Eaton Powerware 9x55 series Manual

p/n:
Revision 1
9x55 8–15 kVA Battery Upgrade
For use with the Eaton®9155 and 9355 (8–15 kVA)
Powerware Series

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©Copyri ht 2017 Eaton, Ralei h, NC, USA. All ri hts reserved. No part of this document may be reproduced in any way without the
express written approval of Eaton.
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 de la PDU. Veuillez consulter entièrement ces instructions
avant de faire fonctionner l équipement et conserver ce manuel afin de pouvoir vous y reporter
ultérieurement.

9x55 8–15 kVA Battery Up rade (8–15 kVA) —Rev 1 iii
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iv 9x55 8–15 kVA Battery Up rade (8–15 kVA) —Rev 1
Table of Contents

9x55 8–15 kVA Battery Up rade (8–15 kVA) —Rev 1 1
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Eaton has designed a new harness (see Figure 16) for the battery trays within the 9X55 8-15KVA products as an
effort to provide arc flash mitigation. Battery trays should be replaced to include the adapter on every battery
shelf. This adapter is included in models starting in September 2016. Older models require this battery
upgrade.
Prior to the upgrade, the two battery trays in a shelf are oriented in opposite directions. The positive terminal of
the left tray is to the front of the unit while the negative terminal of the right tray is in the front. After this
upgrade, all trays will be oriented with the positive terminals to the front.
Installing the new adapter requires that you cut the existing terminals off of the red and black wires on the front
of the battery shelf, strip the wire back 1/4 inch, install and crimp the new adapter onto the wires, and add
shrink wrap over the crimped terminal.

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Introduction

9x55 8–15 kVA Battery Up rade (8–15 kVA) —Rev 1 3
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WARNING
This procedure involves interacting with components that may be energized.
Any and all work can involve hazards when working on electrical equipment. The work must be done in
accordance with all applicable local, federal, or other safety requirements and must be performed by qualified
personnel.
!
IMPORTANT
In the event of input power failure while performing this procedure, battery backup will not be available.
1. If possible, remove power from the system. Otherwise, follow the instructions in the UPS Maintenance
section of the User’s Guide to place the 9x55 8-15kVA UPS in Maintenance bypass. First, put the UPS into
bypass then move the switch to maintenance bypass. However, if the UPS cannot be placed in
maintenance bypass, the upgrade can still be performed by removing power from the system.
Figure 1. Bypass Mode (UPS mounted Maintenance Bypass Switch located at the rear of the unit)

4 9x55 8–15 kVA Battery Up rade (8–15 kVA) —Rev 1
2. Verify that the UPS battery circuit breaker CB1, at the rear of the unit, is open. Follow applicable lockout/
tagout procedures.
Figure 2. CB1 s Open (Located at the rear of the unit)
NOTE If an external battery cabinet is attached, it must be disconnected from the UPS. Ensure
that CB1 is open on each associated external battery cabinet.
Battery Up rade Procedure

9x55 8–15 kVA Battery Up rade (8–15 kVA) —Rev 1 5
3. Remove the front dress panel of the battery compartment.
Figure 3. Remove Front Panel
Battery Up rade Procedure

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4. Using a 7mm nut driver, remove the screws that secure the battery dead front and remove the dead front.
Figure 4. Remove Battery Dead Front Screws
Figure 5. Battery Dead Front Removed
Battery Up rade Procedure

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5. Disconnect all the cabinet harnesses from all the battery trays, starting with all the positive (red) wires then
all the negative (black) wires. Ensure that the wires do not come into contact with any metal framing. It is
recommended to isolate the connectors by using a non-conductive electrical tape to secure the end of
each connector.
Figure 6. Disconnect the Cabinet Harnesses
Battery Up rade Procedure

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Figure 7. Disconnected Cabinet Harnesses
WARNING
All battery trays must be disconnected prior to proceeding any further.
Battery Up rade Procedure

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6. Using a voltmeter, measure the voltage between the positive (+) and negative (-) disconnected harness
from each shelf/string to verify that there is no voltage.
Figure 8. Verify Zero Voltage
WARNING
After performing Step 6, there will still be full battery string voltage between the positive (red) and negative
(black) terminals of the battery trays.
Battery Up rade Procedure

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7. Slide one battery tray half way out and disengage the tray to tray jumper from the tray clips.
Figure 9. Disconnect Tray to Tray Jumper From Tray Clips
8. Disconnect the tray to tray jumper (white terminal on a black wire).
Figure 10. Disconnected Tray to Tray Jumper
Battery Up rade Procedure

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9. Slide both battery trays completely out of the unit.
Figure 11. Both Trays Slid Completely Out
Battery Up rade Procedure

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10. Remove and discard the tray to tray jumper.
Figure 12. Discard Tray to Tray Jumper
11. Repeat Steps 7–10 for the other battery shelves until all battery trays have been removed from the unit.
Figure 13. Empty Unit
Battery Up rade Procedure

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12. Slide the new battery trays into the unit. The positive (+) terminal of each tray should face the front of the
unit and be on the right side of the tray (highlighted in yellow in Figure 14). When sliding it into position, lift
the rear of each battery tray onto the shelf to get it started.
Figure 14. nsert New Battery Trays
13. Locate the remaining cabinet wiring that was previously disconnected from the old trays. Use a wire cutter
(preferably the scissor action type as opposed to diagonal cutters) to cut/remove the existing female
Faston® terminal on the cabinet harness (spade terminal off the ends of the red and black wires). It is
preferred to perform this step by doing one string/shelf at a time.
Battery Up rade Procedure

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14. Use a wire stripper (preferably the no-nick type so that no wire strands are cut off or nicked/weakened) to
strip 1/4 inch of insulation from each of the red and black wires.
Figure 15. Strip 1/4 nch of nsulation
Battery Up rade Procedure

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15. Connect the newly provided adapter harness (see Figure 16) to the UPS battery tray wiring, using the
crimp tool (or equivalent) illustrated in Figure 17. It is recommended that crimp tool PN 59824-1 or
equivalent is used in this step. Ensure that the two pieces of black heat shrink (highlighted in yellow in
Figure 18) are on the adapter assembly. Then insert the negative (black) wire into the crimp terminal on the
black wire of the retrofit adapter (see Figure 18).
Figure 16. New Adapter
Figure 17. Recommended Crimp Tool
WARNING
Ensure that no bare wire is exposed outside of the crimp terminal.
Battery Up rade Procedure

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Figure 18. Add New Adapter Harness to the Battery Cabinet Wires
16. Repeat the insertion and crimping steps for the positive (red wire), ensuring that no bare wires are hanging
out of the crimp.
Figure 19. nserting and Crimping the Red Wire to The Adapter Harness
Battery Up rade Procedure