Eaton 9395 SSBM User manual

Eaton 9390 UPS, 9395 UPS, and 9395 SSBM
Sync Control
Installation and Operation Manual
®
Sync Control
Installation and Operation Manual

Eaton 9390 UPS, 9395 UPS, and 9395 SSBM
Sync Control
Installation and Operation Manual
®
Sync Control
Installation and Operation Manual

IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that you should follow during installation and maintenance of the UPS and batteries. Please
read all instructions before operating the equipment and save this manual for future reference.
CONSIGNES DE SÉCURITÉ IMPORTANTES
CONSERVER CES INSTRUCTIONS
Ce manuel comporte des instructions importantes que vous êtes invité à suivre lors de toute procédure d'installation et de maintenance
des batteries et de l'onduleur. Veuillez consulter entièrement ces instructions avant de faire fonctionner l'équipement et conserver ce
manuel afin de pouvoir vous y reporter ultérieurement.
Eaton and X-Slot are registered trademarks of Eaton Corporation or its subsidiaries and affiliates. National Electric Code and NEC are a
registered trademarks of National Fire Protection Association, Inc. All other trademarks are property of their respective companies.
ECopyright 2005–2011 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any
way without the express written approval of Eaton Corporation.

Eaton 9390 UPS, 9395 UPS, and 9395 SSBM Sync Control Installation and Operation Manual SP-164000052 Rev 2 www.eaton.com/powerquality i
Table of Contents
1 Introduction 1-1............................................................................
1.1 Conventions Used in This Manual 1-2..........................................................................
1.2 Safety Warnings 1-3......................................................................................
1.3 For More Information 1-4...................................................................................
1.4 Getting Help 1-4.........................................................................................
2 Installation Plan and Unpacking 2-1............................................................
2.1 Creating an Installation Plan 2-1.............................................................................
2.2 Preparing the Site 2-1.....................................................................................
2.2.1 Environmental and Installation Considerations 2-1............................................................
2.2.2 Eaton Sync Control Wiring Preparation 2-4..................................................................
2.3 Inspecting and Unpacking the Eaton Sync Control 2-4..............................................................
3 Installation 3-1.............................................................................
3.1 Installation and Wiring with an Eaton 9390 UPS 3-1................................................................
3.2 Installation and Wiring with an Eaton 9395 UPS 3-8................................................................
3.3 Installation and Wiring with an Eaton 9395 SBM 3-16...............................................................
4 Operating Instructions 4-1....................................................................
4.1 Startup for UPS Systems Equipped with an Eaton Sync Control 4-1.....................................................
4.2 Understanding Eaton Sync Control Operation 4-1..................................................................
4.3 Operation 4-3...........................................................................................
4.4 Maintenance Operations 4-5................................................................................
5 Warranty 5-1..............................................................................

TABLE OF CONTENTS
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List of Figures
Figure 1‐1. Eaton Sync Control 1-1.........................................................................
Figure 1‐2. Eaton Sync Control with Door Open 1-2..............................................................
Figure 2‐1. Eaton Sync Control Dimensions – Front View 2-2.......................................................
Figure 2‐2. Eaton Sync Control Dimensions – Side Views 2-3.......................................................
Figure 3‐1. Typical Eaton Sync Control Wiring Terminal Locations 3-2................................................
Figure 3‐2. Eaton Sync Control TB1 Terminal Block Detail 3-4......................................................
Figure 3‐3. Eaton 9390 UPS (40–80 kVA) Interface Locations for Eaton Sync Control 3-5....................................
Figure 3‐4. Eaton 9390 UPS (100–160 kVA) Interface Locations for Eaton Sync Control 3-6..................................
Figure 3‐5. TB6 Terminal Block Detail 3-7....................................................................
Figure 3‐6. Mini CSB Interface Terminals 3-7..................................................................
Figure 3‐7. Eaton 9395 UPS (225–275 kVA) Interface Locations for Eaton Sync Control 3-10..................................
Figure 3‐8. Eaton 9395 UPS and Plus 1 UPS (450–550 kVA) Interface Locations for Eaton Sync Control 3-11......................
Figure 3‐9. Eaton 9395 UPS and Plus 1 UPS (650–825 kVA) Interface Locations for Eaton Sync Control 3-12......................
Figure 3‐10. Eaton 9395 UPS (1000–1100 kVA) Interface Locations for Eaton Sync Control 3-13................................
Figure 3‐11. Industrial Relay Card End View for AS400 3-14.........................................................
Figure 3‐12. Industrial Relay Card Terminals for AS400 3-14.........................................................
Figure 3‐13. Relay Interface Card 3-15........................................................................
Figure 3‐14. SBM Control Pan Interface Terminal Locations 3-18......................................................
Figure 3‐15. TB1 and TB2 Interface Terminal Detail 3-19............................................................
Figure 3‐16. TB4 and TB5 Interface Terminal Detail 3-19............................................................
Figure 3‐17. Terminal Block TB2 Connector Assignments 3-20........................................................
Figure 3‐18. Terminal Block TB3 Connector Assignments 3-20........................................................
Figure 3‐19. SBM to UPS Interconnection System Control Wiring 3-21..................................................
Figure 4‐1. Typical Eaton Sync Control Block Diagram with a Eaton 9390 UPS, Eaton 9395 UPS, or 9395 SSBM. 4-2................
Figure 4‐2. Synchronization Reference Control 4-3..............................................................
Figure 4‐3. Eaton Sync Control Controls and Indicators 4-4........................................................

Eaton 9390 UPS, 9395 UPS, and 9395 SSBM Sync Control Installation and Operation Manual SP-164000052 Rev 2 www.eaton.com/powerquality 1-1
Chapter 1 Introduction
The Eaton®Sync Control maintains the critical load outputs of either two separate
single Eaton 9390 UPS or Switchboard System Bypass Module (SSBM) systems or
two separate single Eaton 9395 UPS or SSBM systems in synchronization. Use of the
Eaton Sync Control provides the uninterrupted transfer of the load from one load bus
to another by means of downstream, dual-source, solid-state, transfer switches.
Without the load sync option, the two system output (critical load) buses could
become out of phase with each other. This condition occurs if suitable bypass
sources are not available or if the bypass sources feeding each system are not in sync
with each other. Examples of this condition are two systems supplied by separate
diesel generator sets, or the bypass sources for the two systems are lost.
Figure 1‐1 shows the front view and Figure 1‐2 shows the interior view of the Eaton
Sync Control.
Figure 1‐1. Eaton Sync Control
Figure

INTRODUCTION
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Figure 1‐2. Eaton Sync Control with Door Open
1.1 Conventions Used in This Manual
This manual uses these type conventions:
SBold type highlights important concepts in discussions, key terms in procedures,
and menu options, or represents a command or option that you type or enter at a
prompt.
SItalic type highlights notes and new terms where they are defined.
SScreen type represents information that appears on the screen or LCD.
Icon Description
Information notes call attention to important features or instructions.
[Keys] Brackets are used when referring to a specific key, such as [Enter] or [Ctrl].
In this manual, the term UPS refers only to the UPS cabinet and its internal elements.
The term UPS system refers to the entire power protection system – the UPS
cabinet, the battery cabinet, and options or accessories installed.

INTRODUCTION
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1.2 Safety Warnings
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed during installation and maintenance of
the UPS or SBM and batteries. Please read all instructions before operating the equipment and save this
manual for future reference.
The UPS or SBM cabinet is designed for industrial or computer room applications, and contains safety
shields behind the doors. However, these units comprise a sophisticated power system and should be
handled with appropriate care.
DANGER
The UPS or SBM contain LETHAL VOLTAGES. All repairs and service should be performed by
AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS inside the UPS
or SBM.
WARNING
SThe UPS system contains its own energy source (batteries). The output terminals may carry live voltage
even when the UPS is disconnected from an AC source.
STo reduce the risk of fire or electric shock, install this UPS or SBM in a temperature and humidity
controlled, indoor environment, free of conductive contaminants. Ambient temperature must not exceed
40C (104F). Do not operate near water or excessive humidity (95% maximum). These systems are not
intended for outdoor use.
SEnsure all power is disconnected before performing installation or service.
CAUTION
SKeep the UPS or SBM doors closed to ensure proper cooling airflow and to protect personnel from
dangerous voltages inside the unit.
SDo not operate the UPS or SBM close to gas or electric heat sources.
SThe operating environment should be maintained within the parameters stated in this manual.
SKeep surroundings uncluttered, clean, and free from excess moisture.
SObserve all DANGER, CAUTION, and WARNING notices affixed to the inside and outside of the
equipment.

INTRODUCTION
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1.3 For More Information
Refer to the following manuals for additional information:
SEaton 9390 UPS (40–80 kVA) Installation and Operation Manual
SEaton 9390 UPS (100–160 kVA) Installation and Operation Manual
SEaton 9395 UPS (225–275 kVA) Installation and Operation Manual
SEaton 9395 Plus 1 UPS (225–275 kVA) Installation and Operation Manual
SEaton 9395 UPS (300 kVA) Installation and Operation Manual
SEaton 9395 550/275 UPS (225–550 kVA) Installation and Operation Manual
SEaton 9395 UPS and Plus 1 UPS (450–550 kVA) Installation and Operation Manual
SEaton 9395 UPS and Plus 1 UPS (650–825 kVA) Installation and Operation Manual
SEaton 9395 UPS (1000–1100 kVA) Installation and Operation Manual
SEaton 9395 SBM Installation and Operation Manual
These manuals describe:
SUPS or SBM cabinet, optional components, and accessory installation instructions,
including site preparation, planning for installation, and wiring and safety
information. Detailed illustrations of cabinets and optional accessories with
dimensional and connection point drawings are provided.
SUPS or SBM operation, including cabinet controls, functions of the unit, standard
features and optional accessories, procedures for starting and stopping the UPS or
SBM, and information about maintenance and responding to system events.
SCommunication capabilities of the UPS or SBM system.
Visit www.eaton.com/powerquality or contact Eaton service representative for
information on how to obtain copies of these manuals.
1.4 Getting Help
If help is needed with any of the following:
SScheduling initial startup
SRegional locations and telephone numbers
SA question about any of the information in this manual
SA question this manual does not answer
Please call the Help Desk at:
United States: 1-800-843-9433 or 1-919-870-3028
Canada: 1-800-461-9166 ext 260
All other countries: Call your local service representative

Eaton 9390 UPS, 9395 UPS, and 9395 SSBM Sync Control Installation and Operation Manual SP-164000052 Rev 2 www.eaton.com/powerquality 2-1
Chapter 2 Installation Plan and Unpacking
The Eaton Sync Control is shipped as a separate item and can be mounted on any
surface that can safely bear its weight. See paragraph 2.2 for weight, dimensions, and
wiring preparation.
2.1 Creating an Installation Plan
Before installing the UPS system, read and understand how this manual applies to the
system being installed. Use the procedures and illustrations in the following chapters
to create a logical plan for installing the system.
NOTE Startup and operational checks must be performed by an authorized Eaton Customer Service
Engineer, or the warranty terms as specified on page 5-1 become void. This service is offered as part of the
sales contract for the UPS. Contact service in advance (usually a two-week notice is required) to reserve a
preferred startup date.
2.2 Preparing the Site
For the Eaton Sync Control to operate at peak efficiency, the installation site should
meet the environmental parameters outlined in the applicable Eaton 9390 or Eaton
9395 UPS or SSBM installation and operation manual listed in paragraph 1.3.
2.2.1 Environmental and Installation Considerations
The life of the Eaton Sync Control is adversely affected if the system is not installed in
a temperature and humidity controlled indoor area free of conductive contaminants.
Failure to follow guidelines may void your warranty.
The UPS equipment operating environment must meet the weight requirements
shown in Table 2‐1 and the size requirements shown in Figure 2‐1 and Figure 2‐2.
Dimensions are in millimeters (inches).
Table 2‐1. Equipment Weight
Model
Weight
kg (lb)
Shipping Installed
Eaton Sync Control 45.4 (100) 36.3 (80)
Figure

INSTALLATION PLAN AND UNPACKING
Eaton 9390 UPS, 9395 UPS, and 9395 SSBM Sync Control Installation and Operation Manual SP-164000052 Rev 2 www.eaton.com/powerquality
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FRONT VIEW
66.27
[26.09]
Dimensions are in millimeters [inches].
61.18
[24.09]
Four Mounting Holes
in Rear of Panel
3.18
[1.25]
56.9
[22.0] 64.77
[25.5]
Figure 2‐1. Eaton Sync Control Dimensions – Front View

INSTALLATION PLAN AND UNPACKING
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LEFT SIDE VIEW RIGHT SIDE VIEW
Knockout Holes for
1-Inch Conduit
Dimensions are in millimeters [inches].
20.32
[8.0]
5.08
[2.0]
6.35
[2.5]
6.35
[2.5]
Figure 2‐2. Eaton Sync Control Dimensions – Side Views

INSTALLATION PLAN AND UNPACKING
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2.2.2 Eaton Sync Control Wiring Preparation
Read and understand the following notes while planning and performing the
installation:
SRefer to national and local electrical codes for acceptable external wiring practices.
SMaterial and labor for external wiring requirements are to be provided by
designated personnel.
SFor external wiring, use 90°C copper wire with a minimum insulation rating of
600V. If wire is run in an ambient temperature greater than 30°C, higher
temperature wire and/or larger size wire may be necessary. See the applicable
wiring information in Table 3‐1 for the Eaton 9390 UPS, Table 3‐2 for the Eaton
9395 UPS, and Table 3‐4 for the Eaton 9395 SSBM.
SUse 14 AWG wiring with a minimum insulation rating of 600V for interconnections
between the Eaton Sync Control, the UPS, and the customer remote monitoring
system.
SUse Class 1 wiring methods (as defined by the NEC®) for interface wiring up to
30V. The wire should be rated at 24V, 1A minimum.
SUse Class 2 wiring methods (as defined by the NEC) for interface wiring from
30 to 600V. The wire should be rated at 600V, 1A minimum and 12 AWG
maximum.
SSync Control dry contacts are rated at 250 Vac/Vdc at 6A per contact (maximum
load).
SWhen installing external wiring between the Eaton Sync Control and the UPS or
SSBM, conduit must be installed between the Sync Control and the UPS or SSBM
cabinet.
SThe Eaton Sync Control can be installed up to a maximum of 152.4m (500 ft) from
the Eaton 9390 UPS, Eaton 9395 UPS or Eaton 9395 SSBM system.
CAUTION
When connecting the bypass and load voltage from another model UPS to an Eaton 9390 or Eaton 9395 UPS
using the Eaton Sync Control accessory, use Phase A, Phase B, and Neutral connections from the other UPS.
DO NOT connect the other model UPS Phase C bypass and load voltage to the Sync Control connection point
when connecting to an Eaton 9390 UPS or Eaton 9395 UPS.
2.3 Inspecting and Unpacking the Eaton Sync Control
The unit arrives covered with protective packaging material.
1. Carefully inspect the outer packaging for evidence of damage during transit.
CAUTION
Do not install a damaged cabinet. Report any damage to the carrier and contact your Eaton service
representative immediately.
2. Remove the protective cardboard covering from the Eaton Sync Control by
cutting where indicated using a knife blade no longer than 25 mm (1”).
3. Remove the plastic bag and foam packing material, and discard or recycle them
in a responsible manner.

Eaton 9390 UPS, 9395 UPS, and 9395 SSBM Sync Control Installation and Operation Manual SP-164000052 Rev 2 3-1
Chapter 3 Installation
WARNING
SOnly qualified service personnel (such as a licensed electrician) shall perform the electrical installation. Risk
of electrical shock.
SShut down all sources of power to the Eaton 9390 UPS or Eaton 9395 UPS or SSBM system before
connecting the control wiring to the Eaton Sync Control enclosure and UPS. Hazardous voltages exist inside
the UPS or SSBM and in the Eaton Sync Control enclosure. Check all terminal conductors with a known
serviceable voltmeter before connecting the wiring.
Once the Eaton Sync Control has been moved to its installed location, unpacked, and
inspected, it is ready for installation and wiring.
Use the applicable procedure from the following list to install the Eaton Sync Control
to the UPS:
SWith an Eaton 9390 UPS, proceed to paragraph 3.1.
SWith an Eaton 9395 UPS, proceed to paragraph 3.2.
SWith an Eaton 9395 SSBM, proceed to paragraph 3.3.
3.1 Installation and Wiring with an Eaton 9390 UPS
NOTE When installing wiring connections, conduit must be installed between the Eaton Sync Control and the
UPS cabinet.
To install and wire:
1. Install the Eaton Sync Control panel to the selected mounting location.
See Figure 2‐1 on page 2-2 for mounting hole dimensions and Figure 2‐2 on
page 2-3 for conduit entrance locations.
2. Unfasten the front door latches and swing the door open.
3. Complete all control wiring interconnections using Table 3‐1 for wiring
requirements.
Figure 3‐1 shows the Eaton Sync Control TB1 terminal block and ground terminal
locations. Figure 3‐2 shows the TB1 terminal block wiring detail.
Figure 3‐3 and Figure 3‐4 show the typical locations of the UPS TB1, TB2, and
TB6 interconnect terminal blocks. Figure 3‐5 shows the TB6 detail.
Refer to the applicable Eaton 9390 UPS Installation and Operation Manual listed
in paragraph 1.3 for UPS cabinet terminal locations and assignments, termination
requirements, conduit landing locations, and terminal access instructions.
4. Verify the jumper is installed between Sync Control terminal TB1-40 and TB1-41
(see Figure 3‐2).
5. When all wiring is complete, close the door and secure the latches.
Figure

INSTALLATION
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CAUTION
When connecting the bypass and load voltage from another model UPS to an Eaton 9390 UPS using the Eaton
Sync Control accessory, use Phase A, Phase B, and Neutral connections from the other UPS. DO NOT connect the
other model UPS Phase C bypass and load voltage to the Sync Control connection point when connecting to an
Eaton 9390 UPS.
TB1
Ground
Terminal
Figure 3‐1. Typical Eaton Sync Control Wiring Terminal Locations

INSTALLATION
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Table 3‐1. Eaton 9390 UPS System Control Wiring Interconnections
From UPS System-A To Sync Control Function Note
TB6-1 TB1-4 Bypass Voltage Phase A
14 AWG
Twist Together
TB6-2 TB1-5 Bypass Voltage Phase B
TB6-3 TB1-6 Bypass Voltage Neutral
TB6-4 TB1-13 Output Voltage Phase A
14 AWG
Twist Together
TB6-5 TB1-14 Output Voltage Phase B
TB6-6 TB1-15 Output Voltage Neutral
TB6-9 TB1-17 Bypass Voltage Phase B Return 14 AWG
P5-5 TB1-22 Transfer to Bypass Disable (24 Vdc) 14 AWG
Twist Together
P5-6 TB1-23 Transfer to Bypass Disable Return (24 Vdc)
P5-7 TB1-26 Sync Control Trouble (24 Vdc) 14 AWG
Twist Together
P5-8 TB1-27 Sync Control Trouble Return (24 Vdc)
TB-4 (Relay Interface Card)* TB1-1 On Bypass Common 14 AWG
Twist Together
TB-6 (Relay Interface Card)* TB1-2 On Bypass NO
OR
J2-5 (Industrial Relay Card)* TB1-1 On Bypass Common 14 AWG
Twist Together
J2-6 (Industrial Relay Card)* TB1-2 On Bypass NO
From UPS System-B To Sync Control Function Note
TB6-1 TB1-10 Bypass Voltage Phase A
14 AWG
Twist Together
TB6-2 TB1-11 Bypass Voltage Phase B
TB6-3 TB1-12 Bypass Voltage Neutral
TB6-4 TB1-7 Output Voltage Phase A
14 AWG
Twist Together
TB6-5 TB1-8 Output Voltage Phase B
TB6-6 TB1-9 Output Voltage Neutral
TB6-9 TB1-20 Bypass Voltage Phase B Return 14 AWG
P5-5 TB1-24 Transfer to Bypass Disable (24 Vdc) 14 AWG
Twist Together
P5-6 TB1-25 Transfer to Bypass Disable Return (24 Vdc)
P5-7 TB1-28 Sync Control Trouble (24 Vdc) 14 AWG
Twist Together
P5-8 TB1-29 Sync Control Trouble Return (24 Vdc)
TB-4 (Relay Interface Card)* TB1-1 On Bypass Common 14 AWG
Twist Together
TB-6 (Relay Interface Card)* TB1-3 On Bypass NO
OR
J2-5 (Industrial Relay Card)* TB1-1 On Bypass Common 14 AWG
Twist Together
J2-6 (Industrial Relay Card)* TB1-3 On Bypass NO
* Both relay Interface card (RIC) and the Industrial Relay Card (IRC) shall be set up / verified for RMP by the Eaton Field Service Engineer.

INSTALLATION
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UPS System-A – Bypass Voltage Phase A
UPS System-A – Bypass Voltage Phase B Return
UPS System-A – Bypass Voltage Phase B
UPS System-A – Bypass Voltage Neutral or Phase C for SBM
UPS System-B – Bypass Voltage Phase A
UPS System-B – Bypass Voltage Phase B
UPS System-B – Bypass Voltage Neutral or Phase C for SBM
UPS System-B – Bypass Voltage Phase B Return
UPS System-A – Output Voltage Phase A
UPS System-A – Output Voltage Phase B
UPS System-A – Output Voltage Neutral or Phase C for SBM
UPS System-B – Output Voltage Phase A
UPS System-B – Output Voltage Phase B
UPS System-B – Output Voltage Neutral or Phase C for SBM
On Bypass Common
UPS System-A – On Bypass NO
UPS System-B – On Bypass NO
UPS System-A –
UPS System-A –
UPS System-B –
UPS System-B –
Jumper (Required if using NO contact for On Bypass signal)
Transfer to Bypass Disable
NOTE Any unused Building Alarm(s) may be used.
Transfer to Bypass Disable
UPS System-A –
UPS System-A –
UPS System-B –
UPS System-B –
Sync Control Trouble
Sync Control Trouble
Building
Alarms
Figure 3‐2. Eaton Sync Control TB1 Terminal Block Detail

INSTALLATION
Eaton 9390 UPS, 9395 UPS, and 9395 SSBM Sync Control Installation and Operation Manual SP-164000052 Rev 2 3-5
TB1
TB2
TB6
Mini CSB Building Alarm Terminal Block P5
Figure 3‐3. Eaton 9390 UPS (40–80 kVA) Interface Locations for Eaton Sync Control

INSTALLATION
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TB6
TB1
TB2
Mini CSB Building Alarm Terminal Block P5
Figure 3‐4. Eaton 9390 UPS (100–160 kVA) Interface Locations for Eaton Sync Control