Eaton® BladeUPS® User’s Guide (Preassembled and Standard Systems) For use with Eaton BladeUPS 5 kVA to 60 kVA (N+1) systems
Class A EMC Statements FCC Part 15 This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
Requesting a Declaration of Conformity Units that are labeled with a CE mark comply with the following harmonized standards and EU directives: l Harmonized Standards: IEC 61000-3-12 l EU Directives: 73/23/EEC, Council Directive on equipment designed for use within certain voltage limits 93/68/EEC, Amending Directive 73/23/EEC 89/336/EEC, Council Directive relating to electromagnetic compatibility 92/31/EEC, Amending Directive 89/336/EEC relating to EMC The EC Declaration of Conformity is available upon
Special Symbols The following are examples of symbols used on the UPS or accessories to alert you to important information: RISK OF ELECTRIC SHOCK - Observe the warning associated with the risk of electric shock symbol. CAUTION: REFER TO OPERATOR'S MANUAL - Refer to your operator's manual for additional information, such as important operating and maintenance instructions. This symbol indicates that you should not discard the UPS or the UPS batteries in the trash.
Table of Contents Table of Contents 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 SAFETY WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3 PREASSEMBLED SYSTEM INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 6 7 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 8 SERVICE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Service and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Typical Alarms and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Silencing the Alarm . . . . . . . . . . . . . . . . . . .
Chapter 1 Introduction The Eaton® BladeUPS® is an uninterruptible power system (UPS) that protects your sensitive electronic equipment from the most common power problems, including power failures, power sags, power surges, brownouts, and line noise. Power outages can occur when you least expect it, and power quality can be erratic. These power problems have the potential to corrupt critical data, destroy unsaved work sessions, and damage hardware—causing hours of lost productivity and expensive repairs.
Introduction l l l l l l Normal operating mode that minimizes heat generation by operating typically at >98% efficiency. The UPS filters incoming AC power and provides consistent power to your equipment without draining the battery. For utility line input that exceeds normal operating range, automatic transfer to an online, double-conversion, high-frequency UPS design with pure sine wave output and power-factor correction.
Introduction The following accessories for the BladeUPS are available: l l l Maintenance Bypass Module (MBM) to safely service the UPS without disrupting power. External Battery Interconnect to connect a customer-supplied external battery to the UPS for extended runtime. EBM for extended runtime. NOTE l Install up to four EBMs per UPS. Each EBM includes a 0.9m (3 ft) connector cable. A 0.9m (3 ft) battery extension cable is also available.
Introduction Note the following guidelines when configuring your BladeUPS standalone module or parallel system: l l l l l The UPS accommodates a maximum of four EBMs. The EBM(s) for a standalone UPS can be mounted directly below the UPS or, with rack side panels removed, in an adjacent rack to the left or right of the rack containing the UPS. The EBMs for a parallel system can be mounted in an adjacent rack to the left or right of the rack containing the UPS (rack side panels removed).
Chapter 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. Read all instructions before operating the equipment and save this manual for future reference. 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.
Safety Warnings Sikkerhedsanvisninger VIGTIGE SIKKERHEDSANVISNINGER — GEM DISSE ANVISNINGER Denne manual indeholder vigtige instruktioner, som skal følges under installation og vedligeholdelse af UPS’en og batterierne. Læs venligst alle instruktioner inden betjening af udstyret og gem denne manual mhp. fremtidige opslag. FARE Denne UPS indeholder LIVSFARLIG HØJSPÆNDING. Alle reparationer og vedligeholdelse bør kun udføres af en AUTORISERET SERVICETEKNIKER.
Safety Warnings GEVAAR Deze UPS bevat LEVENSGEVAARLIJKE ELEKTRISCHE SPANNING. Alle reparaties en onderhoud dienen UITSLUITEND DOOR ERKEND SERVICEPERSONEEL te worden uitgevoerd. Er bevinden zich GEEN ONDERDELEN in de UPS die DOOR DE GEBRUIKER kunnen worden GEREPAREERD. WAARSCHUWING l l l l l Deze UPS bevat een eigen energiebron (accu’s). De UPS-uitgang kan onder spanning staan, zelfs wanneer de UPS niet is aangesloten op de netspanning.
Safety Warnings VAROITUS Tässä UPS-virtalähteessä on oma energianlähde (akut). UPS-virtalähteen lähdössä voi olla jännite, vaikka UPS-virtalähdettä ei ole kytketty verkkovirtaan. l Vähentääksesi tulipalon ja sähköiskun vaaraa asenna tämä UPS sisätiloihin, joissa lämpötila ja kosteus on säädettävissä ja joissa ei ole virtaa johtavia epäpuhtauksia. Ympäristön lämpötila ei saa ylittää 40 °C. Älä käytä lähellä vettä ja vältä kosteita tiloja (95 % maksimi).
Safety Warnings AVERTISSEMENT! l l l l l Cette onduleur possède sa propre source d’alimentation (batteries). Il est possible que la sortie de l’onduleur soit sous tension même lorsque l’onduleur n’est pas connectée à une alimentation CA. Pour réduire les risques d’incendie et de décharge électrique, installer l’onduleur uniquement à l’intérieur, dans un lieu dépourvu de matériaux conducteurs, où la température et l’humidité ambiantes sont contrôlées. La température ambiante ne doit pas dépasser 40 °C.
Safety Warnings ACHTUNG l l l l l Dieses USV (Unterbrechungsfreies Stromversorgungssystem) enthält eine eigene Energiequelle (Batterien). Der USV-Ausgang kann Spannung führen, auch wenn das USV nicht an eine Wechselstromquelle angeschlossen ist. Um die Brand? oder Elektroschockgefahr zu verringern, diese USV nur in Gebäuden mit kontrollierter Temperatur und Luftfeuchtigkeit installieren, in denen keine leitenden Schmutzstoffen vorhanden sind. Die Umgebungstemperatur darf 40°C nicht übersteigen.
Safety Warnings AVVERTENZA l l l l l L’UPS contiene la propria fonte di energia (batterie). Le prese d’uscita dell’UPS possono essere sotto tensione anche quando l’UPS non è collegato all’alimentazione elettrica CA. Per ridurre il rischio di incendio o di scossa elettrica, installare il gruppo statico di continuità in un ambiente interno a temperatura ed umidità controllata, privo di agenti contaminanti conduttivi. La temperatura ambiente non deve superare i 40°C.
Safety Warnings FARLIG l l l l l UPS-enheten inneholder sin egen energikilde (batterier). UPS-utgangen kan være strømførende selv når UPS-enheten ikke er koblet til et strømuttak. For å redusere fare for brann eller elektriske støt, bør denne UPS’en installeres i et innendørs miljø med kontrollert temperatur og luftfuktighet som er fritt for ledende, forurensende stoffer. Romtemperaturen må ikke overskride 40°C. Den må ikke brukes i nærheten av vann eller ved meget høy luftfuktighet (95% maks.).
Safety Warnings ADVERTÊNCIA l l l l l Este no-break possui sua própria fonte de energia (baterias). A saída do no-break pode estar energizada mesmo que este não esteja conectado a uma fonte de energia elétrica. Para reduzir o risco de incêndios ou choques elétricos, instale a UPS em ambiente interno com temperatura e umidade controladas e livres de contaminadores condutíveis. A temperatura ambiente não deve exceder 40°C. Não opere próximo a água ou em umidade excessiva (máx: 95%).
Safety Warnings ПРЕДУПРЕЖДЕНИЕ l l l l l В данном ИБП установлены собственные источники энергии (батареи). В ИБП может иметься напряжение даже в том случае, если он не подключен к сети переменного тока. Для снижения опасности пожара или поражения электрическим током устанавливайте ИБП в закрытом помещении с контролируемыми температурой и влажностью, в котором отсутствуют проводящие загрязняющие вещества. Температура окружающего воздуха не должна превышать 40°С.
Safety Warnings ADVERTENCIA l l l l l Este SIE contiene su propia fuente de energía (baterías). La salida del SIE puede transportar voltaje activo aun cuando el SIE no esté conectado con una fuente de CA. Para reducir el riesgo de incendio o de choque eléctrico, instale este SIE en un lugar cubierto, con temperatura y humedad controladas, libre de contaminantes conductores. La temperatura ambiente no debe exceder los 40°C. No trabaje cerca del agua o con humedad excesiva (95% máximo).
Safety Warnings VARNING l l l l l Den här UPS-enheten innehåller sin egen energikälla (batterier). UPS-enhetens uttag kan vara spänningsförande även då UPS-enheten inte är ansluten till spänningsnätet. Minska risken för brand eller elektriska stötar genom att installera denna UPS-enhet inomhus, där temperatur och luftfuktighet är kontrollerade och där inga ledande föroreningar förekommer. Omgivande temperatur får ej överstiga 40°C.
Chapter 3 Preassembled System Installation The preassembled system comes with the BladeUPS Bar, wireway, and BladeUPS modules already installed. For configurations with five and six UPS systems, some batteries are shipped uninstalled for better weight distribution.
Preassembled System Installation NOTE You may find it useful to use a magnetized screwdriver when removing or replacing mounting screws. Floor Loading When planning the installation, consider the system weight for floor loading. The strength of the installation surface must be adequate for point and distributed loadings. Approximate weights are shown in Table 1. Table 1. Weights Number of UPSs Shipping Weight (Pallet, Rack, Wireway, BladeUPS Bar, and UPSs) System Weight (Excludes Pallet) 1 471.
Preassembled System Installation Figure 4. Inserting the Forklift Jacks 3. Five and six UPS systems only. Locate the battery cartons on the separate pallet (see Figure 5). 4. If the battery pallet is not already moved, verify that the forklift or pallet jack you will use is rated to handle the weight of the batteries and the pallet (see Table 1 on page 18 for battery weight). 5. Insert the forks of the forklift or pallet jack between the skids on either side of the pallet to move it.
Preassembled System Installation Pallet Front Pallet Rear Note: Battery cartons for five and six UPS systems only. Figure 5. Moving the Battery Pallet NOTE 7. You will install the batteries in the top two UPS cabinets after the system is installed in the final location (described in “Installing the UPS Internal Batteries” on page 30). Continue to the“Installing the Ramp” section. Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Preassembled System Installation Installing the Ramp To install the ramp: 1. Remove the outer plastic wrap and the four protective cardboard corners from the system. 2. Discard or recycle the packaging in a responsible manner, or store it for future use. 3. Locate the ramp on the back of the cabinet. Hold the ramp in place while you cut the strap that binds it to the system (see Figure 6). CAUTION If not held in place when the strap is cut, the ramp can fall and cause injury.
Preassembled System Installation 4. Lift the ramp from the back of the cabinet. Attach it to the pallet by inserting the left and right ramp pins (tee nuts) into the pre-drilled holes at the rear of the pallet (see Figure 7). 5. Continue to the“Unloading the System” section. Tee nut Pre-drilled hole Pallet Front Ramp Pallet Rear Figure 7. Attaching the Ramp to the Pallet Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Preassembled System Installation Unloading the System CAUTION The system is heavy. See Table 1 on page 18 for system weight. If unloading instructions are not closely followed, the system can cause serious injury. CAUTION Do not tilt system more than 10° sideways from vertical.To unload the system: NOTE There is a front and a rear stabilizing bracket to secure the system for shipping. The brackets are bolted both to the pallet and the cabinet. The bolts must be removed before unloading the system. 1.
Preassembled System Installation 4. If the leveling feet are not fully retracted, turn the leveling feet clockwise until they are retracted (see Figure 9). Caster Leveling Foot Figure 9. Locating the Leveling Feet Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Preassembled System Installation CAUTION The system is heavy. See Table 1 on page 18 for system weights. CAUTION To prevent possible injury, do not stand in the path of the system when unloading the system from the pallet. Unloading the system requires three people: one behind the system and one on each side. If unloading instructions are not closely followed, the system can cause serious injury. NOTE 5. For five and six UPS systems, batteries are shipped on a separate pallet.
Preassembled System Installation Preassembled System Setup CAUTION Only qualified service personnel (such as a licensed electrician) shall perform the electrical installation. Risk of electrical shock. NOTE The BladeUPS is a transformerless UPS that requires an unbroken neutral from the AC source.
Preassembled System Installation Preparing the Rack To prepare the rack for wiring: 1. Remove the accessory box that is located in the rear of the system behind the rack doors. 2.
Preassembled System Installation Top Entry Installation Figure 11 shows input and output wiring in a top entry system. Figure 11. Top Entry Wiring Installation Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Preassembled System Installation To install the parallel system input and output wiring: 1. Verify that all battery circuit breakers on all UPSs are in the OFF (O) position (see Figure 12). Load (RPM) Connector Breaker Input Breaker Battery Breaker Figure 12. BladeUPS Module Rear Panel Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Preassembled System Installation 2. To remove the upper side panels from the cabinet (see Figure 13): - At the top of the cabinet, unlock the upper side panels with the key. - Remove the left and right upper side panels and set them aside. - Secure the key so it will be available when you are ready to replace the upper side panels. Right Upper Side Panel Left Upper Side Panel BACK FRONT Figure 13. Removing the Upper Side Panels Eaton BladeUPS 5.
Preassembled System Installation 3. Use a magnetized Phillips screwdriver to remove the trim on each side of the cabinet top panel (see Figure 14): - Remove and retain the four interior trim screws located on the inside of the side panel (A, B, C, and D). - Remove and retain the four pairs of outside trim screws located at the top on each rack (1 through 8). - Remove and retain the top trim panels. - Place both top trim panels and all mounting screws together in the same accessible location.
Preassembled System Installation 4. Use a ratcheting socket wrench with a 3/8-inch socket or a screwdriver to loosen the bolts that secure the cabinet top panel (see Figure 15): - Locate the five top panel bolts inside the rack. Three bolts are located at the front of the rack and two bolts are at the back of the rack. - Loosen the bolts, but do not remove them. Leave them protruding about 1/8 inch. 1/8” Front Interior View Back Interior View Front Screws Back Screws Overhead View Figure 15.
Preassembled System Installation 5. With the back doors open, reach up inside the rack and push up the cabinet top panel to lift it off of the loosened bolts. Retain the panel (see Figure 16). Front Screws Back Screws Cable Trough Cover Top Entry Wireway Access Cover Figure 16. Removing the Top Panel Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Preassembled System Installation 6. Remove the six screws on the conduit landing plate and retain. Remove and retain the plate (see Figure 17). Top Entry Conduit Landing Plate Ferrite Assembly (mounted) Figure 17. Removing the Top Entry Conduit Landing Plate 7. Use a Greenlee® punch to provide one or more holes in the conduit landing plate to accommodate the input and output wiring for the system. 8. Replace the conduit landing plate. 9.
Preassembled System Installation Table 4. BladeUPS Bar Wiring Specifications BladeUPS Bar Terminal Block Output Input Terminal Position BladeUPS Bar Wire Function 1 [Output A] Phase 1 Out 2 [Output B] Phase 2 Out 3 [Output C] Phase 3 Out 4 [Input A] Phase 1 In 5 [Input B] Phase 2 In 6 [Input C] Phase 3 In 7 Neutral Neutral 8 Neutral 9 Neutral Safety Ground Ground Ground Terminal Wire Size Rating* Tightening Torque 31.1 Nm (275 lb in) 13.
Preassembled System Installation 15. If installing optional EBM(s), continue to “EBM Installation” on page 43. Otherwise, go to “Parallel System Initial Startup” on page 51. Bottom Entry Installation Figure 19 shows input and output wiring in a bottom entry system. Figure 19. Bottom Entry Wiring Installation Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Preassembled System Installation To install the parallel system input and output wiring: 1. Verify that all battery circuit breakers on all UPSs are in the OFF (O) position (see Figure 20). Load (RPM) Connector Breaker Input Breaker Battery Breaker Figure 20. BladeUPS Module Rear Panel 2. Remove the five screws on the bottom entry wireway access cover and retain. Remove the cover and retain (see Figure 21). Figure 21. Removing the Wireway Access Cover (Bottom Entry Rack Shown) Eaton BladeUPS 5.
Preassembled System Installation 3. Remove the six screws on the conduit landing plate and retain. Remove the plate and retain. See Figure 22. Bottom Entry Rack Ferrite Assembly (mounted) Figure 22. Removing the Conduit Landing Plate 4. Use a Greenlee® punch to provide one or more holes in the conduit landing plate to accommodate the input and output wiring from the utility to the BladeUPS Bar. 5. Replace the conduit landing plate, and attach approved electrical conduit to the plate. 6.
Preassembled System Installation Table 5. BladeUPS Bar Wiring Specifications BladeUPS Bar Terminal Block Output Input Terminal Position BladeUPS Bar Wire Function 1 [Output A] Phase 1 Out 2 [Output B] Phase 2 Out 3 [Output C] Phase 3 Out 4 [Input A] Phase 1 In 5 [Input B] Phase 2 In 6 [Input C] Phase 3 In 7 Neutral Neutral 8 Neutral 9 Neutral Safety Ground Ground Ground Terminal Wire Size Rating* Tightening Torque 31.1 Nm (275 lb in) 13.
Preassembled System Installation To install the battery trays into the UPS 5 cabinet: 1. Verify that all battery circuit breakers on all UPSs are in the OFF (O) position (see Figure 24). Load (RPM) Connector Breaker Input Breaker Battery Breaker Figure 24. BladeUPS Module Rear Panel NOTE 2. The load connector breaker controls the load connector only, not the output power cord. Remove the UPS front cover and set it aside (see Figure 25).
Preassembled System Installation 3. Remove the eight screws on the battery cover plate and retain. Remove the plate and retain. See Figure 26. Figure 26. Removing the UPS Battery Cover Plate 4. Slide the battery trays into the cabinet (see Figure 27 for two battery string installations or Figure 28 for single-string installations). Verify that each tray is properly aligned before sliding in the tray. NOTE 5. When installing single-string battery trays for BladeUPS 5.
Preassembled System Installation Figure 28. Installing the UPS Single-string Battery Trays for 5.1 kVA BladeUPS 6. Reinstall the battery cover plate. 7. Install the UPS front cover (see Figure 29): Plug the LCD cable from the control panel on the front cover into the connector on the electronics module. Use care to loop the LCD cable gently in front of the electronics module. Push the top of the front cover firmly into place, and then push the bottom firmly into place. LCD Cable Figure 29.
Preassembled System Installation EBM Installation The BladeUPS EBM comes with all hardware required for installation in a standard EIA or JIS seismic rack-mount configuration with square and round mounting holes. The rail assemblies adjust to mount in standard 19-inch racks with front to rear rail distances from 61 to 81 cm (26 to 32 inches) deep. Figure 30 shows an example EBM installation. Optional Battery Extension Cables Figure 30. Example EBM Installations in Parallel Systems Eaton BladeUPS 5.
Preassembled System Installation Checking the EBM Accessories Verify that the following items are included with the EBM: l EBM front cover l Mounting brackets and fasteners (if not already installed): - (2) mounting brackets - (4) 6-32 flat-head screws l Rails and fasteners: - (2) sliding rail assemblies (left and right) - (2) rear hold-down brackets - (12) hex-head screws - (4) U-shaped 10-32 clip nuts l EBM user’s guide NOTE Discard the EBM user’s guide. Use this user’s guide to install the EBM.
Preassembled System Installation 2. Select the proper holes in the rail for positioning the EBMs in the rack. Place the first rail for the first EBM above the UPS, using positions 37 and 42 for the front hex-head screws. If you are installing additional rails, place the next rail 4 holes above the last installed screw (see Figure 32). NOTE Verify that the hole patterns on the rails and mounting brackets align with the hole pattern on the rack.
Preassembled System Installation Position 13 Position 15 Second Rail Position 11 Second Rail Position 10 Position 6 Position 4 First Rail First Rail Position 2 Position 1 Front Rail Screw Positions Rear Rail Screw Positions Figure 33. Rail Screw Positions for the EBM Bottom Installation 3. Secure the rail to the front of the rack with two hex-head screws (see Figure 34). Figure 34. Securing the Front Rail 4.
Preassembled System Installation Clip Nuts Figure 35. Securing the Rear Rail 5. Repeat Steps 3 and 4 for the other rail. 6. Tighten the assembly wing nuts on both rail assemblies. CAUTION The EBM is heavy (see page 130). Moving the EBM requires a minimum of two people. 7. Place the EBM on a flat, stable surface with the front of the EBM facing toward you. 8.
Preassembled System Installation 11. Secure the front of the EBM to the rack using two hex-head screws in each mounting bracket as shown in Figure 37. Hex-Head Screws Figure 37. Securing the EBM Mounting Brackets 12. Attach the rear hold-down brackets to the rail and slide the brackets into the slots on the EBM rear panel (see Figure 38). Rear Hold-Down Bracket Figure 38. Securing the Back of the EBM 13.
Preassembled System Installation 14. Verify that all battery circuit breakers on all UPSs are in the OFF (O) position (see Figure 39). 15. Plug the EBM cable(s) into the battery connector(s) as shown in Figure 39. Up to four EBMs may be connected to each UPS. 16. Parallel system only. Repeat Steps 14 and 15 for each UPS with EBM(s). See Figure 40 on page 50 and Figure 41 on page 51 for examples of EBM connections in a parallel system. NOTE Each UPS in a parallel system must have the same number of EBMs.
Preassembled System Installation Figure 40. Example EBM Installations in Preassembled Parallel Systems NOTE Figure 40 shows systems using the supplied EBM cables and optional 0.9m (3 ft) battery extension cables. Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Preassembled System Installation Figure 41. Example EBM Installation in a Large Parallel System Parallel System Initial Startup To start up a parallel system: NOTE 1. Verify that the total equipment ratings do not exceed the parallel system capacity to prevent an overload alarm. Verify that all circuit breakers on all UPSs are in the OFF (O) position (see Figure 24 on page 40). NOTE The load connector breaker controls the load (RPM) connector only, not the output power cord. Eaton BladeUPS 5.
Preassembled System Installation 2. Switch on utility power where the UPS is connected. 3. Remove the breaker ties from the battery circuit breakers. 4. Switch the UPS input circuit breaker on each UPS to the ON () position. 5. Wait for the front panel display on each UPS to illuminate. The indicator flashes on each UPS. 6. Check each UPS front panel display for active alarms or notices (other than “Batteries Disconnected”). Resolve any active alarms before continuing.
Preassembled System Installation 17. To change any other factory-set defaults, see “Operation” on page 93. NOTE 1 Eaton recommends setting the Date and Time and the Start screen. NOTE 2 Verify that the Parallel Operation Settings are set appropriately for your system. For example, if you know the load will exceed the redundancy level of the system, set the Parallel Operation Mode to “Capacity Mode” to prevent unnecessary alarms (see Chapter 5, “Operation”). 18.
Chapter 4 Standard System Installation For standard systems, the BladeUPS modules are installed in the rack after delivery.
Standard System Installation Unpacking the Components CAUTION CAUTION l l Unpacking the cabinet in a low-temperature environment may cause condensation to occur in and on the cabinet. Do not install the cabinet until the inside and outside of the cabinet are absolutely dry (hazard of electric shock). The cabinet and batteries are heavy (see page 136). Removing the cabinet and batteries from their cartons requires a minimum of two people.
Standard System Installation UPSs in a parallel configuration require a dedicated branch circuit that meets the following requirements: l Three-phase, 4-wire plus ground, 208Y/120V nominal (BladeUPS 12 model) or 400Y/230V nominal, 380–415 Vac acceptable (BladeUPS 12i model) l 50/60 Hz l Wall-mounted breaker that is readily accessible to the operator l Flexible or rigid metal conduit l Circuit with overcurrent protection, depending on parallel configuration (see Table 6) Table 6.
Standard System Installation WARNING Use caution so door does not fall and cause an injury 6. c. Lift off the door and set aside d. Remove the door hinges and flip 180° to mount them on corresponding attachment holes on opposite side of the rack. e. Pinch together top and bottom of the plastic grabber latch clips from inside the rack frame to remove them from rack frame. Put them in the corresponding square holes in the opposite side of the rack frame f.
Standard System Installation 7. Plan where each cabinet will be located in the rack and determine the “U” marks to use for mounting the rails. For example, for a rack containing six UPSs and a bottom wireway, plan to mount the bottom of the rails at the following marks (see Figure 42): 37 31 7 25 19 13 7 Figure 42. Recommended Rail Locations (Example Configuration) NOTE 8. Recommended rail locations are for example only. Adjust the locations as needed for your system’s configuration.
Standard System Installation Installing the Input and Output Wiring Figure 43 shows input and output wiring in a bottom entry rack and a top entry rack. Wiring in a Bottom Entry Rack Wiring in a Top Entry Rack Figure 43. Wiring Entry Options Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Standard System Installation To install the parallel system input and output wiring: 1. Remove the five screws on the wireway access cover and retain. Remove the cover and retain. NOTE 2. For top wireway applications, see “top of cabinet” removal instructions in “Top Entry Installation”, Step 2 on page 30. Remove the six screws on the conduit landing plate and retain. Remove the plate and retain. See Figure 44. Bottom Entry Rack Top Entry Rack Figure 44. Removing the Conduit Landing Plate 3.
Standard System Installation Table 7. BladeUPS Bar Wiring Specifications BladeUPS Bar Terminal Block Terminal Position BladeUPS Bar Wire Function Terminal Wire Size Rating* Tightening Torque Output 1 [Output A] Phase 1 Out 31.1 Nm (275 lb in) 2 [Output B] Phase 2 Out 13.
Standard System Installation 10. If installing optional EBM(s), see “EBM Installation” on page 43. Otherwise, continue to “UPS Setup” on page 63. NOTE If you are installing the EBM with a new UPS at the same time, use the UPS user’s guide to install both the UPS and the EBM. NOTE Mounting rails are required for each individual cabinet. UPS Setup The UPS comes with all hardware required for installation in a standard EIA or JIS seismic rack-mount configuration with square and round mounting holes.
Standard System Installation Rack Setup for the UPS CAUTION The UPS is heavy (see page 136). Removing the UPS from its carton requires a minimum of two people. Use the corrugated lifting sling (packaged with the UPS) to move the UPS. NOTE Mounting rails are required for each individual cabinet. To install the UPS rail kit: 1. Select the proper holes in the rack for positioning the UPS in the rack (see Figure 46). NOTE 1 The UPS rails take up position 1 through position 12.
Standard System Installation 2. Pre-assemble four M6 hex nuts to the rail assembly: Assemble two of the nuts and the rear hold-down bracket and finger-tighten only. Assemble the other two nuts to the rail and finger-tighten only. See Figure 47. Repeat for the other rail. M6 Hex Nuts Rear Rear Hold-Down Bracket Front Figure 47. Installing the Rail Hardware (Right Rail Assembly Shown) NOTE 3. Verify that the holes in the rail align properly with the hole pattern in the rack.
Standard System Installation Cage Nuts Rear M5 Screws Position 8 Position 7 Rail Stud Position 4 Position 2 Bottom of Rack or Top of Other Cabinet Position 1 Figure 49. Securing the Rear Rail (Right Rail Assembly Shown) 6. Tighten all screws at the front and rear of the rail, then tighten the rail adjustment screws. Leave the screws through the hold-down brackets loose. 7. Repeat Steps 3 through 6 for the other rail. 8. Parallel system only.
Standard System Installation Electronics Module Locking Screw Ring Handle Figure 50. Removing the Electronics Module 11. If the mounting brackets are not already installed, align the two mounting brackets with the screw holes on the sides of the UPS and secure with the supplied 6-32 flat-head screws (see Figure 51). Mounting Bracket 6-32 Flat-Head Screws Figure 51. Installing the UPS Mounting Brackets 12. Slide the UPS into the rack. 13. Parallel or parallel-ready system only.
Standard System Installation 14. Using four M5 machine screws, secure the front of the cabinet to the rack as shown in Figure 52. Position 9 M5 Screws Position 4 Figure 52. Securing the Front of the UPS 15. Insert the two rear hold-down brackets on the rails into the slots on the rear of the cabinet (see Figure 53). a. If necessary, push out on the rack upright to allow the clearance needed to insert the bracket. The rack upright flexes easily. b.
Standard System Installation Wire Saddle 2-Pin Connector 2-Pin Connector 2-Pin with Jumper 2-Pin Connector 2-Pin with Jumper Wire Saddle 3-Pin Connector Figure 54. Installing the Communication Terminal Block Connectors 20. Continue to the “Installing the UPS Internal Batteries” section. Installing the UPS Internal Batteries CAUTION The UPS internal batteries are heavy (see page 136). Each battery tray holds two rows of five batteries. Use caution when handling the heavy battery trays.
Standard System Installation 3. Slide the battery trays into the cabinet (see Figure 56 for two battery string installations and Figure 57 for single-string installations). Verify that each tray is properly aligned before sliding the tray in. NOTE 4. When installing single-string battery trays for BladeUPS 5.1 kVA, always install the single-string trays in the bottom battery compartment. When a tray is fully installed, tuck the plastic handle on the end of the tray into place. Figure 56.
Standard System Installation 6. Install the UPS front cover (see Figure 58): Plug the LCD cable from the control panel on the front cover into the connector on the electronics module. Use care to loop the LCD cable gently in front of the electronics module. Push the top of the front cover firmly into place, and then push the bottom firmly into place. Figure 58. Installing the UPS Front Cover 7. Parallel system only.
Standard System Installation Optional Battery Extension Cables Figure 59. Example EBM Installations in Parallel Systems Standalone UPS Installation NOTE Do not make unauthorized changes to the UPS; otherwise, damage may occur to your equipment and void your warranty. Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Standard System Installation The UPS requires a dedicated branch circuit that meets the following requirements: l Circuit with overcurrent protection as follows: - 50A (BladeUPS 12 model) - 30A (BladeUPS 12i or BladeUPS 8 model) - 20A (BladeUPS 5.1 model) l l Three-phase, 4-wire plus ground, 208Y/120V nominal (BladeUPS 12 model) with 5-pin IEC309-60 amp receptacle or in-line connector (GH560C9W or similar).
Standard System Installation Load Connector Breaker Input Breaker Battery Breaker REPO (NO) REPO (NC) Load Connector UPS Battery Connector Surge Protection (leave installed) X-Slot Communication Bay 1 Communication Port X-Slot Communication Bay 2 Ground Bonding Screw Output Power Cord Input Power Cord Figure 60. BladeUPS Module Rear Panel (Standalone UPS Shown with IEC 309-60A Output Power Cord) NOTE The load connector breaker controls the load connector only, not the output power cord.
Standard System Installation Parallel UPS Installation These installation procedures provide the steps to configure the CAN Bridge cards for parallel operation. There are three types of parallel UPS installation. Follow the applicable procedure listed in Table 9 for the type of parallel configuration: Table 9. Parallel UPS Installation Types Procedure Parallel Configuration Page New Multiple Parallel UPS Installation Installing multiple UPSs in a new parallel configuration.
Standard System Installation 4. Unpack the Powerware Hot Sync CAN Bridge Card and verify that the card was not damaged during shipment (see Figure 61). Figure 61. Powerware Hot Sync CAN Bridge Card 5. If there is a Jumper J7 on the Powerware Hot Sync CAN Bridge Card, remove and discard (see Figure 68 on page 86).
Standard System Installation 9. Install one of the two supplied blue terminating plugs (see Figure 62) into the CAN IN port on the first UPS (UPS 1 in Figure 64). 333 Blue Terminating Plug (CAN IN) Figure 62. Installing the Blue Terminating Plug (First UPS) Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Standard System Installation 10. Install the second supplied blue terminating plug (see Figure 63) into the CAN OUT port on the last UPS (UPS 3 in Figure 64). Blue Terminating Plug (CAN OUT) Figure 63. Installing the Blue Terminating Plug (Last UPS) 11. Verify that only the first and last UPSs in the configuration have a blue terminating plug installed. 12.
Standard System Installation Standalone/ Parallel (remove) UPS 3 For Parallel Use Only CAN CAN IN OUT Blue Terminating Plug Redundant Signal Cable Standalone/ Parallel UPS 2 For Parallel Use Only CAN Bridge Card Cable Standalone/ Parallel UPS 1 Blue Terminating Plug Figure 64. Typical CAN Bridge Card and Redundant Signal Wiring 13. Install a redundant signal cable between the For Parallel Use Only and Standalone/Parallel terminals on each UPS as shown in Figure 64.
Standard System Installation 14. Remove the Standalone/Parallel terminal block connector from the last UPS (UPS 3 in Figure 64). 15. Tighten the screws securing each Powerware Hot Sync CAN Bridge Card in its X-Slot communication bay. 16. If you are installing power management software, connect your computer to the UPS communication port or optional X-Slot card (see “Installing Communication Options and Control Terminals” on page 108). For the communication port, use the supplied serial cable.
Standard System Installation Plug Retainer 1 2 3 Figure 65. Connecting UPSs to the BladeUPS Bar (Bottom Entry Shown) Single Parallel-Ready UPS Installation CAUTION Only qualified service personnel (such as a licensed electrician) shall perform the electrical installation. Risk of electrical shock. NOTE Do not make unauthorized changes to the UPSs; otherwise, damage may occur to your equipment and void your warranty. To install one UPS in a parallel-ready configuration: 1.
Standard System Installation NOTE The load connector breaker controls the load connector only, not the output power cord. 4. Unpack the Powerware Hot Sync CAN Bridge Card and verify that the card was not damaged during shipment (see Figure 61 on page 76). 5. If there is a Jumper J7 on the Powerware Hot Sync CAN Bridge Card, remove and discard (see Figure 68 on page 86).
Standard System Installation 9. Tighten the screws securing the Powerware Hot Sync CAN Bridge Card in its X-Slot communication bay. NOTE 1 Since there is only one UPS module, retain the redundant signal cable. NOTE 2 Also retain one of the two pin terminal blocks, which has the small jumper wire, used on the external connection terminal strip.
Standard System Installation Plug Retainer 1 2 3 Figure 67. Connecting UPSs to the BladeUPS Bar (Bottom Entry Shown) UPS Installation into an Existing Parallel System CAUTION Only qualified service personnel (such as a licensed electrician) shall perform the electrical installation. Risk of electrical shock. NOTE Do not make unauthorized changes to the UPSs; otherwise, damage may occur to your equipment and void your warranty.
Standard System Installation NOTE 3. The load connector breaker controls the load connector only, not the output power cord. Unpack the Powerware Hot Sync CAN Bridge Card and verify that the card was not damaged during shipment (see Figure 61 on page 76). NOTE Eaton recommends installing the Powerware Hot Sync CAN Bridge Card in X-Slot Communication Bay 2 (see Figure 60 on page 74), leaving the X-Slot Communication Bay 1 available for other types of X-Slot cards. 4.
Standard System Installation Jumper J7 - Pins 1 and 2 (First and Last UPS) Shown Figure 68. Removing the Jumper J7 (Side View) e. Reinstall each Powerware Hot Sync CAN Bridge Card in the open X-Slot communication bay #2 on its UPS rear panel.Install screws and tighten. f. Reconnect the CAN Bridge Card Cable to the Powerware Hot Sync CAN Bridge Card. 10.
Standard System Installation 13. For a parallel system not previously shut down, verify that any alarms related to reconfiguring the CAN Bridge Cards have cleared. 14. Install a redundant signal cable between the For Parallel Use Only and Standalone/Parallel terminals on each UPS as shown in Figure 64 on page 79. Be sure to check correct polarity when installing the cable. CAUTION If polarity or wiring is not correct, the parallel system does not operate normally.
Standard System Installation 27. Press any button on the front panel display to activate the menu options, and then press the button until the TURN UPS ON/OFF menu displays. button to display the TURN UPS ON option; press the 28. Press the 29. Confirm the selection. Press and hold the button. button for three seconds, until the UPS stops beeping. a.
Standard System Installation 12. Verify that the “Batteries Disconnected” alarm has cleared. Verify that no other alarms appear on the UPS front panel display. If the indicator is flashing, do not proceed until all alarms are clear. Check the UPS status from the front panel to view the active alarms. Correct the alarms and restart if necessary. 13. Press any button on the front panel display to activate the menu options, and then press the button until the TURN UPS ON/OFF menu displays. 14.
Standard System Installation NOTE The load connector breaker controls the load connector only, not the output power cord. 2. Switch on utility power where the UPS is connected. 3. Remove the breaker ties from the circuit breakers. 4. Switch the UPS input circuit breaker on each UPS to the ON () position. 5. Wait for the front panel display on each UPS to illuminate. The indicator flashes on each UPS. 6.
Standard System Installation On each UPS, press any button on the front panel display to activate the menu options, and then press the button until the IDENTIFICATION menu displays. Press the button to display the identification data, including the firmware version. If any firmware versions do not match, install the firmware from the supplied BladeUPS: Documents, Firmware, and Installation Video CD or visit www.eaton.com/powerquality to download the latest version and the instructions for installing it.
Chapter 5 Operation This chapter contains information for operating the BladeUPS module, including: l Control panel operation l Operating modes l UPS startup and shutdown l Transferring the UPS between modes l Setting the power strategy l Configuring the UPS for battery settings Control Panel Functions The UPS has a four-button graphical LCD with backlight. It provides UPS load status, events, measurements, current settings, and other useful information (see Figure 69).
Operation Table 10 shows the indicator icons and provides indicator status and descriptions. Table 10. Indicator and Status Description Indicator UPS OPERATION MODE Green BATTERY MODE Status Description On The UPS is operating normally. Flashing l The UPS is starting up or is shut down and waiting for power to return. l A new information message is active. l Bypass is not available. Off The UPS is turned off and will not turn on automatically. On The UPS is in Battery mode.
Operation Table 11. Menu Map for Display Functions Main Menu Submenu Display Information or Menu Function UPS Status System Normal | High Efficiency Power: % / Battery Resting | Battery Floating UPS in Parallel Mode / Parallel Unit Number x / Units on CAN Bus / Units on Load Event Log Displays up to 100 events and alarms Measurements Parallel System kW [by unit] / kW [Parallel total] For more information about measurements, see “Metering” on page 118.
Operation Table 12. User Settings (Continued) Description Available Settings Default Setting Serial Port Config Port: [X-Slot-1] [X-Slot-2/Serv] Speed: [19200] [9600] [2400] [1200] 19200 Parallel Operation Settings Parallel Operation Mode: [Redundant Mode] [Capacity Mode] Redundant Mode This setting is not available for six-unit systems (must be Redundant Mode only). Parallel XCP: [System] [Sub Unit] System Select Sub Unit for PowerVision® software. Select System for other software.
Operation Table 12. User Settings (Continued) Description Available Settings Default Setting Reset Custom Event Settings 0 through 32 Total: 0/32 REPO Configuration [Enabled][Disabled] Enabled Delayed Rectifier Startup Settings Group number: 0 through 10 (integers only); 0 (Zero disables this feature) Delay in seconds: 2 through 5 sec (integers only) 5 SEE NOTE NOTE Delayed rectifier startup increases existing delays for utility outages.
Operation If battery capacity becomes low while in Battery mode, the indicator flashes slowly and the audible alarm becomes continuous. If the Battery Low alarm is set, the indicator also illuminates solid. This warning is approximate, and the actual time to shutdown may vary significantly. NOTE Depending on the UPS load and the number of Extended Battery Modules (EBMs), the Battery Low warning may occur before the batteries reach 25% capacity. See Table 28 on page 138 for estimated runtimes.
Operation NOTE The load connector breaker controls the load connector only, not the output power cord. 2. Verify that the UPS power cord is plugged in. 3. Switch on utility power where the UPS is connected. 4. Switch the UPS input circuit breaker to the ON () position. 5. Wait for the UPS front panel display to illuminate. The indicator flashes on the UPS. 6. Check the UPS front panel display for active alarms or notices (other than “Batteries Disconnected”).
Operation 6. Wait for the front panel display on each UPS to illuminate. The indicator flashes on each UPS. 7. Check each UPS front panel display for active alarms or notices (other than “Batteries Disconnected”). Resolve any active alarms before continuing (see “Troubleshooting” on page 135). 8. Switch all UPS battery circuit breakers to the ON () position. 9. If optional EBMs are installed, switch all EBM battery circuit breakers to the ON () position. 10.
Operation 7. Check the UPS front panel display for active alarms or notices (other than “Batteries Disconnected”). Resolve any active alarms before continuing (see “Troubleshooting” on page 135.) 8. Switch the UPS battery circuit breaker to the ON () position. 9. If optional EBMs are installed, switch all EBM battery circuit breakers to the ON () position. 10. Verify that the “Batteries Disconnected” alarm has cleared. Verify that no other alarms appear on the UPS front panel display.
Operation 2. Press any button on the front panel display to activate the menu options. Select TURN UPS ON/OFF, TURN UPS OFF, and press the button. 3. Confirm the selection. Press and hold the button for three seconds, until the UPS stops beeping. The output relays open, the UPS transfers to Standby mode, and the indicator turns off. 4. Switch the UPS battery circuit breaker to the OFF (O) position. 5. If optional EBMs are installed, switch all EBM battery circuit breakers to the OFF (O) position.
Operation Setting Power Strategy To set the power strategy: 1. Press any button to activate the menu options, then select SETTINGS, USER SETTINGS, and POWER STRATEGY. 2. Select HIGH EFFICIENCY or STANDARD, and OK to confirm. Configuring Battery Settings The following battery settings are available: l Configure the UPS for EBMs l BladeUPS 12i model only.
Operation NOTE To install the External Battery Interconnect accessory, refer to the External Battery Interconnect User’s Guide. 1. Press any button on the front panel display to activate the menu options, then select SETTINGS, USER SETTINGS, BATTERY SETUP, and EXTERNAL BATTERY CAPACITY. 2. Use the or buttons to select the Watts per cell. For the correct Watts per cell, see the specifications sheet for the customer-supplied external batteries. 3. 4. Press the Press the button to save the setting.
Operation Table 14. Suggested Battery Low Alarm Level Settings (Continued) Warning Time (in Minutes) 20% Load 50% Load 100% Load 1 1.835 1.884 1.941 2 1.818 1.863 1.903 3 1.799 1.849 1.883 4 1.803 1.823 1.865 5 NOTE Battery Low Alarm Level (User Setting) Number of EBMs Installed Values are approximate. Running Automatic Battery Tests Battery tests may rely on backfeeding the utility, using the utility as a load.
Chapter 6 Communication This chapter describes the: l DB-9 communication port l X-Slot cards l Relay output contacts l Programmable signal inputs l Remote emergency power-off (REPO) l Parallel communication Figure 71 shows the location of the communication options and control terminals on the UPS.
Communication Installing Communication Options and Control Terminals To install the communication options and control terminals: 1. Install the appropriate X-Slot card and/or necessary cable(s) (see Figure 71 and Figure 72). Figure 72. Installing Communication Cables 2. Connect the cables to the appropriate location. See “Communication Options” on page 108 or “Control Terminals” on page 110 for detailed information. 3. Route and tie the cable(s) out of the way. 4.
Communication NOTE 1 You can configure relays, signal inputs, and the serial port baud rate through the front panel menus (see Table 12 on page 95). NOTE 2 In a UPS connected to utility power, X-Slot cards remain powered on even if the input breaker is off. DB-9 Communication Port To establish communication between the UPS and a computer, connect your computer to the UPS communication port using the supplied communication cable.
Communication l l Industrial Relay Card (IRC) - is used to indicate the operating status of the UPS system using the customer’s monitoring equipment. The IRC uses four isolated normally-open or normally-closed dry relay contacts to indicate the UPS status. You can monitor Normal, Bypass, Battery, and Alarm mode. Power Xpert UPS Card - has SNMP and HTTP capabilities as well as monitoring through a Web browser interface; connects to a twisted-pair Ethernet (10/100BaseT) network.
Communication Relay Output Contacts The UPS incorporates a programmable relay output with potential free contacts for remote alarm indications (see Figure 71 on page 107). You can obtain an additional four relay outputs with the X-Slot compatible Relay Interface Card. CAUTION The relay output contacts must not be connected to any utility connected circuits; the utility requires reinforced insulation. The relay output contacts have a maximum rating of 30 Vac/1A and 60 Vdc/2A nominal values.
Communication Remote Emergency Power-off REPO is used to shut down the UPS from a distance. This feature can be used for shutting down the load and the UPS by thermal relay, for example in the event of room overtemperature. When REPO is activated, the UPS shuts down all converters, de-energizes all system relays, trips the UPS battery circuit breaker, and powers down within 10–15 seconds.
Communication Installing REPO for a Standalone UPS To install a REPO switch for a standalone UPS: 1. Verify that the UPS is turned off and all power sources are removed. See “Standalone UPS Shutdown” on page 102 for shutdown instructions. 2. Securely mount the remote REPO switch. Recommended locations include near operator’s consoles or near exit doors. Refer to the REPO switch manufacturer’s installation instructions for enclosure dimensions and wiring knockouts. 3.
Communication Installing REPO for a Parallel System You can install an optional REPO circuit that shuts down the entire parallel system using a single switch. To install a REPO switch for a parallel system, the selected REPO command (NO or NC) contacts from each UPS in the system must be in parallel. To install a REPO switch for a parallel system: 1. Verify that the UPS system is turned off and all power sources are removed. See “Parallel System Shutdown” on page 103 for shutdown instructions. 2.
Communication UPS 6 REPO Terminals Normally-Open Normally-Closed 2 + Polarity 1 – Polarity 2 + Polarity 1 – Polarity UPS 5 REPO Terminals Normally-Open Normally-Closed 2 + Polarity 1 – Polarity 2 + Polarity 1 – Polarity 2 + Polarity 1 – Polarity UPS 4 REPO Terminals Normally-Open Normally-Closed 2 + Polarity 1 – Polarity UPS 3 REPO Terminals Normally-Open Normally-Closed 2 + Polarity 1 – Polarity 2 + Polarity 1 – Polarity UPS 2 REPO Terminals Normally-Open Normally-
Communication UPS 6 REPO Terminals Normally-Open Normally-Closed 2 + Polarity 1 – Polarity 2 + Polarity 1 – Polarity NOTE Remove factory-install jumper wires and replace with REPO switch wiring.
Communication Parallel Communication The CAN Bridge Card in each paralleled UPS provides connectivity for system metering and operational mode control. Startup, shutdown, and auto-calibration commands given at one UPS also command the other UPSs in the parallel system. The UPSs in a parallel system are in constant communication to monitor settings and status information.
Communication Metering The Output and Load Receptacle meter readings differ between a parallel system and a standalone UPS. In a parallel system, one UPS reads the Load Receptacle value for the total system (the others read zero), but each UPS displays its own Output value.
Chapter 7 UPS Maintenance This chapter explains how to: l Care for the UPS and batteries l Replace the UPS batteries and EBMs l Test new batteries l Replace the electronics module l Replace a UPS in a parallel system l Recycle used batteries or UPS l Update the UPS firmware UPS and Battery Care For the best preventive maintenance, keep the area around the UPS clean and dust-free. If the atmosphere is very dusty, clean the outside of the system with a vacuum cleaner.
UPS Maintenance WARNING l l l Servicing should be performed by qualified service personnel knowledgeable of batteries and required precautions. Keep unauthorized personnel away from batteries. Batteries can present a risk of electrical shock or burn from high short circuit current. Observe the following precautions: 1) Remove watches, rings, or other metal objects; 2) Use tools with insulated handles; 3) Do not lay tools or metal parts on top of batteries, 4) Wear rubber gloves and boots.
UPS Maintenance How to Replace UPS Internal Batteries CAUTION l l The UPS internal batteries are heavy (see page 136). Each battery tray holds two rows of five batteries. Use caution when handling the heavy battery trays. Pull the battery trays out onto a flat, stable surface. The battery trays are unsupported when you pull them out of the UPS. To replace the battery trays in the UPS cabinet: 1. Verify that the battery circuit breaker is in the OFF (O) position (see Figure 60 on page 74). 2.
UPS Maintenance 3. Remove the eight screws on the battery cover plate and retain. Remove the plate. See Figure 81. Figure 81. Removing the UPS Battery Cover Plate CAUTION l l 4. The UPS internal batteries are heavy (see page 136). Each battery tray holds two rows of five batteries. Use caution when handling the heavy battery trays. Pull the battery trays out onto a flat, stable surface. The battery trays are unsupported when you pull them out of the UPS.
UPS Maintenance Figure 82. Installing the UPS Battery Trays (Two Battery Strings) Figure 83. Installing the UPS Single-string Battery Trays for 5.1 kVA BladeUPS 7. Reinstall the battery cover plate. 8. Replace the UPS front cover (see Figure 84): Plug the LCD cable from the control panel on the front cover into the connector on the electronics module. Use care to loop the LCD cable gently in front of the electronics module.
UPS Maintenance 9. Verify that no alarms are indicated on the control panel. Figure 84. Replacing the UPS Front Cover Testing New Batteries NOTE 1 The batteries must be fully charged and the UPS must not be in Battery mode to perform the battery test. NOTE 2 For an accurate battery test, test the UPS with at least 10% load applied to the UPS. To test new batteries: 1. Plug the UPS into a power outlet for 48 hours to charge the battery. 2. Press any button to activate the menu options. 3.
UPS Maintenance Replacing the Electronics Module You can easily replace the electronics module without turning the UPS off or disconnecting the load. Battery mode is not available and your equipment is not protected; however, the utility power continues to be filtered passively by the UPS. If you prefer to remove input power to change the electronics module, see “Individual UPS Shutdown” on page 102. NOTE DO NOT DISCONNECT the electronics module while the UPS is in Battery mode.
UPS Maintenance Electronics Module Locking Screw LCD Cable Ring Handle Figure 85. Removing the UPS Front Cover and Electronics Module 4. Label the original module with masking tape or some other identifier. Record the serial number of the replacement module for your warranty. If not returning the electronics module for warranty, see the following section, “Recycling the Used Battery or UPS” on page 129 for proper disposal. 5. Insert the replacement module by sliding it carefully into the cabinet.
UPS Maintenance 10. Verify that all UPSs are set to use the same power strategy (High Efficiency or Standard). You can change the power strategy from the front panel. See User Settings in Table 12 on page 95. Figure 86. Replacing the UPS Front Cover Replacing a UPS in a Parallel System You can replace a UPS in a parallel system without powering down the system or protected load. Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
UPS Maintenance NOTE DO NOT TURN OFF the system. To replace a UPS in a parallel system: 1. Press any button on the front panel display of the UPS to be replaced to activate the menu options. Select TURN UPS ON/OFF, TURN UPS OFF, and press the button. 2. Confirm the selection. Press and hold the button for three seconds, until the UPS stops beeping. The UPS removes power to the UPS output. The output relays open, the UPS transfers to Standby mode, and the indicators turn off. 3.
UPS Maintenance 10. Remove the eight screws on the battery cover plate and retain. Remove the plate. See a similar removal in Figure 81 on page 122. CAUTION l l The UPS internal batteries are heavy (see page 136). Each battery tray holds two rows of five batteries. Use caution when handling the heavy battery trays. Pull the battery trays out onto a flat, stable surface. The battery trays are unsupported when you pull them out of the UPS. 11. Untuck the plastic handle at the end of a battery tray.
UPS Maintenance NOTE Firmware v2.0 does not operate in a parallel system with v1.xx. When adding a new UPS to a parallel system, verify that all UPSs in the parallel system are updated to v2.x. See Step 15 on page 91 to view the firmware version on the display panel. Eaton BladeUPS 5.1 kVA to 60 kVA (N+1) User’s Guide 164201649—Rev 9 www.eaton.
Chapter 8 Service and Troubleshooting Service and Support Use the troubleshooting chart in this chapter to determine the UPS alarm condition and resolution. If you have additional questions or problems with the UPS, call your Local Distributor or the Help Desk at one of the following telephone numbers and ask for a UPS technical representative.
Service and Troubleshooting Table 18. Troubleshooting Alarms and Conditions Alarm or Condition Possible Cause Action ON BATTERY A utility failure has occurred and the UPS is in Battery mode. The UPS is powering the equipment with battery power. Prepare your equipment for shutdown. The UPS is in Battery mode and the battery is running low. This warning is approximate, and the actual time to shutdown may vary significantly.
Service and Troubleshooting Table 18. Troubleshooting Alarms and Conditions (Continued) Alarm or Condition Possible Cause OVERTEMPERATURE The UPS internal temperature is too high or a fan has failed. Shut down the UPS. Clear vents and remove any heat sources. Allow the UPS to cool. Ensure that the airflow around the UPS is not restricted. Restart the UPS. If the condition persists, contact your service representative.
Service and Troubleshooting Table 18. Troubleshooting Alarms and Conditions (Continued) Alarm or Condition Possible Cause Battery test aborted. The bypass utility became unavailable during the test. Verify that the bypass utility is available and within limits. Restart the battery test. If the battery test aborts repeatedly, see “Running Automatic Battery Tests” on page 105. User cancelled the battery test through the front panel. Restart the battery test. The bypass utility does not qualify.
Chapter 9 Specifications This chapter provides the following specifications: l Model list l Weights and dimensions l Electrical input and output l Environmental and safety l Battery Table 19. Model List UPS Model Number Power Levels (Rated at Nominal Inputs) BladeUPS 12 12 kVA or 12 kW at 208V See Note BladeUPS 12i 12 kVA or 12 kW at 400V See Note BladeUPS 8 8 kVA or 8 kW at 208VSee Note BladeUPS 5.1 5.1 kVA or 5.
Specifications Table 20. Weights and Dimensions UPS Extended Battery Module (EBM) 441 x 660 x 261 mm 17.4” x 26” x 10.3” (6U) 438 x 660 x 131 mm 17.2” x 26.0” x 5.2” (3U) BladeUPS 12 model without internal batteries: 61 kg (135 lb) BladeUPS 12i model without internal batteries: 63.5 kg (140 lb) BladeUPS 12 model with internal batteries: 141 kg (311 lb) BladeUPS 12i model with internal batteries: 143 kg (316 lb) BladeUPS 5.1 model with single string of internal batteries: 100 kg (219 lb) BladeUPS 5.
Specifications Table 23. Electrical Input BladeUPS 12 Model BladeUPS 12i Model Input Power Factor Input Mode Input Source BladeUPS 8 Model BladeUPS 5.1 Model High Efficiency setting: load dependent Standard setting: >0.99 Three-phase 5-wire with continuous neutral. NOTE: Contact your Eaton UPS sales specialist for operation with 4-pole ATS switches. Table 24. Electrical Output Nominal Output Voltage Output Voltage Variation BladeUPS 12 Model BladeUPS 12i Model BladeUPS 8 Model BladeUPS 5.
Specifications Table 25. Environmental and Safety BladeUPS 12 Model BladeUPS 12i Model BladeUPS 8 Model Relative Humidity Operating: 5–95% noncondensing Non-operating: 5–95% relative humidity, 38.7°C (101.
Specifications Table 28. Parallel UPS System Battery Runtimes at Full/Half Load (in Minutes at Capacity) Number of UPSs kW UPS Internal Batteries +1 EBM +2 EBMs +3 EBMs +4 EBMs 4 48/24 4.7/13.6 9.5/27 17/42 27/60 34/76 5 60/30 4.7/13.6 9.5/27 17/42 27/60 34/76 NOTE Battery times are approximate and vary depending on the load configuration and battery charge. Table 29.
Chapter 10 Warranty Limited Warranty Eaton® UPS Model: BladeUPS® (Global) WARRANTOR: The warrantor for the limited warranties set forth herein is Eaton Corporation, an Ohio Corporation (“Eaton”). LIMITED WARRANTY: This limited warranty (this “Warranty”) applies only to the original Purchaser (the “End-User”) of any Eaton BladeUPS Products (individually and collectively, the “Product”) purchased and registered with Eaton and cannot be transferred.
Warranty This Warranty is not valid if the Product’s serial numbers have been removed or are illegible. Any Warranted Items repaired or replaced pursuant to this Warranty will be warranted for the remaining portion of the original Warranty subject to all the terms thereof. Eaton shall not be responsible for any charges for testing, checking, removal, or installation of Warranted Items. EATON DOES NOT WARRANT EQUIPMENT NOT MANUFACTURED BY EATON.
