Analyse the problem with the help of 9155’s alarm table (refer to pages 3 – 10).
Note: Not all XCP protocol events are used for 9155/9355.
4. If parts need to be replaced, refer to the respective replacement instruction, to be found in chapter 2
of the service manual 1022609.
NUM
Is the number displayed on the LCD screen and in the log file. This is however not identical with the
event number based on the XCP protocol.
Modem
Default settings since DSP release I6:
Active Events marked yes, cause a telephone call, when a modem is installed.
You can change the settings in Service settings, Set Modem Call Events.
Relay activation:
9155, and 9355 have one built in relay. They support up to eight additional X-Slot relays.
The Relays configuration can be found in the “User Settings” sub menu of the UPS display.
There are six logic relay signals defined that can be mapped to the available physical relays.
Events:
Part numbers of :
Front panel 10 22 878
Fan assembly 10 22 818
Input/output choke(s), L3 – L8 10 21 865
Battery choke(s), L1 – L2 10 22 276
Note: Before replacing any part, save the alarm log and label the file with the serial number
of the unit (refer to service software description……..chapter ……). If necessary,
inform the customer, that the load has to be transferred to bypass.
1. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
2. Unscrew the two (2) fixing bolts of the front panel and pull it towards you (refer to front panel
assembly drawing 1022170, section “DISPLAY” of service manual).
5. Check the display firmware for it’s revision and if necessary update it (refer to service software
description ….. chapter …..)
1. Transfer the load via display to static bypass, refer to display description …
2. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
3. Unscrew the four (4) fixing bolts of the fan assembly and pull it’s upper edge towards you. (refer
to “El-step 4” assembly drawing 1022405, section “MAIN CIRCUIT” of service manual, -> for
details refer to “fan” assembly drawing, 1022171).
5. Re-assemble the new fan module and transfer the load via display back to “normal operation”.
C) Replacement of choke(s)
1. Transfer the load to mechanical bypass -> refer to the user’s guide 1022403, page 30 !
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer of
the fact, that the load has to be switched off for the time of servicing the UPS !
2. Shut down the UPS -> refer to the user’s guide 1022403, page 27 ! Turn rectifier input circuit
breaker F2 and battery circuit breaker F1 off..
Note: The depleting of the DC bus takes about 5 minutes.
3. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
4. Unscrew the fixing bolts of the hood -> eight (8) at front, ten (10) at the back of the unit. Lift the
hood off the unit.
5. To be on the save side, check with a DMM between the power board terminals X24 and X15, DC
bus positive, and terminals X24 and X11, DC bus negative, the voltages to be less than 50V (for
terminal locations refer to board layout 1021592).
6. Disconnect the cables of the chokes to be replaced, after having made sure, that they are labelled
correctly. To do so, slide the bushing sidewise out of the frame an gently spread it to get the cables
pulled out (refer to assembly drawings 1022282 and 1022174, chapter “MAIN CIRCUIT” of the
service manual).
7. Remove the top plate of the choke assembly and replace the choke(s) referring to dwg. 1022282.
8. After having re-assembled the top plate tighten both nuts evenly to the level that the bolts to the
back plate can fitted.
9. Reconnect the cables of the replaced choke(s) and check once more mechanics and connections
to be correct.
10. Put the UPS back into normal operation referring to instructions of the user’s guide, pages 27
and 31.
11. Measure the voltage(s) before and after the replaced choke(s) for correct level.
9155 / 8-10kVA
Part number power board 10 21 589
Part number IGBT 10 21 761***
*** Note: Do not touch the contacts of the IGBT module(s). Be aware, that according manufacturer’s
specification, the spring loaded contacts of an IGBT do not guarantee for good connection
after being more than three (3) times re-assembled !
1. Save the alarm log and label the file with the serial number of the unit (refer to service bulletin 7)
Inform the customer, that the load has to be transferred to bypass.
2. Transfer the load to bypass -> refer to the user’s guide 1022403 resp. 1023625, chapter 8.
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer of the
fact, that the load has to be switched off for the time of servicing the UPS !
3. Shut down the UPS -> refer to the user’s guide 1022403 resp. 1023625, chapter 7.
4. Turn rectifier input circuit breaker F2 and battery circuit breaker F1 off.
Note: The depleting of the DC bus takes about 5 minutes.
5. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
6. Unscrew the fixing bolts of the hood -> twelve (12) at front, fourteen (14) at the back of the unit.
Lift the hood off the unit.
7. To be on the save side, check with a DMM between the power board terminals X24 and X15, DC
bus positive, and terminals X24 and X11, DC bus negative, the voltages to be less than 50V (for
terminal locations refer to board layout 1021592, resp. 1022656).
10. Remove the X-slot bays after their ribbon cables to X55 and X56 of the power board have been
disconnected. Squeeze the bay gently by it’s height and lift it off.
11. Remove the sockets of the EPO and remote indications/alarms, X44, X45, X12 X52 and X57 and
disconnect the cable of the RS232 port X53.
13. Remove the three (3) fixing bolts at the front edge of the power board, squeeze the retainer tongues
of the six (6) plastic supports and lift the board towards the back of the unit.
14. Check the on board contacts to the IGBT for burn marks and damaged tracks.
a) If the board shows physical damage, replace it by proceeding with step 12.
b) If the board seems to be “OK”, but one or more IGBTs damaged, proceed with step 13.
c) If neither board nor IGBTs seems to be faulty, re-assemble the power board.
15. After having checked the cables to the power board for correct labelling, disconnect them, and lift
the board out of the unit.
16. Use a thin bladed knife to remove the faulty IGBT from the heat sink, by gently lifting off it’s front
edge.
17. Clean the surface of the heat sink from the heat conducting paste.
Note: Make sure, that the surface of the heat sink is clean and smooth (no scratches), before
assembling the new IGBT.
18. Place an even, thin layer of heat conducting paste to the base (copper) of the new IGBT and place
it on the top of the lower edge of the heat sink frames respective cut out. To keep the IGBTs in
place make temporary use of their fixing bolt (without cover plate).
Note: Remember, do not touch the contacts of the IGBT module(s).
19. Make sure of the boards correct configuration, and if necessary remove the coding resistor R72
9155 / 8-10kVA = R72 + R73 assembled
9155 / 12-15kVA + 9355 = R73 assembled, R72 removed
Refer to layout drawings 1021592 for 9155 up to 10kVA or 1022656 for 9155 /12-15kVA + 9355 !
20. While re-assembling the power board, make sure, that the IGBTs will be positioned correctly by
their centre and upper left pivots.
21. Re-assemble the power board’s fixing bolts, but DO NOT YET tighten them.
22. Remove the centre bolts of the IGBTs and re-assemble them with the IGBTs cover plates, torque
shall be 2 – 2,5 nm.
23. Finish the re-assembling of the power board by tightening all screws, reconnecting cables and
sockets of peripherals. Recheck bolts and cables once more.
24. Re-assemble X-slot bays, X-slot boards, peripherals and the control board.
25. Apply power to the unit by closing rectifier input breaker F2 and/or battery breaker F1. At the display
the following window shall appear:
Note: It might happen, that after the power has been applied to unit, the control board is verifying
EEPROM data, which may take up to 1 minute. During that time the display remains dark, and the
green LED on the control board remains in steady state ON.
If for what ever reason the this condition remains, turn F1 and F2 off, remove and thereafter re-plug
the control board, then close F1 and/or F2.
26. Via UP/DOWN soft keys make sure, that the arrow points TOWARDS the MIRROR, and press
ENTER. The unit’s data is copied from the control board EEPROM to the power board EEPROM
(except calibration values).
EEPROM content of control board:
Calibration values, identification data (string, CAA {CTO} number) part number, serial number),
parameters, event log.
EEPROM content of power board (MIRROR):
Identification data (string, CAA {CTO} number) part number, serial number), parameters, event log.
27. If advised by service bulletins, update the firmware by using LangLoader or PWFlash (refer to
firmware update instruction 1024759.
28. Transfer the load to UPS (NORMAL MODE) -> refer to the user’s guide 1022403 resp. 1023625,
chapter 8.
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer, that the
load will be switched back on.
29. Make sure, that both circuit breakers, F1 and F2 are closed, and no alarm is active.
1. Save the alarm log and label the file with the serial number of the unit (refer to service bulletin
SB9x55:7. Inform the customer, that the load has to be transferred to bypass.
2. Transfer the load to bypass -> refer to the user’s guide 1022403, resp. 1023625, chapter 8.
3. Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer of
the fact, that the load has to be switched off for the time of servicing the UPS !
4. Shut down the UPS -> refer to the user’s guide 1022403, resp. 1023625, chapter 7.
5. Turn rectifier input circuit breaker F2 and battery circuit breaker F1 off.
Note: The depleting of the DC bus takes about 5 minutes.
6. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
7. Unscrew the fixing bolts of the hood -> twelve (12) at front, fourteen (14) at the back of the unit.
Lift the hood off the unit.
8. To be on the save side, check with a DMM between the power board terminals X24 and X15, DC
bus positive, and terminals X24 and X11, DC bus negative, the voltages to be less than 50V (for
terminal locations refer to assembly drawing 1021596, resp. 1021718).
9. Disconnect all cables from the I/O board, after you have made sure, that their labelling is correct.
10. Remove the four (4) earthing bolts as well as the fixing bolts of the static switch thyristors and
squeeze the retainer tongues of the four (4) plastic supports to lift the board out of the unit.
11. Make sure, that the configuration in terms of unit model is correct.
12. Replace the board and re-check for correct assembling and connections.
Part number 10 21 278 (same part for all 9x55 units, since hardware revision “A2”)
1. Save the alarm log label the file with the serial number of the unit (refer to service bulletin
SB9155:7). Inform the customer, that the load has to be transferred to bypass.
2. Transfer the load to bypass -> refer to the user’s guide 1022403, resp. 1023625, chapter 8.
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer of
the fact, that the load has to be switched off for the time of servicing the UPS !
3. Shut down the UPS -> refer to the user’s guide 1022403, resp. 1023625, chapter 7.
4. Turn rectifier input circuit breaker F2 and battery circuit breaker F1 off.
5. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
6. Unscrew the fixing bolts of the hood -> twelve (12) at front, fourteen (14) at the back of the unit.
Lift the hood off the unit.
7. Check for the display being dark, and the control board’s LED (green) is OFF.
8. Disconnect the ribbon cable X6 and the display cable X17 (RJ 45) from the power board.
9. Remove the plastic nut in the, located in the middle of the power board, near it’s upper edge.
10. Remove the plastic screws, squeeze the retainer tongue of the plastic support(s) and lift the near
by edge of the control board slightly up. Press both thumbs against the power board and pull the
control board out of it’s sockets.
Note: The control board shall not be bent, since otherwise SMD components soldering points
might suffer by getting cracked.
11. Check the spare board’s firmware revision and if necessary update it -> refer to step 12.
12. Assemble the spare board to the unit and reconnect the cables to X6 and X17 to the power board.
13. Make sure, that all tools are removed from the unit, thereafter close F2 and/or F1. Do NOT yet
start up the unit!
Note: It might happen, that after the power has been applied to unit, the control board is verifying
EEPROM data, which may take up to 1 minute. During that time the display remains dark, and the
green LED on the control board remains in steady state ON.
If for what ever reason the this condition remains, turn F1 and F2 off, remove and thereafter
re-plug the control board, then close F1 and/or F2.
15. Via UP/DOWN soft keys make sure, that the arrow points TOWARDS the CONTROL
BOARD, and press ENTER. The unit’s data is copied from the power board EEPROM to the
control board EEPROM (except calibration values).
EEPROM content of control board:
Calibration values, identification data (string, CAA {CTO} number) part number, serial number),
parameters, event log.
EEPROM content of power board (MIRROR):
Identification data (string, CAA {CTO} number) part number, serial number), parameters, event
log.
16. If advised by service bulletins, update the firmware by using LangLoader or PWFlash (refer to
firmware update instruction 1024759.
17. Transfer the load to UPS (NORMAL MODE) -> refer to the user’s guide 1022403 resp. 1023625,
chapter 8.
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer, that
the load will be switched back on.
18. Make sure, that both circuit breakers, F1 and F2 are closed, and no alarm is active.
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 1 (13)
9155/9355
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 2 (13)
9155/9355
The formula typically used to adjust any 10 000 based (linear) calibration factor is as follows:
All the offset factors are 10 000 by default. The analog channels can be often “auto-zeroed” by the firmware
and correct values written to corresponding offset EEPs. The spare parts are factory calibrated. Need for
field calibration is limited.
At the low end of the measuring range the offset has the biggest influence to error and as measured values
increase, effect of the scale factors increase. When the metering is calibrated, first the offset has to be
adjusted up or down to make the metered value zero when actual value is zero. This matches the “starting
points” of the curves.
Next step is to adjust the scale factors so that the formula gain equals the gain of the analog circuit i.e. both
curves have the same angular coefficient.
Now the metered value matches actual value throughout the measuring range.
When the offset is adjusted with RMS calculation (AC measurements), the metering doesn’t get negative
values since the samples are squared. Both negative and positive offset in signal will make the metered value
to increase. During the calibration one has to find the “bottom” of the V-curve. Minimum value may not
reach zero due noise on the signal.
The UPS has rectifier supplies connected and logic power on but UPS is not turned on (output is off). Prior
applying power for the rectifier input, jumpers have been installed inside UPS to zero metering signals. For
detailed instructions see 1.3 Calibration procedures.
Calibration value found from this location is 10000.
Meter value as seen by the XCP Service Tool (and DSP) shows 1.6Vac.
Meter value as seen by a calibrated DMM shows 0.1Vac.
Adjust the DSP EEP 3011 from 10000 with step of 10 increments to either direction. If metered value
increases, adjust to opposite direction. Adjust EEP value until a minimum value is achieved. To get best
possible result it may be necessary to use smaller steps than 10 increments.
This means that meter calibration factor must be decreased by 1.43% to a new EEP value of 9857 (98.57%).
Value 10000 in DSP EEP 3040 is replaced with a value of 9857. The metered value now seen by UPS
should be 227.7Vac, a true representation of the actual voltage measurement.
• NOTE#1: Exact EEP values for meter calibration factors may have to be altered slightly from
calculated result in able to achieve exact meter values desired.
• NOTE#2: When a metering is used as a controller’s feedback, like inverter voltage or DC link,
the value seen by the UPS does not change since the controller will adjust it’s own output to
match the feedback with the reference (target) level. In this case the correct calibration has to
be verified from DMM i.e. to adjust the output to the desired level.
The same techniques just illustrated above are used for calibrating meter values and display values as they
relate to current and power values.
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 4 (13)
9155/9355
AC Voltage Measurements
EEP Measurement Test Point Reference
3010/3012/3014 Output Volts *L1/L2/L3-N Scale X2-L1/L2/L3 N
3026/3028/3030 Bypass Volts *L1/L2/L3-N Scale X1-L1/L2/L3 N
3040 Utility Volts **L1-N Scale F2-L1 N
3042 Utility Volts L2-N Scale F2-L2 To N
3044 Utility Volts L3-N Scale F2-L3 N
3056/3058/3060 Inverter Volts *L1/L2/L3-N Scale A2-F1/F2/F3 N
3070/3072/3074 Output DC Volts *L1/L2/L3-N --- ---
Scale
AC Current Measurements
EEP Measurement Test Wire From / To
3032/3034/3036 Output Current *L1/L2/L3 Scale
3046 Utility Current **L1 Scale
3048 Utility Current L2 Scale To
3050 Utility Current L3 Scale
3062/3064/3066 Inverter Current *L1/L2/L3 Scale
DC Voltage Measurements
EEP Measurement Test Point Reference
3018 Battery Volts Scale CB-F1 + CB-F1 -
To
3020 DC Link Positive Scale A1-X15 N
3022 DC Link Negative Scale A1-X1 N
DC Current Measurements
EEP Measurement Test Wire From / To
3052 Battery Amps Scale To
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 5 (13)
9155/9355
1.2.3 OFFSETS
AC Voltage Measurements
EEP Measurement Jumper From/ To
3011/3013/3015 Output Volts *L1/L2/L3-N Offset A2-J6/J13/J15
3027/3029/3031 Bypass Volts *L1/L2/L3-N Offset A2-J50/J55/J60
3041 Utility Volts **L1-N Offset ---
3043 Utility Volts L2-N Offset ---
3045 Utility Volts L3-N Offset --- TO A2-J54
3057/3059/3061 Inverter Volts *L1/L2/L3-N Offset A2-F1/F2/F3
3069 Chassis Volts Offset ---
3071/3073/3075 Output DC Volts *L1/L2/L3-N A2-J6/J13/J15
Offset
AC Current Measurements
EEP Measurement
3033/3035/3037 Output Current *L1/L2/L3 Offset --- ---
3047 Utility Current **L1 Offset --- ---
3049 Utility Current L2 Offset --- ---
3051 Utility Current L3 Offset --- ---
3063/3065/3067 Inverter Current *L1/L2/L3 Offset --- ---
DC Voltage Measurements
EEP Measurement Jumper From/To
3019 Battery Volts Offset A2-J7 or J23
3021 DC Link Positive Offset A1-X15 TO A2-J54
3023 DC Link Negative Offset A1-X1
DC Current Measurements
EEP Measurement
3053 Battery Amps Offset --- ---
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 6 (13)
9155/9355
If customer’s loads are supplied by the UPS, all the calibrations are preferred to do while in Maintenance
Bypass whenever possible. Otherwise load may have to be disconnected for some of the calibrations.
• NOTE: The Internal Maintenance Bypass disconnects the NEUTRAL from the UPS. The
neutral is required whenever the UPS is operating from mains supplies. This applies also for
the logic power supplies. Closing the bypass switch may be needed to provide a neutral for
the UPS even the calibration wouldn’t require it.
The Auto-Standby function can be enabled and disabled via XCP Service Tool Options screen. The UPS
logic power has to be recycled for changes to take effect. Spare PCBAS Control boards should have Auto-
Standby disabled (firmware’s default setting). After the calibrations the Auto-Standby should be enabled for
UPS normal operation unless otherwise instructed.
If at any time during this procedure an alarm condition prevents the continued execution of the following
steps, please verify the issued alarm to determine and correct the cause of the event annunciation.
The current offset calibrations have to be verified after a board replacement since part of the analog circuits
of current measurements locates on IO-Board. Those may have to be performed manually for each offset
calibration according the instructions in this document.
The voltage offset calibrations needs to be adjusted on field only in rare occasions. The instructions how to
perform voltage offset calibrations are provided in this document. The procedure for the voltage offset
calibrations requires carefulness and should not be done unless instructions fully understood. These
calibartion steps like any other calibrations are meant to be done by trained and authorized personnel only.
The UPS must be restored to normal condition after the calibrations or any other service procedures.
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 7 (13)
9155/9355
1. Begin with all power removed from UPS, input and battery breaker open.
If using a MBS, make sure the maintenance isolation switch is open.
2. Remove the covers of the UPS if not done so yet.
3. Place jumpers inside UPS,
FROM: UDC+, Power Board X15
UDC-, Power Board X1
TO: N, I/O Board J54
NOTE: Connect the jumpers to instructed locations or damage to the unit may occur.
Proceed with steps 4 – 10 only if voltage offset need to be calibrated. Not required for
a factory calibrated (spare) control board.
4. Close battery breaker and wait for logic power, disable Auto-Standby with XCP Service Tool
if enabled.
5. Open battery breaker and make sure the UPS is isolated from all power sources.
6. Place jumpers inside UPS,
FROM: UDC+, Power Board X15
UDC-, Power Board X1
Battery +, IO Board J7 or J23
Bypass, IO Board *J50/J55/J60
Output, IO Board *J6/J13/J15
Inverter, IO Board *F1/F2/F3
TO: N, IO Board J54
NOTE: Connect the jumpers to instructed locations or damage to the unit may occur and
calibrations may fail.
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 8 (13)
9155/9355
7. Close rectifier input breaker. Neutral is required to enable logic power supplies. NOTE:
Bypass isolation breaker of the MBS may be closed for this, but if Auto-Standby is not
disabled, severe damege to unit may occur if bypass supply voltage is connected.
8. Use XCP Service Tool and calibrate offsets:
a) Adjust EEP 3011 to get Uout L1 voltage meter to zero.
9355 -> repeat procedure for EEP 3013 (L2) and EEP 3015 (L3)
b) Adjust EEP 3027 to get Ubyp L1 voltage meter to zero.
9355 -> repeat procedure for EEP 3029 (L2) and EEP 3031 (L3)
c) Adjust EEP 3057 to get Uinv L1 voltage meter to zero.
9355 -> repeat procedure for EEP 3059 (L2) and EEP 3061 (L3)
d) Adjust EEP 3071 to get Uout DC L1 voltage meter to zero.
9355 -> repeat procedure for EEP 3073 (L2) and EEP 3075 (L3)
e) Adjust EEP 3021 to get DC Bus POS voltage meter to zero.
f) Adjust EEP 3023 to get DC Bus NEG voltage meter to zero.
g) Adjust EEP 3019 to get Battery Vdc voltage meter to zero.
h) Adjust EEP 3033 to get Iout L1 current meter to minimum value.
9355 -> repeat procedure for EEP 3035 (L2) and EEP 3037 (L3)
i) Adjust EEP 3053 to get Battery Adc current meter to minimum value.
j) Adjust EEP 3047 to get Iutil L1 current meter to minimum value. Add 165 to
calibration value in **EEP 3047.
k) Adjust EEP 3049 to get Iutil L2 current meter to minimum value. Add 165 to
calibration value in EEP 3049.
l) Adjust EEP 3051 to get Iutil L3 current meter to minimum value. Add 165 to
calibration value in EEP 3051.
m) Adjust EEP 3063 to get Iinv L1 current meter to minimum value. Add 165 to
calibration value in EEP 3063.
9355 -> repeat procedure for EEP 3065 (L2) and EEP 3067 (L3)
OR
Run the automatic offset calibration of the UPS that will calibrate all the offsets.
Note: Not supported by service software yet.
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 9 (13)
9155/9355
9. Open rectifier input breaker and make sure the UPS is isolated from all power sources.
10. Disconnect the jumpers inside the UPS but leave jumpers to UDC+, UDC- and N.
11. Close battery breaker.
NOTE: Before closing the breaker make sure there’s no jumper in Battery +, IO Board
R216(L).
12. Calibrate Battery Volts:
a) Measure Battery Voltage from battery breaker.
b) Adjust EEP 3018 until Battery Vdc voltage meter matches DMM.
13. Calibrate current offsets if steps 4 – 10 weren’t done:
a) Adjust EEP 3033 to get Iout L1 current meter to minimum value.
9355 -> repeat procedure for EEP 3035 (L2) and EEP 3037 (L3)
b) Adjust EEP 3053 to get Battery Adc current meter to minimum value.
c) Adjust **EEP 3047 to get Iutil L1 current meter to minimum value. Add 165 to
calibration value in EEP 3047.
d) Adjust EEP 3049 to get Iutil L2 current meter to minimum value. Add 165 to calibration
value in EEP 3049.
e) Adjust EEP 3051 to get Iutil L3 current meter to minimum value. Add 165 to calibration
value in EEP 3051.
f) Adjust EEP 3063 to get Iinv L1 current meter to minimum value. Add 165 to calibration
value in EEP 3063.
9355 -> repeat procedure for EEP 3065 (L2) and EEP 3067 (L3)
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 10 (13)
9155/9355
1. Begin with rectifier input power connected. Bypass supplies may be required to provide a
neutral for the UPS
2. Calibrate Utility Volts:
a) Measure Utility Input Voltage from Input Breaker (F2) L1 to N
b) Adjust **EEP 3040 until Uutil L1 voltage meter matches DMM
c) Measure Utility Input Voltage from Input Breaker L2 to N
d) Adjust EEP 3042 until Uutil L2 voltage meter matches DMM
e) Measure Utility Input Voltage from Input Breaker L3 to N
f) Adjust EEP 3044 until Uutil L3 voltage meter matches DMM
NOTE: In case of a single phase input model, use Input Breaker L1 also in steps c) and e).
3. Calibration completed.
1. Begin with all input power removed from UPS, rectifier and battery breaker open.
If using a MBS, make sure the maintenance isolation switch is open.
2. Remove the covers of the UPS if not done so yet.
3. Apply rectifier input power, UPS in STANDBY mode (Auto-Standby enabled). Bypass
supplies may be required to provide a neutral for the UPS.
4. Calibrate DC Link Positive Volts:
a) Measure DC Link Positive Voltage from Power Board X15-1 to X22-1 (N).
b) Adjust EEP 3020 until DC Bus POS voltage meter matches DMM
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 11 (13)
9155/9355
1. Begin with UPS bypass and rectifier supplies connected, STANDBY mode (Auto-Standby
enabled).
2. Calibrate Bypass Volts:
a) Measure Bypass Input Voltage from X1-L1 to J29(N) on I/O-Board.
b) Adjust EEP 3026 until Ubyp L1 voltage meter matches DMM
9355 -> repeat procedure for EEP 3028 (L2) and EEP 3030 (L3)
3. Calibration completed.
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 12 (13)
9155/9355
1. Begin with UPS in NORMAL mode. If in Maintenance Bypass, make sure the maintenance
isolatation switch is open before starting the UPS.
2. Calibrate Output Volts:
a) Measure UPS Output Voltage from X2 L1 to N.
b) Adjust EEP 3010 until Uout L1 voltage meter matches DMM
9355 -> repeat procedure for EEP 3012 (L2) and EEP 3014 (L3)
3. Calibration completed.
1.4 Warning
This document provides additional information about 9155 / 9355 for a service purposes. Service should not
be performed anyone else except trained and authorized service personnel.
This document is not to be used with any other product than 9155 / 9355. Doing so, may cause severe
damage to the equipment.
Title
Calibration instruction for Field Service
EATON Power Quality Approved PK
Finland Checked RR No 10 22759 Rev B
Issued JP 30.9.2005 Page 13 (13)
9155/9355
Save the alarm log and label the file with the serial number of the unit (refer to service bulletin SB9x55:7.
Inform the customer, that the load has to be transferred to bypass.
A) Replacement with optional maintenance bypass assembled, bypass input NOT linked to
rectifier input !
1. Transfer the load to bypass -> refer to the user’s guide 1022403, resp. 1023625, chapter 8.
2. Shut down the UPS -> refer to the user’s guide 1022403, resp. 1023625, chapter 7.
3. Turn rectifier input circuit breaker F2 and battery circuit breaker F1 off.
5. If there is (are) additional battery cabinet towers connected to the UPS, terminal X3, open their
circuit breaker (located at the back of the cabinet).
6. Remove the (black) front cover of the UPS and all battery all cabinets below the UPS, by pulling
at the middle of it’s lower edge and lifting it upwards.
7. Remove the metal sheet cover plate of the battery cabinet(s) BELOW the UPS, in order to get
access to the battery.
8. Disconnect the cable of it’s (their) battery positive (located at the 1st battery [front] of the upper
shelve to the left) of each battery cabinet at the same time.
9. Disconnect the cable of it’s (their) battery negative (located at the 1st battery [front] of the upper
shelve to the right) of each battery cabinet at the same time.
10. Remove the cable cover between the connection box and the bypass cabinet.
12. Check all the terminals, X1, X2, X3, F1 and F2 to be powerless.
13. If step 12 is OK, disconnect the cables of terminals X1, X2, X3, F1 and F2, after you have made
sure, that they are labelled accordingly.
15. Loosen (do NOT remove) the 7 (seven) screws keeping the bypass cabinet attached to the battery
cabinet, 2 (two) screws on top, 1 (one) to the left, and 4 (four) close to the lower edge.
16. Lift the cabinet gently off, by keeping in mind, that load is still powered, and secure it’s position !
17. Remove the 4 (four) screws in front (lower edge) and the 4 (four) at the back (lower edge) of the
UPS.
18. To lift the UPS (electronic module, 45kg) off the battery cabinet, two people are required.
Note: If there is NO maintenance bypass switch (optional) assembled (or externally available), inform
the customer of the fact, that the load has to be switched off for the time of servicing the UPS !
This Preventative Maintenance Instruction is for use with the preventative maintenance work of the
Powerware UPS products. The products which this instruction concerns are listed in this document in
chapter Measurements and Calibrations. This document describes the maintenance activities that are
common to all the UPS products of the above mentioned list. The instructions for maintenance tasks
that are unique to specific UPS products are described in attached documents. See chapter
Measurements and Calibrations.
Long life batteries under maintenance contract or under extended warranty time shall be handled
according to instruction Annual Preventative Maintenance Instructions for Batteries Under
Preventative Maintenance Contract, 1005611.
SAFETY PRECAUTIONS
This instruction and the attached documents for specific products are for use of the qualified personnel
only. A qualified person in this case means a person who has completed Powerware service training for
the specific product type the maintenance work is to be performed.
Many components inside the UPS - and battery cabinets carry high AC- or DC- voltages. To touch them
may prove fatal. All maintenance and repair work must be performed with extreme caution.
The following general safety precautions must be observed when performing maintenance to
Powerware UPS'.
1: No repair or maintenance activity shall be performed unless repair/maintenance personnel
fully understand and carry out the necessary repair or maintenance procedures.
2: When a UPS unit is shut down for maintenance work the DC-voltage will occur several
minutes inside the cabinet. Before performing any maintenance work the discharge of the
DC-capacitor bank MUST be measured.
3: Test equipment such as an oscilloscope etc. MUST be isolated from the commercial ground.
The chassis of an oscilloscope MUST NOT be in touch with the chassis of the UPS. Only one
ground lead of an oscilloscope can be used.
4: The battery bank carries high voltage also when the unit is shut down and must therefore be
handled extremely carefully. The batteries include corrosive materials that can be harmful for
eyes, skin and clothing. Any leakage must be cleaned carefully.
5: Any metal articles such as watches, rings, chains etc. must not be worn.
6: Use common sense to avoid hazards.
GENERAL INSTRUCTIONS
If repairs are needed they shall be carried out for units under contract and costs will be borne by
Powerware or customer depending on the maintenance level of the contract. For units not under
contract repairs shall be proposed to the customer and carried out at customers expense after approval
from customer.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 1 (6)
Powerware
CUSTOMER INFORMATION
Fill in correct customer name and contact person responsible for maintenance of system. Check other
customer data on FSR and make changes if incorrect.
UNIT INFORMATION
Fill in unit type number and serial number from type plate located inside the door.
SITE CONDITIONS
Room Temp
Measure room temperature using an electronic thermometer. Room temperature shall
normally between +18 and +25°C, (O- +40°C is maximum according to specification). If
temperature is outside normal values then the customer shall be advised. If temperature is
significantly outside normal values customer actions shall be proposed. Service contracts
are only valid if temperature is kept below 40°C.
The ambient temperature requirements can alter by the battery brand. Refer to the
specification and warranty terms of the battery manufacturer.
Humidity
Check that site location is dry and non-condensing and give status in report: dry, acceptable
or wet. If acceptable or wet customer actions shall be proposed
Cleanliness
Check that site location is clean and free from dust and dirt and give status in report: clean,
acceptable or dirty. If acceptable or dirty customer actions shall be proposed.
INSTALLED OPTIONS
Identify up what options the customer has bought with the system and make notes in report: product
type and serial number for standard options.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 2 (6)
Powerware
CLEANING
Before commencing cleaning, put the UPS to manual bypass and switch it off, disconnect possible
external battery circuit breaker and make sure that the unit is "dead". Be careful with battery voltage.
Inspect DC connections
Check that all DC connections are free from oxide, clean and well greased, if not clean and
grease.
TECHNICAL UPDATES
Installed bulletins
For the units under contract install all actual bulletins from bulletin list and note in report
number of bulletins installed. For the units not under contract customers should be offered to
have bulletins installed according to Service Bulletin price list.
SAFETY GROUNDING
UPS - battery cabinet
Check the ground connection between the UPS and the battery cabinets for tightness and
good connection. Measure also the voltage between battery cabinet and UPS cabinet. The
voltage shall be zero, if not follow up and fix the grounding arrangement.
VISUAL CHECKS
Electrical modules
Check that all electrical modules are securely fitted, free from damage and other visible
weaknesses.
Internal connections
Check that all internal connectors are securely connected and free from damage and other
visual weaknesses. All screw and nut connections shall be tightened.
Electrolytic capacitors
Check all electrolytic capacitors for visual leakage.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 3 (6)
Powerware
Cooling fans
Check mechanical status of cooling fans, test that they are running smoothly without
abnormal vibrations or noise.
Batteries
Check the battery bank for visual leakage or other damages.
Battery connections
Check and tighten all external connections to UPS, battery and load. Check that mains and
distribution fuses are correct according to cable area and load power. Check the tightening
torque of some battery terminals according to the battery manufacturers data.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 4 (6)
Powerware
RMS current
Measure the RMS current using a power meter or DMM with current clamp and note in
report the value.
Peak current
Measure the peak current using an oscilloscope and note in report the value. Check that actual
peak current is within UPS specification, if not give warning note and suggest corrective
actions to customer.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 5 (6)
Powerware
BATTERY TEST
The following activities will mainly be performed with voltage on. Ensure all activities are performed
safely.
Date installed
Check date of installation of battery from maintenance log or check manufacturing date on
batteries and note in report.
Battery size
Check and note battery data: manufacturer, quantity and type.
Back-up time
Measure the actual battery back-up time. Refer to attached document for details of procedure
relevant to specific UPS type.
Battery status
Based on the result of the above measurement give status in report from the following
categories: OK, WEAK or NO GOOD. Give comments in report.
NOTES
Give special notes related to items above using a number marker in "Note" column.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 6 (6)
9x55
This preventative maintenance instruction for 9155 and 9355 8-15 kVA is for use with 9x55
Service Manual 1022609 and Preventative Maintenance Report 1019448. Preventative
maintenance is to be done by qualified service personnel having necessary knowledge about this
product to prevent personal injury and damage on equipment.
Note: The following activities will mainly be performed with voltage on. Service personnel should be
aware of live circuits inside UPS. Ensure that all activities are performed safely.
Equipment:
PROCEDURE
Follow the procedure below and mark measurements, readings, check points and notes to Preventative
Maintenance Report 1019448. If a section can not be filled it should be marked with --. The checkings
may be done in different order if it’s more convenient.
ENVIRONMENTAL
Check the UPS installation site and environmental conditions. Make a note of all abnormalities.
OPTIONS
If there’s optional devices installed with UPS, check the device condition and operation.
VISUAL INSPECTION
Shutdown the UPS to maintenance bypass, or remove from critical bus in parallel system, if possible.
This requires customers approval. Remove the required bezels and covers for the measurements
and visual inspection.
Visually inspect all the contactors, breakers, switches, cable connections, internal wiring, control boards
etc. and verify there’s no signs of loosening or heating or other abnormal condition. Note: When
shutting down to maintenance bypass some components inside UPS have lethal voltage. Precaution
required during inspection and cleaning.
UPDATES
Perform the firmware updates and modifications according instructions in service bulletins or service
manual or other documentation.
UNIT MEASUREMENTS
Start-up the UPS and transfer to normal mode. Note: Precaution required due open access to live
circuits with lethal voltage.
After completing all the measurements and access inside bezels is not anymore required, shutdown the
UPS to maintenance bypass and restore the UPS to normal condition.
RECTIFIER
• Measure input volts, line to line and line to neutral (ground), for each phase on input terminals X1. If
voltage is out of, or close to specification, check with customer about reason and possibilities for
improvement.
• Measure the input currents.
• Measure the input frequency. If the frequency is out of or close to specification, check with customer
about reason and possibilities for improvement.
• Compare measurements to LCD display’s readings. Verify that readings are within 3 %, if not,
calibrate UPS.
UPS OUTPUT
• Measure the UPS output voltages, line to line and line to neutral, for each phase on UPS output
terminals X3. Verify that voltages balanced within 2 %.
• Verify that output voltages are within 1% of the nominal.
• Measure the output frequency.
• Measure the output currents.
• Compare measurements to LCD display readings. Verify that readings are inside 3%, if not,
calibrate UPS.
• Measure the Bypass voltages, line to line and line to neutral (ground), for each phase on Bypass
input terminals X2. Verify that voltages are inside specification.
• Measure the frequency. Verify that the frequency is inside specification.
• Compare all the Bypass measurements to LCD display’s readings. Verify that readings are within
3%, if not, calibrate UPS.
• Transfer the UPS to Bypass mode.
• Measure or read the bypass (output) currents. In parallel system when all the units are in bypass,
compare the output currents between units. Compare the current balance between units to previous
measurements. If there’s big changes in balance, inspect the connections of the power cables.
• Transfer back to normal mode.
• Open rectifier input breaker and verify UPS operation in battery mode.
• Measure the discharge current and battery voltage in beginning of the discharge test. Mark the
readings to report and calculate the battery power.
• Measure the battery voltage at the end of test. Mark the end voltage and duration of test to report.
• Close the input breaker and measure the charging voltage in float mode.
• Calculate the estimated back-up time to report.
• Verify the ABM operation and battery cabinet/room temperatures.
FANS
Check the operation of fans. If the fans are > 4 years old, replace to new ones.
If remote communication options are installed, verify that all remote communications function properly.
Building alarms, signal inputs, alarm relay, cards in X-slots.
SERVICE BULLETINS
Verify all applicable modifications, per Field Service Bulletins, have been performed.
Parameter settings
Parameter 0 (U)
Start screen Default : 0, Powerware logo.
Option : 1, mimic screen.
Parameter 1 (U)
Language selection Default : 0, first language in the language pack, English.
Options: 1- 3 (refer attached table)
Parameter 2 (U)
User password Default : 0, password for user settings disabled.
Option : 1, password for user settings, "USER" enabled.
Parameter 3 (U)
Audible alarms Default : 1, audible alarms are enabled.
Option : 0, UPS remains permanently silent.
Parameter 4 (U)
Behavior on input break Default : 1, prefer bypass.
Option : 0. prefer battery.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 5 (U)
Transfer to bypass when overload Default : 0, transfer immediately.
Option : 1, transfer to bypass after a delay depending on the
the amount of load (refers to overload levels as listed
in chapter “10. Technical Data” of the user’s guide).
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 6 (U)
Transfers to bypass Default : 0, unsynchronized transfers to bypass
Option : 1, synchronized transfers to bypass.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 7 (U)
Synchronization Default : 0, enabled.
Options: 1, disabled, inverter free running
2, disabled, if redundant (N+1 operation) in parallel
systems. ENABLED if “N” units in operation.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 8 (U)
Bypass operation Default : 0, enabled.
Option : 1, transfer to bypass disabled
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 9 (U)
Site wiring fault notice Default : 0, notice enabled.
Option : 1, disabled, ? Alarms # 194, "site wiring fault", and
# 259, "neutral fault" are suppressed. If conditions leading
to these alarms are present during start up, the "UPS on"
command is suppressed and the start up discontinued.
Parameter 10
EPO Default : 0, EPO is enabled.
Option 1, EPO input X52 is ignored and X12 disabled.
Note: For DSP firmware releases up to E4, changing of
parameter 10 requires the recycling of the logic, in other
words, the unit has to be switched OFF and re-started in
order to take effect.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 11 (U)
Control commands from X-SLOT1 Default : 0, control commands enabled.
Option : 1, control commands disabled.
Control commands are: Go to bypass, delayed and
immediate UPS on/off and restart, set clock, set
configuration, set communication parameter, set
power strategy…..
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 12 (U)
Contr. commands X-SLOT2/SERV. Refers to Parameter 11
Parameter 14 (U)
ABM Default : 0, ABM enabled.
Option : 1, ABM disabled, the batteries are permanently
charged, refers to parameter 26.
Parameter 15
Temperature compensat. charging Default : 0, temperature charging enabled
Option : 1, temperature compensation disabled.
Note: The temperature source for temperature
compensated charging is at for the moment temperature
sensor U1 on the power board of the UPS. If the battery
(e.g rack mount, additional external battery cabinets), is
located in a different room than the UPS, the charging
voltage might be somewhat inaccurate.
Parameter 16
Modem installed Default : 0, no modem installed:
Options: 1: modem connected to X-slot 1.
2: modem connected to X-slot 2/service port.
Parameter 17
Battery operation delay Default : 5
Option : 0 – 4, 6 – 99, sets the delay (in steps of 1 second) for
alarm # 168 “Battery operation”.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 18 (U)
Re-start up delay (auto standby) Default : 0, no delay
Options : 1s - 9h in steps of 1second
If the delay time is positive, the units re-starts
automatically after a low battery shut down or after a
delayed shut down while in battery operation (refer to
parameter 19)
-1, ? User and/or remote start up only, commanded via
X44, X45, X-SLOTS, XCP-service tool or front panel.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 19 (U)
Battery operation shut down delay Default : -1, disabled.
Option : 0 – 10800, in steps of 1 second. Positive numbers
indicate the shut down delay in seconds.
Note: It means, that any other value than "-1" leads
to predetermined shut down, regardless of the available
battery back up capacity. The UPS re-starts, once the
utility is available within the specified tolerance.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 20 (U)
Input signal shutdown delay Default : 120 seconds.
Option : 1s - 18,2h, in steps of 1 second.
If a signal input is set to execute a delayed shutdown
and re-start (after approx 30 seconds).
Note: This delay is also in use, if alarm # 201 "output
transformer overtemperature" gets active.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 21 (U)
X-slot signal input activation delay Default : 5 seconds.
Option : 0 – 4 and 6 – 65, in steps of 1 second.
After the set time delay, the RS232 RX pin is
recognized to be an active signal (3 -12VDC). Refers
to functions of signal inputs.
Parameter 22 (U)
Number of battery strings Default : 1, equals 1 string.
Option : 0 and 2 – 15 (max. 15 strings)
A battery string consists of 32 batteries.
Parameter 24 (U)
Battery size Default : 24 W/cell.
Option : 1 - 65535 in steps of 1W
Size is given in W/cell for a 15 minutes discharge period.
Parameter 25 (U)
Battery low alarm level Default : 1.880 V/cell.
Option : 1,750 - 1,950 V/cell.
If the battery voltage drops below the "Battery
low" level (alarm # 56), gets active.
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 26
Constant float charge voltage Default : 2.270 V/cell.
Option : 2,150 - 2,335 V/cell.
This is the battery target (float) charge voltage (refers to
25°C), if the ABM is disabled, while the charger is
permanent in operation.
Parameter 27 (U)
Battery charger current limit Default : 3,0 ampere.
Option : 0 – 2,9 and 3,1 - 25A for all units, in steps of 0,1 A..
Parameter 28 (U)
Output voltage Default : 230 volts.
Option : 220V - 240V in steps of 10V
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 30 (U)
Bypass voltage, high limit Default : Nominal output voltage +10% (refer to parameter 28)
Option : Can be reset in steps of 1% in the range of 1 - 20%.
Parameter 31 (U)
Bypass voltage, low limit Default : Nominal output voltage -15% (refer to parameter 28)
Option : Can be reset in steps of 1% in the range of 1 - 20%.
Parameter 32 (U)
Bypass synchronization window Default : +/- 2.0Hz.
Option : 0,5 - 3,0Hz in steps of 0,1Hz .
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 33
Utility synchronization window Default : +/- 1.0Hz.
Option : 0,5 - 3,0Hz in steps of 0,1Hz .
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 34 (U)
Output frequency Default : 50Hz (HV models)
Option : 60Hz (default LV models)
Note: All units of a parallel systems update the
parameter at the same time, when set for ONE unit.
Parameter 36 (U)
Slew rate Default : 0.2Hz/s.
Option : 0,1 - 1,0Hz in steps of 0,1Hz .
The slew rate determines how fast the inverter can
follow the bypass source, by remaining synchronized.
Parameter 37 (U)
Rectifier input current limit Default : 66 A for 8 - 10kVA, single phase input (range 48-120A)
22 A for 8 - 10kVA, three phase input (range 16-40A)
29 A for all 12 - 15kVA, (range 16-40A)
56 A for 20 - 30kVA, (range 32-80A)
Option : Adjustable in steps of 1A within the respective range
Parameter 38
Reset modem Default : 0.
Option : 1, the UPS sends a reset command to the modem. The
modem ends communications and resets modem related
errors.
Parameter 39
Clear event log Default : 0.
Option : 1 The UPS clears the memory's event history.
Note: Works like push button
Parameter 40 (U)
Reset factory settings Default : 0.
Option : 1, -> clears the custom alarm settings, like:
resets the relays, the modem, sets the clock to 0, and
resets all parameters to their default, except:
• 10 – EPO
• 22 – Number of battery strings
• 24 – Battery size
• 27 – Battery charger current limit
• 34 – Nominal output frequency
• 37 – Rectifier input current limit
• 43 – Parallel unit number
• 44 – Min. number of units support. Load
Parameter 41
Lock RS232 RX to service port Default : 0, X-slot 2 RX (receive) enabled.
Option : 1, Communication with UPS only via service port (X53).
Parameter 48 (I2)
Power recycling mode Default : 0, inactive -> UPS operates normally.
Option : 1, active -> UPS operates in “test mode”
Note: The recycling mode is designed to be used ONLY
for test purposes, while the customers load is switched off.
Recycling mode procedure:
• Switch the customers load OFF
• Switch the UPS OFF
• Set parameter 48 to “1”
• Close the bypass switch S1
• Re-start the UPS.
The UPS (inverter) will feed back into the bypass mains
while increasing the output current up to ~ 70% of it’s
nominal value.
Parameter 50 (G4)
Zero offset calibration Default : 0
Option : 1, automatic zero offset calibration active
In order to get correct results, refer to the calibration
instruction 1022754.
Proceed as following:
• Bypass the UPS, or switch the load off.
• Proceed as described in calibration instruction
1022754, chapters 1.3 + 1.3.1 but do not execute
the actual calibration step, just disconnect power
as required, and connect the respective jumpers.
• Set parameter 50 to “1” ? logic performs the zero
offset calibration automatically and writes the
respective values into the EEPROM.
• Set parameter 50 back to “0” and remove all
jumpers.
• Proceed with the calibration of the UPS as
instructed in 1022754, chapters 1.3.2 – 1.3.6
Parameter 53 (J2)
Logic power off delay Default : 3600 = 1h
Option : 30s – 1h in steps of 1 second
When the UPS is off, the logic power (aux. supply) for
display, X-slots, boards etc. turns off after the set delay.
Note: All units of a parallel systems update the parameter
at the same time, when set for ONE unit.
Parameter 54 (J6)
EMP battery charge control Default : 0 = EMP not installed
Option : 1 / 2: refers to X-Slot number
The Environmental Monitoring Probe (EMP) is connected
to the Web/SNMP adapter’s COM port. The EMP contains
a temperature sensor, a humidity sensor, and two signal
inputs. If parameter 54 is set to 1 or 2, the UPS uses the
EMP-temperature as the source for battery compensated
charging. If the UPS cannot get valid sensor data, it uses
25°C by default. The valid data timeout is 5 minutes.
In Parallel Systems:
If only one EMP per system is installed, the control
boards of the other units will use the EMP as source for
temperature compensated charging as well.
If there are more than one EMP installed, the units without
EMP use the highest reported temperature for
compensation. The units with EMP always use their own
EMP temperature.
Parameter 55 (J6)
Hot Sync Card peripherals Default : 0 = UPS ignores relay and signal input of Hot Sync Card.
Option : 1 / 2: refers to X-Slot number.
The Hot Sync Card offers a signal input and a relay output.
Signal input configuration:
Refers to document 1024629, 9x55 display description,
X-SLOT 1, or X-SLOT 2/SERV, menu <signal inputs>
of user settings.
Note: The UPS recognizes only the binary signal of the
Hot Sync Card, not the COM port RX break for this port.
Relay configuration:
Refers to document 1024629, 9x55 display description.
The UPS uses the relay function for X-SLOT 1-1, or
X-SLOT 2-1, menu <relay config> of user settings.
Parameter 56 (j4)
Relay Delay Time Default : 5 = 5 seconds delay until relay activates.
Option : 0 – 4, 6 – 3600, delay up to one hour.
This delay time delays all relays, for which the bit by
Parameter 57 is set.
Parameter 57 (j4)
Delayed Relays Default : 0 = No extra delay for any relays.
Option : “………” to “lllllllll”: Bit field, from left to right:
Items 1 – 9 as listed below
“.” Is: No delay.
“l” is: Delay set at Parameter 56 is applied to relay.
Bit: Delay for Relay:
1 UPS built in ALARM-1
2 X-SLOT1-1
3 X-SLOT1-2
4 X-SLOT1-3
5 X-SLOT1-4
6 X-SLOT2-1
7 X-SLOT2-2
8 X-SLOT2-3
9 X-SLOT2-4
(xx)
Note: Only since revision: XX !
Note : Parameters 13, 23, 29, 35, 42 and 45 are not in use yet,
Parameters labeled with (U) can also be set under user settings.
UPDATE INSTRUCTION
If a unit's firmware shall be updated, refer to the instructions within this document. Service
bulletins will inform periodically about the availability and "update urgency" of new firmware,
which can be downloaded from the service web as a complete package including LangLoader.
1. Langloader
User: Customers, service engineer (main (DSP) firmware + display firmware)
DSP
The DSP is the main firmware, located in the main processor D1 of the control board (refer to
figure 1). Next to the control functions and the communication services, it includes a package
of 2- 4 languages. Available DSP firmware are:
9155 9355
Figure 1
The LangLoader is easy to use, and allows therefore the user to update and/or change the
display language package according the following instruction:
• Connect the laptop to the RS232 port X53 of the UPS and start up the LangLoader
Shortcut to langLoader.exe.lnk
From the pull down menu you can select the COM port, or let "autodetect" find it.
Note:
• Do NOT keep service software tools within the "START UP" menu, otherwise the
COM port(s) of your PC might be blocked.
• Before you confirm the selection of the COM port, by clicking onto "Next>>", make sure,
that the "Power Options" of your PC are set to minimum:
Select <Start - Settings - Control Panel - Power Options - Power Schemes>
Turn off monitor after 10 min (or longer)
Turn off hard disk after 10 min (or longer)
System stand by after 10 min (or longer)
If the "Power Options" for hard disk and/or system stand by are set to a shorter time, you might
risk, that during the data transfer to the UPS, the PC will go to sleep mode and therefore will
reduce the baud rate automatically. As a result, the download requires more time or is stopped
completely.
Note: If however the window "Could not find any supported UPS..." is displayed, check the
baud rate of the serial port of the UPS. Select from the display: <Settings - User Settings - Serial
Port Config. - XSlot-2/Serv.> and set the baud rate to 19200. Make also sure, that parameter 12
(User settings - Contr. commands X-SLOT2/SERV) is set to "allowed" !
• Select from the pull down menu the most suitable language, "Revision info" informs about
the DSP and display revisions going to be downloaded.
• From the display submenu "Control" select "Go to Bypass Mode". The bypass operation is
confirmed by the yellow LED (third from top) of the front panel being lit. If no bypass is
available, inform the customer, that the load has to be switched off. Select from the display
"Turn UPS off" and press "Enter" for 5 seconds. KEEP THE CIRCUIT BREAKERS "F1"
AND "F2" CLOSED !
Note: If you forget to do so, the UPS will remind you once more by displaying the following
window:
If you confirm by clicking "Yes" but still didn't perform the action, the UPS will then
automatically switch to bypass mode, or switch itself off and start to download of the selected
firmware after the confirmation by clicking "Yes", or the displayed time within the following
window:
After the firmware has been downloaded, the following windows will appear:
• Confirm by clicking "OK", and proceed as instructed within the following window:
Note: The help folder (use pull down menu) within the above widow includes the file
"Quick-start guide (F1). In case, you encounter difficulties to download the firmware, read
this document before taking further actions.
2. Flash
User: Service engineer (Tool to download all firmware except "Bypass", 1022770)
Pwflas~3.exe
On top of the "Flash PROM Loader" the following window shall appear:
Note: If the communication settings are incorrect, the "Flash" software will inform:
If all communication settings are "OK", the following window shall appear.
• Select from the tool bar the "FOLDER" icon and within the folder the firmware you'd like
to flash. Refer to figure 1, at page 1 of this document.
• "Open" the firmware. As a result the 5th icon (from the left) of the "Flash PROM Loader"
window toolbar turn from gray to red.
• Click this icon to start the download. Within the following window it will be confirmed by
text: "Programming started"
Note: If the UPS for some reason still would be in normal mode (inverter operation) the
following window will appear and the "Flash PROM Loader" window turns from green
to red:
Once the programming has been completed the firmware is verified. The last action of the
download is, the reset command to the UPS, which will put it few seconds later automatically
back into normal operation.
CODE DESCRIPTION
CODE DESCRIPTION
CODE DESCRIPTION
Select the COM-port, the country where the UPS is located, set flow control to
none and the communication speed to 1200 bps (this communication speed is
recommended if standard FORS modem setup is used, traditionally UPSCode
units have had this speed).
Run ”Initialize modem” (this may take a while).
b) Configure the UPS built-in serial port settings. The required settings are: serial
port communication speed 9600, UPSCode enabled, control command enabled.
Save the changes.
c) Configure the modem settings and activate the X-Slot number where the
modem is installed. Save the changes.
Example: ATX3DT0,123456
This AT-command is: do not wait for a dial tone, dial a zero (0) for outline, dial
phone number 123456
Close the terminal or terminal emulation software and remove the serial
communication cable from the UPS serial port. Configuration is now done.
XSLOT Modem is made for UPS remote monitoring purpose. It is installed to UPS XSLOT extension place and it
offers one RJ-11 phone-jack connector for telephone network connection and four LEDs to indicate its status on
its face plate. There are also onboard RS-232 port and DC-socket for the configuration purpose (which are not
available when Modem is installed in UPS).
XSLOT Modem is based on Conexant SocketModem (or Multitech ModemModule) chip. SocketModem is fully
functional modem which needs only +5 VDC and some external components for interfaces to operate. In the
following are explained functional parts of the modem board.
Functional parts:
Fully functional modem chip. There are two alternative manufacturers, Conexant and Multitech.
With these jumpers are set modem behaviour in terms of hardware signals. In the Assembly
picture is explained how to assemble these jumpers. By default, hardware signals are not used.
POWERWARE
Checked LM No 1019139 Rev A
Approved RAK Page 1 (2)
Telephone network interface consist of RJ-11 connector and overvoltage- (V9) and overcurrent
(F1) surge arresters.
Indicator LEDs shows modem status. There are four LEDs: Receiving (RX), Sending (TX), Data
Carrier Detect i.e. modem is off-hook (DCD) and Data Terminal Ready i.e. modem is ready
(DTR), which will lit nearly always.
RS-232 interface consist of 9-pin RS-232 port and MAX3232 voltage level conversion IC (D1).
This port is for configuration purposes. Modem should be configured before it is assembled in
UPS.
6. +5V DC-DC converter (C1 - C3, C10, L1, N1, R1, V5, V8)
This part of circuit will make operating voltage to modem board. It will convert 8 - 25 V input DC-
voltage offered by XSLOT +V to +5 VDC. DC-DC converter is based on National Simple
Switcher IC (N1).
Current limiter is situated between XSLOT +V (8-25 VDC) output and +5V DC-DC converter
input. It protects UPS power supplies from overloading. Current is limited to under 550 mA with
transistor circuitry. Shortcircuit protection is implemented with fusible resistors R3 and R4.
8. DC-socket (X4)
This DC-socket is for configuration purposes. Via this connector is supplied 9 - 25 VDC when
modem board is configured.
Face plate of the modem board is attached through these terminals. There is no any electrical
connection between modem circuitry and terminals (and face plate).
Modem draws its power and communicates with UPS through XSLOT connector when modem
is assembled into UPS.
POWERWARE
Checked LM No 1019139 Rev A
Approved RAK Page 2 (2)
Relay Interface Card for Powerware X-Slot
General
This Relay Interface Card (p/n 1018460) provides potential free true relay interface for AS/400 and other
relay connected computers and industrial applications. This relay interface uses a 15-pin D-sub connector as
well as wiring connections and this Relay Interface Card is installed in the X-Slot of the UPS.
Installation
The UPS does not have to be shut down when installing this Relay Interface Card.
1. Remove the cover on the X-slot of UPS to install the Relay Interface Card.
2. Put the Relay Interface Card into the slot and attach it to UPS´s panel by using screws.
1018947 Rev. B
1/2
Table 1. Bypass relay information is not supported by the Powerware 5115 and 5125 UPSes. UPS
Alarm/OK relay information is supported only by the Powerware 9340 UPS.
Table 1
Table 2
* Normally closed (NC) /open (NO) connection state when the Relay Interface Card is not powered.
** The shutdown pin (15) needs minimum of 5 seconds high level signal (connection to +12VDC) to
perform the UPS shutdown.
NOTICE: The relay contacts must not be galvanically connected to any mains connected circuits. Do not use
+12VCD (Pin13) of the Relay Interface Card for any power supply purposes for external devices. Reinforced
insulation to the mains is required for equipment and cables connected to these connections.
The relay contacts are rated for maximum 1A/30VAC or 200mA/60VDC. All relay outputs are galvanically
isolated from the other circuits of the UPS (IEC 950, EN 50091-1, FCC Class A).
1018947 Rev. B
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1018345A.sch-1 - Fri Mar 12 09:17:29 2004
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POWERWARE OY
BILL OF MATERIAL FOR PRODUCT 1022584 a1
SUBAS 9155 battery cabinet 32x0Ah (no batt. incl.)
PART NUMBER DESCRIPTION QUANTITY DESIGNATOR