Eaton 91PS Manual

User’s and Installation
Guide
Eaton 91PS/93PS UPS 8–40 kW
P-164000493

Approvals and version history
REVI-
SION DATE DESCRIPTION OF CHANGE APPROVED BY
001 17.04.2015 First issue Otto Asunmaa
002 06.07.2015 Minor updates Otto Asunmaa
003 14.07.2016 Updated to cover 93PS 8–20 kW
UPS C-model
Otto Asunmaa
004 28.05.2018 Minor updates. Recommended
secure hardening guidelines
added.
Otto Asunmaa
005 12.09.2018 91PS addition Otto Asunmaa
006 08.04.2020 Environmental and installation
considerations updated. MiniSlot
cards changed.
Otto Asunmaa
These are the original instructions.
Copyright © 2020 Eaton Corporation plc. All rights reserved.
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.
This is a product for commercial and industrial application in the second environment.
Installation restrictions or additional measures may be needed to prevent disturbances.
The contents of this manual are the copyright of the publisher and may not be
reproduced (even extracts) without the written approval of Eaton Corporation. Every care
has been taken to ensure the accuracy of the information contained in this manual, but
no liability can be accepted for any errors or omission. The right to make design
modifications is reserved.
Unauthorized copying and lending are prohibited.
Eaton Power Quality Oy
Address: Koskelontie 13
FI-02920 Espoo
FINLAND
Internet: www.eaton.eu
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 2 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

Contents
1 How to read this manual .............................................................7
1.1 Safety-related signs......................................................... 7
1.2 Symbols and abbreviations ............................................... 7
1.3 Conventions used in this document................................... 10
1.4 Glossary ..................................................................... 10
2 Safety instructions .................................................................. 12
2.1 Safety instructions......................................................... 12
2.2 Audience..................................................................... 14
2.3 CE marking ................................................................. 15
2.4 User precautions .......................................................... 15
2.5 Environment ................................................................ 16
2.6 Symbols on the UPS and accessories ............................... 16
2.7 For more information ..................................................... 17
3 Introduction to Eaton UPS ........................................................ 18
3.1 About the Eaton UPS..................................................... 18
3.2 Looking inside the UPS system ........................................ 19
3.3 UPS operating modes.................................................... 21
3.3.1 Normal operating modes ..................................... 22
3.3.2 Stored energy and battery mode ........................... 26
3.3.3 Bypass mode.................................................... 27
3.4 UPS features ............................................................... 29
3.4.1 Advanced Battery Management............................ 29
3.4.2 Powerware Hot Sync.......................................... 29
3.4.3 Power Conditioner ............................................. 30
3.4.4 Frequency Converter.......................................... 30
3.5 Software and connectivity features ................................... 30
3.5.1 User interface ................................................... 30
3.5.2 Power Management Software .............................. 31
3.6 Options and accessories ................................................ 31
3.6.1 Maintenance Bypass Switch (optional) ................... 31
3.6.2 Field Installed UPM (accessory)............................ 31
3.7 Battery system ............................................................. 32
3.8 Basic system configurations ............................................ 32
4 UPS installation plan and unpacking.......................................... 35
4.1 About UPS installation ................................................... 35
4.2 Create an installation plan............................................... 35
4.3 Installation checklist ...................................................... 35
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 3 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

4.4 Site preparations .......................................................... 37
4.4.1 Environmental considerations .............................. 37
4.4.2 Installation considerations ................................... 38
4.4.3 UPS system power wiring preparations .................. 42
4.5 Unpack and unload the UPS ........................................... 55
5 UPS system installation............................................................ 60
5.1 About UPS system installation ......................................... 60
5.2 Steps to install the UPS.................................................. 61
5.3 Battery system installation .............................................. 63
5.3.1 Battery trip wiring............................................... 64
5.4 Installing UPS external battery cabinet and battery power
cabling........................................................................ 65
5.5 Install a remote EPO switch............................................. 66
5.6 Installing interface connections ........................................ 67
5.6.1 Installing customer input signals interface ............... 67
5.6.2 Battery breaker wiring interface ............................ 68
5.6.3 Relay output interface connections ........................ 68
5.6.4 Industrial Relay Card interface connections............. 68
5.6.5 MiniSlot interface connections .............................. 69
5.6.6 Installing signal interface connections in a parallel
system ............................................................ 69
5.7 Wiring parallel 91PS/93PS UPS systems ........................... 70
5.7.1 Power wiring overview ........................................ 70
5.7.2 Control signals overview ..................................... 73
5.7.3 Installing parallel control wiring ............................. 73
5.8 UPS system interface wiring preparation ............................ 75
6 Communication interfaces ........................................................ 77
6.1 About communication interfaces....................................... 77
6.2 Native signal terminals ................................................... 78
6.3 MiniSlot cards .............................................................. 79
6.4 Intelligent Power Software .............................................. 81
6.5 Signal input monitoring................................................... 82
6.6 General purpose relay contact ......................................... 82
6.7 Configuring relays ......................................................... 83
7 UPS operating instructions....................................................... 88
7.1 How to operate the UPS ................................................. 88
7.2 UPS controls and indicators ............................................ 88
7.2.1 Control panel .................................................... 88
7.2.2 Status indicators................................................ 89
7.2.3 Color LED indicators .......................................... 90
7.2.4 System events .................................................. 91
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 4 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

7.2.5 Menu structure of the 91PS/93PS UPS .................. 91
7.3 Signing in .................................................................... 94
7.4 System control instructions ............................................. 95
7.4.1 Starting the UPS system in the double conversion
mode .............................................................. 95
7.4.2 Start the UPS system in the bypass mode............... 96
7.4.3 Transfer from the double conversion mode to the
bypass mode .................................................... 96
7.4.4 Transfer from the bypass mode to the double
conversion mode ............................................... 97
7.4.5 Transferring from the double conversion mode to the
Energy Saver System mode................................. 97
7.4.6 Transferring from the Energy Saver System mode to the
double conversion mode ..................................... 97
7.4.7 Transferring from the double conversion mode to the
Variable Module Management System mode ........... 98
7.4.8 Transferring from the Variable Module Management
System mode to the double conversion mode .......... 98
7.4.9 Shutting down the UPS system and critical load ....... 99
7.4.10 De-energizing the critical load .............................. 99
7.5 UPS control instructions ............................................... 100
7.5.1 Starting a single UPS ....................................... 100
7.5.2 Shut down a single UPS.................................... 101
7.5.3 Enable and disable the battery charger................. 101
7.6 UPM control instructions............................................... 101
7.6.1 Starting the UPMs ........................................... 101
7.6.2 Shut down the UPMs........................................ 102
7.7 Using the Remote Emergency Power-off switch................. 103
7.8 Turning the UPS from the double conversion mode to the
maintenance bypass mode ........................................... 104
7.9 Turning the UPS from the maintenance bypass mode to the
double conversion mode............................................... 105
8 UPS maintenance .................................................................. 108
8.1 Introduction to UPS maintenance ................................... 108
8.2 Important safety instructions.......................................... 108
8.3 Preventive maintenance ............................................... 109
8.3.1 Daily maintenance ............................................110
8.3.2 Monthly maintenance ........................................110
8.3.3 Periodic maintenance ........................................110
8.3.4 Annual maintenance ......................................... 111
8.3.5 Battery maintenance ......................................... 111
8.4 Recycling the used UPS or batteries ................................ 111
8.5 Maintenance training ....................................................112
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 5 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

9 Technical data........................................................................113
9.1 About technical data .....................................................113
9.2 Directives and standards ...............................................113
9.3 UPS system input ........................................................114
9.4 UPS system output.......................................................115
9.5 UPS environmental specifications....................................116
9.6 Battery specification .....................................................117
10 Warranty ...............................................................................118
10.1 General information about warranty .................................118
10.2 Whom to contact in case of Warranty ...............................119
APPENDIX A: Recommended secure hardening guidelines.................. 120
Index............................................................................................. 124
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 6 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

1 How to read this manual
1.1 Safety-related signs
These are the safety-related signs used in this document.
DANGER
DANGER indicates a hazard with a high level of risk which, if not
avoided, will result in serious injury or death.
WARNING
WARNING indicates a hazard with a medium level of risk which, if not
avoided, could result in serious injury or death, or damage to the
machine.
CAUTION
CAUTION indicates a hazard with a low level of risk which, if not
avoided, could result in minor or moderate injury, or damage to the
machine.
NOTE: Notes are used to indicate important information and useful tips.
1.2 Symbols and abbreviations
Hazard symbols
These symbols indicate a hazardous situation or action. Symbols are used to
warn of situations, which can cause environmental damage and personal injury.
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 7 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

General warning sign
Explosion and fire hazard
Battery hazard
Corrosive hazard
Electrical hazard
Prohibited action symbols
These symbols are used in warnings and notifications to indicate an action that
should not be taken. The prohibited action symbols are shown below.
No smoking
Limited or restricted access
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 8 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

General symbol for prohibited action
Do not touch
Mandatory action symbols
These symbols are used in warnings and notifications to indicate an action that
must be taken. The mandatory action symbols are shown below.
Wear eye protection
General symbol for mandatory action
Read the manual or instructions
Disconnect from power source
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 9 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

First aid
Pb
Batteries marked with this sign must be recycled
1.3 Conventions used in this document
This document uses the following type conventions:
Bold 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.
Italic type highlights notes and new terms when they are defined.
Screen type represents information that appears on the screen or LCD.
1.4 Glossary
The following acronyms are used in Eaton documentation to refer to Eaton UPS
products or their parts.
Table 1: Glossary of acronyms
ABM Advanced Battery Management
BIB Bypass Input Breaker
BIS Bypass Input Switch
EBC External Battery Cabinet
EMBS External Maintenance Bypass Switch
EPO Emergency Power-Off
ESS Energy Saver System
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 10 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

IPM Intelligent Power Manager
IPP Intelligent Power Protector
MBP Maintenance Bypass
MBS Maintenance Bypass Switch
MCB Miniature Circuit Breaker
MIS Maintenance Isolation Switch
MOB Module Output Breaker
REPO Remote Emergency Power-Off
RIB Rectifier Input Breaker
RIS Rectifier Input Switch
SCR Silicon-Controlled Rectifier
STSW Static Switch
UPS Uninterruptible Power Supply
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 11 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

2 Safety instructions
2.1 Safety instructions
DANGER
Important safety instructions
Keep these instructions
This document contains important instructions that must be followed during the
installation, operation and maintenance of the UPS and the batteries. Read all of
the instructions before operating the equipment. Keep this manual for future
reference. These instructions are also available for download at www.eaton.com/
91psand93ps.
DANGER
Operations inside the UPS must be performed by an authorized Eaton
Field Service Engineer or by other qualified service personnel
authorized by Eaton. There are no user-serviceable parts inside the UPS.
The UPS operates with mains, battery or bypass power. It contains components
that carry high currents and voltage. A properly installed enclosure is earthed and
IP20 rated against electrical shock and foreign objects. However, the UPS is a
sophisticated power system and only qualified personnel can install and service
it.
DANGER
This UPS carries lethal voltages. All repairs and service must be
performed by authorized personnel only. There are no user-serviceable
parts inside the UPS.
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 12 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

WARNING
The UPS is powered by its own energy source (batteries). The output
terminals may be energized even when the UPS is disconnected from an
AC source. To reduce the risk of fire or electric shock, install this UPS in
a temperature and humidity controlled, indoor environment that is free
of conductive contaminants.
The ambient temperature must not exceed 40 °C (104 °F, non-
condensing conditions). Do not operate the UPS near water or excessive
humidity (95% relative humidity maximum). The system is not intended
for outdoor use.
Before you start any installation or service work, make sure that all AC
and DC power sources are disconnected. Power may come from multiple
sources. Also ensure system grounding / PE continuity.
In a parallel system, the output terminals may be energized even when
the UPS is turned off.
WARNING
Batteries present a risk of electrical shock or burn from high short-
circuit current. Obey proper precautions.
Electric energy hazard. Do not attempt to alter any battery wiring or
connectors. Attempting to alter wiring can cause injury.
Do not open or mutilate batteries. Released electrolyte may be toxic and
is harmful to the skin and eyes.
Batteries may contain HIGH VOLTAGES, and CORROSIVE, TOXIC and
EXPLOSIVE substances. Because of the battery string the output
receptacles may carry high voltage even when the AC supply is not
connected to the UPS. Read the shutdown instructions carefully.
IMPORTANT: The battery may consist of multiple parallel strings. Make
sure that you disconnect all strings before installation.
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 13 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

CAUTION
Only qualified service personnel knowledgeable of batteries and the
required precautions can do installation or service work on batteries.
Keep unauthorized personnel away from the batteries. Before you install
or replace batteries, consider all the warnings, cautions, and notes
concerning appropriate handling. Do not disconnect the batteries when
the UPS is in the Battery mode.
Make sure that your replacement batteries are of the same number and
type as the battery that was originally installed in the UPS. See more
accurate instructions on the UPS.
Before you connect or disconnect battery terminals, disconnect the
charging source by opening the corresponding battery circuit breaker.
Examine if the battery is inadvertently grounded. If it is, remove the
source of the ground. Contacting any part of a grounded battery can
cause a risk of electric shock. If you disconnect the grounding
connection before you work on the batteries, the risk of an electric
shock is less likely.
Discard batteries according to your local disposal requirements. Do not
dispose of batteries in a fire. When exposed to flame, batteries may
explode.
To ensure proper cooling airflow and to protect personnel from
dangerous voltages inside the unit, keep the UPS door closed and the
front panels installed.
Do not install or operate the UPS system close to gas or electric heat
sources. Keep the operating environment within the parameters stated
in this document.
CAUTION
Keep the surroundings of the UPS uncluttered, clean, and free from
excess moisture.
Obey all DANGER, CAUTION, and WARNING notices affixed to the
equipment.
2.2 Audience
The intended audience of this document are as follows:
•People who plan and do the installation of the UPS
•People who use the UPS
This document provides guidelines for how to examine the UPS delivery and how
install and operate the UPS.
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 14 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

The reader is expected to know the fundamentals of electricity, wiring, electrical
components and electrical schematic symbols. This document is written for a
global reader.
CAUTION
Read this document before you start to operate or do work on the UPS.
2.3 CE marking
The product has a CE marking in compliance with the following European
directives:
•LVD Directive (Safety) 2014/35/EU
•EMC Directive 2014/30/EU
•RoHS Directive 2011/65/EU
Declarations of conformity with UPS harmonized standards and directives EN
62040-1 (Safety), EN 62040-2 (EMC) and EN 50581 (RoHS) are available at
www.eaton.eu or by contacting your nearest Eaton office or authorized partner.
2.4 User precautions
The only permitted user operations are as follows:
•Startup and shutdown of the UPS, excluding the commissioning startup.
•Use of the LCD control panel and the Maintenance Bypass Switch (MBS).
•Use of optional connectivity modules and their software.
Follow the precautions and only perform the described operations. Any deviation
from the instructions can be dangerous to the user or cause accidental load loss.
DANGER
Do not open any other screws in the unit than those holding the cover
plates of the MiniSlots and the MBS locking plate. Failure to recognize
the electrical hazards can prove fatal.
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 15 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

CAUTION
The 8-40 kW models are available as a C2 UPS product in regard to
emissions and a C3 UPS product in regard to immunity. The UPS can be
placed both in residential and commercial or industrial environments.
When included in a residential environment, this product may cause
radio interference, in which case you may have to take additional
preventive measures.
2.5 Environment
The UPS must be installed according to the recommendations in this document.
Never install the UPS in an airtight room, in the presence of flammable gases, or
in an environment exceeding the specifications.
Excessive amount of dust in the operating environment of the UPS may cause
damage or lead to malfunction. Always protect the UPS from the outside weather
and sunshine. In order to maximize internal battery service life time, the
recommended operating temperature range is from +20 ºC to +25 ºC.
WARNING
During charge, float charge, heavy discharge, and overcharge, hydrogen
and oxygen gases are emitted from lead-acid and NiCd batteries into the
surrounding atmosphere. Explosive gas mixture may be created if the
hydrogen concentration exceeds 4% by volume in air. Ensure the
necessary air flow rate for the ventilation of the UPS location.
2.6 Symbols on the UPS and accessories
The following are examples of symbols used on the UPS or its accessories. The
symbols are used to alert you of important information.
RISK OF ELECTRIC SHOCK
Indicates that a risk of electric shock is present and the associated warning
should be observed.
CAUTION: REFER TO OPERATOR'S MANUAL
Refer to your operator's manual for additional information, such as
important operating and maintenance instructions.
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 16 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

Pb
This symbol indicates that you may not discard the UPS or the UPS
batteries in the trash. This product involves sealed, lead-acid batter- ies
and they must be disposed of properly. For more information, contact your
local recycling / reuse or hazardous waste center.
This symbol indicates that you may not discard waste electrical or
electronic equipment (WEEE) in the trash. For proper disposal, contact
your local recycling / reuse or hazardous waste center.
2.7 For more information
Address any inquiries about the UPS and the battery cabinet to the local office or
an agent authorized by the manufacturer. Quote the type code and the serial
number of the equipment.
Contact your local service representative if you need help with any of the
following.
•scheduling initial startup
•regional locations and telephone numbers
•a question about any of the information in this manual
•a question that this manual does not answer
NOTE: For more information about the installation space, safe operation and
working, see IEC 62485-2: Safety requirements for secondary batteries and
battery installations.
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 17 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

3 Introduction to Eaton UPS
3.1 About the Eaton UPS
Figure 1: 15/20 kW C-model frame, 15/20 kW standard frame and 30/40 kW
frame
The Eaton® 91PS/93PS uninterruptible power supply (UPS) is a true online,
continuous-duty, transformerless, double-conversion, solid-state single-phase
(91PS) or three-phase (93PS) system. It supplies conditioned and uninterruptible
AC power to critical load and protects it from power failures.
The UPS is used to prevent loss of valuable electronic information, minimize
equipment downtime, and minimize the adverse effect on production equipment
due to unexpected power problems.
The Eaton UPS continually monitors incoming electrical power and removes the
surges, spikes, sags, and other irregularities that are inherent in commercial
utility power. Working with a building’s electrical system, the UPS system
supplies clean, consistent power that sensitive electronic equipment require for
reliable operation. During brownouts, blackouts, and other power interruptions,
batteries provide emergency power to safeguard operation.
The UPS system is housed in a single, free-standing cabinet with safety shields
behind the door for protection against hazardous voltage. Each UPS cabinet has
a centralized system static bypass. The available static bypass ratings are 15
and 30 kW for 91PS and 20 kW and 40 kW for 93PS. The static bypass size is
chosen according to UPS system power. For example, if a future requirement is
to upgrade the UPS capacity, the UPS bypass rating has to be selected
accordingly. In addition, the bypass ratings of all the UPS cabinets in a parallel
system need to be matched.
Eaton 91PS/93PS output power ratings are based on 15 kW or 20 kW rated
uninterruptible power modules (UPMs).
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 18 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

91PS/93PS is also available as a C-model, which consists of the electrical part of
the 91PS/93PS UPS 15/20 kW frame without the battery compartment.
Table 2: UPS frames and UPMs
UPS frame Number of UPMs Ratings
91PS 15 kW 1 8, 10, 15 kW
91PS 30 kW 1 or 2 8, 10, 15, 20, 30 kW
93PS 20 kW 1 8, 10, 15 or 20 kW
93PS 40 kW 1 or 2 8, 10, 15, 20, 30 or
40 kW
UPM includes a rectifier, inverter, battery converter, and independent controls.
Each UPM is able to operate independently from the other power modules.
NOTE: Startup and operational checks must be done by an authorized Eaton
Customer Service Engineer or by other qualified service personnel authorized by
Eaton, or the terms specified in the Warranty (see 10.1 General information
about warranty) 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.
3.2 Looking inside the UPS system
Figure 2: Looking inside the 15/20 kW standard and C-model frames
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 19 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide

Figure 3: Looking inside the 30/40 kW frame
1. Control panel
2. Door latch
3. Power module (UPM)
4. Internal battery (not included
in the C- model)
5. Communications area
6. Input switch (optional in some
regions)
7. Battery breaker for internal
batteries *
8. Maintenance bypass switch
(optional)
*) In the C-model for external batteries
The system level static bypass in the UPS cabinet determines the attainable
output power of the UPS. The static bypass line consists of a static switch and a
backfeed protection isolation device connected in series. In addition, there is a
system level control unit that constantly monitors the power delivered through the
bypass line or to the input of the UPS. Transfers to static bypass are seamless
and performed automatically by the system as needed, for example, in case of an
extended system overload.
Each UPM includes a rectifier, battery converter, inverter and independent
controls. Each UPM is able to operate and share the load independently, despite
the status of the other UPMs.
In addition, the system can have a UPS-internal maintenance bypass switch as a
factory-installed option.
Table 3: UPS configurations
UPS frame Number of UPMs Static switch [kW] Internal battery
93PS 20 kW 1 20 Yes
93PS 20 kW C-
model
1 20 No
93PS 40 kW 1 or 2 40 Yes
91PS 15 kW 1 15 Yes
© Eaton Corporation plc 2020. All rights reserved. Revision: 006 Document ID: P-164000493 20 (126)
Eaton 91PS/93PS UPS 8–40 kW User’s and Installation Guide