Eaton Powerware 9395 User manual

Eaton 9395 High Performance*
Installation and Operation Manual
®
Sync Control
Installation and Operation Manual
*Referenced throughout as 9395P

Eaton 9395 High Performance*
Installation and Operation Manual
®
Sync Control
Installation and Operation Manual
*Referenced throughout as 9395P

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 2015 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 Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1 i
Table of Contents
List of Figures ii..............................................
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 2-5..............................................................
3 Installation 3-1.............................................................................
3.1 Installation and Wiring with an Eaton 9395P UPS 3-1...............................................................
3.2 Installation and Wiring with an Eaton 9395P SBM 3-10..............................................................
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
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1
ii
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 3-3..................................................
Figure 3‐2. Eaton Sync Control TB1 Terminal Block Detail 3-5........................................................
Figure 3‐3. TB6 Terminal Block Detail 3-6......................................................................
Figure 3‐4. Mini CSB Interface Terminals 3-6....................................................................
Figure 3‐5. Eaton 9395P UPS Interface Locations for Eaton Sync Control 3-7..............................................
Figure 3‐6. Relay Interface Card End View 3-8...................................................................
Figure 3‐7. Relay Interface Card Terminals 3-8...................................................................
Figure 3‐8. Industrial Relay Card 3-9..........................................................................
Figure 3‐9. SBM Control Pan Interface Terminal Locations 3-12........................................................
Figure 3‐10. TB1 and TB2 Interface Terminal Detail 3-13.............................................................
Figure 3‐11. TB4 and TB5 Interface Terminal Detail 3-13.............................................................
Figure 3‐12. Terminal Block TB2 Connector Assignments 3-14.........................................................
Figure 3‐13. Terminal Block TB3 Connector Assignments 3-14.........................................................
Figure 3‐14. SBM to UPS Interconnection System Control Wiring 3-15...................................................
Figure 4‐1. Typical Eaton Sync Control Block Diagram with a Eaton 9395P 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 Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1 1-1
Chapter 1 Introduction
The Eaton®Sync Control maintains the critical load outputs of two separate single
Eaton 9395P 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
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1
1-2
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
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1 1-3
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.
DANGER!
Cet onduleur peut générer des TENSIONS MORTELLES. L’installation et l’entretien ne doivent être
effectués que par le PERSONNEL AUTORISÉ. Ne contient AUCUNE PIÈCE REMPLAÇABLE.
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.
AVERTISSEMENT!
SL’onduleur est alimenté par sa propre source d’énergie (batteries). Les bornes de sortie peuvent être sous
tension, même lorsque l’onduleur est débranché d’une source de courant alternatif.
SPour réduire les risques d’incendie et de décharge électrique, installer l’onduleur à l’intérieur, dans un
endroit exempt d’éléments conducteurs et où la température et l’humidité sont régulées. La température
ambiante ne doit pas dépasser 40C (104F). Ne pas faire fonctionner près d’une source d’eau ou dans
un endroit très humide (95 % maximum). Le système n’est pas conçu pour une utilisation extérieure.
SToutes les sources d’alimentation doivent être débranchées avant de procéder à l’installation et à
l’entretien.
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
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1
1-4
MISE EN GARDE!
SGarder les portes de l’onduleur fermées pour garantir une circulation adéquate de l’air de refroidissement
et pour protéger le personnel des tensions dangereuses dans l’unité.
SNe pas installer ni faire fonctionner l’onduleur près d’une source de chaleur au gaz ou à l’électricité.
SLe milieu de fonctionnement doit toujours correspondre aux paramètres établis dans ce manuel.
SMaintenir les lieux rangés, propres et exempts d’une humidité excessive.
SRespecter les étiquettes DANGER, MISE EN GARDE et AVERTISSEMENT se trouvant à l’intérieur et à
l’extérieur de l’équipement.
1.3 For More Information
SEaton Power Xpert 9395P (675–900 kVA) Installation and Operation Manual
SEaton Power Xpert 9395P (1000–1200 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 Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1 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 9395P 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 43.0 (94.7) 33.8 (74.7)
Figure

INSTALLATION PLAN AND UNPACKING
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1
2-2
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
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1 2-3
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
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1
2-4
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 9395P UPS, and Table 3‐3 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 9395P UPS or Eaton 9395 SSBM system.
CAUTION
When connecting the bypass and load voltage from another model UPS to an Eaton 9395P 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 9395P UPS.
MISE EN GARDE!
Lorsque vous connectez le dispositif de dérivation et la tension de la charge d’un autre modèle d’UPS à un
onduleur UPS 9395 d’Eaton à l’aide du module Sync Control d’Eaton, utilisez la phase A, la phase B et la
connexion du neutre de l’autre UPS. NE connectez PAS le dispositif de dérivation et la tension de la charge
de la phase C de l’autre modèle d’UPS au point de raccordement du Sync Control lors de la connexion à l'UPS
9395 d’Eaton.

INSTALLATION PLAN AND UNPACKING
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1 2-5
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.
MISE EN GARDE!
Ne pas installer une armoire endommagée. Signaler les dommages au transporteur et communiquer avec un
représentant du service Eaton immédiatement.
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.

INSTALLATION PLAN AND UNPACKING
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Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1 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 9395P 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.
AVERTISSEMENT!
SSeul le personnel qualifié, comme les électriciens agréés, peut effectuer l’installation électrique. Risque
d’électrocution.
SCouper toutes les sources d’alimentation de chaque UPS avant de connecter le câblage de commande à
l’enveloppe du module Sync Control et à l’UPS d’Eaton. Des tensions dangereuses sont présentes dans l’UPS
ou le SSBM et dans l’enveloppe du Sync Control d’Eaton.
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 9395P UPS, proceed to paragraph 3.1.
SWith an Eaton 9395 SSBM, proceed to paragraph 3.2.
3.1 Installation and Wiring with an Eaton 9395P 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 3‐5 shows the typical locations of the UPS TB3, TB6, and X-Slot®
Communication bays. Figure 3‐3 shows the TB6 detail.
Refer to the applicable Eaton 9395P UPS Installation and Operation Manual listed
in paragraph 1.3 on page 1-4 for UPS cabinet terminal locations and assignments,
termination requirements, conduit landing locations, and terminal access
instructions.
Figure

INSTALLATION
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1
3-2
NOTE Complete the wiring to the X-Slot Relay Interface Card or Industrial Relay Card terminals before
installing the cards in the Communication Bay in each of the UPS cabinets.
4. Route wires through the strain relief bushing and connect to the terminals on the
X-Slot Relay Interface Card in each of the UPS cabinets (see Figure 3‐8).
5. Install the X-Slot Relay Interface Card or Industrial Relay Card into an open X-Slot
communication bay on the front of the UPS (see Figure 3‐5). Refer to the
applicable Eaton 9395P UPS Installation and Operation Manual listed in
paragraph 1.3 on for UPS cabinet access instructions.
6. Verify the jumper is installed between Sync Control terminal TB1-40 and TB1-41
(see Figure 3‐2).
7. When all wiring is complete, close the door and secure the latch.
CAUTION
When connecting the bypass and load voltage from another model UPS to a Eaton 9395P 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 9395P UPS.
MISE EN GARDE!
Lorsquevous connectez le dispositif de dérivation et la tension de la charge d’un autre modèle d’UPS à un
onduleur UPS 9395 d’Eaton à l’aide du module Sync Control d’Eaton, utilisez la phase A, la phase B et la
connexion du neutre de l’autre UPS. NE connectez PAS le dispositif de dérivation et la tension de la charge de la
phase C de l’autre modèle d’UPS au point de raccordement du Sync Control lors de la connexion à l'UPS 9395
d’Eaton.

INSTALLATION
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1 3-3
TB1
Ground
Terminal
Figure 3‐1. Typical Eaton Sync Control Wiring Terminal Locations

INSTALLATION
Eaton Power Xpert™9395P Sync Control Installation and Operation Manual SP-164000502 Rev 1
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Table 3‐1. Eaton 9395P 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 Phase C
TB6-5 TB1-13 Output Voltage Phase A
14 AWG
Twist Together
TB6-6 TB1-14 Output Voltage Phase B
TB6-7 TB1-15 Output Voltage Phase C
TB6-8 TB1-16 Bypass Voltage Phase A Return
14 AWG
Twist Together
TB6-9 TB1-17 Bypass Voltage Phase B Return
TB6-10 TB1-18 Bypass Voltage Phase C Return
TB3-1 TB1-22 Transfer to Bypass Disable (24 Vdc) 14 AWG
Twist Together
TB3-2 TB1-23 Transfer to Bypass Disable Return (24 Vdc)
TB3-3 TB1-26 Sync Control Trouble (24 Vdc) 14 AWG
Twist Together
TB3-4 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 Phase C
TB6-5 TB1-7 Output Voltage Phase A
14 AWG
Twist Together
TB6-6 TB1-8 Output Voltage Phase B
TB6-7 TB1-9 Output Voltage Phase C
TB6-8 TB1-19 Bypass Voltage Phase A Return
14 AWG
Twist Together
TB6-9 TB1-20 Bypass Voltage Phase B Return
TB6-10 TB1-21 Bypass Voltage Phase C Return
TB3-1 TB1-24 Transfer to Bypass Disable (24 Vdc) 14 AWG
Twist Together
TB3-2 TB1-25 Transfer to Bypass Disable Return (24 Vdc)
TB3-3 TB1-28 Sync Control Trouble (24 Vdc) 14 AWG
Twist Together
TB3-4 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.