Eaton Powerware 9390 User manual

Powerware 9390 and 9395
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, Powerware, and X−Slot are registered trademarks of Eaton Corporation or its subsidiaries and affiliates. NEC is a registered
trademarks of National Fire Protection Association, Inc. All other trademarks are property of their respective companies.
ECopyright 2005–2009 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 Powerware®9390 and 9395 Sync Control Installation and Operation Manual S164201571 Rev E www.powerware.com 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 Powerware Sync Control Wiring Preparation 2−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Inspecting and Unpacking the Powerware Sync Control 2−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Powerware Sync Control Installation 3−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Installation and Wiring with a Powerware 9390 UPS 3−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Installation and Wiring with a Powerware 9395 UPS 3−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Powerware Sync Control Operating Instructions 4−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Startup for UPS Systems Equipped with a Powerware Sync Control 4−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Understanding Powerware Sync Control Operation 4−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Operation 4−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Customer Monitoring 4−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Maintenance Operations 4−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Warranty 5−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS
EATON Powerware®9390 and 9395 Sync Control Installation and Operation Manual S164201571 Rev E www.powerware.com
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List of Figures
Figure 1-1. Powerware Sync Control 1−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-2. Powerware Sync Control with Door Open 1−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-1. Powerware Sync Control Dimensions – Front View 2−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-2. Powerware Sync Control Dimensions – Side Views 2−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-1. Powerware Sync Control Typical Control Wiring Termination Locations 3−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-2. Powerware Sync Control TB1 Terminal Block Detail 3−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-3. Powerware 9390 UPS (40–80 kVA) Interface Locations for Powerware Sync Control 3−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-4. Powerware 9390 UPS (100–160 kVA) Interface Locations for Powerware Sync Control 3−6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-5. TB6 Terminal Block Detail 3−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-6. Powerware 9395 UPS (225–275 kVA) Interface Locations for Powerware Sync Control 3−9. . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-7. Powerware 9395 UPS and Plus 1 UPS (450–550 kVA) Interface Locations for Powerware Sync Control 3−10. . . . . . . . . . . . . . . .
Figure 3-8. Powerware 9395 UPS and Plus 1 UPS (650–825 kVA) Interface Locations for Powerware Sync Control 3−11. . . . . . . . . . . . . . . .
Figure 3-9. Powerware 9395 UPS (1000–1100 kVA) Interface Locations for Powerware Sync Control 3−12. . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-10. Relay Interface Card 3−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-11. Relay Interface Card Terminals 3−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-1. Typical Powerware Sync Control Block Diagram with a Powerware 9390 or Powerware 9395 UPS System 4−2. . . . . . . . . . . . .
Figure 4-2. Synchronization Reference Control 4−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 4-3. Powerware Sync Control Controls and Indicators 4−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EATON Powerware®9390 and 9395 Sync Control Installation and Operation Manual S164201571 Rev E www.powerware.com 1−1
Chapter 1 Introduction
Eaton’s Powerware®Sync Control maintains the critical load outputs of either two
separate single Powerware 9390 UPS systems or two separate single Powerware
9395 UPS systems in synchronization. Use of the Powerware 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.
The Powerware Sync Control can provide customer remote monitoring of sync
control operation and alarms. See section 4.4 for detailed information.
Figure 1-1 shows the front view and Figure 1-2 shows the interior view of the
Powerware Sync Control.
Figure 1-1. Powerware Sync Control
Figure 1Table 1

INTRODUCTION
EATON Powerware®9390 and 9395 Sync Control Installation and Operation Manual S164201571 Rev E www.powerware.com
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Figure 1-2. Powerware 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 Powerware®9390 and 9395 Sync Control Installation and Operation Manual S164201571 Rev E www.powerware.com 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 and batteries. Please read all instructions before operating the equipment and save this manual for
future reference.
The UPS cabinet is designed for industrial or computer room applications, and contains safety shields behind
the doors. However, the UPS system is a sophisticated power system and should be handled with
appropriate care.
DANGER
This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by AUTHORIZED
SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS inside the UPS.
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 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). The system is not intended for
outdoor use.
SEnsure all power is disconnected before performing installation or service.
CAUTION
SKeep the UPS doors closed to ensure proper cooling airflow and to protect personnel from dangerous
voltages inside the unit.
SDo not operate the UPS system 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 Powerware®9390 and 9395 Sync Control Installation and Operation Manual S164201571 Rev E www.powerware.com
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1.3 For More Information
Refer to the followong manuals for additional information:
SPowerware 9390 UPS (40–80 kVA) Installation and Operation Manual
SPowerware 9390 UPS (100–160 kVA) Installation and Operation Manual
SPowerware 9395 UPS (225–275 kVA) Installation and Operation Manual
SPowerware 9395 Plus 1 UPS (225–275 kVA) Installation and Operation Manual
SPowerware 9395 UPS (300 kVA) Installation and Operation Manual
SPowerware 9395 550/275 UPS (225–550 kVA) Installation and Operation Manual
SPowerware 9395 UPS and Plus 1 UPS (450–550 kVA) Installation and Operation
Manual
SPowerware 9395 UPS and Plus 1 UPS (650–825 kVA) Installation and Operation
Manual
SPowerware 9395 UPS (1000–1100 kVA) Installation and Operation Manual
These manuals describe:
SUPS 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 operation, including UPS cabinet controls, functions of the UPS, standard
features and optional accessories, procedures for starting and stopping the UPS,
and information about maintenance and responding to system events.
SCommunication capabilities of the UPS system.
Visit www.powerware.com 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 Eaton Help Desk for Eaton Corporation products 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 Powerware®9390 and 9395 Sync Control Installation and Operation Manual S164201571 Rev E www.powerware.com 2−1
Chapter 2 Installation Plan and Unpacking
The Powerware 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 Powerware Sync Control to operate at peak efficiency, the installation site
should meet the environmental parameters outlined in the applicable Powerware
9390 or Powerware 9395 UPS Installation and Operation Manual listed in
paragraph 1.3.
2.2.1 Environmental and Installation Considerations
The life of the Powerware 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
Powerware Sync Control 45.4 (100) 36.3 (80)
Figure 2Table 2

INSTALLATION PLAN AND UNPACKING
EATON Powerware®9390 and 9395 Sync Control Installation and Operation Manual S164201571 Rev E www.powerware.com
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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. Powerware Sync Control Dimensions – Front View