Powerware Series

Eaton 9390 Service Manual

Uninterruptible Power Supply
20-160 kVA

p/n: 164201537-001
Revision H00
 NOTICE OF PROPRIETARY INFORMATION

The equipment discussed herein is capable of causing great harm to life, limb, and/or property.
Installation, maintenance, and/or repair of the equipment referenced herein must be performed
by Eaton Corporation duly authorized or trained, certified personnel.

Notwithstanding the foregoing, Eaton Corporation assumes NO responsibility for any damage or
injury to any persons or property which may be caused to any extent by reliance on the informa-
tion provided herein except to the extent such damage or injury results solely and directly from
the willful negligence of Eaton Corporation, its agents, or employees.

Additionally, Eaton Corporation shall not be liable for any indirect, special incidental, or conse-
quential damages, such as, but not limited to, loss of anticipated profits, good will, or other eco-
nomic loss in connection with or arising out of the existence of, the furnishing of, or the use of the
information provided for in this agreement, whether or not the possibility of damage was dis-
closed to or could have been reasonably foreseen by EatonCorporation.

The information contained herein is proprietary to Eaton Corporation. IT IS UNLAWFUL TO

COPY OR REPRODUCE THIS DOCUMENT OR ANY PART THEREOF IN ANY MEDIA OR TO
USE OR REFERENCE SAME EXCEPT FOR THOSE PURPOSES IN THE MEANS AND QUANTI-
TIES SPECIFIED BY WRITTEN AGREEMENT WITH Eaton CORPORATION.

Periodically, changes are made to the contents herein. Please contact Eaton Corporation or your
original source for any modification, updates, or new additions. Due to the possibility of such
changes, RELIABILITY ON THE CONTENTS HEREIN IS AT THE RECIPIENT’S/USER’S OWN
RISK.

©2009 Eaton Corporation. Company Confidential. All rights reserved.

9390 Service Manual

Table 1-1 9390 Change Sheet

REV. # DATE DESCRIPTION

H00 September Added 9390 refresh information throughout the manual. Also edited and
2009 updated information as necessary.
Ch. 1, System Overview - Added ESM RT and Parallel modes of operation.
Ch. 2, Safety - No significant changes.
Ch. 3, Installation and Startup - Added 9390 IT internal battery and Energy
Saver Mode information to startup procedure; moved load sync control
procedure to Ch. 6, Options.
Ch. 4, Functional Descriptions - Updated firmware functional descriptions with
DSP 5.2 information; added easy capacity test and energy saver mode
functional descriptions; updated communication server board information to
reflect changes with the mandatory CSB.
Ch. 5, Connectivity and Communications - Updated XCP screens. Added a
summary alarm relay customization procedure.
Ch. 6, Options - Added 9390 IT internal battery information; added Vycon
flywheel connection to 9390 information; added easy capacity test extended
commissioning test information.
Ch. 7, Removal and Replacement - Added a 160 kVA DC fuse removal and
replacement procedure.
Ch. 8, Calibration - Updated the parallel load share calibration procedure.
Ch. 9, Troubleshooting and Maintenance - Updated the preventive
maintenance procedure and the XCP alarm chart.
Ch. 10, Parts - Added ESM upgrade kits, capacitor upgrade kits, and contactor
part numbers for ABB and Cutler Hammer contactors.
Ch. 11, Schematics - Added new CTO chart, new control board and interface
board schematics, relay interface board schematic, internal battery schematic,
Eaton 12V 34W battery specification sheet, and Vycon flywheel connection to
9390 information.

© 2009 Eaton Corporation. Company Confidential. –1

 9390 Service Manual

Table 1-1 9390 Change Sheet

REV. # DATE DESCRIPTION

G.00 November Updated chapter layout to match that of the 9395. Rearranged information
2008 accordingly to make the manual more intuitive for users. Fixed errors and typos
as found during the revision process.
Ch. 1, System Overview - No significant changes.
Ch. 2, Safety - No significant changes.
Ch. 3, Installation and Startup - Added NiCAD battery setup instructions; added
parallel wiring diagrams.
Ch. 4, Functional Descriptions - Added information about the new common
control and interface boards and the mandatory CSB release. Provided
description of DSP code 5.0 operation. Added a precharge DC link graph,
NiCAD Battery information, AutoRestart description, and updated the mini-CSB
description; fixed the K5 functional description.
Ch. 5, Connectivity and Communications - Added XCP Service Tool 03.16.01
overview.
Ch. 6, Options - No significant changes.
Ch. 7, Removal and Replacement - Added explanation of new common control
and interface board compatibility as it relates to removal and replacement.
Ch. 8, Calibration - Added display meters calibration procedure.
Ch. 9, Troubleshooting and Maintenance - Added a description of gate power
meters and how to interpret them. Added a description of reduced battery string
operation and how to setup. Moved kVA upgrade and PM sheets to Chapter 9.
Ch. 10, Parts - Updated parts lists, fixed errors, and added 400V RPO unit part
lists to the 400V HPO parts section.
Ch. 11, Schematics - Added new CTO chart.

–2 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual

Table 1-1 9390 Change Sheet

REV. # DATE DESCRIPTION

F.00 May 2007 NOTE: 9390 UPS power ranges from 20 kVA, not 40, to 160 kVA. All updates
for Rev. F shown in bold here and in Service Manual pages. Includes new
information from NPSE News Flash newsletters, classroom, and lab exercises.
Edited and reviewed all changes with 9390 engineers and technical instructors.
Ch. 1, System Overview - Added text and photos of 160 kVA UPS front and
inside views.
Ch. 2, Safety - No significant changes
Ch. 3, Installation & Startup - Added photos of 80 kVA and 160 kVA Terminal
Blocks. Corrected Mechanical Inspection procedure 4.c. Updated parallel
inspections with XCP PCB/Startup procedures. Added single and dual feed
installation note.
Ch.4, Functional Descriptions - No significant changes
Ch. 5, Connectivity & Communication - Updated Modem Setup procedures for
CRC and Customer Paging, Single Module. (HOLD-Added photo and
information for a second CAN Bridge card, with RJ-45 connectors.) Added text
and photo for X-Slot locations.
Ch. 6, Troubleshooting & Maintenance - Added schematics for 80 and 160 kVA
CAN Network, with CAT5 control harness cables, and Mini-CSB option. Added
note for Field and Tech Support Feedback. Set torque of 30 inch-pounds for
TB3 connections.
Ch. 7, Parts - (HOLD-Added second CAN Bridge card, RJ-45 part number.)
Added part numbers for 80, 120, and 160 kVA CAT5 cables. Added Terminal
Block Control harness, fuse, and label part numbers. Added a parts web site for
400-volt units built in Finland. Added Field Kit assembly numbers for DB-9
(HOLD-and RJ-45) CAN Bridge cards. Added Neutral-Forming Transformer
Field Kit part numbers.
Ch. 8, Options & Accessories - Added more references to encourage CSEs to
read I/O manuals concerning single-feed jumper situations. Added photo of
TB3 with ISB Contactor and Snubber PC Board. Added text and photo of field
kits for Neutral-Forming Transformers. Added Sidecar Cabinet inside view.
Ch. 9, Prints - Added two prints for 80 and 160 kVA Neutral-Forming
Transformer Field Kits. Updated 110720556 to Rev C00.

© 2009 Eaton Corporation. Company Confidential. –3

 9390 Service Manual

Table 1-1 9390 Change Sheet

REV. # DATE DESCRIPTION

E.00 October NOTE: 9390 system power ranges from 20 kVA, rather than 40. HPO
2006 engineers added extensive information in Chapters 3, 5, 6, and 9 for 400 Volt
units. Added cross references throughout Service Manual, and to the BBS Web
site. Added Partial Table of Contents to first page(s) of each chapter. Edited,
reviewed all changes with several engineers.
Ch. 1, System Overview - No significant changes
Ch. 2, Safety - No significant changes
Ch. 3, Installation & Startup - Added cross reference to CAN Bridge print.
Reversed MOB wiring NO and NC relay contacts in Section 3.2.1.1 and Figure.
Added latest Parallel Wiring for NO MOB AUX and With MOB AUX. Added
400V information for Single and Parallel Modules and Startup Worksheets.
Updated XCP Service Tool Battery Startup procedures for single and parallel
modules. Added text and figures for new Terminal Blocks TB1 and TB2, wiring
charts, Load Sync Control, and Mini-CSB installation. Added text for Power
Conditioner Mode.
Ch.4, Functional Descriptions - Added Battery Start Charge Voltage description
and updated the charging cycle graph on Figure 4-4 to show this.
Ch. 5, Connectivity & Communication - Updated information for X-Slot device
locations. Added information for flashing the Control Board and Mini-CSB
Board. Added latest Parallel Wiring charts and figures for NO MOB AUX and
With MOB AUX. Added HyperTerminal Emulation procedure and screens at
end of chapter. Added Modem Procedure, Active Response for CRC.
Ch. 6, Troubleshooting & Maintenance - Corrected Inverter AC Output voltages
and calibration. Updated alarm description recommended actions. Updated
Table 6-1, Scalar Limits. Updated calibration for inverter AC output voltage.
Updated Parallel Load Share Calibration for EEPROM 220. Updated
Calibration procedures that use automatic features of XCP Service Tool, V3.04.
Updated calibration procedures to include 100-160 kVA UPSs. Updated
Firmware and Flash procedures on the gstechsupport website. Updated
Interface & Control Board recommissioning procedure. Added Field feedback
notes. Added Document Nos. for Field Conversion and kVA Reconfiguration
procedures found on the web sites.
Ch. 7, Parts - Added 400 Volts spare parts listings, including most common
parts. Added Load Sync Control Harness kits.
Ch. 8, Options & Accessories - Added text for Power Conditioner Mode.
Ch. 9, Prints - Updated, changed, or added total of fifty-two drawings. Added
400-Volt HPO drawings.

–4 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual

Table 1-1 9390 Change Sheet

REV. # DATE DESCRIPTION

D.00 Nov. 2005

Added additional cross referencing to figures, tables, sections, and to other
chapters throughout Service Manual. Added Partial Table of Contents to first
page(s) of each chapter. Edited, ran Spell check throughout.
Ch. 1 - Added 9390 Parallel with MOB information. Updated Figures 1-2, 1-3, 1-
4, 1-5, 1-9, 1-10. Added Internal Service Switch option text and Figure 1-8.
Removed Specification information and referred CSEs to User’s Guide.
Ch. 2 - No significant changes
Ch. 3 - Deleted older firmware version information. Deleted electrical inspection
text for 9390 that have dual sources with dual feeds. Added battery
temperature compensation text for the Environmental Monitoring Probe. Added
pull chain wiring text and figures and Sidecar Cabinet text. Redefined Customer
neutral-to-ground bonding requirements.Added single module operational
inspection with no MOB AUX contacts and parallel units with MOB AUX
contacts. Updated firmware flashing version levels. Added figures for examples
of parallel unit pull chain and MBP control wiring.
Ch.4 - Added new Advanced Battery Management text and figures. Updated
Display Module languages. Added Mini-CSB Logging Functions with text,
figures, and screen shots. Added Battery Temperature Compensation text,
chart, and figure. Added Internal Service Switch option text and figure.
Ch. 5 - Setup Procedure for Single Module was changed to Remote Notify from
Active Response; text and screen shots added. Added figures for TB-1 and TB-
2. and Custom Node Bit Mode for Industrial Relay and Relay Interface Cards.
Ch. 6 - Added new alarm definitions and actions for: Rectifier and Inverter
overtemperature trip, rectifier tripped, check static switch, and check input
switchgear. Updated Calibration procedure. Added R&R for the Smart Gate
Drive Board. Added Module No. 2 Isolation and Troubleshooting procedure.
Updated flashing version levels. Added 9390 kVA Reconfiguration procedures.
Ch. 7 - Added cross references to reference information on CD. Updated Parts
Look-Up procedure. Added kva upgrade and contactor vendor change
information. Added figures for serial numbers and deviated transformers.
Added, updated information throughout chapter.
Ch. 8 - Added information on Sidecar Cabinet, IAC (Integrated Accessory
Cabinet), Thinline PDU (Power Distribution Unit), also frequency and voltage
converters. Added RIM II (Remote Interface Module), and SCM II (Supervisory
Contact Module). Updated RMP to RMP II (Remote Monitor Panel).
Ch. 9 - Added or updated various drawings. Added Sidecar Cabinet drawings,
battery watts per cell charts, and battery runtime and weight data.

© 2009 Eaton Corporation. Company Confidential. –5

 9390 Service Manual

Table 1-1 9390 Change Sheet

REV. # DATE DESCRIPTION

C.00 March Applied new formatting & section numbering properties to entire book, added
2005 List of Figures and fill-in-the-blank printable forms, updated illustrated parts
breakdown.
Ch. 1 - Updated Specifications.
Ch. 2 - Minor grammatical changes only.
Ch. 3 - Updates throughout, including options and procedural changes due to
new releases, such as Load Sync Control, in product & firmware.
Ch. 4 - Added & updated ABM information, added constant float with battery
test section, updated RMP, CAN & Mini-CSB info.
Ch. 5 - Updated Options chart, updated LV & HV Relay Cards, updated CAN
Bridge Card, added Mini-CSB info & installation.
Ch. 6 - Added various firmware & misc. alarms, added misc. board & network
TS info, added 160kVA R&R procedures, added RT/Parallel conversion
procedures, added performance check & PM procedure & data sheets.
Ch. 7 - Updated changed part numbers, added new parts, kits & usage
information.
Ch. 8 - Added 400V MBP, Power Conditioner Mode, and CAN connection table
for RMP.
Ch. 9 - Added or updated various drawings to reflect latest products.
Ch. 10 - Updated existing manuals, added 160kVA IDC manual & IDC
Application Note #1

B.00 October Ch. 1 - Removed references to SBM, repaginated for clarity, updated
2004 specifications.
Ch. 2 - Updated with battery warnings.
Ch. 3 - Updated RT S/U, Major revision of Parallel S/U.
Ch. 4 - Updates throughout, added new Enhanced Smart Gate Drive Board
information.
Ch. 5 - Updates throughout, repaginated for clarity, added new CAN Bridge
Board information.
Ch. 6 - Reformatted T/S charts for ease of use, updated calibration procedures,
added or updated R/R procedures for 160kVA UPMs where applicable.
Ch. 7 - Added parts for 160kVA UPMs.
Ch. 8 - No significant updates.
Ch. 9 - Added or updated various drawings to reflect latest products.
Ch. 10 - Added 120-160kVA I & O Manual

–6 © 2009 Eaton Corporation. Company Confidential.

Table of Contents
Chapter 1 System Overview ..................................................................................... 1-1
Help for Customer Service Engineers ................................................................................ 1–1
E-ESSDocumentation Mailbox ...................................................................................................1–1
HTTP://GSTECHSUP.POWERWARE.COM Web site ...............................................................1–1
Supporting Documents Internet Web site ...................................................................................1–1
System Description ............................................................................................................ 1–2
Single Module Systems ..............................................................................................................1–2
9390 Model Versions ..................................................................................................................1–4
9390 Refresh Version .................................................................................................................1–5
9390 IT Version with Internal Battery .........................................................................................1–5
Multi-Module Parallel Systems ...................................................................................................1–5
Parallel for Redundancy (1 + 1), (2 + 1), (3 + 1) .........................................................................1–7
Parallel for Capacity (2 + 0), (3 + 0), (4 + 0) ...............................................................................1–8
Modes of Operation - Single Module / Reverse Transfer (RT) ........................................ 1–10
Normal Mode ............................................................................................................................ 1–10
Battery Mode ............................................................................................................................ 1–11
Bypass Mode ............................................................................................................................ 1–13
Energy Saver Mode .................................................................................................................. 1–15
Bypass Mode with Internal Service Switch Option ................................................................... 1–17
Modes of Operation - Parallel Redundant, Capacity. ....................................................... 1–18
Operating the 9390 Parallel with Module Output Breakers (MOBs) with Auxiliaries ................ 1–18
Normal Mode - Parallel ............................................................................................................. 1–19
Battery Mode - Parallel ............................................................................................................. 1–21
Bypass Mode - Parallel ............................................................................................................. 1–24
Energy Saver Mode - Parallel ................................................................................................... 1–27
9390 Specifications .................................................................................................................. 1–29

Chapter 2 Safety ........................................................................................................ 2-1

General Safety Considerations .......................................................................................... 2–1
Tools, Equipment, and Expendable Field Service Supplies .......................................................2–1
General Safety Rules .................................................................................................................2–1
Environmental Safety ......................................................................................................... 2–2
Electrical Safety ................................................................................................................. 2–3
Mechanical Safety .............................................................................................................. 2–5
Eye Safety .......................................................................................................................... 2–5
UPS Safety ........................................................................................................................ 2–6
Operating Environment ...............................................................................................................2–6
Normal Operation .......................................................................................................................2–6
Maintenance/Service ..................................................................................................................2–6
Batteries .....................................................................................................................................2–7
Site Safety .......................................................................................................................... 2–8
Summary .......................................................................................................................... 2–10
Electrostatic Discharge (ESD) Procedure and Equipment Requirements ....................... 2–11
Purpose .................................................................................................................................... 2–11
Scope ....................................................................................................................................... 2–11
Applicable Documents and Materials ....................................................................................... 2–11
Definitions ................................................................................................................................. 2–11
Procedure ................................................................................................................................. 2–12
Removal of Boards ................................................................................................................... 2–12

© 2009 Eaton Corporation. Company Confidential. i

Table of Contents 9390 Service Manual

Packaging of Boards ................................................................................................................ 2–13

General Guidelines for ESD Protection ........................................................................... 2–14

Chapter 3 Installation and Startup .......................................................................... 3-1

EATON® 9390 UNINTERRUPTIBLE POWER SUPPLY (20 - 160 kVA) SINGLE MODULE
(RT) ................................................................................................................................. 3–1
Mechanical Inspection ................................................................................................................3–1
Electrical Inspection ....................................................................................................................3–7
Operational Inspection ................................................................................................................3–9
Basic Easy Capacity Testing .................................................................................................... 3–12
Inspection Completion .............................................................................................................. 3–15
EATON® 9390 UNINTERRUPTIBLE POWER SUPPLY (40 - 160 kVA) Parallel Redundant /
Capacity (PR / PC) ........................................................................................................ 3–16
Mechanical Inspection .............................................................................................................. 3–16
Examples of Parallel Unit Pull chain and Maintenance Bypass Control Wiring ........................ 3–25
Electrical Inspection .................................................................................................................. 3–27
Single Module Operational Inspection, 9390 Parallel Units ...................................................... 3–30
Operational Inspection .............................................................................................................. 3–31
Parallel Operational Inspection ................................................................................................. 3–34
Total System Operational Inspection ........................................................................................ 3–36
Inspection Completion .............................................................................................................. 3–38
TERMINAL BLOCKS ....................................................................................................... 3–39

Chapter 4 Functional Descriptions ......................................................................... 4-1

FIRMWARE ....................................................................................................................... 4–1
DSP Firmware 5.XX Features ....................................................................................................4–1
POWER MODULE ............................................................................................................. 4–2
Introduction .................................................................................................................................4–2
Description and Operation ..........................................................................................................4–3
POWER MODULE - BATTERY CONVERTER .................................................................. 4–7
Introduction .................................................................................................................................4–7
Description and Operation ..........................................................................................................4–7
Boost Charge Mode (208V) ........................................................................................................4–8
Buck Charge Mode (480V) .........................................................................................................4–9
Advanced Battery Management (ABM) ......................................................................................4–9
Battery Lifetime ......................................................................................................................... 4–17
Battery Test .............................................................................................................................. 4–20
User Interface to Battery Test Information ................................................................................ 4–24
NiCd Batteries .................................................................................................................. 4–25
Overview ................................................................................................................................... 4–25
Charge Cycle ............................................................................................................................ 4–25
Battery Information ................................................................................................................... 4–25
POWER MODULE - INVERTER ...................................................................................... 4–26
Introduction ............................................................................................................................... 4–26
Description and Operation ........................................................................................................ 4–26
Neutral Regulator ..................................................................................................................... 4–28
Inverter Regulation and Sync Control ....................................................................................... 4–28
POWER MODULE -SMART GATE DRIVE BOARD-OLD (101073650-001) ................... 4–29
Introduction ............................................................................................................................... 4–29
Description and Operation ........................................................................................................ 4–30
POWER MODULE-SMART GATE DRIVE BOARD-NEW (101073679-001) ................... 4–32
Introduction ............................................................................................................................... 4–32

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9390 Service Manual Table of Contents

Description and Operation ........................................................................................................ 4–32

BYPASS ........................................................................................................................... 4–34
Introduction ............................................................................................................................... 4–34
Description and Operation ........................................................................................................ 4–34
LOGIC POWER SUPPLIES ............................................................................................. 4–37
Description and Operation ........................................................................................................ 4–37
CONTROL CIRCUIT BOARD .......................................................................................... 4–40
Introduction ............................................................................................................................... 4–40
New vs. Old Control Boards ..................................................................................................... 4–40
Operational Commands ............................................................................................................ 4–41
Machine States ......................................................................................................................... 4–42
Inverter Sync ............................................................................................................................ 4–56
Auto Mode ................................................................................................................................ 4–56
Auto Restart Operation ............................................................................................................. 4–57
Interface Circuit Board ..................................................................................................... 4–58
New vs. Old Interface Boards ................................................................................................... 4–58
Introduction ............................................................................................................................... 4–59
Description and Operation ........................................................................................................ 4–59
STATIC SWITCH BOARD ............................................................................................... 4–65
Introduction ............................................................................................................................... 4–65
Description and Operation ........................................................................................................ 4–66
COMMUNICATIONS SERVER BOARD (CSB) .............................................................. 4–70
CSB .......................................................................................................................................... 4–70
Mandatory CSB ........................................................................................................................ 4–70
Features with and without CSB ................................................................................................ 4–71
CSB Logging Functions ............................................................................................................ 4–72
DISPLAY MODULE ........................................................................................................ 4–73
Overview ................................................................................................................................... 4–73
Specifications ........................................................................................................................... 4–74
User Interface Controller .................................................................................................. 4–76
User Interface Control Processor ............................................................................................. 4–76
Languages ................................................................................................................................ 4–77
LCD Setup with CSB ................................................................................................................ 4–78
Graphics ................................................................................................................................... 4–79
Serial Ports & X-slots ................................................................................................................ 4–79
Output Relays ........................................................................................................................... 4–81
Building Alarm Inputs ................................................................................................................ 4–81
Remote Monitor Panel .............................................................................................................. 4–82
Parallel System Communications ............................................................................................. 4–82
ESM Mode ....................................................................................................................... 4–83
ESM Operation ......................................................................................................................... 4–83
Parallel ESM Operation ............................................................................................................ 4–84
ECT (Easy Capacity Test) ............................................................................................... 4–86
Testing Capabilities of Easy Capacity Test .............................................................................. 4–86
Easy Capacity Test Basics .......................................................................................................4–86

Chapter 5 Connectivity & Communication ............................................................. 5-1

9390 XCP Service Tool Overview ...................................................................................... 5–2
The CTO Tab ..............................................................................................................................5–2
The Meters Tab ..........................................................................................................................5–3
The Modem Tab .........................................................................................................................5–5
The EEPROM Tab ......................................................................................................................5–7

© 2009 Eaton Corporation. Company Confidential. iii

Table of Contents 9390 Service Manual

The PCB Tab ..............................................................................................................................5–7

Battery Startup Tab ....................................................................................................................5–8
The Options Tab ....................................................................................................................... 5–10
Reports ..................................................................................................................................... 5–12
The Flash Tab .......................................................................................................................... 5–13
The Building Tab ...................................................................................................................... 5–14
The Events Alarm ..................................................................................................................... 5–15
Battery Options Tab .................................................................................................................. 5–16
The Distributed Bypass Tab ..................................................................................................... 5–20
The ECT Tab ............................................................................................................................ 5–21
The Configuration Tab .............................................................................................................. 5–23
The About Tab .......................................................................................................................... 5–26
Summary Alarm Relay Configuration ............................................................................... 5–27
Customizing an event ............................................................................................................... 5–27
9390 X-SLOT CONNECTIVITY DEVICES ..................................................................... 5–29
Basic Serial Communication ..................................................................................................... 5–30
Relay Signaling ......................................................................................................................... 5–31
Building Alarm Inputs ................................................................................................................ 5–31
Additional Connectivity & Software ........................................................................................... 5–31
Low Voltage (LV) Relay Interface Card .................................................................................... 5–31
High Voltage (HV) Industrial Relay ........................................................................................... 5–33
10/100 MB SNMP/Web/Hub Card Adapter .............................................................................. 5–34
MODBUS Communications Card ............................................................................................. 5–35
Modem Card ............................................................................................................................. 5–37
CAN Bridge Card ...................................................................................................................... 5–38
MODEM Setup, ACTIVE RESPONSE MONITORING TO CRC-single module .............. 5–42
Scope ....................................................................................................................................... 5–42
General Notes .......................................................................................................................... 5–42
Requirements ........................................................................................................................... 5–42
UPS Setup Procedure .............................................................................................................. 5–43
Programming UPS for EatonPW Monitoring ............................................................................ 5–45
Test Procedure ......................................................................................................................... 5–47
CUSTOMER INFORMATION FORM .............................................................................. 5–48
Setup for 9390 REMOTE NOTIFY, CUSTOMER PAGING -single module ..................... 5–50
Scope ....................................................................................................................................... 5–50
General Notes .......................................................................................................................... 5–50
Requirements ........................................................................................................................... 5–50
UPS Setup Procedure .............................................................................................................. 5–51
Customizing Node Bits for Remote Notify with Mini-CSB Installed .......................................... 5–54
Customizing Node Bits for Remote Notify without Mini-CSB Installed .................................... 5–56
Test Procedure ........................................................................................................................ 5–57
9390 HYPERTERMINAL COMMUNICATIONS .............................................................. 5–58
Basic Serial Communications ...................................................................................................5–58
Hyper Terminal Emulation Configuration for 9390 UPS ........................................................... 5–58
Hyper Terminal Log Capture Procedure ................................................................................... 5–62
9390 COMMUNICATION ACCESS LEVELS .................................................................. 5–66
Default Passwords .................................................................................................................... 5–67

Chapter 6 Options & Accessories ........................................................................... 6-1

EATON® 9390 UPS Internal Options ................................................................................ 6–1
Single or Dual-Feed Input ...........................................................................................................6–1
Internal Maintenance Bypass Switch (400V Units Only) ............................................................6–1
Internal Service / Bypass Switch (ISS / ISB) ..............................................................................6–2

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9390 Service Manual Table of Contents

Sync Control ...............................................................................................................................6–5

Seismic Capability ......................................................................................................................6–5
Power Conditioner Mode ............................................................................................................6–5
Convert an RT to Power Conditioner Mode ................................................................................6–5
NEUTRAL-FORMING TRANSFORMER FIELD KITS ....................................................... 6–8
Frequency Converter / Voltage Converter ......................................................................... 6–9
Energy Saver Mode ......................................................................................................... 6–10
ECT Extended Commissioning Test ................................................................................ 6–11
9390 Battery Options ....................................................................................................... 6–12
9390 IT Internal Battery ............................................................................................................ 6–12
VRLA Battery Cabinets ............................................................................................................. 6–12
Wet Cell Battery ........................................................................................................................ 6–13
9390 EXTERNAL ACCESSORIES .................................................................................. 6–16
Parallel Tie / Maintenance Bypass “Sidecar” Cabinet .............................................................. 6–16
External Maintenance Bypass (MBP) ....................................................................................... 6–17
Remote Emergency Power Off (REPO) ................................................................................... 6–18
Environmental Monitoring Probe (EMP) ................................................................................... 6–18
Integrated Accessory Cabinet (IAC) ......................................................................................... 6–18
Thinline PDU (PCDU) ............................................................................................................... 6–19
Wall Mounted Maintenance Wrap-around ................................................................................ 6–19
Remote Monitoring Panel (RMP II) ........................................................................................... 6–19
Relay Interface Module (RIM II) ................................................................................................ 6–20
Supervisory Contact Module (SCM II) ...................................................................................... 6–21
Integrated Distribution Cabinets (IDC) ...................................................................................... 6–22
Vycon Flywheel ................................................................................................................ 6–26
9390 RT EEP Setup (without mini CSB) for 1 or more Vycon Flywheels ................................ 6–26
9390 RT EEP Setup (with mini CSB) for 1 or more Vycon Flywheels ...................................... 6–27
LOAD SYNC CONTROL PROCEDURE .......................................................................... 6–29
Confirm Installation and Setup Software .................................................................................. 6–29
Electrically Verify Hardware and Software Setups ................................................................... 6–32
Verify Sync Control Operation from UPS-B with S1=UPS-A .................................................... 6–33
Verify Sync Control Operation from UPS-A with S1=UPS-A .................................................... 6–34
Verify Sync Control Operation from UPS-B with S1=UPS-B .................................................... 6–36
Verify Sync Control Operation from UPS-A with S1=UPS-B .................................................... 6–38

Chapter 7 Removal / Replacement .......................................................................... 7-1

Eaton® 9390 UPS Required Tools .................................................................................... 7–1
SMART GATE DRIVE BOARD ......................................................................................... 7–2
Preparation .................................................................................................................................7–2
Removal .....................................................................................................................................7–3
Replacement ............................................................................................................................ 7–11
Recommissioning ..................................................................................................................... 7–14
POWER MODULE (20-80 kVA) ....................................................................................... 7–15
Preparation ............................................................................................................................... 7–15
Removal ................................................................................................................................... 7–15
Replacement ............................................................................................................................ 7–23
Recommissioning ..................................................................................................................... 7–25
POWER MODULE (100-160kVA) .................................................................................... 7–27
Preparation ............................................................................................................................... 7–27
Removal ................................................................................................................................... 7–27
Replacement ............................................................................................................................ 7–33
Recommissioning ..................................................................................................................... 7–34

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STATIC SWITCH ASSEMBLY (20-80kVA) ..................................................................... 7–35

Preparation ............................................................................................................................... 7–35
Removal ................................................................................................................................... 7–35
Replacement ............................................................................................................................ 7–39
Recommissioning ..................................................................................................................... 7–39
STATIC SWITCH ASSEMBLY (100-160kVA) ................................................................. 7–41
Preparation ............................................................................................................................... 7–41
Removal ................................................................................................................................... 7–41
Replacement ............................................................................................................................ 7–42
Recommissioning ..................................................................................................................... 7–42
STATIC SWITCH BOARD PCB (20-80kVA) .................................................................... 7–44
Preparation ............................................................................................................................... 7–44
Removal ................................................................................................................................... 7–44
Replacement ............................................................................................................................ 7–46
Recommissioning ..................................................................................................................... 7–48
STATIC SWITCH BOARD PCB (100-160kVA) ................................................................ 7–49
Preparation ............................................................................................................................... 7–49
Removal ................................................................................................................................... 7–49
Replacement ............................................................................................................................ 7–50
Recommissioning ..................................................................................................................... 7–51
POWER SUPPLY BOARD PCB (20-80 & 100-160kVA) ................................................. 7–52
Preparation ............................................................................................................................... 7–52
Removal ................................................................................................................................... 7–52
Replacement ............................................................................................................................ 7–53
Recommissioning ..................................................................................................................... 7–53
Interface & Control Board PCBs (20-80kVA) ................................................................... 7–55
Preparation ............................................................................................................................... 7–55
Procedure ................................................................................................................................. 7–55
Removal ................................................................................................................................... 7–57
Replacement ............................................................................................................................ 7–57
Recommissioning ..................................................................................................................... 7–58
Feedback from the Field ........................................................................................................... 7–60
FAN ASSEMBLIES (20-80 & 100-160kVA) ..................................................................... 7–61
Preparation ............................................................................................................................... 7–61
Removal ................................................................................................................................... 7–63
Replacement ............................................................................................................................ 7–64
Recommissioning ..................................................................................................................... 7–65
HV & LV Capacitor Assembly (20-80 & 100 160kVA) ...................................................... 7–66
Preparation ............................................................................................................................... 7–66
Removal ................................................................................................................................... 7–66
Replacement ............................................................................................................................ 7–69
Recommissioning ..................................................................................................................... 7–69
DISPLAY ASSEMBLY (20-80 & 100-160kVA) ................................................................. 7–71
Preparation ............................................................................................................................... 7–71
Removal ................................................................................................................................... 7–71
Replacement ............................................................................................................................ 7–73
Recommissioning ..................................................................................................................... 7–73
Mini-Communication Server Board (CSB) ....................................................................... 7–75
DC LINK FUSES (100-160 kVA) ...................................................................................... 7–77
Preparation ............................................................................................................................... 7–77
Removal ................................................................................................................................... 7–77
Replacement ............................................................................................................................ 7–78
Recommissioning ..................................................................................................................... 7–79

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INPUT CONTACTOR K1 (20-80 & 100-160 kVA HV UNITS) ......................................... 7–80

Preparation ............................................................................................................................... 7–80
Removal ................................................................................................................................... 7–80
Replacement ............................................................................................................................ 7–81
Recommissioning ..................................................................................................................... 7–81
INPUT CONTACTOR K1 (20-80 & 100-160 kVA LV UNITS) .......................................... 7–82
Preparation ............................................................................................................................... 7–82
Removal ................................................................................................................................... 7–82
Replacement ............................................................................................................................ 7–86
Recommissioning ..................................................................................................................... 7–87
OUTPUT CONTACTOR K3 (20-80 & 100-160kVA HV UNITS) ...................................... 7–88
Preparation ............................................................................................................................... 7–88
Removal ................................................................................................................................... 7–88
Replacement ............................................................................................................................ 7–89
Recommissioning ..................................................................................................................... 7–89
OUTPUT CONTACTOR K3 (20-80 & 100-160kVA LV UNITS) ....................................... 7–90
Preparation ............................................................................................................................... 7–90
Removal ................................................................................................................................... 7–90
Replacement ............................................................................................................................ 7–91
Recommissioning ..................................................................................................................... 7–93
BACKFEED PROTECTION CONTACTOR K5 (20-80 & 100-160kVA HV UNITS) ......... 7–94
Preparation ............................................................................................................................... 7–94
Removal ................................................................................................................................... 7–94
Replacement ............................................................................................................................ 7–95
Recommissioning ..................................................................................................................... 7–95
BACKFEED PROTECTION CONTACTOR K5
(20-80 & 100-160 kVA LV UNITS) ................................................................................. 7–96
Preparation ............................................................................................................................... 7–96
Removal ................................................................................................................................... 7–96
Replacement ............................................................................................................................ 7–97
Recommissioning ..................................................................................................................... 7–98

Chapter 8 Calibration ................................................................................................ 8-1

Tools Required ................................................................................................................... 8–1
General Calibration Information ......................................................................................... 8–1
Voltage Calibration ............................................................................................................. 8–1
Neutral Calibration ......................................................................................................................8–4
Calibrate Input Single Phase B Voltage .....................................................................................8–6
Calibrate Bypass Single Phase B Voltage ..................................................................................8–7
Calibrate Bypass AC Input Voltage ............................................................................................8–8
Calibrate Utility AC Input Voltage ...............................................................................................8–8
Calibrate Output Single Phase B Voltage ...................................................................................8–9
Calibrate Battery Voltage .......................................................................................................... 8–10
Calibrate DC Link Voltage ........................................................................................................ 8–10
Calibrate Inverter AC Output Voltage ....................................................................................... 8–11
Inverter Output Display Meter Calibration ................................................................................ 8–13
Current Calibration ........................................................................................................... 8–16
Calibrate Bypass Current ......................................................................................................... 8–16
Calibrate Utility Current ............................................................................................................ 8–17
Calibrate Battery Current .......................................................................................................... 8–18
Calibrate Inverter Current ......................................................................................................... 8–18
Parallel Calibration ........................................................................................................... 8–20

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Parallel Load Share .................................................................................................................. 8–20

Measurements for 208 and 480-Volt Calibrations ........................................................... 8–21
Measurements for 400-Volt Calibrations ......................................................................... 8–24

Chapter 9 Troubleshooting and Maintenance ........................................................ 9-1

Troubleshooting Procedures .............................................................................................. 9–1
Smart Gate Drive Board .............................................................................................................9–1
Gate Power (Firmware 5.00 and Newer) ....................................................................................9–6
Communication Server Board (CSB) ........................................................................................ 9–11
Isolation and Troubleshooting, Parallel Modules ...................................................................... 9–11
Maintenance .................................................................................................................... 9–16
Temporary Reduced Battery String Operation ......................................................................... 9–16
REVERSE TRANSFER & PARALLEL CONVERSION PROCEDURES ......................... 9–17
FIELD PARALLEL CONVERSION PROCEDURE ................................................................... 9–19
9390 kVA CONFIGURATION PROCEDURE .................................................................. 9–20
kVA RECONFIGURATION (UPGRADE) INSTRUCTIONS ...................................................... 9–20
Call Center, Logistics, and Depot Procedure ........................................................................... 9–20
Eaton® 9390, 20-160kVA UPS ............................................................................................... 9–24
Preventive Maintenance Procedure Purpose .................................................................. 9–25
Preparing to Complete a PM ............................................................................................ 9–26
Preventive Maintenance Procedure ................................................................................. 9–27
Required Materials ................................................................................................................... 9–27
Download and Save ................................................................................................................. 9–27
Review Alarm / Event Queue / Unit Configuration with Customer ............................................ 9–27
Customer Site and Unit Performance Discussion .................................................................... 9–28
Secure the Load ....................................................................................................................... 9–28
Verify Modifications, Grounding, Field Service Bulletins, and other options are terminated correctly.
9–29
Signs of Overheating .................................................................................................... 9–30
Fan Inspection .......................................................................................................................... 9–30
Battery Inspection ..................................................................................................................... 9–30
Transfer Verification ................................................................................................................. 9–31
Temperature Checks ................................................................................................................ 9–31
Metering Verification ................................................................................................................. 9–32
Fan Tachometer Verification .................................................................................................... 9–32
Generator and ATS verification (if applicable) .......................................................................... 9–33
Cleaning .................................................................................................................................. 9–33
Returning the unit to service ............................................................................................ 9–34
PREVENTIVE MAINTENANCE CHECKSHEET ............................................................. 9–35
Eaton® 9390, 20-160kVA UPS ................................................................................................ 9–35
Troubleshooting Charts .................................................................................................... 9–39
Action Levels ............................................................................................................................ 9–39
Alarm, Notice, & Status Definitions ...........................................................................................9–41

Chapter 10 Parts ..................................................................................................... 10-1

Information ....................................................................................................................... 10–1
Parts for EATON® 9390 UPS Units Built in Finland ................................................................. 10–1
RPO Parts Breakdown/Lookup Search Tool ............................................................................ 10–1
U.S. Assembled 380/400/415 Volt Units .................................................................................. 10–1
9390 Spare Parts Listings, 208V and 480V ..................................................................... 10–2
9390 SPARE PARTS LISTINGS, 400V ........................................................................... 10–7

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9390 UPM Subassemblies ............................................................................................. 10–13

Common Parts ............................................................................................................... 10–22
X-SLOT CONNECTIVITY DEVICE OPTIONS ............................................................... 10–27
ESM Upgrade Kits ......................................................................................................... 10–30
9390 Capacitor Replacement Kits ................................................................................. 10–31
NEUTRAL-FORMING TRANSFORMER FIELD KITS ................................................... 10–35
Contactor Vendor Change from ABB to Cutler-Hammer ............................................... 10–36
Contactor Vendor Change Documentation ............................................................................. 10–37
Reading HPO Format Circuit Board Part Numbers ................................................................ 10–38
9390 Power Supply Usage .....................................................................................................10–39
9390 Gate Drive Transformer Core Issue .............................................................................. 10–39
9390 Interface Board Fuse F7 Issue ...................................................................................... 10–40
Integrated Distribution Cabinets (IDC) (80kVA) ...................................................................... 10–41
Integrated Distribution Cabinets (IDC) (160kVA) ........................................................... 10–43
Parts Break-down / Look-up Procedure ......................................................................... 10–45
Requirements: ........................................................................................................................ 10–45
Enovia Access to Part Numbers ............................................................................................. 10–45

Chapter 11 Prints .................................................................................................... 11-1

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List of Figures
Figure 1-1 20-80 (left) and 100-160 (right) kVA UPS Front View ........................... 1–2
Figure 1-2 Basic Single Module System................................................................. 1–3
Figure 1-3 20-80 (left) and 100-160 (right) kVA UPS Inside View .......................... 1–4
Figure 1-4 9390 IT Version ..................................................................................... 1–5
Figure 1-5 Parallel Redundant System (1 + 1) ....................................................... 1–8
Figure 1-6 Parallel Capacity System (2 + 0)........................................................... 1–9
Figure 1-7 Normal Mode....................................................................................... 1–10
Figure 1-8 Battery Mode ....................................................................................... 1–12
Figure 1-9 Bypass Mode....................................................................................... 1–13
Figure 1-10 Energy Saver Mode............................................................................. 1–16
Figure 1-11 Bypass Mode with Internal Service Switch Option .............................. 1–17
Figure 1-12 Normal Mode Parallel Redundant (1 + 1)............................................ 1–19
Figure 1-13 NORMAL Mode Parallel Capacity (2+0) ............................................. 1–20
Figure 1-14 BATTERY Mode Parallel Redundant (1 + 1)....................................... 1–22
Figure 1-15 BATTERY Mode Parallel Capacity (2 + 0) .......................................... 1–23
Figure 1-16 BYPASS Mode Parallel Redundant (1 + 1)......................................... 1–25
Figure 1-17 BYPASS Mode Parallel Capacity (2 + 0) ............................................ 1–26
Figure 1-18 ESM Mode Parallel Redundant ........................................................... 1–28
Figure 1-19 ESM Mode Parallel Capacity............................................................... 1–29
Figure 3-1 Mini-CSB Plastic Tab Under Battery ..................................................... 3–3
Figure 3-2 Mini-CSB Logic Jumpers J9 - J12 ......................................................... 3–3
Figure 3-3 9390 IT .................................................................................................. 3–6
Figure 3-4 Basic Capacity Test Selected.............................................................. 3–14
Figure 3-5 Parallel Redundant / Capacity Power Wiring Diagram........................ 3–18
Figure 3-6 CAN Bridge Termination Jumper J7.................................................... 3–19
Figure 3-7 Two-Module Parallel Control Wiring.................................................... 3–24
Figure 3-8 Maintenance Bypass Switch Breaker Status....................................... 3–25
Figure 3-9 Maintenance Bypass Switch with Solenoid/Kirk-Key (Optional).......... 3–25
Figure 3-10 Remote to Bypass (Optional) .............................................................. 3–26
Figure 3-11 Old and New Terminal Blocks, TB1 .................................................... 3–39
Figure 3-12 Old and New Terminal Blocks, TB2 .................................................... 3–40
Figure 3-13 New Terminal Block Multi-Module Parallel Control Wiring .................. 3–41
Figure 3-14 80 kVA New Terminal Blocks, TB1and TB2, With Harness, Fuse ...... 3–46
Figure 3-15 160 kVA New Terminal Blocks, TB1and TB2, With Harness, Fuse .... 3–47
Figure 4-1 Power Module ....................................................................................... 4–2
Figure 4-2 Rectifier Functional Block Diagram ....................................................... 4–4
Figure 4-3 DC Link Voltage Over Time During Precharge ..................................... 4–5
Figure 4-4 Battery Converter Functional Diagram .................................................. 4–7
Figure 4-5 Normal ABM Charging Cycle .............................................................. 4–12
Figure 4-6 Typical Float Charge with Battery Test Cycle ..................................... 4–14
Figure 4-7 Typical Time Based Auto-Battery Equalize Cycle ............................... 4–16
Figure 4-8 Battery Charger Voltages per Temperature ........................................ 4–20
Figure 4-9 Inverter Functional Diagram ................................................................ 4–27
Figure 4-10 AC Voltage Sensing Channels Wave Form. ....................................... 4–27

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Figure 4-11 Smart Gate Drive Board ...................................................................... 4–30

Figure 4-12 Temperature vs. Duty Cycle and Voltage............................................ 4–31
Figure 4-13 AC Voltage Sensing Channels Wave Form ........................................ 4–33
Figure 4-14 Internal Static Switch Bypass Functional Block Diagram .................... 4–34
Figure 4-15 AC Power Flow Through Bypass SCRs .............................................. 4–35
Figure 4-16 Logic Power Supply Functional Block Diagram................................... 4–38
Figure 4-17 9390 Control Circuit Board .................................................................. 4–40
Figure 4-18 Machine State Transitions................................................................... 4–42
Figure 4-19 9390 Interface Circuit Board (Old Version) ......................................... 4–58
Figure 4-20 Interface Board Fuses ......................................................................... 4–61
Figure 4-21 Static Switch Board (SSB)................................................................... 4–66
Figure 4-22 Static Switch Board Block Diagram..................................................... 4–67
Figure 4-23 CSB Card ............................................................................................ 4–70
Figure 4-24 Display Module.................................................................................... 4–73
Figure 4-25 Display CAN Interface ......................................................................... 4–74
Figure 4-26 Display Communications..................................................................... 4–74
Figure 4-27 Display Graphics ................................................................................. 4–79
Figure 4-28 X-Slot #1.............................................................................................. 4–80
Figure 4-29 X-Slot #2.............................................................................................. 4–80
Figure 4-30 X-Slots #3 & 4 ..................................................................................... 4–81
Figure 4-31 Current Flow During ECT .................................................................... 4–86
Figure 4-32 Two (2) AC Sources Connected by the Same Inductance.................. 4–87
Figure 4-33 ECT Full Battery Discharge................................................................. 4–88
Figure 5-1 The XCP Tool CTO Tab ........................................................................ 5–2
Figure 5-2 Unit and Display Meters ........................................................................ 5–3
Figure 5-3 Gate Power and Temperature Meters................................................... 5–5
Figure 5-4 The Modem Tab .................................................................................... 5–6
Figure 5-5 The EEPROM Tab ................................................................................ 5–7
Figure 5-6 PCB Tab................................................................................................ 5–8
Figure 5-7 Battery Startup Tab ............................................................................... 5–9
Figure 5-8 The Options Tab.................................................................................. 5–10
Figure 5-9 The Reports Tab ................................................................................. 5–12
Figure 5-10 The Flash Tab ..................................................................................... 5–13
Figure 5-11 The Building Tab ................................................................................. 5–14
Figure 5-12 The Events Tab ................................................................................... 5–15
Figure 5-13 The Battery Options Tab ..................................................................... 5–16
Figure 5-14 Continuous Float Setting ..................................................................... 5–17
Figure 5-15 Auto Battery Equalize.......................................................................... 5–18
Figure 5-16 Battery Temperature Compensation ................................................... 5–18
Figure 5-17 On Generator Current Limit................................................................. 5–19
Figure 5-18 Temporary Battery Cell Option............................................................ 5–19
Figure 5-19 Distributed Bypass Setup Tab............................................................. 5–20
Figure 5-20 Basic Easy Capacity Test.................................................................... 5–21
Figure 5-21 ECT Extended Commissioning Test ................................................... 5–22
Figure 5-22 Normal Configuration Settings ............................................................ 5–23
Figure 5-23 Configuration Limits............................................................................. 5–24

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Figure 5-24 Configuration Overloads...................................................................... 5–24

Figure 5-25 Configuration ABB/C-H Parallel Contactors ........................................ 5–25
Figure 5-26 The About Tab..................................................................................... 5–26
Figure 5-27 XCP Service Tool Events Tab............................................................. 5–27
Figure 5-28 X-Slot Locations .................................................................................. 5–30
Figure 5-29 Low Voltage Relay Interface Card....................................................... 5–31
Figure 5-30 High Voltage Industrial Relay Card ..................................................... 5–33
Figure 5-31 10/100 Megabyte SNMP/Web/Hub ..................................................... 5–34
Figure 5-32 SNMP/Web/Hub Card Components.................................................... 5–35
Figure 5-33 MODBUS Communications Card ........................................................ 5–35
Figure 5-34 MODBUS Communications Card Components................................... 5–36
Figure 5-35 Modem Card........................................................................................ 5–37
Figure 5-36 CAN Bridge Card with DB-9 Connections .......................................... 5–38
Figure 5-37 CAN Bridge Card J3 Terminals ........................................................... 5–39
Figure 5-38 CAN Bridge Card with RJ-45 CAN Connections ................................. 5–41
Figure 5-39 Modem Setup Screen ......................................................................... 5–44
Figure 5-40 Alarm/Event Configuration ................................................................. 5–46
Figure 5-41 Confirm Message Box ........................................................................ 5–46
Figure 5-42 Events Configuration Message Box .................................................... 5–47
Figure 5-43 Example of Customer Information Form ............................................ 5–49
Figure 5-44 Modem Setup Screen.......................................................................... 5–53
Figure 5-45 Alarm / Event Configuration Screen ................................................... 5–55
Figure 5-46 Selection of Node Bit to Customize..................................................... 5–56
Figure 5-47 Select Modem Phone Number 1, 2, or Both (WithOUT Mini-CSB) ..... 5–57
Figure 5-48 Path to Hyper Terminal Application..................................................... 5–59
Figure 5-49 Hyper Terminal Opening Screen Selections ...................................... 5–59
Figure 5-50 Select COM1 or COM2 from Drop-Down Menu .................................. 5–60
Figure 5-51 Port Parameter Setup.......................................................................... 5–61
Figure 5-52 File, Properties Menu Options, Settings Tab, Emulation Drop-Down . 5–61
Figure 5-53 Font Settings Menu ............................................................................. 5–62
Figure 5-54 Hyper Terminal Capture Text .............................................................. 5–63
Figure 5-55 Hyper Terminal Capture Text .............................................................. 5–63
Figure 5-56 Hyper Terminal Capture Text Start Capture........................................ 5–64
Figure 5-57 Hyper Terminal Capture Text Stop Capture........................................ 5–64
Figure 5-58 Hyper Terminal Capture Text File on Desktop .................................... 5–65
Figure 6-1 Internal Maintenance Bypass (MBP) Block Diagram ............................ 6–2
Figure 6-2 80 kVA Terminal Block TB3, ISB Contactor and Snubber .................... 6–2
Figure 6-3 208 Volt Internal Service Switch with Handle........................................ 6–4
Figure 6-4 ISS Depiction......................................................................................... 6–5
Figure 6-5 Battery Options Tab, Enable Power Conditioner Mode......................... 6–6
Figure 6-6 CTO Tab, Invalid CTO .......................................................................... 6–7
Figure 6-7 Neutral-Forming Transformer ............................................................... 6–8
Figure 6-8 9390 IT ................................................................................................ 6–12
Figure 6-9 570mm & 1085mm Battery Cabinets .................................................. 6–13
Figure 6-10 XCP Service Tool Battery Options Tab ............................................... 6–14
Figure 6-11 XCP Service Tool Battery Startup Tab................................................ 6–15

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Figure 6-12 9390 with attached “Sidecar” Cabinet ................................................. 6–17

Figure 6-13 External Maintenance Bypass (MBP) Block Diagram ......................... 6–18
Figure 6-14 9390 Integrated Accessory Cabinet (Internal View) ............................ 6–19
Figure 6-15 9390 with attached Thinline PDU. ....................................................... 6–20
Figure 6-16 Remote Monitor Panel II...................................................................... 6–21
Figure 6-17 Relay Interface Module II. ................................................................... 6–22
Figure 6-18 Supervisory Contact Module II. ........................................................... 6–23
Figure 6-19 9390 Integrated Distribution Cabinet. (160 kVA) ................................ 6–24
Figure 6-20 9390 Integrated Distribution Cabinet (80 kVA UPS Mode) ................. 6–25
Figure 6-21 9390 Integrated Distribution Cabinet (160 kVA UPS Mode) ............... 6–26
Figure 6-22 Load Sync Control TB-6 Wiring Diagram ............................................ 6–31
Figure 6-23 9390 TB1 & TB2 and Load Sync Control TB1 Wiring Diagram........... 6–32
Figure 7-1 Power Module Retaining Bracket .......................................................... 7–4
Figure 7-2 Double Wires Removed ........................................................................ 7–5
Figure 7-3 Power Module Tray Screw .................................................................... 7–5
Figure 7-4 Fan Plugs FPP1 and FPP2 ................................................................... 7–6
Figure 7-5 Power Module Ribbon and CAT5 Cables (FRONT -->) ........................ 7–7
Figure 7-6 Smart Gate Drive Board ........................................................................ 7–7
Figure 7-7 Removing (or Attaching) Black Module Clip ......................................... 7–8
Figure 7-8 “Unlocking” the Power Module Assembly.............................................. 7–9
Figure 7-9 Smart Gate Drive Board, Side View .................................................... 7–10
Figure 7-10 Power Module Assembly “Lock”.......................................................... 7–11
Figure 7-11 Power Module Wire Routing and Tie Wrapping .................................. 7–12
Figure 7-12 TB3 Power Module Wiring and Tie Wrapping ..................................... 7–13
Figure 7-13 Power Module Retaining Bracket ........................................................ 7–16
Figure 7-14 Double Wires Removed ..................................................................... 7–17
Figure 7-15 Power Module Tray Screw .................................................................. 7–17
Figure 7-16 Fan Plugs FPP1 and FPP2 ................................................................. 7–18
Figure 7-17 Power Module Ribbon & CAT5 Cables (FRONT -->) .......................... 7–19
Figure 7-18 9390 CAN Network 80 kVA CAT5 Cables, with Mini-CSB .................. 7–20
Figure 7-19 Removing (or Attaching) Module Clip.................................................. 7–21
Figure 7-20 “Unlocking” the Power Module Assembly ........................................... 7–22
Figure 7-21 Power Module Assembly “Lock” ......................................................... 7–23
Figure 7-22 Power Module Wire Routing and Tie Wrapping .................................. 7–24
Figure 7-23 TB3 Power Module Wiring and Tie Wrapping .................................... 7–25
Figure 7-24 100-160 kVA Power Modules and Power Supplies 3 and 4................ 7–28
Figure 7-25 Power Supply Assembly Mounting Screws ......................................... 7–30
Figure 7-26 9390 CAN Network 160 kVA CAT5 Cables, with Mini-CSB ................ 7–32
Figure 7-27 K5 Contactor Wiring, 208V & 480V Units............................................ 7–36
Figure 7-28 E9, E10, & E11 Wiring, 208V & 480V Units ........................................ 7–37
Figure 7-29 Static Switch Hold-down Screws......................................................... 7–38
Figure 7-30 Static Switch Plugs P2 & P4................................................................ 7–38
Figure 7-31 Static Switch Insertion (Rear View) ..................................................... 7–39
Figure 7-32 Static Switch SCR Gating Leads......................................................... 7–45
Figure 7-33 Static Switch SCR Bus Bar Screws..................................................... 7–46
Figure 7-34 Static Switch PCB Fan Sensing Jumper J9 (Close-up)....................... 7–47

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Figure 7-35 Static Switch SCR Gating Leads (Close-up) ....................................... 7–47
Figure 7-36 Power Supply Cover............................................................................ 7–53
Figure 7-37 Power Supply LEDs D5 & D8 Lit ......................................................... 7–54
Figure 7-38 Interface Board & Control Board ........................................................ 7–57
Figure 7-39 Power Supply Fan Fail LEDs .............................................................. 7–63
Figure 7-40 Fan Assembly and Numbering ............................................................ 7–63
Figure 7-41 Fan Plugs FPP1, FPP2, and Fan Assembly Screws........................... 7–64
Figure 7-42 Capacitor Tray with EMI Capacitors.................................................... 7–67
Figure 7-43 Capacitor Tray with TB3...................................................................... 7–68
Figure 7-44 Capacitor Board Mounting Screw........................................................ 7–68
Figure 7-45 Capacitor Board Spade Lug Connectors............................................. 7–69
Figure 7-46 Removing Display Assembly............................................................... 7–72
Figure 7-47 Display CAT-5 Cable........................................................................... 7–73
Figure 7-48 DC Link Fuse Location ........................................................................ 7–78
Figure 7-49 Contactor Wires Removed from E1, E2, and E3................................. 7–83
Figure 7-50 Disconnecting Wires from E1, E2, and E3 to K1................................. 7–83
Figure 7-51 View of Tie Wrap to Cut ...................................................................... 7–84
Figure 7-52 Contactor Mounting Screw Removal................................................... 7–84
Figure 7-53 Fuse Bracket Close-up........................................................................ 7–85
Figure 7-54 Fuse Bracket Bolts .............................................................................. 7–85
Figure 7-55 Fuse Assembly Mounting Bolts Close-up............................................ 7–86
Figure 7-56 Wires Disconnected from E9, E10, E11 and E12 to K3 ...................... 7–91
Figure 8-1 XCP Service Tool, V3.04, Meters Screen ............................................. 8–4
Figure 8-2 Interface Board Disconnect and Jumper ............................................... 8–5
Figure 8-3 Calibration Voltage Input Screen........................................................... 8–7
Figure 8-4 Calibration Target Value Screen ........................................................ 8–13
Figure 8-5 Calibration Current Input Screen......................................................... 8–16
Figure 8-6 TB3 Terminal Block for 208 and 480-Volt UPS Systems .................... 8–23
Figure 8-7 X5 or X6 Terminal Blocks for 400-Volt UPSs ...................................... 8–26
Figure 9-1 Gate Drive Board Identification Sequence ............................................ 9–2
Figure 9-2 Gate Power and Temperature Meters................................................... 9–8
Figure 9-3 Call Center KVA Upgrade Flowchart .................................................. 9–21
Figure 10-1 Serial Number Close Up.................................................................... 10–38
Figure 10-2 Example of Gate Drive Board Date Codes........................................ 10–40
Figure 10-3 Fuse F7 Marked As 5 Amps, Requires 10 Amp ................................ 10–41

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List of Tables
Table 1-1 9390 Change Sheet .............................................................................. 1–1
Table 3-1 Parallel Interface Wire Chart using MOB Aux Contacts ...................... 3–42
Table 3-2 Parallel Interface Wire Chart with no MOB Aux Contacts ................... 3–44
Table 4-1 Battery Setup Data .............................................................................. 4–21
Table 4-2 Auto Restart Operation with “Enable Retry On Load Dump” selected. 4–57
Table 5-1 X-Slot Connectivity Device Options ..................................................... 5–29
Table 5-2 Relay Interface Card Translation Table ............................................... 5–33
Table 5-3 MODBUS Communications Card Connector Pins .............................. 5–36
Table 5-4 CAN Bridge Card Remote Monitor Connections ................................. 5–39
Table 5-5 Terminal J-3 Descriptions .................................................................... 5–39
Table 5-6 Hyper Terminal Setup ......................................................................... 5–60
Table 6-1 9390 Vycon Setup w/o CSB ................................................................ 6–27
Table 6-2 9390 Vycon Setup w/o CSB ................................................................ 6–29
Table 7-1 Fan LED Location Diagram ................................................................. 7–62
Table 8-1 Scalar Limits and Calibration Sequence ............................................... 8–2
Table 8-2 Inverter Voltage Calibrations ............................................................... 8–11
Table 8-3 AC Voltage Measurements ................................................................. 8–21
Table 8-4 DC Voltage Measurements ................................................................. 8–21
Table 8-5 AC Current Measurements .................................................................. 8–22
Table 8-6 DC Current Measurements ................................................................. 8–22
Table 8-7 AC Voltage Measurements ................................................................. 8–24
Table 8-8 DC Voltage Measurements ................................................................. 8–24
Table 8-9 AC Current Measurements .................................................................. 8–25
Table 8-10 DC Current Measurements ................................................................. 8–25
Table 9-1 Rectifier Gate Power Normal Mode Readings .................................... 9–10
Table 9-2 Inverter Gate Power Normal Mode Readings ..................................... 9–10
Table 9-3 Alarm Action Levels ............................................................................. 9–39
Table 9-4 Alarm Description and Definition ......................................................... 9–42
Table 9-5 Symptom Troubleshooting Table ........................................................ 9–79
Table 10-1 9390 80kVA 208V “A” spares - 106 711 150 ....................................... 10–2
Table 10-2 9390 80kVA 480V “A” spares - 106 711 151 ....................................... 10–2
Table 10-3 9390 160kVA 208V “A” spares - 106 711 156 ..................................... 10–3
Table 10-4 9390 160kVA 480V “A” spares - 106 711 157 ..................................... 10–3
Table 10-5 9390 80kVA 208V “B” spares - 106 711 164 ....................................... 10–4
Table 10-6 9390 80kVA 480V “B” spares - 106 711 165 ....................................... 10–5
Table 10-7 9390 160kVA 208V “B” spares - 106 711 166 ..................................... 10–5
Table 10-8 160kVA 480V “B” spares - 106 711 167 .............................................. 10–6
Table 10-9 9390 80kVA 400V “A” spares - 1023581 (Helsinki mfd. units) ............ 10–7
Table 10-10 9390 80KVA US 400V "A" spares - 106711295 (US version) ............. 10–7
Table 10-11 9390 80kVA 400V s/n>318167 Kit “A1” spares - 1025186 (Helsinki) . 10–8
Table 10-12 9390 80kVA 400V “B” spares - 1023582 (Helsinki mfd. units) ............ 10–9
Table 10-13 80kVA 400V “C” spares - 1023583 (Helsinki mfd. units) ..................... 10–9
Table 10-14 9390 160kVA 400V “A” spares - 1024456 Old (Helsinki mfd. units) . 10–10
Table 10-15 9390 160KVA US 400V "A" spares - 106711296 (US version) ......... 10–10

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List of Tables 9390 Service Manual

Table 10-16 9390 160kVA 400V Kit "A" spares - 1024456 New (Helsinki) ........... 10–11
Table 10-17 9390 160kVA 400V “B” spares - 1024457 (Helsinki mfd. units) ........ 10–12
Table 10-18 9390 160kVA 400V “C” spares - 1024458 (Helsinki mfd. units) ........ 10–12
Table 10-19 9390 40kVA 400V - 103 006 736 (US VERSION) ............................. 10–13
Table 10-20 9390 80kVA 208V - 103 003 656 ...................................................... 10–13
Table 10-21 9390 80kVA 480V - 103 003 657 ...................................................... 10–14
Table 10-22 9390 80kVA 400V - 103 003 802 (Raleigh mfd.) ............................... 10–14
Table 10-23 9390, 80KVA, 400V, US VERSION - 103006737 ............................. 10–14
Table 10-24 9390 120kVA 208V - 103 004 507 .................................................... 10–15
Table 10-25 9390 120kVA 480V - 103 004 508 .................................................... 10–15
Table 10-26 UPS, 120KVA, 400V, US VERSION - 103006738 ............................ 10–16
Table 10-27 UPS, 160 kVA, 400V, US VERSION - 103006739 ............................ 10–17
Table 10-28 9390 160kVA 208V - 103 003 857 .................................................... 10–18
Table 10-29 9390 160kVA 480V - 103 003 85 ...................................................... 10–18
Table 10-30 UPS Printed Circuit Boards ............................................................... 10–18
Table 10-33 UPS MINI-CSB KITS ......................................................................... 10–19
Table 10-31 UPS Batteries .................................................................................... 10–19
Table 10-32 UPS ACCESSORIES ........................................................................ 10–19
Table 10-34 9390 20-80kVA Mini-CSB Kit - 103 004 409 ..................................... 10–20
Table 10-35 9390 100-160kVA Mini-CSB Kit - 103 004 410 ................................. 10–20
Table 10-36 Assembly, X-Slot W/CSB - 103 003 754 ........................................... 10–20
Table 10-37 400V 9390 PM Enhanced GDB New PCB - 103005788 ................... 10–21
Table 10-38 MOST COMMON PARTS, 20-80 KVA, 400 VOLTS ......................... 10–22
Table 10-39 MOST COMMON PARTS, 100-160 KVA, 400 VOLTS ..................... 10–24
Table 10-40 US 400V INDIVIDUAL PARTS .......................................................... 10–26
Table 10-41 CAN BRIDGE FIELD KIT - 103 004 336 ........................................... 10–27
Table 10-42 9390 INTERNAL SERVICE SWITCH ASSEMBLIES ........................ 10–27
Table 10-43 9390 ISS Circuit Breakers ................................................................. 10–27
Table 10-44 9390 KVA UPGRADE KITS, 208 VOLT and 480 VOLT .................... 10–28
Table 10-45 9390 KVA UPGRADE KITS, 400 VOLT ............................................ 10–28
Table 10-46 LOAD SYNC CONTROL HARNESS KITS ........................................ 10–28
Table 10-47 NO NEUTRAL KIT, 400 VOLT .......................................................... 10–29
Table 10-48 TERMINAL BLOCK CONTROL HARNESSES ................................. 10–29
Table 10-49 9390 ESM Upgrade Kit ...................................................................... 10–30
Table 10-50 9390 ESM Upgrade Kit ...................................................................... 10–30
Table 10-51 9390 ESM Upgrade Kit ...................................................................... 10–30
Table 10-52 9390 ESM Upgrade Kit ...................................................................... 10–31
Table 10-53 9390 40 400/480V AC I/O Cap Upgrade 103007583 ........................ 10–31
Table 10-54 9390 40 400/480V DC Link Cap Upgrade 103007584 ...................... 10–31
Table 10-55 9390 80 400/480V AC I/O Cap Upgrade 103007585 ........................ 10–32
Table 10-56 9390 80 400/480V DC Link Cap Upgrade 103007586 ...................... 10–32
Table 10-57 9390 120 400/480V AC I/O Cap Upgrade 103007587 ...................... 10–32
Table 10-58 9390 120 400/480V DC Link Cap Upgrade 103007588 .................... 10–32
Table 10-59 9390 160 400/480V AC I/O Cap Upgrade 103007589 ...................... 10–33
Table 10-60 9390 160 400/480V DC Link Cap Upgrade 103007590 .................... 10–33
Table 10-61 9390 40 208V AC I/O Cap Upgrade 103007607 ............................... 10–33

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Table 10-62 9390 40 208V DC Link Cap Upgrade 103007608 ............................. 10–33
Table 10-63 9390 80 208V AC I/O Cap Upgrade 103007609 ............................... 10–33
Table 10-64 9390 80 208V DC Link Cap Upgrade 103007610 ............................. 10–34
Table 10-65 9390 120 208V AC I/O Cap Upgrade 103007611 ............................. 10–34
Table 10-66 9390 120 208V DC Link Cap Upgrade 103007612 ........................... 10–34
Table 10-67 9390 160 208V AC I/O Cap Upgrade 103007613 ............................. 10–34
Table 10-68 9390 160 208V DC Link Cap Upgrade 103007614 ........................... 10–34
Table 10-69 Contactor Serial Numbers for Vendor Change .................................. 10–36
Table 10-70 EatonPW Installation/Operation Manuals .......................................... 10–37
Table 10-71 9390 Contactors ................................................................................ 10–37
Table 10-72 9390 80kVA Distribution Cabinet Parts ............................................. 10–41
Table 10-73 9390 160kVA Distribution Cabinet Parts ........................................... 10–43

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xx © 2009 Eaton Corporation. Company Confidential.

 1
System Overview
1.1 Help for Customer Service Engineers
1.1.1 E-ESSDocumentation Mailbox
The MultiMedia/Technical Documentation Department has a Microsoft Outlook
mailbox. It is listed in Eaton’s Outlook Global Address List as: PQSO Raleigh,
E-ESSDocumentation. Outside of Eaton Corp., the address is E-
[email protected]. Use this e-mail address for:
• Ordering interactive Service Manual CDs.
• Ordering Service Manuals.
• Ordering drawings, schematics, top-level drawings, etc.
• Reporting errors in the Service Manuals.
• Making suggestions to improve the Service Manuals.

1.1.2 HTTP://GSTECHSUP.POWERWARE.COM Web site

Check this web site on a regular basis for “What’s New” on products, tools,
services, and procedures. The “Site Links” column provides access to
documentation, downloads, Field Service Bulletins, firmware versions, setup
tools, and training.

1.1.3 Supporting Documents Internet Web site

The Marketing Group updates and releases user guides and installation
instructions regularly to the Eaton Internet web site at: http://
powerquality.eaton.com/.
Periodically check the web site for current releases.

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System Overview 9390 Service Manual

1.2 System Description

See Figure 1-1, 20-80 (left) and 100-160 (right) kVA UPS Front View and Figure
1-2, Basic Single Module System.
9390 documentation, including User Guides and 9390 specifications, can be
found at: http://powerquality.eaton.com/.

1.2.1 Single Module Systems

The 9390 is a true online, continuous-duty, transformerless, double-conversion,
solid-state, three-phase system that provides conditioned and uninterruptible
AC power to the UPS system output protecting the customer’s load from all nine
power problems.
These systems are designed to be the best of all Eaton® products, using the
most successful controls, functions, and features found in many previous UPS
systems, including several improvements. The basic system consists of a
rectifier, inverter, battery converter, monitoring/operation control panel,
integrated communications server, and microprocessor controlled (DSP) logic.

Figure 1-1 20-80 (left) and 100-160 (right) kVA UPS Front View

Additional options include Energy Saver Mode (a purchased upgrade for

existing 9390s), Easy Capacity Test, extended commissioning tests, an
Integrated Distribution Cabinet (IDC), External Maintenance Bypass Switch,
PowerVision Monitoring Application, dual feed option, XCP connectivity
protocol, Parallel Operations, and Advanced Battery Management Plus (ABM+).

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9390 Service Manual System Overview

The UPS module may be configured for stand alone (single module, reverse
transfer, “RT”) operation or multi-module (parallel redundant “PR” or parallel
capacity “PC”) operation, referred to as Distributed Bypass Parallel Setup.
A single module operates independently to support an applied load from the
inverter providing conditioned and uninterruptible AC power to the module
output. During an outage, the inverter continues to operate, supporting power to
the load from the module battery. If the unit requires service, applied loads are
transferred to the internal bypass full-duty static switch either automatically or
manually. No other cabinets or equipment are required for the single module to
successfully support its applied loads.

K5 Contactor, Backfeed Protection

Current
Sensor Static Switch

~ DC Link (Rail Voltage) =

= ~
Rectifier
K1 Input Inverter K3 Contactor,
Contactor = Battery Output Isolation
= Converter

Battery
Breaker

Figure 1-2 Basic Single Module System

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System Overview 9390 Service Manual

Figure 1-3 20-80 (left) and 100-160 (right) kVA UPS Inside View

1.2.2 9390 Model Versions

The 9390 is available in 20, 40, 50, 60, 80, 100, 120, and 160 kVA ratings.
• 9390 20/40 kVA is an optimized version and can be programmed for a
rating of 20 kVA or 40 kVA. These models are designated with the CTO
second character set as A (e.g. xAxxxxxxxxx). Contains two power
modules: 1 rectifier and 1 inverter.
• 9390 80/40, 80/50, 80/60, and 80/80 kVA units are upgradeable versions
and can be programmed for a rating of 40 to 80 kVA. These models are
designated with the CTO second character set as B. Contains four power
modules: 2 rectifiers and 2 inverters.
• 9390 120/100 and 120/120 kVA units are optimized versions and can be
programmed for a rating of 100 kVA or 120 kVA via firmware. These
models are designated with the CTO second character set as C. Contains
six power modules: 3 rectifiers and 3 inverters.
• 9390 160/100, 160/120, and 160/160 are upgradeable versions and can be
programmed for a rating of 100 kVA to 160 kVA. These models are
designated with the CTO second character set as D. Contains eight
power modules: 4 rectifiers and 4 inverters.

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9390 Service Manual System Overview

1.2.3 9390 Refresh Version

In 2009 the 9390 was updated to improve functionality and add features. The
9390 was originally released with an option for the customer to order a
Communication Server Board that added two X-Slots and other features. See
“COMMUNICATIONS SERVER BOARD (CSB) ” on page 70 of Chapter 4 for
more detail. Beginning in 2009 all 9390s manufactured will be delivered with the
Communication Server Board as standard equipment. These units will have
DSP firmware version 5.XX installed from the factory.
Existing units with DSP firmware 2.XX must not be upgraded to 5.XX firmware
without first opening a service ticket and then making the necessary hardware
and software changes. A CSB is required to run firmware 5.XX. The upgrade kit
is listed in the parts chapter and includes the procedure.

1.2.4 9390 IT Version with Internal Battery

In 2009 the 9390 20/40 kVA UPS was offered with an internal battery
configuration. The 9390 IT is an optimized version, meaning it has only one
rectifier module and one inverter module, and can be configured for 20 kVA or
40 kVA. It includes one to three strings of batteries in a sidecar. At a load of 40
kVA with three strings of batteries, run time is estimated to be 4.5 minutes.

Figure 1-4 9390 IT Version

1.2.5 Multi-Module Parallel Systems

See Figure 1-5, Parallel Redundant System (1 + 1) and Figure 1-6, Parallel
Capacity System (2 + 0).

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System Overview 9390 Service Manual

The 9390 can be configured for either Parallel Redundant or Parallel Capacity
operation; the output of an Uninterruptible Power Module (UPM) can be tied
together with the output of other UPMs to support a common output. UPMs
configured in this manner are considered to be part of a “distributed bypass
parallel system.”
Up to four units can be paralleled for redundancy or capacity without the need
for any additional cabinets. The basic technology provides the ability to parallel
units without the use of an external fully-rated static switch or wrap-around
contactor.
A tie cabinet or wall-mounted enclosure with UPS output disconnect switches is
offered for customer convenience. All wiring from the UPS modules to a
common tie point must be of equal lengths to ensure adequate loadsharing in
the event all UPS modules are on static bypass.
A parallel system is redundant (2 + 1) so long as there is always a kVA surplus
equivalent to one or more UPMs than is required to support the load. A good
rule of thumb is (N + #) where N is the number of UPMs required to support a
given load and # is the number of additional or redundant UPMs in the system.
In a system where two UPMs are paralleled together, and the load can be
supported by a single UPM, the system is said to be Redundant (1 + 1). If the
load is such that both UPMs in the system are required to support the load, then
the system is said to be paralleled for Capacity (2 + 0). Two modules are
needed to power the load and no backup module is available.
Similar to the single module system, a parallel system will support a critical load
in four different modes of operation: Normal, Battery, Bypass, and Energy
Saver. The system automatically changes modes, as required, without operator
intervention.
In a Parallel Redundant (N + 1) arrangement, the static switch (STSW) in each
module operates as a continuous-duty switch to support the applied loads on
bypass. If both units are operating normally and one unit trips offline, the
remaining unit will transfer to bypass for a few seconds before transferring to
Normal Mode. Units with DSP firmware 2.02 and older will not transfer to
Bypass during a trip of one unit in a redundant system.
In Parallel Capacity (N + 0) configurations, if one unit trips offline and goes to
bypass, the remaining units will also go to bypass.
As described and shown previously, the 9390 can be paralleled in one of
several different parallel configurations (1 + 1), (2 + 0), (2 + 1), and so on, as
follows:
Parallel for Redundancy (1 + 1)
• System Bypass Module (SBM) not required
• All module outputs are tied together at the customer’s distribution panel
• Modules are of the same voltage and power rating

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9390 Service Manual System Overview

• Unit MOBs with auxiliaries are used for service isolation

• Static switch in both units can be used to support loads on bypass
• External Control Area Network (ECAN) is used between cabinets
• The same firmware must be installed in all parallel units

Parallel for Capacity (2 + 0), (3 + 0)

• No System Bypass Module (SBM) required
• All module outputs are tied together at the customer’s distribution panel
• Modules are of the same voltage and power rating
• Static switch in both units can be used for emergency transfers to bypass
• External Control Area Network (ECAN) is used between cabinets
• The same firmware must be installed in all parallel units

Parallel for Capacity / Redundancy (2 + 1), (3 + 1)

• Same as 2(or 3) + 0 with an additional module for redundancy

1.2.6 Parallel for Redundancy (1 + 1), (2 + 1), (3 + 1)

See Figure 1-5, Parallel Redundant System (1 + 1).
The referenced figure shows that if two UPMs are capable of supporting 80 kVA
each, and the total load applied on the output of the system was 80 kVA, either
UPM would be capable of supporting the applied load individually. With each of
the two UPMs in parallel, the load would be shared equally between the two
UPMs (40 kVA each).

© 2009 Eaton Corporation. Company Confidential. 1–7

System Overview 9390 Service Manual

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect MOB #1

LOAD
UPM #1 80KVA BATTERY 80KVA

MOB #2

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect

UPM #2 80KVA
BATTERY

Figure 1-5 Parallel Redundant System (1 + 1)

1.2.7 Parallel for Capacity (2 + 0), (3 + 0), (4 + 0)

See Figure 1-6, Parallel Capacity System (2 + 0).
The referenced figure shows that if two UPMs are capable of supporting 80 kVA
each, and the total load applied on the output of the system was 150 kVA, both
UPMs would be required to support the applied load. With each UPM in parallel,
the load would be shared equally between the two available UPMs (75 kVA
each). Additionally, because two UPMs must be online to support the applied
load, the entire system will transfer to Bypass automatically if one UPM fails or is
taken offline.

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9390 Service Manual System Overview

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect MOB #1

LOAD
UPM #1 80KVA BATTERY 150KVA

MOB #2

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect

UPM #2 80KVA
BATTERY

Figure 1-6 Parallel Capacity System (2 + 0)

© 2009 Eaton Corporation. Company Confidential. 1–9

System Overview 9390 Service Manual

1.3 Modes of Operation - Single Module / Reverse

Transfer (RT)
The 9390 will support a critical load in four different modes of operation: Normal
mode, Battery mode, Bypass mode, and Energy Saver mode. The UPS can
automatically changes modes, as required, without operator intervention.
Sophisticated detection and control logic is used to ensure any change in
operating mode is automatic and transparent to the load while internal
monitoring systems indicate the current mode of operation. In the next few
pages, the modes of operation will be discussed in more detail using block level
diagrams.

1.3.1 Normal Mode

See Figure 1-7, Normal Mode.
During normal UPS operation, power for the system is derived from a utility input
source through the rectifier input contactor K1. “NORMAL” appears on the front
panel and indicates that the critical load is supported by the inverter. Three-
phase AC input power is converted to DC using IGBT devices to produce a
regulated DC voltage to the inverter. The battery is charged directly from the
regulated rectifier output through a buck or boost DC converter depending on
whether the system is 208 or 480-volts and upon the size of the battery string
attached to the unit.

STATIC SWITCH

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

EXTERNAL
DISCONNECT

BATTERY

Figure 1-7 Normal Mode

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9390 Service Manual System Overview

The DC converter derives its input from the regulated DC output of the rectifier
and provides either a boosted or bucked regulated DC voltage charge current to
the battery. The battery charge condition is monitored by the UPS and reported
by status indicators located on the LCD monitor panel. The battery is always
connected to the UPS and ready to support the inverter should the utility input
become unavailable.
The neutral from the system input is connected to the neutral regulator on the
power modules. The output neutral of the system is connected with the required
neutral supplied at E12 in the lower section of the unit and should never be
bonded to ground at the module output.
The inverter produces a three-phase AC output to the critical load without the
use of a transformer. The inverter derives regulated DC from the rectifier and
uses IGBT devices and pulse-width modulation (PWM) to produce a regulated
and filtered AC output. The AC output of the inverter is delivered to the system
output through the output contactor (K3).
The normal LED energizes on the module front panel to indicate that the system
is operating normally.

1.3.2 Battery Mode

See Figure 1-8, Battery Mode.
The UPS automatically transitions to Battery mode during a utility power failure
or if the input power to the rectifier is out of specifications (refer to input
specifications in the User Guide). During a utility power failure, the rectifier no
longer has an AC utility source to supply the DC output power required to
support the inverter. The input contactor (K1) is opened, the rectifier is turned
off, and the flow of DC current to the input of the DC converter transitions from
the rectifier to the awaiting battery. Energy stored in the battery is supplied
instantaneously to the DC converter and is either bucked or boosted so that the
inverter can support the customer’s load without interruption. If the bypass is
common with the rectifier input, the backfeed protection contactor (K5) will also
open. Opening the contactors (K1 & K5) prevents system voltages from
bleeding backwards through the static switch and rectifier “snubber”
components and entering the input source, endangering utility workers.
While in Battery Mode, the UPS will sound a horn, light an indicator lamp on the
front panel (ON BATTERY), and make an entry into the alarm event history. As
the battery discharges, the converter and inverter constantly make minute
adjustments to maintain a regulated output. The UPS will remain in this
operating mode until the input power to the rectifier is again within specifications
(refer to input specifications in the User Guide).

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System Overview 9390 Service Manual

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect

BATTERY

Figure 1-8 Battery Mode

If the input power fails to return or is not within specification for normal
operation, the battery will continue discharging until a DC voltage level is
reached where the inverter output can no longer support the connected loads.
When this occurs, the unit will issue another set of audible and visual alarms
indicating SHUTDOWN IMMINENT. Unless the rectifier has a valid input, the
output will only be supported for two (2) minutes before the output of the system
shuts down.
If at any time during the battery discharge the input power becomes available,
contactors K1 and K5 are closed, the rectifier will gate on and assume the
inverter load from the DC-DC converter. The rectifier will also charge the battery
through the DC-DC converter. At this time, the unit returns to NORMAL
operation. Depending on the amount of load on the system and the duration of
the battery discharge, battery and rectifier input current limit alarms may be
seen for a short time due to the current required to recharge the battery.
The total system operating time on battery will depend on many factors. Some
factors that affect battery support times are battery type and capacity, number of
parallel strings, environmental temperatures, age of the battery, and fluctuations
in load demand during the discharge. The greater the load, the less support time
the battery will have. Decrease the load, and the battery support time will
generally increase.

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9390 Service Manual System Overview

1.3.3 Bypass Mode

See Figure 1-9, Bypass Mode.
In Bypass Mode, the output of the system is provided with three-phase AC
power directly from the system input. While in this mode, the output of the
system is not protected from voltage or frequency fluctuations or power outages
from the source. Some power line filtering and spike protection is provided to the
load, but no active power conditioning or battery support is available to the
output of the system in the bypass mode of operation.
A solid-state silicon-controlled rectifier (SCR) static switch (STSW) and a
backfeed protection contactor (K5) comprise the internal bypass circuit. The
static switch (STSW) is a continuous-duty device that is used anytime the
inverter is unable to support the applied load. The static switch (STSW) is wired
in series with the backfeed protection contactor (K5) and together they are wired
in parallel with the rectifier and inverter. Since the static switch is an
electronically controlled device, it can be turned on immediately to support the
load, as the inverter output contactor (K3) opens to isolate the inverter. The
backfeed protection contactor (K5) is normally always closed to support the
static switch (STSW), unless the bypass input source becomes unavailable.

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect

BATTERY

Figure 1-9 Bypass Mode

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System Overview 9390 Service Manual

During an outage, transfers to bypass are prohibited. For the safety of those
who may be working on the power lines upstream from the UPS, the backfeed
protection contactor (K5) is opened, preventing system output voltage from
bleeding across the static switch “snubber” components to the bypass input
source.
If the inverter is unable to support the load, the UPS will complete a make-
before-break transfer of the load to internal bypass. The transfer is initiated by
turning on the static switch (STSW) and opening the inverter output contactor
(K3). This kind of transfer is normally referred to as a “make-before-break”
transfer. The transfer will happen in under 4 msec (one-quarter cycle) to ensure
loads on the system output are not interrupted. The static switch (STSW)
remains on until either the inverter is able to support the system output or until
the unit is placed into a maintenance configuration and repairs can be made.
Some example alarms that cause the output of the system to be transferred
automatically to the internal bypass include: system output exceeds acceptable
voltage or frequency tolerances, the system is overloaded, or the system
experiences an inverter failure.
If the UPS initiates a transfer to bypass, the UPS will attempt to restart the
inverter (if not running already) and transfer online. Three attempts will be made
within ten minutes to bring the inverter back online automatically before the UPS
will lock out any further attempts. After three (3) attempts have been made, the
UPS will remain in bypass and an alarm condition will be annunciated. If the
condition clears, the UPS can be transferred to inverter using the front panel
controls.

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9390 Service Manual System Overview

1.3.4 Energy Saver Mode

1.3.4.1 ESM Overview
Energy saver mode is an option based on unit CTO. Existing UPS and UPS that
were ordered without the ESM CTO cannot be upgraded to ESM unless the
customer orders the ESM upgrade kit. ESM Upgrade kits are listed in the parts
chapter. See Chapter 10, Parts.
In Energy Saver Mode (ESM), the output of the system is provided with three-
phase AC power directly from the bypass input. The input (K1) and output (K3)
contactors remain closed while in ESM. The DC Link voltage is maintained
through the IGBT protection diodes. If the microprocessor detects an outage, a
forward transfer to Battery mode is completed in less than 1/4 cycle.
While in ESM mode, the output of the system is only protected from voltage or
frequency fluctuations if they exceed system specifications. Limited power line
filtering and spike protection is provided to the load, but no active power
conditioning is available to the output of the system in the energy saver mode of
operation. See “ESM Mode” on page 83 of Chapter 4 for details about ESM.

1.3.4.2 ESM Performance During an Outage

In case of an outage, the inverter will transfer online and use the batteries to
power the load. When power returns the system will return to ESM mode.
After a battery discharge, and power returns, the system returns to ESM mode,
and the batteries are charged through the inverter IGBT diodes. The 9390 400
volt units will turn on the rectifier to charge the batteries. The rectifier is also
used while in ABM float mode. When the batteries have been charged, the
rectifier is turned off and the DC link is sustained through the inverter IGBT
diodes.

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System Overview 9390 Service Manual

1.3.4.3 ESM Circuitry

A solid-state silicon-controlled rectifier (SCR) static switch (STSW) and a
backfeed protection contactor (K5) comprise the internal bypass circuit. The
static switch (STSW) is a continuous-duty device that passes current from the
input to the load. The backfeed protection contactor (K5) is normally always
closed to support the static switch (STSW), unless the bypass input source
becomes unavailable.

STATIC SWITCH

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

EXTERNAL
DISCONNECT

BATTERY

Figure 1-10 Energy Saver Mode

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9390 Service Manual System Overview

1.3.5 Bypass Mode with Internal Service Switch Option

If the optional Internal Service Switch (ISS) is installed, the CSE has the ability
to put the load in bypass, shut down the power modules, and secure logic
power. Power supply connectors have extensions on them, providing an
accessible plug to disconnect, securing input power to the power supplies while
maintaining the customer load through the UPS cabinet. See Figure 1-11,
Bypass Mode with Internal Service Switch Option.
An Anderson connector is used between the output and the Static Switch to
prevent backfeeding the Static Switch. This configuration allows removal of the
Static Switch while continuing to support the load.
Note:
This procedure is make-before-break to ensure the customer’s load remains
supported. Transfer the ISS to bypass to make, then disconnect the Anderson
to break.
The limitations with this line up are:
• No maintenance can be performed on any contactors.
• Dangerous voltages remain present in the lower half of the unit.

ISS
STATIC SWITCH

K5 ANDERSON
CONNECTOR

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect

BATTERY

Figure 1-11 Bypass Mode with Internal Service Switch Option

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System Overview 9390 Service Manual

1.4 Modes of Operation - Parallel Redundant, Capacity.

9390 Parallel Systems (Redundant and Capacity) will support a critical load in
four different modes of operation: Normal mode, Battery mode, Bypass mode,
and Energy Saver Mode. The system automatically uses all four modes, as
necessary, without operator intervention. To achieve this, sophisticated
detection and control logic located in each Uninterruptible Power Module (UPM)
is used to ensure any change in operating mode is automatic and transparent to
the load. Internal monitoring systems located within each UPM will indicate the
current mode of operation. The modes of operation will be discussed in more
detail using block level diagrams to show the power flow through a parallel
system.
The individual modules of the parallel system contain the same basic functions
as a single module system. Each module contains a rectifier, inverter, and static
switch (STSW). The operation and power flow through each module is identical
to that of the single module system.

1.4.1 Operating the 9390 Parallel with Module Output

Breakers (MOBs) with Auxiliaries
The Pullchain wiring instructions, for old and new terminal blocks, are shown in
Section 3.2.1.4, Parallel Network Wiring for OLD and NEW Terminal Blocks.
Note:
This information is for MOBs with auxiliary contacts only.
Note:
The ‘Module Output Brk Installed’ on the XCP Service Tool Option Tab must be
set.
1. Disconnecting a unit with an MOB installed.
• Open the MOB to disconnect the output from critical loads.
• Ensure that the alarm “Output Breaker Open” appears in the Active
Events Screen. If it doesn’t, check MOB auxiliary wiring.
• The unit will now operate as a Reverse Transfer unit.
2. Connecting a unit with an MOB installed.
• Put the unit in Shutdown (load off).
• Close the MOB to reconnect the unit to the system output.
• Start the unit using the Normal command.

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9390 Service Manual System Overview

1.4.2 Normal Mode - Parallel

See Figure 1-12, Normal Mode Parallel Redundant (1 + 1), and Figure 1-13,
NORMAL Mode Parallel Capacity (2+0).
The referenced figures show the path of electrical power through Parallel
Redundant and Capacity type systems when operating in Normal mode. Modes
of operation for a single module system should be reviewed and understood
thoroughly before continuing this description.
In Normal mode, each UPM conditions the incoming AC power and provides
clean, regulated, AC power to a tie and/or distribution panel (EATON® or
customer provided) for parallel systems of up to four modules. The applied load
is equally shared among the available UPMs in the system.

STATIC SWITCH

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
MOB # 1
Disconnect
LOAD
UPM #1 80KVA BATTERY 80 KVA

MOB # 2

STATIC SWITCH

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect
UPM #2 80KVA
BATTERY

Figure 1-12 Normal Mode Parallel Redundant (1 + 1)

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System Overview 9390 Service Manual

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect MOB #1

LOAD
UPM #1 80KVA BATTERY 150KVA

MOB #2

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect

UPM #2 80KVA
BATTERY

Figure 1-13 NORMAL Mode Parallel Capacity (2+0)

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9390 Service Manual System Overview

1.4.3 Battery Mode - Parallel

See Figure 1-14, BATTERY Mode Parallel Redundant (1 + 1) and
Figure 1-15, BATTERY Mode Parallel Capacity (2 + 0).
The referenced figures show the path of electrical power through the parallel
system when the system is operating in Battery mode.
Battery mode is entered into automatically by each UPM during a utility power
failure or deviation from voltage and frequency specifications (refer to input
specifications listed in the "Installation & Operation" manual). If either of these
conditions occurs, each rectifier will turn off and the flow of DC current to the
inverters transitions from each rectifier to the batteries. If bypass input
experiences the same loss of valid power, the backfeed protection contactor
(K5) will open. Opening the backfeed protection contactor (K5) prevents static
switch (STSW) output voltage from bleeding backwards through the static
switch "snubber" components and entering the input source.
Since the output of each rectifier is tied directly to both the inverter input and the
battery, the system output is maintained without interruption to the supported
load. While in Battery mode, each UPM will activate a horn and an indicator
lamp on the front panel (SYSTEM NORMAL, ON BATTERY), and make an
entry into the alarm event history. As the battery discharges, the inverter
constantly makes minute adjustments to maintain a steady and balanced output.
The system will remain in this operating mode until the input power to the
system is again within voltage and frequency specification.
If the input power fails to return or is not within the specifications required for
normal rectifier operation, the batteries will continue discharging until a DC
voltage level is reached where the inverter output of each UPM can no longer
support the shared loads. As this occurs on each UPM, another set of audible
and visual alarms indicating a SHUTDOWN IMMINENT WARNING (two minute
warning) will be seen on both the active alarm message screen and in the alarm
event history for those UPMs about to shut down. Unless the system has a valid
input, redundant UPMs will begin shutting down until there are no longer enough
UPMs online to support the connected load. If at any time during the battery
discharge input power becomes available, each rectifier will turn on, support the
inverter, and begin recharging the batteries. The system returns to normal
operation. Depending on the amount of load on the system and the duration of
the battery discharge, battery and rectifier input current limit alarms may be
seen for a short time due to the current required to recharge the batteries.
The system's total operating time on the batteries will depend on many factors.
Some factors that affect battery support times are battery type and capacity,
number of parallel strings, environmental temperatures, age of the battery, and
fluctuations in load demand during the discharge. The greater the load, the less
support time the battery will have. Decrease the load, and the battery support
time will generally increase.

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System Overview 9390 Service Manual

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External MOB #1
Disconnect

UPM #1 80KVA LOAD

BATTERY 80KVA

MOB #2
STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect
UPM #2 80KVA

BATTERY

Figure 1-14 BATTERY Mode Parallel Redundant (1 + 1)

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9390 Service Manual System Overview

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External MOB #1
Disconnect

UPM #1 80KVA LOAD

BATTERY
150KVA

MOB #2

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect
UPM #2 80KVA

BATTERY

Figure 1-15 BATTERY Mode Parallel Capacity (2 + 0)

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System Overview 9390 Service Manual

1.4.4 Bypass Mode - Parallel

See Figure 1-16, BYPASS Mode Parallel Redundant (1 + 1) and
Figure 1-17, BYPASS Mode Parallel Capacity (2 + 0).
The referenced figures show the path of electrical power through a parallel
system when operating in Bypass mode.
In Bypass mode, the output of the system is provided with three-phase AC
power directly from the bypass input. The output of the system is not protected
from fluctuations, spikes, or power outages from the source. No power filtering,
conditioning, or battery support is available to the output of the system in the
Bypass mode of operation.
In a parallel redundant or capacity type system, each module operates
independently but shares the load in parallel and transfers to bypass with the
other UPMs. The bypass source for the load is passed from the bypass input of
one or both modules through the modules’ internal static switch. If a module is
taken offline, the other module remains online to support the load. If the second
module must be taken offline, the load must be transferred to Maintenance
Bypass or shut down.
Like a single module, if a parallel system transfers to Bypass for any reason
other than operator intervention, each module within the system will attempt to
transfer online to support the output of the system. Three attempts will be made
within ten (10) minutes to bring the system back online automatically before the
system will lock out any further attempts. After three (3) attempts have been
made, the system will remain in Bypass and an alarm condition will be active.
Examples of the three attempts are:
• Inverter DCOV
• Inverter DCUV
• Inverter current limit
The Bypass mode may also be used when the modules in the system must be
shut down to perform routine maintenance or repairs.

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9390 Service Manual System Overview

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External MOB #1
Disconnect
UPM #1 80KVA
LOAD
BATTERY 80KVA

MOB #2
STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect
UPM #2 80KVA
BATTERY

Figure 1-16 BYPASS Mode Parallel Redundant (1 + 1)

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System Overview 9390 Service Manual

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External MOB #1
Disconnect
UPM #1 80KVA
LOAD
BATTERY 150KVA

MOB #2
STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect
UPM #2 80KVA
BATTERY

Figure 1-17 BYPASS Mode Parallel Capacity (2 + 0)

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9390 Service Manual System Overview

1.4.5 Energy Saver Mode - Parallel

1.4.5.1 Parallel ESM Overview
In Parallel Energy Saver Mode (ESM), the output of the system is provided with
three-phase AC power directly from the bypass inputs through the parallel static
switches. See Figure 1-18, ESM Mode Parallel Redundant and Figure 1-19,
ESM Mode Parallel Capacity. The input (K1) and output (K3) contactors remain
closed while in ESM. The DC Link is maintained through the IGBT protection
diodes. If the microprocessor detects an outage, a forward transfer of all UPMs
to Battery mode is completed in less than 1/4 cycle.
If a UPM fails, the UPMs will attempt to forward transfer to Battery and then
Normal mode. If a static switch failure caused the transfer, bypass may be
unavailable.
While in ESM mode, the output of the system is only protected from voltage or
frequency fluctuations if they exceed system specifications. Limited power line
filtering and spike protection is provided to the load, but no active power
conditioning is available to the output of the system in the energy saver mode of
operation. See “Parallel ESM Operation” on page 84 of Chapter 4 for details.

1.4.5.2 ESM Performance During an Outage

In case of an outage or line disturbance, all of the inverters will transfer online
(forward transfer) and use the batteries to power the load. The system will then
start the rectifiers and return to Normal operation. When power returns, the
system will return to ESM Mode. If the unit completes three forward transfers in
one hour, the system will remain in ESM for one hour before attempting to return
to ESM Mode.
After a battery discharge, and power returns, the system returns to ESM mode,
and the batteries are charged through the inverter IGBT diodes. The 9390 400
volt units will turn on the rectifier to charge the batteries. The rectifier is also
used while in ABM float mode. When the batteries have been charged, the
rectifier is turned off and the DC link is sustained through the inverter IGBT
diodes.

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System Overview 9390 Service Manual

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External MOB #1
Disconnect
UPM #1 80KVA
LOAD
BATTERY 75KVA

MOB #2
STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect
UPM #2 80KVA
BATTERY

Figure 1-18 ESM Mode Parallel Redundant

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9390 Service Manual System Overview

STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External MOB #1
Disconnect
UPM #1 80KVA
LOAD
BATTERY 150KVA

MOB #2
STSW

K5

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect
UPM #2 80KVA
BATTERY

Figure 1-19 ESM Mode Parallel Capacity

1.4.6 9390 Specifications

See Chapter 6, Options, and the Installation & Operation Manuals, for more
information on options, installation, and product specifications.
All 9390 documentation, including User Guides with specifications, can be found
at: http://powerquality.eaton.com/.

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This page was left blank intentionally.

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 2
Safety
2.1 General Safety Considerations
2.1.1 Tools, Equipment, and Expendable Field Service
Supplies
When performing service calls or procedures on Eaton Corporation equipment,
the following rules must be observed. These rules pertain to tools, testers,
solvents, adhesives, and lubricants.
• Ensure that electrical hand tools, such as power drills, are inspected
regularly.
• Replace worn and broken tools and test equipment with new tools and
equipment.

2.1.2 General Safety Rules

Incorporate the following safety rules for working with electrical and mechanical
equipment into the maintenance and repair procedures.

© 2009 Eaton Corporation. Company Confidential. 2–1

Safety 9390 Service Manual

2.2 Environmental Safety

Observe the following rules:

WARNING
DO NOT WORK ALONE IN POTENTIALLY HAZARDOUS CONDITIONS OR
NEAR EQUIPMENT THAT HAS POTENTIALLY DANGEROUS VOLTAGES.

1. Always inform the appropriate supervisor/manager of conditions or

voltages that might pose a threat to safety. Take all steps necessary
to maximize safety.
2. Always look for possible hazards such as moist floors, non-grounded
extension cables, power supplies, and missing safety grounds.
3. Do not make unauthorized changes or modifications to the
equipment. This creates a hazard and unsafe equipment.
4. Before starting the equipment, ensure that other service and customer
personnel are not exposed to any unsafe conditions.
5. Do not wear loose clothing that can be trapped in the moving parts of
a machine. Ensure sleeves are fastened or rolled above the elbow.
6. If wearing a necktie or scarf insert it into the clothing or fasten it with a
nonconductive clip at approximately 8 centimeters (3 inches) from its
end. This prevents the tie from being caught by a moving part of the
equipment.
7. Fasten long hair to make it safe.
8. Lift the equipment or parts by pushing up with the leg muscles to
prevent strain on the back. Do not lift any equipment or parts that
cannot be lifted comfortably.
9. Always keep tool kits away from walk areas so as not to present a
tripping hazard. If possible, keep the tool kit on or under a table.
10. Observe good housekeeping practices in the area of the UPS while
performing maintenance and after completing the job.
11. Place removed UPS covers in a safe place while servicing the UPS.
Reinstall the covers before returning the UPS to the customer.
12. Reinstall all safety devices, such as guards, shields, and ground
wires. Replace worn or defective safety devices. Remember the
safety devices protect personnel from a hazard. Ensure all safety
devices are reinstalled when the maintenance/service has been
completed.

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9390 Service Manual Safety

2.3 Electrical Safety

Observe the following rules when working on electrical machinery:
1. Follow the manual shutdown and maintenance bypass procedures to
prevent loss of power to the customer’s load. Switch input and logic
power off, if recommended in the Service manual:
• Before removing or assembling the main units of the equipment
• Before working near power supplies
• Before inspecting power supplies
• Before installing changes in machine circuits
2. Unless the maintenance documents specifically instruct otherwise, do
not make unauthorized changes or modifications to the equipment.
This creates a hazard and unsafe equipment.

WARNING
DO NOT SERVICE INPUT, OUTPUT, OR BYPASS CIRCUIT BREAKERS,
CONTACTORS, CHOKES, TRANSFORMERS, OR CURRENT TRANSFORMERS
(CTs) WITH POWER ON.

3. If working on equipment that has exposed live electric circuits,

OBSERVE the following precautions:
• Ensure another person who is properly trained in the power-off
controls is within a close distance at all times to switch off power if
necessary
• Do not wear jewelry, chains, metal frame eyeglasses, or other
personal metal objects
• Use only insulated probe tips or extenders with the proper voltage
rating for the circuit you are testing
• Use one hand while you are working on or near energized
equipment. Keep one hand in your pocket or behind the back to
prevent electric current flow across the heart
• Do not touch objects that are grounded, such as metal floor strips,
machine frames, or other conductors. Use suitable rubber mats.
Obtain the mats locally, if necessary
• When using test equipment, set the controls as referenced in the
operator or service manual. Use only properly insulated probes
4. When working with machines having voltages more than 30 Vac or
42.4 VDC, observe special safety instructions referenced in Field
Service Manuals and Bulletins.

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Safety 9390 Service Manual

WARNING
NEVER ASSUME THAT POWER HAS BEEN REMOVED FROM A CIRCUIT.
CHECK AND ENSURE THAT POWER HAS BEEN REMOVED BY USING A
KNOWN GOOD VOLTMETER.

5. Do not touch live electric circuits with the surface of a dental mirror.
The handle of the mirror is conductive and can cause equipment
damage and/or personal injury.
6. If an electrical accident occurs:
• Use caution; do not become a victim. Switch off the power.
• Instruct another person to get medical aid

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9390 Service Manual Safety

2.4 Mechanical Safety

CAUTION
Do not touch moving mechanical parts at any time (including fans).

2.5 Eye Safety

CAUTION
Safety glasses shall be worn at all times.
Use additional caution when using the following equipment or when performing
procedures listed below:
• Using a hammer
• Using a power drill
• Using a spring hook
• Soldering parts
• Cutting wire or removing steel bands
• Using solvents, chemicals, or cleaners to clean parts
• Working in any other condition that might injure the eyes (i.e., a UPS
module under power, input, or bypass)
• Do not wear soft contact lenses when working on or around electrical
equipment.

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Safety 9390 Service Manual

2.6 UPS Safety

WARNING
THE OSCILLOSCOPE MUST BE ISOLATED BY USING AN ADAPTER THAT
ISOLATES THE SCOPE AND EARTH GROUND. USE EXTREME CAUTION,
THE SCOPE WILL HAVE POTENTIAL BETWEEN THE UPS FRAME AND THE
SCOPE. DO NOT TOUCH THE UPS AND THE SCOPE AT THE SAME TIME.

2.6.1 Operating Environment

1. Keep surroundings clean and free from excess moisture.
2. Do not operate close to gas or electric heat sources.
3. The system is not intended for outdoor use.
4. Operating environment should be within parameters listed in the
Installation & Operation Manual(s).

2.6.2 Normal Operation

1. Keep equipment doors closed to ensure proper cooling air flow, and to
protect from dangerous voltages within the unit.
2. Ensure all conduit knockouts and/or unnecessary openings are
sealed.
3. Do not make any assumptions about the electrical state of the UPS.
CHECK THE ELECTRICAL STATUS WITH A KNOWN GOOD
VOLTMETER!

WARNING
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.

The following safety cautions are intended to provide important specific

information about the safe operation of the UPS. Violation of these precautions
could result in serious damage to the UPS and/or injury or death.

2.6.3 Maintenance/Service
1. Always wear appropriate eye protection.
2. Remove restrictive or loose clothing and remove all jewelry.
3. Use correct documentation and appropriate tools as outlined in this
manual.
4. Use a static secured work area and ESD procedures when performing
component replacement or modifications.

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9390 Service Manual Safety

5. Ensure power is disconnected before performing installation or

service when possible.
6. Observe all CAUTIONS, WARNINGS, AND DANGER notices fixed to
the inside and/or outside of the equipment.
7. Always comply to more detailed safety precautions described in the
appropriate section later in this manual.

2.6.4 Batteries
1. Lead-acid batteries are sealed and maintenance-free. No electrolyte/
water can be added.
2. Dangerous voltage is always present at battery terminals.

WARNING
Batteries can present a risk of electrical shock or burn from high short-circuit
current and high voltage. Observe proper precautions. Incorrect connection
of batteries may cause electrical shock, fire, injury, or death.

3. The battery contains sulfuric acid. If any spillage occurs, take the
following precautions:
• Contact with skin:
– Wash immediately with soap and water
– Contact a physician if any burn results
• If acid splashes in eyes:
– Wash for 20 minutes under running water
– Contact a physician

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Safety 9390 Service Manual

2.7 Site Safety

UPS personnel are aware of the presence of potentially lethal voltages within
the UPS. Observe the following precautions to ensure personnel safety and
continued equipment operation.
1. Keep surroundings clean and free from excess moisture.
2. Do not operate near gas or electric heat sources.
3. The system is not intended for outdoor use.
4. Operating environment should be within parameters listed in the
Installation & Operation Manual(s).
5. Ensure the site is safe.
6. Inspect power cables and plugs; check for loose, damaged, or worn
parts.

WARNING
VOLTAGES ACROSS CHARGED CAPACITORS CAN BE IN EXCESS OF 300
VDC. BE CERTAIN THE FILTER CAPACITORS ARE FULLY DISCHARGED
AND INPUT POWER IS OFF BEFORE PERFORMING ANY MAINTENANCE OR
TROUBLESHOOTING.

7. Review all procedures in the maintenance documents before

removing a part that can hold an electric charge. Carefully discharge
the parts exactly as instructed by the procedures.
8. Do not use a normal light (for example, a table lamp) for illumination
when performing maintenance on the UPS. Use a flashlight with a
nonconductive case.

NOTICE
Note:

Never assume that a UPS or a circuit is safe. Follow all procedures and safety
precautions in the maintenance documents and all other applicable
manufacturers publications.
9. Always be aware of the following potentially hazardous conditions.
Take the necessary safety steps to protect against the existence of
these potential hazards:
• Power receptacles wired incorrectly
• Safety devices or features missing or defective
• Maintenance or change history wrong or incomplete
• A UPS design problem
• A damaged UPS due to shipping

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9390 Service Manual Safety

• An unsafe change or attachment installed in the UPS

• An engineering change or a sales change installed incorrectly
• A defective part
• Potentially unsafe UPS because the unit is old or operated in an
extreme environment

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Safety 9390 Service Manual

2.8 Summary
Prevention is the key to electrical safety. Always think about electrical safety and
use good preventive practices before performing any work on equipment.
These are some of the ways that the condition of the UPS that could affect
safety. Before starting maintenance or repair procedures, USE GOOD
PREVENTIVE JUDGMENT and USE CAUTION; SAFETY COMES FIRST!

WARNING
DO NOT WORK ALONE IN POTENTIALLY HAZARDOUS CONDITIONS OR
NEAR EQUIPMENT THAT HAS POTENTIALLY DANGEROUS VOLTAGES.

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9390 Service Manual Safety

2.9 Electrostatic Discharge (ESD) Procedure and

Equipment Requirements
2.9.1 Purpose
To provide guidelines on handling electrostatic sensitive materials.

2.9.2 Scope
To provide a procedure which specifies ESD criteria when handling electrostatic
sensitive materials.

2.9.3 Applicable Documents and Materials

• 3M Product catalog 1986/1987
• 3M Series 2100 bags or better
• Wrist strap 3M 2221-2223 or better
• Table mats (grounded) 3M 8200 series or better
• Antistatic (pink poly)
• 3M Dissipative mats (field kits) or better
• Tables (grounded) with equivalent or better than surface of mat

2.9.4 Definitions
Antistatic material: Material that neither generates static electricity nor does it
provide protection against static field, and typically has a surface resistivity of
109 to 1014 ohm/cm.
Conductive material: Material that provides a Faraday cage effect and protects
against static generation and static field with a surface resistivity of <105  per
cm.
Dissipative material: Material that provides some protection against static field
and typically has a surface resistivity of 105 to 109  per cm.
Faraday Cage or Faraday Shield: A conductive enclosure capable of
protecting its contents from any outside static charge or electrostatic field. An
example would be an ESD bag which is closed.
Frame ground: Any unpainted surface of a unit or subassembly to which a wrist
strap may be firmly connected.
Ground: Building/earth ground.
Static safeguard stations: Any area with provisions for controlling electrostatic
discharge.

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Safety 9390 Service Manual

Static sensitive material: Any static sensitive component/device

(semiconductors, film resistors, capacitors, etc.) or boards with such
components/devices mounted on them.
Static shield: Must be capable of providing a Faraday cage (protective from
static discharge as well as electrostatic fields).
Static Protective equipment/tools: As a minimum must include but not be
limited to a wrist strap with 1 meg ohm resistor, conductive table mat or
grounded work surface, and dissipative mats for field engineers.

WARNING
100% ESD PREVENTION REQUIRES REMOVAL OF ALL POWER FROM THE
UPS (I.E., INPUT, BYPASS, AND LOAD) CAUSING A LOAD INTERRUPTION.
THE FOLLOWING RECOMMENDATIONS ARE MADE TO ENSURE THE
BOARDS AND OTHER STATIC SENSITIVE COMPONENTS WILL NOT BE
DAMAGED.

2.9.5 Procedure
1. All static sensitive material shall be packaged in approved antistatic
protective packaging.
2. Wrist straps, grounded mats, or a grounded table (with equivalent or
better than surface of mat), shall be used when handling static-
sensitive material.
3. When removing or installing boards in a unit or subassembly, use a
wrist strap and connect it to the frame of the unit or subassembly.
4. Rejected boards (returned to factory/rework center) are just as
sensitive to electrostatic discharge and shall be handled with the
same protection as good/accepted boards (i.e., in a static protected
environment).
5. All static sensitive devices, and boards with such devices, shall be
stored/handled in their static protected tubes and bags. Tubes and
bags provide a complete Faraday cage which is necessary protection
for static-sensitive devices and required at all times.
6. All sales and field engineering personnel are required to use a
portable static controlled field service kit when handling static-
sensitive material.

2.9.6 Removal of Boards

CAUTION
When removing a board without pull out tabs, handle the board on the edges.
Lethal voltage may be present on the traces of the board.

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9390 Service Manual Safety

Use correct removal procedure to remove all boards from the unit. If the board
has pull out tabs, remove the board with the use of these tabs. For boards
without pull out tabs, pull the board by grabbing the edge of the board. Do not
touch any static sensitive component/device (semiconductors, film resistors,
and capacitors, and so on). The following procedure provides guidelines on
handling electrostatic sensitive materials.
1. All static-sensitive material shall be packaged in approved anti-static
protective packaging.
2. Wrist straps, grounded mats, or a grounded table (with equivalent or
better than surface of mat), shall be used when handling static-
sensitive material.
3. When removing or installing boards in a unit or subassembly, use a
wrist strap and connect it to the frame of the unit or subassembly.
4. Rejected boards (returned to factory/rework center) are just as
sensitive to electrostatic discharge and shall be handled with the
same protection as good/accepted boards (i.e., in a static protected
environment).
5. All static-sensitive devices, and boards with such devices, shall be
stored/handled in their static protected tubes and bags. Tubes and
bags provide a complete Faraday cage which is necessary protection
for static-sensitive devices and required at all times.
6. All CSEs are required to use a portable static controlled field service
kit when handling static sensitive material.

2.9.7 Packaging of Boards

NOTICE
Note:

Packaging of boards, unless otherwise specified, will be packaged in egg-crate

type cartons, separating each board with partitions.

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Safety 9390 Service Manual

2.10 General Guidelines for ESD Protection

All printed circuit boards without static-sensitive components must, as a
minimum, have a pink poly wrap for static protection. Boards with
semiconductor devices must be in ESD shielded bags. Boards with on-board
batteries must be wrapped with pink poly (for protection against battery
discharge) prior to insertion into standard shielded bags.
1. Material used is designed to protect static sensitive components and
assemblies from both internal and external static charge during
transfer between static safe work areas.
2. Protective bag construction must provide protection inside against
static buildup from movement of devices, outside against electrostatic
fields and must insulate against a direct static discharge.
3. Resistivity requirements are as follows:
• Interior (anti-static) 109 to 1014  per square.

NOTICE
Note:

The resistivity will be the same for any size square. 144 x 144 x 144 will have
the same resistivity as a 244 x 244 x 244 square.
• Inter-layer (insulating and direct discharge protection) greater than 1014 
per square
• Exterior (conductive) less than or equal to 105  per square
• Total thickness of static bags (including all layers) must be 3 MILS
minimum
• Static bags must be sealed in some manner

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9390 Service Manual Safety

HANDLING FLOWCHART
Handling of Handling for
Handling of Boards Components Field Engineers
and Sales Personnel

Wrist straps and grounded Wrist straps and grounded

mats, or tables with a mats, or tables with a Dissipative mats are to be
equivalent surface will be equivalent surface will be used by field engineers and
used when handling all used when handling all static sales personnel.
static sensitive material. sensitive material.

Boards without static All static sensitive

sensitive material, as a Field engineering personnel
components must arrive in shall be equipped with
minimum, must be in pink antistatic tubes or shielding portable static controlled field
poly wrap for protection. packages. service kits.

Static sensitive components All other ESD procedures for

Boards with static sensitive boards. and components will
material must be in static shall be handled at a static be observed by field
shield bags. safe--guard station only personnel.

All boards with on board

batteries must be placed in Transport static sensitive
pink poly wrap prior to components in a static
insertion in static shielding shielding bag or container
bag.

Rejected boards are to be

handled with the same care
as accepted boards, (i.e.
good boards).

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 3
Installation and Startup
3.1 EATON® 9390 UNINTERRUPTIBLE POWER
SUPPLY (20 - 160 kVA) SINGLE MODULE (RT)
3.1.1 Mechanical Inspection
1. Visually inspect the module for any shipping damage:
a. Perform an external and internal inspection (no dents, paint
blemishes, frame is straight).
b. Ensure that internal subassemblies and ALL wiring connections
are secure.
c. Remove the protective film from the front panel (Use a ground
strap while removing the protective film).
d. Remove the shipping cover from the top of the unit. If the cover
was removed by the installer, remove modules and inspect for
debris which may have fallen through the ventilation openings.
Note:
Place the covers on top of the ventilation holes if the UPS is stopped for long
periods of time or if construction work is performed near the UPS.
2. Visually inspect the module for proper installation and:
a. for properly rated feeder breaker and wire size (refer to the
installation and operation manual for recommended breaker and
wire sizes).
b. the UPS label matches the application (voltage, kVA, frequency,
power).
c. Input, output, bypass, and battery connections are properly
wired.
d. If the customer’s load requires a neutral, then the system neutral
must be supplied by the utility input power source from a Wye
transformer. Refer to the “9390 Supported Source and Load

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Installation and Startup 9390 Service Manual

Configurations” document available on the 9390 Service Manual

CD.
Note:
400V systems: If no neutral is provided, the factory installs a No-Neutral kit that
ensures correct operation in all modes. (Part Number 1025568 for “No Neutral
Kit.”) See Chapter 10 Parts, for No-Neutral Kit, 400 Volt parts.

If the customer’s load does not require a neutral, follow the neutral-to-ground
bonding requirements in the 20 to 80 kVA Installation and Operation manual
(164201535 or 164201603) and the 120 to 160 kVA Installation and Operation
manual (164201554 or 164201604).

Neutral to ground bond cannot be used when the source has a high impedance
ground.
Note:
The vendor for the 9390 contactors has changed from ABB to Cutler-
Hammer®. Refer to the Adobe Acrobat Interactive CD version of this service
manual for more information. Additionally, separate Installation and Operation
manuals have been created for each vendor. See Chapter 10 Parts, Contactor
Vendor Change from ABB to Cutler-Hammer® for CTO and Assembly
numbers.

Part Number Installation & Operation Manual Description

164201535 9390 40/80 kVA, with ABB Contactors

164201554 9390 100/160 kVA, with ABB Contactors

164201603 9390 40/80 kVA, with Cutler-Hammer® Contactors

164201604 9390 100/160 kVA, with Cutler-Hammer® Contactors

3. Verify all options are installed and wired properly:

• Module single feed option, not recommended for 400V.
• Module dual feed option.
– 80 kVA and below: Verify jumpers from E1, E2, and E3 to E6,
E7, and E8 are removed. No jumpers in 400V units, always
dual feed.
– 100 kVA and above: Refer to Installation and Operation
Manual 164201554 or 164201604.
• If the Mini-CSB is installed:
– Remove the plastic tab under the battery (see Figure 3-1, Mini-
CSB Plastic Tab Under Battery).
– Verify that the CAT-5 cable is connected to the RJ-45 at J3
and power is connected at J4.

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9390 Service Manual Installation and Startup

– Ensure the logic jumpers J9-J12 are set to 2 & 3 shorted on

the Mini-CSB card. See Figure 3-2, Mini-CSB Logic Jumpers
J9 - J12.

Figure 3-1 Mini-CSB Plastic Tab Under Battery

See Section 5.2.7, Mini-CSB for more communication information.

Figure 3-2 Mini-CSB Logic Jumpers J9 - J12

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Installation and Startup 9390 Service Manual

• If Load Sync Control option is installed, See Section , END OF

CHAPTER 3 for details.
• X-Slot Connectivity Devices
– Relay Card (isolated form C contacts, AS400 type status)
– UPS SNMP / Web Adapter
– External Modem or X-Slot Modem Card (either V.34 or V.90)
– CAN Bridge Card (Required for Parallel and RMP, RIM, or
SCM)
– ModBus Card
– Power Xpert Gateway Card
• Inspect the Remote Emergency Power Off (REPO).
Note:
A twisted pair is required for REPO connections
The REPO switch must be a latching type (not momentary)
– If customer’s connection has Normally Closed (N.C.) contacts,
remove terminal block jumper and attach REPO
– If customer’s connection has Normally Open (N.O.) contacts,
ensure terminal block jumper is installed
• Inspect the Integrated Distribution Cabinet (IDC) (or customer
provided)
• Inspect the External Maintenance Bypass (MBP) (can be located
in IDC, Sidecar, or customer provided)
– For Sidecar refer to drawing numbers 9390INST-001GE and
9390INST-002GE in Chapter 11, Prints
– See the 9390 Sidecar Installation and Operation manual,
164201586
– See Chapter 6 Options, Parallel Tie / Maintenance Bypass
“Sidecar” Cabinet
• Inspect the External Transformers (IDC or customer provided)
• Inspect the Remote Monitoring Panel (RMP II) *
• Inspect the Relay Interface Module (RIM II) *
• Inspect the Supervisory Contact Module (SCM II) *
* RMP II, RIM II, and SCM II require the CAN Bridge Card and must be enabled
using the XCP Service Tool Options tab.
• Inspect the Environmental Monitoring Probe (EMP) ** if Battery
Temperature Compensation will be used.
** Refer to the Installation and Operation Manual for additional information,
available on the Service Manual CD or www.powerwarequality.eaton.com.

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9390 Service Manual Installation and Startup

• Inspect the External Battery Cabinets (EBC) or internal batteries if

the customer has the 9390 IT.
WARNING
THE FOLLOWING STEPS CANNOT BE PERFORMED IF THE BYPASS AND
LOAD ARE ALREADY ENERGIZED.

4. Verify there are no installation ground faults using a DVM. (This

includes the UPS module and any optional cabinets.)
a. Unplug P2 from the Interface Board
b. Unplug P5 from all Power Supplies.
c. Test E1, E2, E3, E6, E7, E8, E9, E10, and E11 to ground (Main
and bypass inputs and outputs; all three phases, phase-to-
ground)
– All readings should be 2M  or greater.
d. Reconnect plug P2 on the Interface Board and plug P5 on all
Power Supplies.

WARNING
Batteries can cause electrical shock or burns from high short circuit current
and high voltage. Observe proper precautions. Incorrect connection of
batteries may cause electrical shock, fire, injury, or death.

5. Verify that the batteries have been properly assembled and attached
to the UPS.
For systems with multiple battery cabinets, only one cabinet has the harness to
connect to the UPS. If the cabinets were not installed in the correct positions,
the UPS harness can be moved; however, the jumpers also need to be
changed. Refer to 164201536 Battery Installation Manual for detailed
interconnection schematics.
If you have a UPS rated at 100 kVA or larger, with only one string of VRLA
batteries, and you’ve completed a PCB setup on a Control Board, you must
change the Battery Charge current on the XCP Service Tool Battery Tab. The
default is set for two battery cabinets, so divide that number in half if you have
only one battery cabinet.
a. Check the inter-tray connections (Red to Black; Black to Red) for
batteries in series.
b. If the unit is not a 9390 IT, skip to step c. If the customer has the
9390 IT, verify that the strings are connected red to black
internally and red to red, black to black in parallel (the parallel
connections have tie wrap tags affixed to the wire near the

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Installation and Startup 9390 Service Manual

connectors). The bottom four trays of batteries constitute the first

string, second four up the second, and the top four trays the third
string. See Figure 3-3, 9390 IT.

Figure 3-3 9390 IT

c. Check the inter-cabinet connections for strings in parallel.

d. Verify the polarity of all parallel strings match BEFORE making
final connections.
e. The open cell voltage for any string should be > 384 VDC to 480
VDC (varies based on total number of cells).
f. The batteries must NOT be ground referenced (either pole tied to
ground).
– Verify battery strings, each pole to ground < 1 VDC

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9390 Service Manual Installation and Startup

g. Verify the undervoltage release (UVR) and auxiliary contact

wiring to the battery disconnect device.
Note:
If the Customer Service Engineer installs the battery auxiliary and UVR wiring,
use double-insulated wires to reduce mechanical wearing. Use twisted-pair
wires and route them separately from all other power wiring.
h. Temporarily disable any automated battery disconnect devices
to prevent the unit from closing the battery disconnect before the
voltage and polarity of the battery have been verified.

3.1.2 Electrical Inspection

WARNING
The following steps will energize the UPS module and its output.

If customer loads are not to be energized at this time, ensure downstream

breakers are open before proceeding.

NOTICE
Note:

Use the Startup Worksheets and Checksheet found at the end of this chapter.

NOTICE
Note:

If the system has a Load Sync Control installed,TB6 must be disconnected at

J100/P100, the configuration jumper (TB1 40-41) installed in the Load Sync
Control, and the Load Sync Control powered off in order to complete this
procedure. See Section for the Load Sync Control
Installation Verification procedure.
1. Energize Power to the System Input.
a. Apply main input power to the UPS. If bypass is a separate
source, apply bypass power.
b. Logic power energizes and the Display Panel shows the Eaton®
logo.
c. Backfeed contactor (K5) closes if bypass input is in limits.
2. Using a DVM, verify the system has correct input voltages (main and
bypass):
a. Verify AC voltages: phase-to-phase, phase-to-neutral, and
phase-to-ground.
b. Verify voltage neutral to ground at E12 is less than 5 Vac rms

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Installation and Startup 9390 Service Manual

3. Using an oscilloscope, verify ABC phase rotation at the following

locations:
a. Main input (E1, E2, and E3)
b. Bypass input (E6, E7, and E8)
c. Optional IDC (if applicable) at TB1 Main, Bypass, and Output.
4. Verify front panel operations:
a. Press any button to access functions on the display panel.
b. Verify a CONFIGURATION ERROR alarm is active. There is no
CONFIGURATION ERROR alarm in 400V units.
c. Ensure that all buttons are in working order.
d. Select SETUP, then select UNIT TYPE. Verify the unit CTO
number and power ratings correspond to the unit labeling and
installation.

NOTICE
Note:

If the UPS is configured as a power conditioner, then disregard all the battery
setup requirements. See Chapter 6 Options, Power Conditioner Mode, for
more details.
5. Using XCP Service Software Tool, verify unit setup.
a. If the unit has VRLA or wet cell batteries, proceed to step b. For
NiCd batteries, follow the step below.
– NiCd battery setups are loaded based on the CTO. After
verifying the CTO, simply open the XCP Service Tool battery
setup tab and press “Battery Configuration Complete.” Do not
change any settings. Proceed to step c.
b. For VRLA or wet cell batteries, or for the 9390 IT, use the
BATTERY Startup Tab to configure the UPS for the connected
battery:
– Check for correct # of cells in the battery string(s).
– Check for correct # of battery strings.
– Enter the Watts per Cell at 15 minutes for the battery
– Once battery is setup, click on “Battery Configuration
Complete.”
c. Using OPTIONS tab, verify customer options are correctly
enabled or disabled.
d. Using the MODEM tab, configure the unit for outcall operations
(if applicable).

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9390 Service Manual Installation and Startup

3.1.3 Operational Inspection

1. Verify Power Supply functions.
a. Verify the following LEDs are illuminated on both power supplies:
D5 (+48V) and D8 (+15V).
b. If any of these LEDs is not illuminated at this point in the
procedure, resolve the power supply problem before proceeding.
2. From CONTROL, select BYPASS
a. The front panel indicates BYPASS.
b. Verify output voltage and phase sequence on E9, E10, and E11.
– Measure bypass A to output A. Should read <1 Vac.
– Measure bypass B to output B. Should read <1 Vac.
– Measure bypass C to output C. Should read <1 Vac.
3. Using the XCP Service Tool meters tab, verify that all gate powers are
consistent and close to the tolerances shown in Table 9-1 on page 10
and Table 9-2 on page 10. An abnormal reading may indicate an
IGBT fault.
4. Perform DC Link Bleed and Inverter IGBT Verification. For test points
see Figure 1-3, 20-80 (left) and 100-160 (right) kVA UPS Inside View
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems.
a. Connect a DVM set to DCV to TB3-6 and TB3-7.
b. From CONTROL, select PM ON, but be ready to quickly select
PM OFF when the DC Link approaches 200VDC.
c. When the DC Link reaches 200VDC, select PM OFF.
– The DC Link should bleed down very slowly.
d. Connect an oscilloscope reference lead to TB3-11. Use the other
lead on TB3-8, 9, and 10 sequentially in the next steps.
e. From the CONTROL menu, select LOAD OFF.
f. Monitor the bleed off of the DC Link and the inverter IGBT gating
by looking for a sine wave on the oscilloscope and a rapid
decrease of the DC voltage on the DC Link.
g. Repeat steps b. through f. for all three inverter phases.
5. From CONTROL, select PM ON
a. The Power Module (PM) indicates DC STARTING (pre-charging)
b. Verify capacitor pre-charge voltages

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Installation and Startup 9390 Service Manual

– TB3-6 to TB3-7 should be approximately 260 Vdc with a 208

Vac input, 650 Vdc with a 480 Vac input, and 540 Vdc with a
··
Prech arg e = 0.9  2  V  line – to – line 

400 Vac input. :

– If pre-charge voltage is not present, determine and correct the
pre-charge problem before proceeding.
c. Input contactor K1 closes in less than 2 minutes, otherwise
CHECK PRECHARGE alarm will appear.
d. Power Module (PM) indicates DC STARTING (rectifier starting).
– DC Link will rapidly increase to approximately 324 Vdc with a
208 Vac input, 750 VDC with a 480 Vac input, and 650 Vdc
with a 400 Vac input. DCLink = 1.1  2  V  line – to – line 
e. Power Module (PM) indicates INVERTER STARTING.
f. Power Module (PM) indicates SYNCING (inverter syncing to
bypass).
g. Power Module (PM) indicates READY.
h. Power Module (PM) indicates CLOSE BATTERY BREAKER
alarm. Ignore at this point; press any button to silence the horn.
6. System Battery Verification.
a. Verify DC voltage and polarity on both sides of battery breaker
CB1 in the battery cabinet or battery strings.
– If the voltage and polarity are correct, proceed to the next step.
If voltage and polarity are not correct, determine and correct
the cause of any battery problem before proceeding.
b. Close battery breaker CB1 in the battery cabinet.
– After a short delay the battery charger turns on and indicates
CHARGER ON while the system does a check for proper
battery configuration.
Note:
The default battery charge current for a 100-160 kVA 9390 is set for two battery
cabinets. If the UPS has only one battery cabinet, divide the value o the battery
options tab by two. Use the manufacturer cut sheets to verify charge current
limit.
7. From CONTROL, select NORMAL.
a. K3 will close, the static switch turns off.
b. The Power Module (PM) indicates ONLINE (load is protected).
c. The LCD display indicates NORMAL.

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9390 Service Manual Installation and Startup

d. Determine and correct the cause of any active alarms or notices.

8. Verify ON BATTERY operation:
a. Open main input feeder breaker to UPS utility (and bypass if dual
feed) for 30-60 seconds.
– Contactors K1 and K5 open.
b. Verify stable output voltage and frequency.
– the battery screen shows discharging.
– the BATTERY and NORMAL lamps are lit on front panel; the
horn sounds every 3 seconds.
c. Close the main input feeder breaker (and bypass if dual feed).
– K1 and K5 close.
– The BATTERY lamp turns off.
Note:
The Battery Commissioning button on the XCP Service Tool must be the last
selection prior to departing the site. After selecting Battery Commissioning, go
to the Front Display and cycle the charger OFF and ON - leaving it ON. Failure
to follow this procedure will result in the Battery Time Remaining never being
correct.
d. Verify battery charger turns on and indicates CHARGER ON.
9. Test Energy Saver Mode (if applicable: f/w 5.XX).
a. Command the unit to ESM and verify correct operation in
accordance with the 9390 User Guide.
b. Return the unit to Normal Mode
10. Complete the Easy Capacity Test procedure “Basic Easy Capacity
Testing” on page 12 (if applicable: f/w 5.XX).
11. Verify the operation of all externally connected options.
• X-Slot connectivity / communication options, see note below.
• Environmental Monitoring Probe (EMP), see note below.
• Remote monitoring panels or status relays.
• Active Response Remote Monitoring (if applicable).
• Remote Emergency Power Off (REPO).
• Building alarm inputs (if used).
12. Set time and date correctly.
Note:
Refer to Chapter 5 for procedures and additional information.
Refer to installation and operation manual and additional information which is
available on the CD or www.powerware.com.

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Installation and Startup 9390 Service Manual

13. Apply the customer load to the system and verify all measured values
against the values displayed by both the unit front panel and the XCP
Service Tool.
a. Use the provided worksheet as needed.
b. Perform calibration of out-of-tolerance parameters.
14. Verify all applicable field service bulletins have been applied.

3.1.4 Basic Easy Capacity Testing

The Basic Easy Capacity Test is used for verifying system operation. Common
uses of the test are:
• Component verification after a repair.
• Performing current calibration checks.
• Customer witness tests.
• Battery re-commissioning test after a battery change.
• System verification at the end of a startup.
The Basic Easy Capacity Test is not a commissioning test. The Extended
Commissioning Test is an option that requires a service ticket and scope of
work. Information about the Extended Commissioning Test procedures can be
found in Chapter 6, “ECT Extended Commissioning Test” on page 11 of this
book.
The Easy Capacity Test can be used to perform a (full) load test for a UPS and
to perform current calibrations.
The Easy Capacity Test shall be performed with steady mains conditions and
those performing it must be trained on this product and procedure.

WARNING
DO NOT ATTEMPT TO PERFORM THIS TEST IF NOT PREVIOUSLY
TRAINED.

3.1.4.1 Initial Conditions:

A. Never have any customer load connected to the UPS while
performing the Easy Capacity Test!
B. The unit must be in Normal mode.
C. Use the existing XCP Service Tool version 03.20.6 or newer. The
Easy Capacity Test must only be performed on one UPS at a time.

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9390 Service Manual Installation and Startup

WARNING
Other UPMs must be in the shutdown state during the test (logic power
only or off).

D. Verify from the customer if backfeeding power into building (utility) is

allowed. If not, the Easy Capacity Test CANNOT BE USED to
discharge batteries.
E. Perform the following check-list (as a minimum) and get the
customer’s permission prior to starting the test.
• Does the bypass and Rectifier input come from the same source?
• Are there any customer loads upstream of the UPS input to the
point where bypass and Rectifier inputs are a common point?
• Are there any customer loads upstream of the UPS beyond the
point where bypass and Rectifier inputs are common?
• What is the total load upstream of the UPS?
• Is the total load greater or equal to the percent of battery tested
load?
• Does the facility main breaker have a ground fault trip installed?
• Is the main ground fault setting at maximum?
• Does the facility main breaker have any anti-backfeeding
prevention circuits?
• Is there any regulation preventing the backfeeding of utility if the
customer does not have enough upstream loads to use the power
from the UPS when it tests the battery?
• Is the customer’s load off or on maintenance bypass?
• If the customer’s load is on maintenance bypass, is it connected
prior to the rectifier and bypass inputs?
• If the bypass or rectifier breakers trip will it cause other breakers to
trip?
• Have the UPS calibrations been verified? Especially in multi-
module systems. DC Link, Single Phase "B", and Inverter output
must be within 1 volt between each UPM.
• If calibrating currents, has each test point been verified as
accessible with the available current clamp?
• If performing the Easy Capacity Test after a repair, were voltage
calibrations completed?
• Has the power flow schematic been examined to verify where all
the switchgear panels are located that may be affected when
running the test?

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Installation and Startup 9390 Service Manual

Figure 3-4 Basic Capacity Test Selected

Test Procedure:
On the XCP Service Tool ECT tab, select the Power Module to test (#1 for the
9390) by using the radio buttons on the left of the XCP tool window. (Note: Any
combination of UPMs can be selected.)
Choose the desired kVA for the test at in the Requested kVA window. The range
is 10% to 100% of system nominal.
Starting the test with the lowest load level (10%) is recommended. The load can
then be increased to 100% if desired.
Choose the duration of the test by scrolling the value up or down in the Test
Duration (min) window. The minimum value is limited to 1 minute and the
maximum is 120 minutes. The test can be cancelled at any time by clicking the
red Abort Test button.
After the Basic Easy Capacity Test has started, the Rectifier Control selector
becomes active.

WARNING
Do not operate this switch if backfeeding the utility is not allowed.

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9390 Service Manual Installation and Startup

By moving the selector to the Battery position the Rectifier shuts down and the
unit goes on battery at the kVA selected for the test. Power will be transferred
back through the bypass input and to any upstream loads or utility. If the
selector is moved back to the Normal position, the input contactor will close and
the Rectifier will start and provide power to the Inverter and the battery charger.
Whenever an Easy Capacity Test is running, a "SYSTEM TEST IN
PROGRESS" message is shown in the UPS display and the Bypass LED is lit.
To end ECT, simply click on the Abort Test button or wait for the timer to expire.

3.1.5 Inspection Completion

1. Unit Data and Customer Reports
a. Using the XCP Service Tool, generate:
– Unit Configuration Report
– Unit History report
– Node Bit Report
– Meters Report
– Customized Setup Report
b. Leave a hardcopy printout with the unit.
2. Installation Acceptance Completion
a. Conduct unit operation training for the customer
b. Provide a signed copy of the Installation and Startup Check
sheet and a hardcopy of the Unit Configuration Report to the
customer.

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Installation and Startup 9390 Service Manual

3.2 EATON® 9390 UNINTERRUPTIBLE POWER

SUPPLY (40 - 160 kVA) PARALLEL REDUNDANT
/ CAPACITY (PR / PC)
NOTICE
Note:

The Startup and Installation procedure for Single Module (RT) in Section 3.1
must be performed on each UPM before starting the Parallel procedure.

3.2.1 Mechanical Inspection

1. Visually inspect the Uninterruptible Power Modules (UPMs) for any
shipping damage:
a. Perform an external and internal inspection (no dents, paint
blemishes, frame is straight).
b. Check that the internal subassemblies are secure and ALL
wiring connections are secure.
c. Use a ground strap while removing the protective film from the
control/metering panel(s), if applicable.
d. Remove any shipping covering from the top of the unit which
was preventing debris from falling through the ventilation holes.
(Place the covers on top of ventilation holes if the UPS is
stopped for a long period of time or if construction work is
performed near the UPS).
2. Ensure each UPM in the system is correctly configured for parallel
operation:
a. Verify UPM labels match the application (voltage, kVA,
frequency, power).
b. Ensure each UPM is configured for the same power rating.
c. For dual source systems, ensure the jumpers on Terminal Block
E1, E2, and E3 to E6, E7, and E8 have been removed (There
are no jumpers in 400V units).
d. Verify that the Maintenance Bypass Switch (MBS) of each UPM
has been properly configured for parallel operation and that the
handle is removed (400V systems, old mechanism only).
3. Visually inspect and verify that the system power wiring is configured
correctly.
See Figure 3-5, Parallel Redundant / Capacity Power Wiring Diagram.

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9390 Service Manual Installation and Startup

a. Verify properly rated feeder breakers and wire sizes (reference

the customer’s installation and operation manual for
recommended breaker and wire sizes).
b. Verify that input, output, bypass, and battery connections are
wired to proper terminations.
– Ensure proper wiring between UPMs.
c. If the customer’s load requires a neutral, a system neutral must
be supplied to the bypass input of each module. Do NOT bond
neutral to ground internally to any UPM. Refer to the “9390
Supported Source and Load Configurations” document available
on the 9390 Service Manual CD.
Note:
400V systems: If no neutral is provided, the factory installs a No-Neutral kit that
ensures correct operation in all modes. See Chapter 10 for No-Neutral Kit.

If the customer’s load does not require a neutral, follow the neutral-to-ground
bonding requirements in the 40 to 80 kVA Installation and Operation manual
(164201535 or 164201603) and the 100 to 160 kVA Installation and Operation
manual (164201554 or 164201604). Neutral to ground bond cannot be used
when source has a high impedance ground.
d. If the system is fed from dual sources, the bypass inputs of each
module must be from the same source. Bypass inputs cannot be
supplied by multiple transformers, this constitutes separately
derived sources.

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Installation and Startup 9390 Service Manual

Customer Circuit Breaker UPM Single Feed Inputs to Rectifier & Bypass
Utility
Feed

E1, E2 Rec Byp Rec Byp Rec Byp Rec Byp

and E3
UPM 1 UPM 2 UPM 3 UPM 4

System Output
E9, E10 and E11.
E12 IF NEUTRAL IS
REQUIRED

Customer Circuit Breaker UPM Dual Feed Inputs to Rectifier & Bypass
Rectifier Customer Circuit Breaker
Input Feed Bypass
E1, E2 and E3

----- ----- ----- ----- Remove Input Feed

E6, E7 and E8

Jumpers
-------
Rec Byp Rec Byp Rec Byp Rec Byp

UPM 1 UPM 2 UPM 3 UPM 4

System Output
E9, E10 and E11.
E12 IF NEUTRAL IS
REQUIRED

Figure 3-5 Parallel Redundant / Capacity Power Wiring Diagram

Note: The vendor for the 9390 contactors has changed from ABB to Cutler-
Hammer®. Refer to the Adobe Acrobat Interactive CD version of this Service
Manual for more information. Additionally, separate Installation and Operation
manuals have been created for each vendor. See Chapter 10 Parts, Contactor
Vendor Change from ABB to Cutler-Hammer® for part numbers.

Part Number Installation & Operation Manual Description

164201535 9390 40/80 kVA, with ABB Contactors

164201554 9390 100/160 kVA, with ABB Contactors

164201603 9390 40/80 kVA, with Cutler-Hammer® Contactors

164201604 9390 100/160 kVA, with Cutler-Hammer® Contactors

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4. Visually inspect and verify system interconnecting control wiring,

See Figure 3-6, CAN Bridge Termination Jumper J7. See Chapter 11,
Prints.
a. Set Termination Jumper J7 on the CAN Bridge Boards
– Set J7 to Pins 1 and 2 on the end units.
– Set J7 to Pins 2 and 3 on the middle units.

Figure 3-6 CAN Bridge Termination Jumper J7

b. Install CAN Bridge Boards in X-Slot #2 (preferred)

See Figure 3-7, Two-Module Parallel Control Wiring.
c. Verify the External Controller Area Network (ECAN) CAN-H and
CAN-L connections to the CAN Bridge Boards in all UPMs in the
network.

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Installation and Startup 9390 Service Manual

– Connect CAN Bridge CAN-H of UPM #1 to CAN Bridge CAN-H

of UPM #2, etc., for all remaining UPMs.
– Connect CAN Bridge CAN-L of UPM #1 to CAN Bridge CAN-L
of UPM #2, etc., for all remaining UPMs.
– CAN wiring should be 600V AWG 18 (American Wire Gauge),
shielded, twisted-pair wires.
5. Verify all options are installed and wired properly:
• X-Slot Connectivity Devices:
– Relay Card (isolated form C contacts, AS400 type status).
– Single Port Serial Card (RS-232 and AS400 signal levels).
– Multi-Port Serial Card.
– Connect UPS SNMP / Web Adapter.
– External Modem or X-Slot Modem Card (either V.34 or V.90).
• Remote Emergency Power Off (REPO). If customer’s connection
uses Normally Closed (N.C.) contacts, remove the jumper and
attach REPO; if the customer’s connection uses Normally Open
(N.O.) contacts, ensure the jumper is installed.
• External Integrated Distribution Cabinet (IDC).
• External Maintenance Bypass (MBP) (Can be located in IDC,
Sidecar, or customer provided).
– For Sidecar, refer to drawing numbers 9390INST-001GE and
9390INST-002GE in Chapter 11, Prints.
– See the 9390 Sidecar Installation and Operation manual,
164201586.
– See Chapter 6 Options, Parallel Tie / Maintenance Bypass
“Sidecar” Cabinet.
• External transformers (at the line and load side of the system)
• External Battery Cabinets (EBC)
– Common battery configurations are not allowed on the 9390
• Remote Monitoring Panel(s) (RMP II) *
• Relay Interface Module (RIM II) *
• Supervisory Contact Module (SCM II) *
*-RMP II, RIM II, and SCM II require the CAN Bridge Card and options to be
enabled using the XCP Service Tool, Option tab.
• Environmental Monitoring Probe (EMP) **
– If Battery Temperature Compensation will be used.
**-Refer to the Installation and Operation Manual for additional information,
available on the Service Manual CD or www.powerwarequality.eaton.com.

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9390 Service Manual Installation and Startup

WARNING
THE FOLLOWING STEPS CANNOT BE PERFORMED IF THE BYPASS AND
LOAD ARE ALREADY ENERGIZED.

6. Verify there are no installation ground faults using a DVM. (This

includes the UPS module and any optional cabinets.)
a. Unplug P2 from the Interface Board.
b. Unplug P5 from Power Supplies PS1 and PS2.
c. Test E1, E2, E3, E6, E7, E8, E9, E10, and E11 to ground (Main
and bypass inputs as well as output, all three phases, phase-to-
ground).
– All readings should be 2M  or greater.
d. Reconnect plug P2 on the Interface Board and plug P5 on PS1
and PS2.
7. Enable Battery Temperature Compensation on the Options Tab with
XCP Tool, Version 3.0. With XCP Tool Version GREATER THAN 3.0,
open the Battery Tab.
8. Select the X-Slot to which the EMP is connected.

NOTICE
Note:

Modules operating in a Parallel Capacity configuration cannot use the optional

9390 IDC, especially where individual transformers may be used.

WARNING
THE FOLLOWING STEPS CANNOT BE PERFORMED IF THE BYPASS AND
LOAD ARE ALREADY ENERGIZED.

9. Verify there are no installation ground faults using a known good

DVM:
a. Verify the main and bypass inputs of each UPM.
b. Verify the UPM inputs and combined output to a central
connection device.
c. For all locations test all three phases, phase to ground.
d. Depending on the site, readings may vary from 200K to 2M 
e. Verify external battery strings, each pole to ground (<1VDC).

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Installation and Startup 9390 Service Manual

WARNING
Batteries can cause electrical shock or burns from high short circuit current
and high voltage. Observe proper precautions. Incorrect connection of
batteries may cause electrical shock, fire, injury, or death.

10. Verify the batteries have been properly assembled and attached to
the UPS.
Note:
For systems with multiple battery cabinets, only one cabinet has the harness to
connect to the UPS. If the cabinets were not installed in the correct positions,
the UPS harness can be moved. However, the jumpers also need to be
changed. Refer to 164201536 Battery Installation Manual for detailed
interconnection schematics.
Note:
If you have a UPS larger than 100 kVA, with only one string of batteries and
you’ve done a PCB board setup on a Control Board, you must change the
Battery Charge current on the Battery Tab on the XCP Service Tool. The
default is set for two battery cabinets, so divide that number in half if you have
only one battery cabinet.
• Common or shared batteries can not be used in 9390 parallel
systems.
• Check inter-tray connections (Red to Black; Black to Red) for
batteries in series.
• Check inter-cabinet connections (Red to Red; Black to Black) for
strings in parallel.
• Verify the polarity of all parallel strings matches BEFORE making
final connections.
• Verify open cell voltage for any string should be > 384 VDC to 480
VDC (varies based on total number of cells).
• Batteries must NOT be ground referenced (either pole tied to
ground).

3.2.1.1 Module Output Breaker (MOB) Wiring Requirements

See Figure 3-7, Two-Module Parallel Control Wiring for new and old TB1 and
TB2 wiring information. See Figure 3-7, Two-Module Parallel Control Wiring for
a two-module system and Figure 3-13, New Terminal Block Multi-Module
Parallel Control Wiring. Also see Table 3-1, Parallel Interface Wire Chart using
MOB Aux Contacts and Table 3-2, Parallel Interface Wire Chart with no MOB
Aux Contacts for wiring information.
To complete the MOB wiring setup with two auxiliaries, the following procedures
must be executed. This is MOB Auxiliary state when open:

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9390 Service Manual Installation and Startup

1. Wire an MOB auxiliary into the Building Alarm on the CAN Bridge
Board.
2. Wire an MOB auxiliary into the unit’s pull chain wiring. See Section
3.3, TERMINAL BLOCKS and Figure 3-7, Two-Module Parallel
Control Wiring and note the contacts for both the old and new terminal
blocks.
3. Final Pull chain wiring with an MOB should resemble the figures
below. See Figure 3-7, Two-Module Parallel Control Wiring and
Figure 3-13, New Terminal Block Multi-Module Parallel Control
Wiring.

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Installation and Startup 9390 Service Manual

UPM #1 UPM #2
9390 TWO-MODULE PARALLEL CONTROL WIRING
SHIELD SHIELD
10 10

EXT CAN L EXT CAN L

9 SHIELDED TWISTED PAIR BELDEN 8762 9

EXT CAN H EXT CAN H

8 8

MOB #1 MOB #2

2 2
AUX 1 MOB STATUS AUX 1
N.C. N.C.
1 1

CAN BRIDGE CAN BRIDGE

X-SLOT #2 X-SLOT #2

TB TB
Bldg BLDG ALARM 2 N.O. COM N.O. BLDG ALARM 2 Bldg
Alarm 2 PULL CHAIN Alarm 2
AUX 2 AUX 2
JUMPER

ON Byp ON Byp
(NO) (NO)

Alarm 2 STATIC SWITCH "ON BYPASS" CONTACTS Alarm 2

RTN RTN
JUMPER

ON ON
Bypass Bypass
COM COM

N.C. & N.O designation on MOB Aux contacts are defined with breaker in the OPEN position.
If MOB Aux contacts have flying leads, use same wire gauge. Use correct crimps for the wire gauge.
Recommend twisted pair between module & MOBs.
Always confirm contact operation (N.O. or N.C.) prior to wiring.
External CAN connections on CAN Bridge Board required shielded twisted pair wires between modules.

NEW TB1 OLD TB1

1 Remote EPO (NC) 1 BLDG Alarm 1
2 RTN 2 BlLDG Alarm 2

3 Remote EPO (NO) 3 BLDG Alarm RTN

4 RTN 4 Alarm Relay NC

5 Batt Brkr (Aux) 5 Alarm Relay COM

6 RTN 6 Alarm Relay NO

7 Batt Brkr +48 Vdc 1A 7 EPO NO

8 Batt Brkr Control 8 EPO NC

9 BLDG Alarm 1 9 EPO COM

10 Return 10

NEW TB 2 OLD TB2

1 BLDG Alarm 2 1 Dallas Interface
2 RTN 2 Dallas Interface

3 ON Bypass (NO) 3 Battery AUX +

4 ON Bypass COM 4 Battery AUX -

5 Alarm Relay (NC) 5 Battery UVR +

6 Alarm Relay COM 6 Battery UVR -

7 Alarm Relay (NO) 7 ON Bypass

8 Alarm Relay COM 8 ON Bypass RTN

9 On Inverter K3 AUX (NC) 9 ON Inverter

10 On Inverter K3 Aux COM 10 ON Inverter RTN

Figure 3-7 Two-Module Parallel Control Wiring

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9390 Service Manual Installation and Startup

3.2.2 Examples of Parallel Unit Pull chain and Maintenance

Bypass Control Wiring
See Figure 3-7, Two-Module Parallel Control Wiring, Figure 3-8, Maintenance
Bypass Switch Breaker Status, Figure 3-9, Maintenance Bypass Switch with
Solenoid/Kirk-Key (Optional), and Figure 3-10, Remote to Bypass (Optional) for
examples.

UPM 1 Parallel Tie Cabinet UPM 2

New TB1 Old TB1 New TB1 Old TB1

9 1 9 1

N.O.
MBP
Aux 1

COMM

New TB1 Old TB1 New TB1 Old TB1

10 3 10 3

Figure 3-8 Maintenance Bypass Switch Breaker Status

Figure 3-9 Maintenance Bypass Switch with Solenoid/Kirk-Key (Optional)

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Installation and Startup 9390 Service Manual

Figure 3-10 Remote to Bypass (Optional)

3.2.2.1 External Controller Area Network (ECAN) Wiring Requirements

To complete the ECAN wiring setup for a parallel system, the following must be
executed.
1. Wire the ECAN from UPM1 to UPM2. See Figure 3-7, Two-Module
Parallel Control Wiring
3.2.2.2 External Network Wiring using OLD and NEW Terminal Blocks
External Network wiring is needed to connect two (or more) 9390 units for
Parallel. See Section 1.4.1, Operating the 9390 Parallel with Module Output
Breakers (MOBs) with Auxiliaries.
For Module Output Breakers (MOBs) without auxiliary contacts, see Figure 3-7,
Two-Module Parallel Control Wiring. Wire the ECAN as shown and the pull
chain directly, with no break for MOBs.
Complete/verify the pull chain wiring setup for a Parallel Redundant system by
wiring Building Alarm 2 and the Bypass Relay together between the units.
Note: This wiring is not valid for MOBs with auxiliary contacts. The terminal
block numbers below apply to old terminal block units. See Figure 3-11, Old
and New Terminal Blocks, TB1
• Connect TB1-2 of UPM #1 to TB1-2 of UPM #2, etc., for all
remaining UPMs
• Connect TB1-3 of UPM #1 to TB1-3 of UPM #2, etc., for all
remaining UPMs

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9390 Service Manual Installation and Startup

• Jumper TB1-2 of UPM #1 to TB2-7 of UPM #1 and connect TB1-3

of UPM #1 to TB2-8 of UPM #1. Repeat for all remaining UPMs
• Final wiring without an MOB, or MOB without auxiliary contacts,
should resemble Table 3-2, Parallel Interface Wire Chart with no
MOB Aux Contacts.
See 3.2.3, Electrical Inspection.
Complete / verify the pull chain wiring setup for a Parallel Redundant system by
wiring Building Alarm 2 and the Bypass Relay together between the units.
Note: This wiring is not valid for MOBs with auxiliary contacts. The terminal
block numbers below apply to old terminal block units. See Figure 3-11, Old
and New Terminal Blocks, TB1
• Connect TB2-1 of UPM #1 to TB2-1 of UPM #2, etc., for all
remaining UPMs.
• Connect TB2-2 of UPM #1 to TB2-2 of UPM #2, etc., for all
remaining UPMs.
• Jumper TB2-1 of UPM #1 to TB1-3 of UPM #1 and connect TB2-2
of UPM #1 to TB1-4 of UPM #1. Repeat for all remaining UPMs.
• Final wiring without an MOB, or MOB without auxiliary contacts,
should resemble Table 3-2, Parallel Interface Wire Chart with no
MOB Aux Contacts below.

3.2.3 Electrical Inspection

WARNING
Be aware that the following steps will energize the UPS module and its output

If customer loads are not to be energized at this time, ensure downstream

breakers are open before proceeding.

NOTICE
Note:

Use Startup Worksheets and Checksheet found at the end of this chapter.
1. Prepare the UPMs for the application of power
a. Ensure main input breaker (if dual feed, bypass breaker also) for
each UPM is in the open or off position
b. Only close those MOBs associated with available UPMs
– The customer may have a tie cabinet capable of supporting
more UPMs than are currently installed allowing for future
expansion. Leave the spare MOBs open.
2. Apply main input power to the system

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Installation and Startup 9390 Service Manual

a. Apply power to the rectifier input of each UPM (if dual feed, apply
bypass input also).
– UPM bypass inputs must be from the same source
b. Logic power energizes.
c. Ensure that “ALARM: Bypass Phase Rotation” is not active. If
this event is active, verify phase rotation at E6, E7, and E8 with a
scope.
3. Using scope/DVM, verify that each UPM in the system has correct
input
a. Verify AC voltages: Phase to Phase, Phase to Neutral, and
Phase to Ground
– Main input at E1, E2, and E3
– Bypass input voltages at E6, E7, and E8
– Bypass input must be same source for all UPMs
– Ensure phase rotation (ABC) at bypass input
b. Verify neutral (E12) to ground voltage is less than 5 Vac RMS
c. Phase rotation (ABC) in all of the above locations must match
4. Verify front panel operations
a. Press any button to access functions on the display panel
b. The time and date are set correctly on each UPM in the system
c. Valid active ALARMS at this point should be
– ALARM: Configuration Error (for the battery)
– ALARM: Output Under Voltage
– ALARM: Parallel Setup Error
d. No events other than those shown above, should be listed. If
other events are indicated, determine their cause before
continuing.
5. Using the XCP Service Tool, verify unit setup parameters. Verify that
each UPM’s CTO number and power rating correspond to the UPM’s
labeling and installation using the CTO tab.
a. Ensure each UPM configuration type is “Parallel” using the PCB
Tab; press the ‘Start PCB Setup’ button.
b. Enter each UPM ID number (1, 2, 3, or 4). Factory default is “0.”
– The value entered must be unique to each UPM.
– As each UPM’s ID is programmed, events will occur indicating
the status of other UPMs. After each UPM’s ID parameters

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9390 Service Manual Installation and Startup

have been programmed, “External COMM Failure” should

clear.
c. Enter the total number of capacity modules (1, 2, 3, etc.). Factory
default is “0.”
– To complete the “Single Module Operation Inspection,”
temporarily set this parameter to “1” on each UPM (final setup
to be completed later).
– The value entered must be the same for each UPM
– If not set to “1” for single module operation, a “Bypass Source
Out of Tolerance” alarm will annunciate when attempting to
start that unit.
d. Total number of UPMs in system (1, 2, 3, or 4). Default is “0”
– To complete the “Single Module Operation Inspection,”
temporarily set this parameter to “1” on each UPM (final setup
to be completed later)
– Value entered must be the same for each UPM
– If not set to “1” for single module operation, a “Bypass Source
Out of Tolerance” alarm will annunciate when attempting to
start that unit.
e. If the unit has VRLA or wet cell batteries, proceed to step f. For
NiCd batteries, follow the step below.
– NiCd battery setups are loaded based on the CTO. After
verifying the CTO, simply open the XCP Service Tool battery
setup tab and press “Battery Configuration Complete.” Do not
change any settings. Proceed to step c.
f. For VRLA or wet cell batteries, or 9390 IT, use the BATTERY
Startup Tab to configure the UPS for the connected battery:
– Check for correct # of cells in the battery string(s).
– Check for correct # of battery strings.
– Enter the Watts per Cell at 15 minutes for the battery
– Once battery is setup, click on “Battery Configuration
Complete.”
g. Verify the availability of customer options using the Options Tab.
h. Configure the unit for outcall operations (if applicable) using the
Modem Tab. See Chapter 5, Modem Setup.
i. Open all MOBs
j. Verify UPM ID, Capacity UPMs, and Number of UPMs remained
programmed in each UPM.

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Installation and Startup 9390 Service Manual

6. From the CONTROL screen of one UPM, momentarily press

“BYPASS”
a. Bypass Contactor K5 closed on all UPMs when logic power was
applied.
– Output Under Voltage alarm clears on each module after the
static switch gates on.
b. BYPASS is indicated on front panel of each UPM.
c. If the system did not go to bypass, determine the cause before
continuing.
– Recheck UPM ID setups or network connections.
d. Ensure that “ALARM: Output Phase Rotation” is not active on
any UPM.
– If alarm is present, verify phase rotation between UPM outputs
using an oscilloscope.

3.2.4 Single Module Operational Inspection, 9390 Parallel

Units
Perform the following steps on one UPM at a time, repeating these steps for
each UPM in the system until all UPMs have been verified to be operational.
• For 9390 units with DSP firmware Version 1.22 and OLDER - and WITH
NO Auxiliary wiring on the MOBs, see Section 3.2.4.1, With No MOB AUX
Contacts and DSP Version 1.22 and Older.
• For 9390 units, with DSP firmware Version 1.24 and NEWER and WITH
Auxiliary contacts on the MOBs, DO NOT REMOVE THE PULLCHAIN
WIRING. See Section 3.2.4.2, With MOB AUX Contacts and DSP 1.24 and
Newer.
See Section 3.2.6, Parallel Operational Inspection.
See Chapter 9, ISOLATION and TROUBLESHOOTING, PARALLEL
MODULES

3.2.4.1 With No MOB AUX Contacts and DSP Version 1.22 and Older
1. An “External COMM Failure” will be active throughout this procedure
because you are isolating each module and the modules are not
operating in parallel.
2. Disconnect Pull chain wires from TB1 and TB2 on the UPM which is
being tested. Removing these wires prevents the pull chain of the unit
under test from affecting parallel units that may be online supporting
the load. Insulate the disconnected pull chain wires, so they will not
accidentally short.

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9390 Service Manual Installation and Startup

3. Ensure that both Pull chain wires from TB1 and TB2 are re-connected
after doing the Parallel Operation Inspection on each UPM.
4. Go to Section 3.2.4, Operational Inspection, Step 1.

3.2.4.2 With MOB AUX Contacts and DSP 1.24 and Newer
The Pull chain wiring instructions are shown in Section 3.2.1.4, Parallel Network
Wiring using OLD and NEW Terminal Blocks.
Note:
Set ‘Module Output Bkr Installed’ on the XCP Service Tool Option Tab.
1. Pull chain wires do NOT have to be removed.
2. Disconnecting a unit with MOB installed.
• Open MOB to disconnect from the output.
• Ensure that the alarm “Output Breaker Open” appears in the Active
Events Screen. If it doesn’t, check the MOB auxiliary wiring.
• The unit will now operate as a Reverse Transfer.
3. Go to Section 3.2.4, Operational Inspection, Step 1.

3.2.5 Operational Inspection

1. Prepare to energize the UPM
a. When testing one UPM, ensure all other UPM utility and bypass
input breakers are OFF
b. Close the input breaker (and bypass, if applicable) on the UPM
being tested
c. Verify the following LEDs are lit on both power supplies: D5
(+48V) and D8 (+15V).
d. If any of these LEDs are not lit at this point in the procedure,
resolve the power supply problem before proceeding.
2. Using the XCP Service Tool meters tab, verify that all gate powers are
consistent and close to the tolerances shown in tableTable 9-1 on
page 10 and Table 9-2 on page 10. An abnormal reading may
indicate an IGBT fault.
3. DC Link Bleed and Inverter IGBT Verification. See Figure 1-3, 20-80
(left) and 100-160 (right) kVA UPS Inside View and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems.
a. Connect a DVM set to DCV to TB3-6 and TB3-7.
b. Connect an oscilloscope reference lead to TB3-11. Use the other
lead on TB3-8, 9, and 10 sequentially in the next steps.
c. From CONTROL, select PM ON, but be ready to quickly select
PM OFF when the DC Link approaches 200VDC.

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Installation and Startup 9390 Service Manual

d. When the DC Link reaches 200VDC, select PM OFF.

– The DC Link should bleed off very slowly
e. From CONTROL, select LOAD OFF.
f. Monitor the bleed off of the DC Link and the inverter IGBT gating
by looking for a sine wave on the oscilloscope and a rapid
decrease of the DC voltage on the DC Link.
g. Repeat steps c. through f. for all three phases of the inverter.
4. From CONTROL, select PM ON
a. Power Module (PM) indicates DC STARTING (pre-charging)
b. Verify capacitor pre-charge voltages
– TB3-6 to TB3-7 should be approximately 260 Vdc with a 208
Vac input, and approximately 650 Vdc with a 480 Vac input,
about 540Vdc with 400 Vac input.
– If pre-charge voltage is not present, determine and correct the
pre-charge problem before proceeding.
c. Input Contactor K1 closes after approximately 2 minutes
– DC Link will ramp up to approximately 324 Vdc with a 208 Vac
input, 746 Vdc with a 480 Vac input, and 650Vdc with 400Vac
input.
d. Power Module (PM) indicates the following in order: DC
STARTING (rectifier starting), INVERTER STARTING,
INVERTER SYNCING (inverter syncing to bypass), and READY
5. System Battery Verification
a. Verify DC voltage and polarity on both sides of battery breaker
CB1 in the battery cabinet.
b. If voltage and polarity are correct, proceed to the next step. If
voltage and polarity are not correct, determine and correct the
cause of any battery voltage or polarity problem before
proceeding.
6. From CONTROL, select NORMAL
a. CLOSE BATTERY BREAKER alarm annunciates
b. Close battery breaker CB1 in the battery cabinet
c. Battery charger turns on and indicates CHARGER ON
d. K3 will close, static switch turns off
e. Power Module (PM) indicates ONLINE (load is protected)
f. LCD display indicates NORMAL

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9390 Service Manual Installation and Startup

g. Determine and correct the cause of any active alarms or notices

7. Verify ON BATTERY operation:
a. Open main input feeder breaker to UPS utility (and bypass if dual
feed) for 30-60 seconds
b. Contactors K1 and K5 open
c. Verify stable output voltage and frequency; battery screen shows
discharging
d. BATTERY and NORMAL lamps lit on front panel; horn every 3
seconds
e. Close main input feeder breaker (and bypass if dual feed)
f. K1 and K5 close
g. BATTERY lamp goes off.
h. Verify battery charger turns on and indicates CHARGER ON.
8. Test Energy Saver Mode (if applicable: f/w 5.XX).
a. Command the unit to ESM and verify correct operation in
accordance with the 9390 User Guide.
b. Return the unit to Normal Mode
9. Verify the operation of all externally connected options.
a. X-Slot connectivity / communication options *
b. Environmental Monitoring Probe (EMP) **
c. Remote monitoring panels or status relays
d. Active Response Remote Monitoring (if applicable)
e. Remote Emergency Power Off (REPO)
f. Building alarm inputs (if used)
g. Set correct time and date
*-Refer to Chapter 5 for procedures and additional information.
**-Refer to installation and additional information which is available on the CD or
www.powerware.com.
10. Using the METERS Tab on the XCP Service Software Tool:
a. Verify that all AC and DC metered voltage values are within
specifications
b. Verify that all AC and DC metered current values are within
specifications
c. Ensure percentage of battery charge and battery time remaining
values are approaching 100%

© 2009 Eaton Corporation. Company Confidential. 3–33

Installation and Startup 9390 Service Manual

11. From the UPM CONTROL screen:

a. Transfer the system to bypass by pressing “BYPASS”
b. UPM K3 opens
c. Power off the UPM by pressing “PM OFF”
d. Open UPM utility (and bypass if dual feed) breakers
12. Repeat all of Section 3.2.4, Operational Inspection for each module in
the system.

3.2.6 Parallel Operational Inspection

See “Single Module Operational Inspection, 9390 Parallel Units” on page 28
before beginning this procedure.
This section to be completed only after each UPM in the system has been
verified individually. This section verifies functionality of UPMs together with the
Tie Cabinet (either Eaton or customer supplied).

NOTICE
Note:

Steps 1. to 4. must be performed with no load or load on maintenance bypass.

1. Apply input power to all UPMs so they have logic power only.
2. Verify module setup.
a. Open the XCP Service Tool PCB tab and press the ‘Start PCB
Setup’ button.
b. Setup the total number of modules in the system (1, 2, 3, etc.)
– Value entered must be the same for each UPM
c. Verify the number of UPMs required to go online
– Temporarily set this parameter to “1” on each UPM (final setup
to be done later)
d. Verify the UPMs are correctly identified, that is, UPM #1, UPM
#2, etc.
3. If the system contains units with ABB contactors and other units with
Cutler-Hammer® contactors, follow the steps below. If not, proceed to
step 4.
a. Open the XCP Service Tool Battery Options Tab on each unit
that contains ABB contactors.
b. Select the “K5 is ABB” option.
c. Set the preliminary msec value to 40msec. (K3 closure
synchronization will be verified later in the procedure.)

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9390 Service Manual Installation and Startup

4. Verify output wiring between UPMs

a. Apply input power to all UPMs, all MOBs open
b. Command UPM1 to bypass. All units should go to BYPASS
mode
c. Close UPM1 MOB in Tie Cabinet
d. Verify voltage and phase rotation at each UPM’s output lugs.
e. Measure voltage across MOB contacts for UPMs 2 through 4 to
ensure correct wiring and phase sequence (UPM output to
common bus, A to A, B to B, and C to C). Should be less than 1
Vac.
f. LOAD OFF each UPM.
g. Close all MOBs.
5. Starting the system
a. Apply input power to all UPMs
– The MOBs should still be closed for all UPMs
b. Ensure PM Status of each UPM is “Shutdown” (CONTROL, PM
OFF)
6. Using PCB tab, press ‘Start PCB Setup’ button in the XCP Service
Software Tool:
– Verify the number of UPMs required to go online if changed in
Step 5. of Section 3.2.2 or Step 2. of Section 3.2.5
7. Paralleling the system
a. From CONTROL of just one UPM, press “NORMAL”
– Each UPM should go to BYPASS (If “To Bypass With Normal”
is selected in the XCP Options Tab).
– Each UPM should automatically begin starting.
b. When each UPM reaches “READY” condition, close the battery
breaker
c. When the required number of capacity UPMs assume the
“READY” condition and the battery breakers are closed, the K3
output contactors will close and the system assumes NORMAL
operation. At this point, any UPM not already online will close its
K3 output contactor when that UPM assumes “READY” status
and its battery breaker is closed.
d. Ensure that each UPM in the system assumes NORMAL
operation and operates in parallel with the other UPMs at no
load.

© 2009 Eaton Corporation. Company Confidential. 3–35

Installation and Startup 9390 Service Manual

8. If the system contains units with ABB contactors and other units with
Cutler-Hammer® contactors, follow the steps below. If not, proceed to
the next step (9).
a. If possible, perform a full load test. If full load is not available, use
as much load as is possible (Not the customer’s load).
b. Connect an oscilloscope to both the ABB unit and the CH unit’s
phase A outputs.
c. Confirm that the currents start within 3 to 5 msec. of each other
when a transfer online is performed.
d. If necessary, use the XCP Service Tool Battery Options Tab to
adjust the ABB contactor closure delay by counts of 5 (5 msec.)
to achieve the 3 to 5 msec. performance.
e. This procedure may need to be repeated two to three times to
confirm consistent operation. For more information, see the 9390
firmware history document.
9. If load bank is available:
a. Load the system to 100% of the system KW rating
– System load sharing improves as load is added up to 100%.
(No load is worst case.)n
b. Verify the total load is shared equally between all UPMs in the
system within + 3%
– This may take up to 10 minutes for the load to stabilize
c. If required, conduct a 9390 Parallel Load Share Calibration.
– See Section 6.3.15, Calibrate Parallel Load Share, if required.

3.2.7 Total System Operational Inspection

This section to be completed only after each UPM in the system has been
individually verified and paralleled with other UPMs in the system. ECAN
operation should have already been proven functional.
1. Verify the system’s operation on battery:
a. Open main input feeder breaker to all UPMs for 30-60 seconds
b. Verify that Contactors K1 and K5 are open
c. Verify stable output voltage and frequency and that the battery
screen shows discharge
– If a load bank is applied, verify UPMs are equally sharing load
d. Verify that Normal lamp flashes to indicate a new Notice and
Battery lamp is lit steady on UPM front panels. Flashing Normal
lamp will go solid when a button is pressed.

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9390 Service Manual Installation and Startup

e. The horn on each UPM should sound every 3 seconds

f. Re-close main input feeder breaker(s) and verify battery
recharge
g. Verify that K1 and K5 close for each UPM (K1 may take longer
than one minute to close).
2. From CONTROL on the front panel of at least one UPM:
a. Transfer the system to “BYPASS,” then back to “NORMAL”
– ALL UPMs should transfer to BYPASS then back to NORMAL
b. Take a UPM offline (PM OFF) then put back online (NORMAL)
– the static switch should gate, K3 of that UPM should open,
then close when returning to NORMAL, and the static switch
should turn off.
Note:
The Battery Commissioning button on the XCP Service Tool must be the last
selection prior to departing the site. After selecting Battery Commissioning, go
to the Front Display and cycle the charger OFF and ON - leaving it ON. Failure
to follow this procedure will result in the Battery Time Remaining never being
correct.
c. Repeat this process for each UPM in the system as required
3. Test Energy Saver Mode (if applicable: f/w 5.XX).
a. Command the system to ESM and verify correct operation in
accordance with the 9390 User Guide.
b. Return the unit to Normal Mode
4. Verify the operation of all externally connected options
a. X-Slot connectivity / communication options
b. Remote monitoring panels or status relays
c. Active Response Remote Monitoring (if applicable)
d. Remote Emergency Power Off (REPO)
e. Applied Building Alarm input 1 and CAN Bridge Card Building
Alarm (if used)
– Building Alarm 2 is pre-set and used for parallel operation
5. Apply the customer load to the system and verify all measured values
against values displayed by both the unit front panel and the XCP
Service Software Tool.
a. Use the work sheets provided
b. Calibrate those parameters that fall outside recommended
tolerances

© 2009 Eaton Corporation. Company Confidential. 3–37

Installation and Startup 9390 Service Manual

6. Ensure all applicable field service bulletins have been applied.

3.2.8 Inspection Completion

1. Unit Data and Customer Reports
a. Using the XCP Service Tool, generate:
– Unit Configuration Report
– Unit History report
– Node Bit Report
– Meters Report
– Customized Setup Report
b. Leave a hardcopy printout with the unit.
2. Installation Acceptance Completion
a. Conduct unit operation training for the customer
b. Provide a signed copy of the Installation and Startup Check
sheet and a hardcopy of the Unit Configuration Report to the
customer.

NOTICE
Note:

For more information on the Load Sync Control, refer to the

“9390 Sync Control Installation and Operation Manual,”
Document No. 164201571. This I & O manual is included in the Interactive CD,
under “Supporting Documents.”
For Customer sites where the Load Sync is being retrofitted, refer to “9390
Load Sync Control Procedure,” Document No. 164700613, which is posted on
the Tech Support Web site. To download, go to: http://
gstechsup.powerware.com. Under “Site Links,” click on “Downloads,” then
“9390.”

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9390 Service Manual Installation and Startup

3.3 TERMINAL BLOCKS

OLD TB 1

1 BLDG Alarm 1
1
2 2 BLDG Alarm 2
3 3 BLDG Alarm RTN
4 4 Alarm Relay NC
5 5 Alarm Relay COM
6 6 Alarm Relay NO
7 7 EPO NO
8 8 EPO NC
9 9 EPO COM
10 10

NEW TB 1
1 Remote EPO NC

1 2 Return
2
3 Remote EPO NO
3
4 Return
4
5 5 Batt Brkr [AUX]
6 Return
6
7 7 Batt Brkr +48 VDC, 1A
8 8 Batt Brkr Control
9
9 BLDG Alarm 1
10
10 Return

Figure 3-11 Old and New Terminal Blocks, TB1

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Installation and Startup 9390 Service Manual

See Figure 3-15, 160 kVA New Terminal Blocks, TB1and TB2, With Harness,
Fuse and Figure 6-22, Load Sync Control TB-6 Wiring Diagram for placement of
terminal blocks.

OLD TB 2

1 1 Dallas Interface
2 2 Dallas Interface

3 3 Battery AUX +
4 4 Battery AUX --
5 5 Battery UVR +
6 6 Battery UVR --
7 7 ON Bypass
8 8 ON Bypass RTN

9 9 ON Inverter

10 10 ON Inverter RTN

NEW TB 2
1 BLDG Alarm 2
1 2 RETURN
2
3 ON Bypass (NO)
3
4 ON Bypass COM
4
5 5 Alarm Relay (NC)
6 6 Alarm Relay COM
7
7 Alarm Relay (NO)
8
8 Alarm Relay COM
9
10 9 On Inverter K3 AUX (NC)

10 On Inverter K3 AUX COM

Figure 3-12 Old and New Terminal Blocks, TB2

See Figure 3-14, 80 kVA New Terminal Blocks, TB1and TB2, With Harness,
Fuse and Figure 3-15, 160 kVA New Terminal Blocks, TB1and TB2, With
Harness, Fuse for placement of terminal blocks.

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9390 Service Manual Installation and Startup

9390 PULLCHAIN WIRING DIAGRAM - DSP 2.xx - MOB'S w/ DUAL AUX

UPM1
Bridge Bd.
MOB1
J3-2
Twisted Pair Aux.1
MOB status
(recommended) NC / BLU
J3-1
COM / BLK
Customer NO / RED
Interface
Aux.2
Parallel System TB2-1
Twisted Pair NC / BLU
Pullchain Input
"Go to Bypass" (recommended) COM / BLK
TB2-2
NO / RED

Static Switch TB2-3

"On Bypass"
relay contacts TB2-4

UPM2
Bridge Bd.
MOB2
J3-2
Twisted Pair Aux.1
MOB status
(recommended) NC / BLU
J3-1
COM / BLK
Customer NO / RED
Interface
Aux.2
Parallel System TB2-1
Twisted Pair NC / BLU
Pullchain Input
"Go to Bypass" (recommended) COM / BLK
TB2-2
NO / RED

Static Switch TB2-3

"On Bypass"
relay contacts TB2-4
SPLICE

UPM3
Bridge Bd.
MOB3
J3-2
Twisted Pair Aux.1
MOB status
(recommended) NC / BLU
J3-1
COM / BLK
Customer NO / RED
Interface
Aux.2
Parallel System TB2-1
Twisted Pair NC / BLU
Pullchain Input
"Go to Bypass" (recommended) COM / BLK
TB2-2
NO / RED

Static Switch TB2-3

"On Bypass"
relay contacts TB2-4

UPM4
Bridge Bd.
MOB4
J3-2
Twisted Pair Aux.1
MOB status
(recommended) NC / BLU
J3-1
COM / BLK
Customer NO / RED
Interface
Aux.2
Parallel System TB2-1
Twisted Pair NC / BLU
Pullchain Input
"Go to Bypass" (recommended) COM / BLK
TB2-2
NO / RED

Static Switch TB2-3

"On Bypass"
relay contacts TB2-4

Figure 3-13 New Terminal Block Multi-Module Parallel Control Wiring

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Installation and Startup 9390 Service Manual

Table 3-1 Parallel Interface Wire Chart using MOB Aux Contacts
NEW TB1 and TB2 SHOWN

2 (or more) Modules

UPM1 UPM2 Function Wire Notes

CAN Bridge Bd J3-10 CAN Bridge Bd J3-10 External CAN Network Shielded Twisted Pair

CAN Bridge Bd J3 - 9 CAN Bridge Bd J3 - 9

CAN Bridge Bd J3 - 8 CAN Bridge Bd J3 - 8

TB2- 2 TB2-4 Pull chain

UPM1 MOB1

CAN Bridge Bd J3 - 1 Aux 1: NC MOB Open Alarm Twisted Pair

CAN Bridge Bd J3 - 2 Aux 1: COM

TB2- 1 Aux 2: NO Pull chain

UPM1 UPM1

Static Switch: On Bypass

TB2- 1 TB2-3
contact

TB2- 2 TB2-4

UPM2 MOB2

CAN Bridge Bd J3 - 1 Aux 1: NC MOB Open Alarm Twisted Pair

CAN Bridge Bd J3 - 2 Aux 1: COM

TB2- 1 Aux 2: NO Pull chain

UPM2 UPM2

Static Switch: On Bypass

TB2- 1 TB2-3
contact

TB2- 2 TB2-4

MOB1 MOB2

Aux 2: COM Aux 2: COM Pull chain MOB common

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9390 Service Manual Installation and Startup

Table 3-1 Parallel Interface Wire Chart using MOB Aux Contacts (Continued)

3 (or more) Modules

UPM2 UPM3 Function Wire Notes

CAN Bridge Bd J3-10 CAN Bridge Bd J3-10 External CAN Network Shielded Twisted Pair

CAN Bridge Bd J3 - 9 CAN Bridge Bd J3 - 9

CAN Bridge Bd J3 - 8 CAN Bridge Bd J3 - 8

TB2- 2 TB2-4 Pull chain

UPM3 MOB3

CAN Bridge Bd J3 - 1 Aux 1: NC MOB Open Alarm Twisted Pair

CAN Bridge Bd J3 - 2 Aux 1: COM

TB2- 1 Aux 2: NO Pull chain

UPM3 UPM3

Static Switch: On Bypass

TB2- 1 TB2-3
contact

TB2- 2 TB2-4

MOB2 MOB3

Aux 2: COM Aux 2: COM Pull chain MOB common

4 (or more) Modules

UPM3 UPM4 Function Wire Notes

CAN Bridge Bd J3-10 CAN Bridge Bd J3-10 External CAN Network Shielded Twisted Pair

CAN Bridge Bd J3 - 9 CAN Bridge Bd J3 - 9

CAN Bridge Bd J3 - 8 CAN Bridge Bd J3 - 8

TB2- 2 TB2-4 Pull chain

UPM4 MOB4

CAN Bridge Bd J3 - 1 Aux 1: NC MOB Open Alarm Twisted Pair

CAN Bridge Bd J3 - 2 Aux 1: COM

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 Installation and Startup 9390 Service Manual

Table 3-1 Parallel Interface Wire Chart using MOB Aux Contacts (Continued)
TB2- 1 Aux 2: NO Pull chain

UPM4 UPM4

Static Switch: On Bypass

TB2- 1 TB2-3
contact

TB2- 2 TB2-4

MOB3 MOB4

Aux 2: COM Aux 2: COM Pull chain MOB common

Recommend black/white twisted pair wire for identification, 22-18 AWG range.

Note:
Note:1. This document is valid only for the new TB1 and TB2 layout (with +48V
fuse holder).
Note:2. NC (and NO) designation on MOB Aux contacts are defined with
breaker in OFF (open) position, as shown in above table.
Note:3. If MOB Aux contacts have flying leads, use the same wire gauge to
connect to UPS and use the correct crimp connections for the wire gauge.
Note:4. If MOB Aux contacts have flying leads, use crimp connection.
Note:5. Recommend twisted pair wiring between module and MOB Aux
contacts.
Note:6. Typical Cutler-Hammer® Aux contacts colors are NO: RED; NC: BLUE;
and COM: BLACK.
Always confirm contact operation (NO or NC) prior to wiring. Breaker color
codes will vary.
Note:7. External CAN connections on CAN Bridge terminals require shielded
twisted-pair wire between modules.

Table 3-2 Parallel Interface Wire Chart with no MOB Aux Contacts
NEW TB1 and TB2 SHOWN

2 (or more) Modules

UPM1 UPM2 Function Wire Notes

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 9390 Service Manual Installation and Startup

Table 3-2 Parallel Interface Wire Chart with no MOB Aux Contacts (Continued)
Shielded Twisted
CAN Bridge Bd J3 - 10 CAN Bridge Bd J3 - 10 External CAN Network
Pair

CAN Bridge Bd J3 - 9 CAN Bridge Bd J3 - 9

CAN Bridge Bd J3 - 8 CAN Bridge Bd J3 - 8

TB2- 1 TB2- 3 Pull chain Twisted Pair

TB2- 2 TB2- 4

UPM1 UPM1

Static Switch: _On Bypass

TB2- 1 TB2- 3
contact

TB2- 2 TB2- 4

UPM2 UPM2

Static Switch: _On Bypass

TB2- 1 TB2- 3
contact

TB2- 2 TB2- 4

3 (or more) Modules

UPM2 UPM3 Function

Shielded Twisted
CAN Bridge Bd J3 - 10 CAN Bridge Bd J3 - 10 External CAN Network
Pair

CAN Bridge Bd J3 - 9 CAN Bridge Bd J3 - 9

CAN Bridge Bd J3 - 8 CAN Bridge Bd J3 - 8

TB2- 1 TB2- 3 Pull chain Twisted Pair

TB2- 2 TB2- 4

UPM3 UPM3

Static Switch: _On Bypass

TB2- 1 TB2- 3
contact

TB2- 2 TB2- 4

© 2009 Eaton Corporation. Company Confidential. 3–45

 Installation and Startup 9390 Service Manual

Table 3-2 Parallel Interface Wire Chart with no MOB Aux Contacts (Continued)
4 (or more) Modules

UPM3 UPM4 Function

Shielded Twisted
CAN Bridge Bd J3 - 10 CAN Bridge Bd J3 - 10 External CAN Network
Pair

CAN Bridge Bd J3 - 9 CAN Bridge Bd J3 - 9

CAN Bridge Bd J3 - 8 CAN Bridge Bd J3 - 8

TB2- 1 TB2- 3 Pull chain Twisted Pair

TB2- 2 TB2- 4

UPM4 UPM4

Static Switch: _On Bypass

TB2- 1 TB2- 3
contact

TB2- 2 TB2- 4

Recommend black/white twisted pair wire for identification, 22-18 AWG range. Refer to Notes on prior page.

Figure 3-14 80 kVA New Terminal Blocks, TB1and TB2, With Harness, Fuse

See Figure 6-23, 9390 TB1 & TB2 and Load Sync Control TB1 Wiring Diagram
for terminal block signal names.

3–46 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Installation and Startup

Figure 3-15 160 kVA New Terminal Blocks, TB1and TB2, With Harness, Fuse

Figure 3-13, Old and New Terminal Blocks, TB1, Customer Common
Connections and Figure 3-14, Old and New Terminal Blocks, TB2, General
Purpose Interface Signals for terminal signal names.

END OF CHAPTER 3

© 2009 Eaton Corporation. Company Confidential. 3–47

Installation and Startup 9390 Service Manual

Installation and Startup Worksheets

Eaton® 9390 (20 - 160 kVA)

Single Module (Reverse Transfer)
Parallel Redundant / Capacity
1. Apply customers load before final readings / measurements
2. Verify all measurements and readings are within 1%
3. Make copies of this worksheet and fill one out for each UPM.
UPM# ______ SN ___________________ IP Address ________________

AC VOLTAGE MEASUREMENTS

Location Recorded Values Expected Values

Measu XCP Tool LCD OK 208V 400V 480V

red

Rectifier Input A-B V V V 208 400 480

(Terminal Block) B-C V V V 208 400 480

(E1 = Phase “A”) C-A V V V 208 400 480

(E2 = Phase “B”) A-N V V V 120 230 277

(E3 = Phase “C”) B-N V V V 120 230 277

C-N V V V 120 230 277

A-G V V V 120 230 277

B-G V V V 120 230 277

C-G V V V 120 230 277

Bypass Input

(E6 = Phase “A”) C-A V V V 208 400 480

(E7 = Phase “B”) A-N V V V 120 230 277

(E8 = Phase “C”) B-N V V V 120 230 277

C-N V V V 120 230 277

A-G V V V 120 230 277

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9390 Service Manual Installation and Startup

AC VOLTAGE MEASUREMENTS

B-G V V V 120 230 277

C-G V V V 120 230 277

Neutral E12 to Ground <5 <5 <5

UPS Output

(E9 = Phase “A”) C-A V V V 208 400 480

(E10 = Phase “B”) A-N V V V 120 230 277

(E11 = Phase “C”) B-N V V V 120 230 277

C-N V V V 120 230 277

A-G V V V 120 230 277

B-G V V V 120 230 277

C-G V V V 120 230 277

UPM# ______ SN ___________________ IP Address ________________

(CONTINUED)

AC CURRENT MEASUREMENTS

Location Recorded Values

Measured XCP Tool LCD OK

UPS Input ØA A A A

(TB3) ØB A A A

(TB3-1,TB3-2, and TB3-3) ØC A A A

ØA A A A

(TB3) ØB A A A

(TB3-8,TB3-9, and TB3-10) ØC A A A

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Installation and Startup 9390 Service Manual

DC MEASUREMENTS

Location Recorded Values Expected Values



DC Link Voltage VDC V V V 328 650V 756

(TB3-6 and TB3-7)

Battery Voltage VDC V V V

(E4 and E5)

Battery Current ADC A A A

DC Link Current ADC A A A

Batt. Time Remaining Mins.

Battery Charge Level % % % %

POWER

Location Recorded Values



Input Power kVA

KW

Hz

PF

kVA

KW

Hz

PF

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9390 Service Manual Installation and Startup

INSTALLATION AND STARTUP CHECKSHEET

Eaton® 9390 (20 - 160 kVA)

Single Module (Reverse Transfer)
Parallel Redundant / Capacity

DATE: _______________
CUSTOMER:__________________________________________________________
SITE CONTACT: ________________________________ PHONE: _______________
UPS MODEL: ___________________________ S/N: _________________________
CTO: ________________________ REQUEST / ORDER #: ____________________
Installation Inspection
___ OK
Mechanical Inspection
___ OK
Electrical Inspection
___ OK
Operational Inspection
___ OK
Environmental Evaluation
___ OK
Installation Notes / Comments / Recommendations:
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_____________________________________________

CUSTOMER ACCEPTANCE

Service Representative: ______________________________Date: ___________

Customer Signature: _________________________________Date: ___________

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This page was left blank intentionally.

3–52 © 2009 Eaton Corporation. Company Confidential.

 4
Functional Descriptions
This chapter provides a functional description for the Eaton® 9390 UPS 20-160
kVA powertrain and the printed circuit boards.

4.1 FIRMWARE
4.1.1 DSP Firmware 5.XX Features
Always refer to the technical support web site for the latest firmware revisions
history document. This section of the manual provides a description of the
changes between DSP 2.12 and DSP 5.XX firmware.
9390 DSP Firmware 5.XX requires a CSB in the unit for operation. The 5.XX
firmware reduces redundant functions in the DSP and CSB, making available
communication and memory space in the unit for the new features. The 9390
DSP Firmware 5.XX has several requirements and provides several features.
Requirements:
• Communication Server Board must be installed in the unit (an upgrade kit
is available). As of 2009, the CSB is now standard equipment with the
9390.
• Parallel units must all contain the same firmware versions.
Features:
• Power Module monitoring of Gate Power to diagnose health of the power
module IGBTs.
• DSP no longer controls the display--the CSB is now the sole controller.
• Improved CAN function.
• Real Time Clock with battery backup (all units with the CSB).
Features with f/w 5.02 and above:
• Easy Capacity Test for current calibrations and system testing.
• Reverse transfer Energy Saver Mode (ESM) providing higher efficiency. A
paid for upgrade that requires firmware, CTO, and, often, hardware
changes to the unit.

© 2009 Eaton Corporation. Company Confidential. 4–1

Functional Descriptions 9390 Service Manual

• Two new building alarms were added for ESM operation.

• Two new selections on front panel to control ESM--ESM Mode and High
Alert Mode.
Features with f/w 5.04 and above:
• Distributed Bypass Energy Saver Mode.

4.2 POWER MODULE

Interior View Exterior View

Figure 4-1 Power Module

4.2.1 Introduction
Reference documents can be found in Chapter 11, Prints.
• 110720506 80kVA, LV (208V) Top Print

4–2 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Functional Descriptions

• 110720507 80kVA, HV (480V) Top Print

The Power Module contains all of the components necessary for power
conversion of a double-conversion UPS except the AC filter. Two to eight
identical power module boards work in tandem to provide 3-phase output power
synthesis plus neutral, harmonic, and power factor corrected rectification and
buck-boost battery requirements for charging or discharging as necessary. The
rectifier and inverter modules are interchangeable and placement in the power
module assembly determines their function.
Functional Requirements:
• All IGBTs and heatsinks.
• Bulk DC capacitor with low impedance connection to the Isolated Gate
Bipolar Transistors (IGBTs).
• Clamp caps and snubbers as necessary.
• High frequency inductors and power connections to IGBTs.
• LEMs at the output end on the high frequency inductors.
• Passive scale down of AC voltage sense.
• Passive scale down of DC voltage sense with design HF filter as
necessary.

4.2.2 Description and Operation

4.2.2.1 Description
See Figure 4-2, Rectifier Functional Block Diagram.
The rectifier in the 9390 product is a three phase IGBT PWM regulated
component located on the power module heat sink. This topology provides an
effective approach to reducing harmonics in converting utility AC input voltage
into DC voltage. In the rectifier, the utility mains control the voltage and the
source impedance affects the loop dynamics. This approach is not only cost
effective by minimizing additional input filtering hardware, but also serves to
increase product reliability.
The rectifier of the 9390 is a three-phase, full-wave rectifier which converts
three-phase utility AC power into clean, stable, and regulated DC power. While
the rectifier does provide charging current to the battery converter for the
battery, the majority of the rectifier current is supplied to the inverter to support
the system output loads.

© 2009 Eaton Corporation. Company Confidential. 4–3

Functional Descriptions 9390 Service Manual

TB3--7

Q4 TB3--6
K1 L7/8
E1 F1 TB3--1 Q1 DC
INPUT Q5 Caps
E2 F2 TB3--2 L9/10
208 VAC L2 L1
E3 F3 TB3--3 L5/6
3 Phase Q3

EMI
Caps Input
Filter
Caps TB3--5
E12
Neutral
TB3--4
208V Rectifier / Battery Converter

TB3--7

K1
E1 F1 TB3--1 Q4 DC
INPUT L7 L8 Caps
E2 F2 TB3--2 Q5 TB3--6
480 VAC L9 L10
E3 F3 TB3--3 Q3 L1 L2 Q1
3 Phase
L5 L6
EMI
Caps Input
Filter
Caps TB3--5
E12
Neutral
TB3--4
480V Rectifier / Battery Converter

Figure 4-2 Rectifier Functional Block Diagram

4.2.2.2 Precharge Operation

The DC capacitors must be precharged and phase B input must be present
before the K1 contactor is closed. The DSP processor monitors the precharge
voltage and issues the close command to K1 when the DC Capacitors reach
approximately 90% of full charge. If precharge voltage is not reached within two
minutes, an alarm goes active and the precharge circuit shuts down. Closing K1
before the capacitors are precharged would cause a large amount of inrush
current through the body diodes of the IGBTs and destroy the capacitors. The
voltage level of the DC Link during precharge will not exceed 0.9*√2*VL-L RMS.
Logic power and precharge voltage are produced from the three-phase AC
bypass input at the line side of the K5 contactor. The precharge circuit on the
power supply sends voltage to the DC Link to charge the DC Capacitors.
When the rectifier begins producing DC voltage on the DC Link, NC relays K1,
K2, and K3 on the power supply boards energize, removing bypass power input
to the power supply. The DC Link then becomes the source for the power supply
boards.

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9390 Service Manual Functional Descriptions

Figure 4-3 DC Link Voltage Over Time During Precharge

4.2.2.3 Rectifier Operation

The rectifier receives AC input power from the utility through the K1 input
contactor after the DC Capacitors have been precharged. The Control Board
provides a low through the Interface Board to close K1 and monitors K1
auxiliaries to verify breaker status. Inductors L5 through L10, with the input filter
capacitors, serve as an input filter for the rectifier. Input power is applied to the
rectifier IGBTs where it is checked for voltage, frequency, and phase rotation. If
the input is within specifications, DC is produced at the rectifier output and
provided to the input of the battery converter and the inverter components. The
utility mains and the inverter output voltage control the rectifier DC output
voltage. When input and output voltage are in phase, the rectifier output is
determined by VL-L rms*√2*110%. If the input and output are not in phase, the
maximum of either the input or output voltage will be used. The DC Link,
therefore, is not static, but changes depending on the changes/demands of
input/output voltage.

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Functional Descriptions 9390 Service Manual

The basic premise of the rectifier control is that of an ideal three-phase machine
connected to a utility source. Power is drawn in by lagging the phase of this
machine from the utility to draw power in across the source (and filter)
inductance and by lowering the voltage of this machine to draw power in across
the source (and filter) resistance. Twenty-five percent current feedback in the
rectifier provides this ideal machine with an apparent large impedance so that
the effect on performance of the source impedance from site to site is minimal.
The phasing of the rectifier with respect to the utility is controlled using phase
lock loop technology. Only the actual location in time of the utility phases is
needed to start the rectifier. Once started, it uses the error of the DC voltage to
regulate the link by advancing or retarding the IGBT firing times.
The rectifier control also regulates the rectifier voltage to draw power in across
the source (and filter) resistance. There are two aspects to this control: a VAR
regulation and a DC voltage feed forward. We presently regulate the VARs to
zero but may choose to regulate to a fixed value. A portion of the DC error is
also integrated into the rectifier voltage reference. Thus if there is a drop in the
DC voltage, the machine will drop its voltage and draw in more power to counter
the drop. The maximum DC Link voltage for the 480V system is 820 Vdc and the
208V system is 373 Vdc.
The Battery Converter is shared among all of the power modules. The rectifier
can provide 15% power for battery charging above that required to support
100% load. The converter is discussed in detail in “POWER MODULE -
BATTERY CONVERTER” on page 7.

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9390 Service Manual Functional Descriptions

4.3 POWER MODULE - BATTERY CONVERTER

4.3.1 Introduction
Reference Documents:
110720506 80kVA, LV (208V) Top Print
110720507 80kVA, HV (480V) Top Print

4.3.2 Description and Operation

See Figure 4-4, Battery Converter Functional Diagram.
The battery converter power components are located on the Power Module and
derive their power from the regulated DC of the rectifier output (maximum 373
Vdc with a 208 Vac utility input and 820 Vdc with a 480 Vac utility input). The
converter works as a buck or boost converter determined by the utility input
voltage. During normal unit operation, the amount of battery charging or
discharging current is displayed on the unit front panel LCD from the battery
converter current sensor Q1.

TB3--7

Q4 TB3--6
K1 L7/8
E1 F1 TB3--1 Q1 DC
INPUT Q5 Caps
E2 F2 TB3--2 L9/10
208 VAC L2 L1
E3 F3 TB3--3 L5/6
3 Phase Q3

EMI
Caps Input
Filter
Caps TB3--5
E12
Neutral
TB3--4
208V Rectifier / Battery Converter

TB3--7

K1
E1 F1 TB3--1 Q4 DC
INPUT L7 L8 Caps
E2 F2 TB3--2 Q5 TB3--6
480 VAC L9 L10
E3 F3 TB3--3 Q3 L1 L2 Q1
3 Phase
L5 L6
EMI
Caps Input
Filter
Caps TB3--5
E12
Neutral
TB3--4
480V Rectifier / Battery Converter

Figure 4-4 Battery Converter Functional Diagram

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Functional Descriptions 9390 Service Manual

Rectifier and inverter power modules, being the same part number, each
contain a converter. The converters operate in parallel with each other to buck
or boost during battery charging or discharging.
Components of the battery converter include four IGBTs, two current sensors,
four inductors, snubber networks, and load share resistors.

4.3.3 Boost Charge Mode (208V)

In Boost Charge Mode of operation, the battery is charged at a voltage level
higher than the input voltage to the converter. In this mode, the converter must
achieve more voltage at its output than its nominal input of 324 Vdc. To do this,
the IGBTs will act as a power switch. While IGBT blocks Q6 and Q11 are
conducting, energy is transferred from the converter input (DC link); through Q1
(battery current sensor), L1, and L2; and on to the battery.
To achieve a higher voltage than the converter input, Q6 and Q11 are turned on
(pulsed at a 25 to 500 µS rate) to create a momentary short across the IGBT
input supply. Energy flows through Q6 and Q11 and is built up or stored across
inductors L1 and L2. L1 and L2 slow the ramping current created by the
conduction of Q6 and Q11, which are then turned off well before the rating of
any module components or conductors is exceeded. When Q6 and Q11 are
turned off, energy from the converter input (324 Vdc) and the energy stored
across L1 and L2 (t *LRC) are added to achieve the desired voltage at the
converter output.
Voltage regulation in the Boost Charge Mode is controlled by the time duration
which Q6 and Q11 are allowed to conduct. The longer Q6 and Q11 are turned
on, the more energy is stored across L1 and L2, and the higher the voltage
becomes on the converter output. The shorter Q6 and Q11 are turned on, the
less energy is stored across L1 and L2 and the lower the voltage becomes.
Since these two sources are added together to achieve the desired output,
changes in the utility input voltage from its nominal value also have an effect on
how long Q6 and Q11 must be turned on to achieve the desired value.
Battery converter current is monitored by Q1, which allows the converter control
to limit the amount of charging current supplied to the battery, ensuring that Q6
and Q11 are not held on too long. Limiting the amount of current being supplied
to the battery is accomplished by turning off the gating of Q6 and Q11 to limit the
amount of current provided to the battery while trying to maintain the converter’s
regulated output voltage target. This conflict is often the case after a battery has
been fully discharged. The battery charge voltage gradually increases over time
towards the nominal voltage charge level as the battery current is maintained at
a level determined by the DSP on the Control Board.

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4.3.4 Buck Charge Mode (480V)

In Buck Charge Mode of operation, the battery is charged at a voltage level
lower than the input voltage to the converter. In this mode, the converter will
achieve less voltage at its output than its nominal input of 746 Vdc by using Q6
and Q11 as power switches. While Q6 and Q11 are conducting, energy is
transferred from the converter input; through Q1 (battery charge current sensor),
L1, and L2; and on to the battery. Q6 and Q11 are gated on just long enough to
achieve the desired voltage at the converter’s output.
Voltage regulation in the Buck Charge Mode is controlled by the duration which
Q6 and Q11 are allowed to conduct. The longer Q6 and Q11 are turned on, the
more energy is built up across L1 and L2, and the higher the voltage to the
converter’s output (564 Vdc being the maximum value without entering the
Boost Charge Mode). The shorter Q6 and Q11 are turned on, the less energy is
bled across L1 and L2 and the lower the voltage becomes on the converter
output. Because the converter’s output voltage is based on the conduction time
of Q6 and Q11, changes in the utility input voltage from its nominal value (input
OV\UV thresholds) have minimal effect on the Q6 and Q11 conduction times to
achieve the desired value.
Battery converter current is monitored by Q1. Using this value, the converter
charging current supplied to the battery is limited by controlling Q6 and Q11.
The firmware controls the need to protect the components, remain within current
limits, and meet battery charge or discharge demands. While charging, the
battery charge voltage gradually increases over time toward the nominal voltage
charge level as the battery current is maintained at a level determined by the
DSP on the Control Board. After the charge voltage level is reached, the current
will begin falling away from the current limit value and Q6 and Q11 will resume
voltage control operation for the remainder of the charge cycle.

4.3.5 Advanced Battery Management (ABM)

Note:
For Battery Run Time and Watts per Cell Charts refer to battery manufacturer’s
specifications. A list of common batteries and run times is provided in Chapter
11, Prints.

4.3.5.1 Introduction
The purpose of this section is to describe common platform ABM operation with
common terminology. ABM is installed and enabled from the factory.

4.3.5.2 Purpose
The purpose of ABM is to extend the life of valve regulated, absorbed electrolyte
lead-acid (VRLA) batteries employed in standby service of an Uninterruptible
Power Supply.

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Functional Descriptions 9390 Service Manual

Studies on the “end of life” mechanisms of batteries in standby service reveal

that the cause of failure is positive grid corrosion due to constant float charging.
Therefore, a key feature of ABM is that the batteries be held at rest rather than
on float for most of their service life.
The length of time for the freshening and the timing of the initiating event can
mitigate the benefit of rest. Care must be taken in limiting the initiating events for
freshening so that excess charging does not occur.

4.3.5.3 General Terms

battery rest – a battery state where it is neither charging nor discharging. Not
gating the battery converter IGBTs effectively disconnects the battery from the
charger.
charge mode - begins a charging cycle; the battery voltage is being charged up
after discharging of batteries for Battery Minimum Discharge Time, after a
complete rest period, or when open cell voltage decreases below Batt.
Opportunity Charge Voltage in rest mode; the mode ends when the battery
voltage reaches Batt. Charge Voltage or if the mode has lasted Batt. Maximum
Charge Time time.
charging cycle – for a normal ABM cycle it consists of charge, float, and rest
mode. First battery voltage is ramped in charge mode, then the voltage is kept
steady in float mode, and finally batteries are left resting. With constant float
mode, the rest period is replaced with a constant float voltage. See Figure 4-5
and Figure 4-6.
float charging - during ABM cycling: charging at a higher voltage level than in
constant-float charging to bring all cells in a battery string to their full charge
state. This is done for a limited period of time.
float mode - after charge mode the battery voltage is kept constant at ABM
Float Voltage during (ABM Float TimeExt + ABM Float Time) time.
OCV - open cell voltage.
rest mode - batteries are left resting after float mode; converter is gated off
VPC - volts per cell.

4.3.5.4 Values and Limits

Battery Charge Time - time for charge mode to make it to Batt. Charge Voltage
setting.
Batt. Maximum Charge Time - battery maximum charge time (default 100
hours); the time allowed for charge mode after which float mode is started even
if the battery voltage has not yet reached Batt. Charge Voltage level.
Batt. Charge Voltage - charge voltage (default 2.34VPC at 25C); the level
where charge mode changes to float mode.

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9390 Service Manual Functional Descriptions

Batt. Charge Reference Voltage

(default 2.39VPC at 25C); a target voltage for the charger that will never be
reached because Batt. Charge Voltage is set lower to trigger the charger to the
ABM Float Mode.
Batt. Continuing Float Voltage - continuous-float voltage (default 2.270VPC at
25C); used to constantly charge batteries in place of the ABM rest period.
ABM Float Voltage

ABM Float Time - ABM cycling float time (default 96 hours).
ABM Float TimeExt - ABM cycling float time extension; ABM Float TimeExt =
1.5 * Battery Charge Time
ABM Rest or Continuous-Float Duration Time - maximum battery rest or
continuous-float time (default 28 days); duration of rest mode if neither
discharging nor Batt. Opportunity Charge Voltage have triggered a new
charging cycle or float mode is not enabled. If float mode is enabled the rest
period is replaced with maintaining the batteries at the defaulted Batt.
Continuing Float Voltage.
Batt. Minimum Discharge Time - minimum discharge time (default 20
seconds); limit for cumulative discharge times during rest mode to initiate a new
charging cycle
Batt. Opportunity Charge Voltage - opportunity charge voltage (default
2.10VPC); if battery voltage decreases below this limit in rest mode, a new
charging cycle is initiated immediately
Batt. Rest Failure Time - battery opportunity charge voltage failure time,
default 10 days in rest mode
Start Batt. Test Time - battery support test time moment (default 48 hours from
the beginning of ABM float mode)
Battery Auto Equalize Voltage – Auto-Equalize voltage (default 2.39VPC /
25C)
Auto-Equalize Start Time Delay – time equalize charge will start after the
battery tests during ABM float mode. This time must be greater than the battery
test start time
Auto-Equalize Duration Time – length of time equalize charge will last
Batt. Test Low Voltage - low voltage limit for battery support test (default
1.9VPC)

4.3.5.5 Discharging
XCP Battery data block reports ABM status: discharging.
Discharging of batteries interrupts any charging mode. Cumulative discharging
time is stored as Batt. Discharge Time.

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Functional Descriptions 9390 Service Manual

If after a discharge period, the value of Batt. Discharge Time exceeds Batt.
Minimum Discharge Time, then a new charging cycle is initiated. Otherwise, the
previous charging mode is continued. See Figure 4-5, Normal ABM Charging
Cycle.

4.3.5.6 Charging Cycles

Charge Mode ABM Float Mode Rest Mode

Batt. Charge Ref. Volt. 2.39V

Batt. Charge Volt. 2.34V Battery Test 1
360sec
ABM Float Volt . 2.31V
Batt. Continuing Float Volt. 2.27V

Battery Test 2
45 sec

Batt
. Opportunity Chrg Volt.. 2.10V
<10days
batRestFailT

Batt. Test Low Volt . 1.90V

batDCUVLogicPwrV 1.80V
batDCUV 1.75V
48Hrs

batAbsDCUV 1.56V batSupTestT

100Hrs max 96H r s + 28 days
batChargeT batFloatT + batFloatTExt ABM Rest Time
Batt. Charge Ref. Volt. 2.39V Shoot for target when starting charge mode.
Batt. Charge Volt. 2.34V Stop at voltage to begin ABM float charge .
ABM Float Volt . 2.31V ABM Float charge level.
Batt. Continuing Float Volt . 2.27V ABM is DISABLED --Constant Float charge level.
Batt. Opportunity Chrg Volt. 2.10V Starts charger if volt level is reached in <10days of rest mode.
Batt. Test Low Volt . 1.90V If reached during battery test -- cancels the test.
batDCUVLogicPwrV 1.80V ACTIVE only after load loss when on battery , shuts logic power off & opens battery breaker.
batDCUV 1.75V DCUV level during battery mode, ”low battery shutdown alarm, logic power on only, starts 2 min. timer.
batAbsDCUV 1.56V Absolute DCUV if reached prior to end of 2 min. timer.
BTR = Battery Time Remaining
Figure 4-5 Normal ABM Charging Cycle

4.3.5.7 ABM Charge Mode

XCP Battery data block reports ABM status: charging.
When a battery is being charged, it is charged at the battery constant current
rate until it reaches Batt. Charge Voltage. The charging cycle is then changed to
ABM float mode. While charging the battery voltage, the Batt. Charge Reference
Voltage prevents too high of a battery voltage in case of faulty battery voltage
measurement or calibration. The duration of charge mode is measured and
stored into UPS internal variable Battery Charge Time. This data is used to
determine value for ABM Float TimeExt.

4.3.5.8 ABM Float Mode

XCP Battery data block reports ABM status: floating.
At initialization of float mode the value for ABM Float TimeExt is calculated:

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9390 Service Manual Functional Descriptions

• ABM Float TimeExt = 1.5 x Battery Charge Time

The battery voltage is kept at constant ABM Float Voltage for time (ABM Float
TimeExt + ABM Float Time).
The automatic battery support test is done during the float mode.

4.3.5.9 ABM Rest Mode

XCP Battery data block reports ABM status: resting.
The battery is effectively disconnected from UPS. The rest mode lasts until:
• Time defined by ABM Max Rest Time has gone,
• The value of Batt. Discharge Time exceeds Batt. Min. Discharge Time.
• The battery voltage has dropped below the level set as Battery Opportunity
Charge Voltage.

4.3.5.10 Continuous-Float Mode

The user has the possibility to disable the charging cycles and select a
continuous charging scheme. Although the batteries are charged constantly, the
UPS keeps the normal ABM timer running. ABM Float mode and battery tests
are still performed. The 28 day float voltage is defined as Batt. Continuing Float
Voltage.

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Functional Descriptions 9390 Service Manual

Charge Mode ABM Float Mode Float Mode

Batt . Charge Ref . Volt. 2.39V

Battery Test 1
Batt. Charge Volt . 2.34V
360 sec
ABM Float Volt . 2.31V
Batt. Continuing Float Volt . 2.27V

Battery Test 2
45 sec

Batt. Test Low Volt . 1.90V

batDCUVLogicPwrV 1.80V
batDCUV 1.75V 48Hrs
batSupTestT
batAbsDCUV 1.56V
1 0 0 H rs ma x 96Hrs + 2 8 da y s +
batChargeT batFloatT + batFloatTExt batMaxRestT
Batt. Charge Ref . Volt. 2.39V Target when starting charge mode .
Batt. Charge Volt . 2.34V Stop at voltage to begin ABM float charge .
ABM Float Volt . 2.31V ABM Float charge level .
Batt. Continuing Float Volt . 2.27V ABM is DISABLED - Constant Float charge level .
Batt. Test Low Volt . 1.90V If reached during battery test - cancels the test.
batDCUVLogicPwrV 1.80V ACTIVE only after load loss when on battery , shuts logic power off & opens battery breaker .
batDCUV 1.75V DCUV level during battery mode , ”low battery shutdown alarm , logic power on only , starts 2 min. timer.
batAbsDCUV 1.56V Absolute DCUV if reached prior to end of 2 min. timer.

Figure 4-6 Typical Float Charge with Battery Test Cycle

1. Charge mode begins when

• The cumulative discharging time (Batt. Discharge Time) exceeds
Batt. Minimum Discharge Time, or
• After ABM Float TimeExt + ABM Float Time + ABM Continuing
Float Time has gone since last charge mode.
2. Charge mode changes to ABM float mode at Batt. Charge Voltage.
3. An external battery charger is controlled just as with normal ABM
cycling: during charge mode and during float time extension, ABM
Float TimeExt.
4. Battery support test is done normally at a point defined by Start Batt.
Test Time, just as if cycling was enabled.
5. While in the ABM float mode, the battery voltage is kept at a constant
voltage, defined by ABM Float Voltage.

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9390 Service Manual Functional Descriptions

6. Rest mode is never entered, but float mode is continued over the
ABM Rest or Continuing Float Time at the Batt. Continuing Float
Voltage level.
The differences to ABM cycling are:
1. Batt. Continuing Float Voltage is lower than ABM Float Voltage.
2. There is no rest mode; float mode continues until cumulative
discharging time (Batt. Discharge Time) exceeds Batt. Minimum
Discharge Time, or ABM Rest or Continuing Float Time has expired.
3. As the ABM cycling timing is internally running, battery support test is
done normally, just as if cycling was enabled.
4. The ABM status is reported normally, charge or float.
5. Battery Test will only be performed if Rest or Continuous Float were
completed.

4.3.5.11 Time Based Auto-Equalize

The user has the option to enable an automatic battery equalize charge. See the
Options Chapter, “Wet Cell Battery” on page 13, for a sample configuration.
During the ABM float mode of operation, a battery equalize charge can be
initiated during each ABM cycle. See Figure 4-7, Typical Time Based Auto-
Battery Equalize Cycle.
Time Based Auto-Equalize must be enabled and the following three settings
adjusted using the XCP Service tool or the Setup Menu on the front display.
1. Auto-Equalize Start Time Delay – the number of hours after the ABM
float mode starts that the equalize mode will begin and the voltage
increases to Battery Auto-Equalize Voltage. This time must be set at
least 1 hour longer than the Start Batt. Test Time unless the battery
test has been disabled.
2. Auto Equalize Duration Time – the length of time in hours the equalize
charge will be active before dropping back down to the ABM float
charge level. Auto-Equalize Start Time Delay + Auto Equalize
Duration Time must be less than 96 hours.
3. Battery Auto-Equalize Voltage is defaulted to 2.39VPC but can be
adjusted based on the installed battery’s requirements.

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Functional Descriptions 9390 Service Manual

Charge ABM Float Mode Float Mode

Mode
Batt. Charge Ref. Volt . 2 .39 V Batt . Auto Equalize Volt .2 .39 V
Auto -Battery
Batt. Charge Volt. 2 .34 V Equalize

ABM Float Volt. 2 .31 V

Batt. Continuing Float Volt. 2 .27 V

Battery Test 1
360 sec
Battery Test 2
45 sec

Batt . Test Low Volt. 1 .90 V

batDCUVLogicPwrV 1 .80 V
batDCUV 1 .75 V
48 Hrs

batSupTestT
batAbsDCUV 1 .56 V

100 Hrs max 96 Hrs + 28 days +

batChargeT batFloatT + batFloatTExt batMaxRestT
Batt . Auto Equalize Volt 2 .39 V Battery Auto Equalize Voltage level.
Batt . Charge Ref . Volt . 2 .39 V Shoot for target when starting charge mode.
Batt . Charge Volt . 2.34 V Stop at voltage to begin ABM float charge.
ABM Float Volt . 2 .31 V ABM Float charge level.
Batt . Continuing Float Volt . 2.27 V ABM is DISABLED- Constant Float charge level.
Batt . Test Low Volt . 1.90 V If reached during battery test- cancels the test.
batDCUVLogicPwrV 1 .80 V ACTIVE only after load loss when on battery,:shuts logic power o ff & opens battery breaker.
batDCUV 1 .75 V DCUV level during batter m o d e , low battery shutdown alarm, logic power on only, starts 2 min . timer .
batAbsDCUV 1.56 V Absolute DCUV if reached prior to end of the 2 min . t i m e r .

Figure 4-7 Typical Time Based Auto-Battery Equalize Cycle

4.3.5.12 Battery Failure Testing

Open Cell Voltage Monitoring
In the rest mode, the open cell voltage (OCV) of the battery is constantly
monitored; however, the OCV monitoring is not done during the first thirty (30)
minutes in the rest mode to allow the battery voltage to settle (after a float mode
or brief discharging).
If the OCV decreases below the batOpChrgV limit during the time defined by
batRestFailT, then the “battery failure” alarm is given and a new charging cycle
is initiated. A passed OCV monitoring test (the voltage kept above the alarm
limit over the batRestFailT period) does not remove an active “battery failure”
alarm.
If the OCV decreases below the voltage limit later, then a new ABM charging
cycle is started without the battery alarm.
Charge Failure Test
The charge mode lasts until the battery voltage reaches the batChargeV limit.
Then the mode is changed to the float mode.

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9390 Service Manual Functional Descriptions

If the battery voltage does not reach the batChargeV limit within
batChargeTMax, then the “battery failure” alarm is given and float mode is
started. A passed test (the charger was able to charge-up the battery voltage)
does not remove an active battery failure alarm.
When ABM charging cycles are disabled, the lower voltage limit is used to
change to the float mode and end this test.
Battery Support Test
This test is started:
• When commanded by XCP.
• When commanded manually from front panel.
• When automatically in float mode at point defined by batSuppTestT.
The Battery support test checks batteries by transferring some or all of the load
to battery and providing any additional load by altering the rectifier gating.
During the test, the battery voltage is constantly monitored. If the voltage drops
below batSuppTestV, the test is immediately interrupted and the battery failure
alarm is given.
The test is disabled, if:
• There is an active battery failure condition (exception: manual battery
support test).
• If the unit is not in normal mode.
• The batteries have not been on ABM or Manual Float charge for at least 48
hours.
• The bypass voltage is not within limits.

4.3.6 Battery Lifetime

4.3.6.1 Introduction
The 9390 battery lifetime algorithm is executed every 1 second. It takes into
account run-time, chronological (wall clock) time, battery temperature, and
battery discharges when calculating the expected battery lifetime available.

4.3.6.2 User Interface

Battery Lifetime, in hours, is maintained in nonvolatile memory and is presented
to the user as a percentage of nominal.

4.3.6.3 User Selectable Values

1. Battery Lifetime can be reset to whatever value the user wants, as
long as it is equal to or less than the nominal battery lifetime. Default
value is 43830 hours or five years.

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Functional Descriptions 9390 Service Manual

2. Nominal Battery Lifetime can be set by the user to any value less
than 4,294,967,296 (2^32) hours. Default value is 43830 hours or 5
years.
3. Battery Discharge Coefficient is the amount of time that is
subtracted from Battery Lifetime every time the unit goes to battery.
Default value is one hour.

4.3.6.4 Operational Sequence

When the 9390 first powers up, 2 hours are subtracted from the battery lifetime
since there isn’t a real time clock to know how long the unit has been powered
down. If it is known that the unit has been powered down for much longer, it is
recommended that the Battery Lifetime be updated accordingly. Based on the
calculated Battery Lifetime, the percentage of remaining battery lifetime is
calculated for display on the battery meter screen. The battery lifetime routine is
called every second thereafter. In subsequent calls to the battery lifetime
routine, only battery discharge and run-time effects are calculated, until a
temperature sensor for the batteries becomes available.

4.3.6.5 Battery Discharge

If the unit goes to battery, the amount of time specified by the Battery Discharge
Coefficient is subtracted from the Battery Lifetime. This value can be changed
with the XCP Service Tool. If the battery discharge is sufficiently short (less than
1 second) it may occur between successive calls to the battery lifetime routine,
in which case the routine may miss the discharge and not update Battery
Lifetime appropriately.

4.3.6.6 Run-Time and Temperature

The algorithm currently does not compensate for temperature degradation of the
battery, due to a lack of a temperature sensor on the batteries. Once an hour, an
hour is subtracted from the Battery Lifetime. This number is stored to nonvolatile
memory every 3 hours. The counter does not run when the unit is off, since
there is no real time clock. The algorithm also does not account for depth of
battery discharge of the battery.
Note:
The system reacts this way if an EMP is not installed, or if Battery Temperature
Compensation is not enabled.

4.3.6.7 Battery Temperature Compensation

Battery temperature variation is compensated by modifying battery charging
voltage accordingly. See Figure 4-8, Battery Charger Voltages per
Temperature.
In ABM charge and float modes, and when ABM charging cycles are disabled,
the charger voltage reference is adjusted according to the highest battery
temperature measurement. The adjusted values are:

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9390 Service Manual Functional Descriptions

• Battery Charge Voltage - the level where Charge Mode changes to Float
Mode
• ABM Float Voltage - ABM cycling Float Mode voltage
• Battery Continuing Float Voltage - ABM rest period is replaced with a
continuous-Float Voltage.
Also, Battery Charge Reference Voltage, the voltage reference value for the
charger while in charge mode, is adjusted. A correctly working ABM charging
scheme never reaches this limit, but changes to float mode at Battery Charge
Voltage.
The values are adjusted in temperature range 0C to 50C. Outside these limits;
the values stay the same.
In the 9390, the battery temperature is monitored in the battery cabinet with an
Environmental Monitoring Probe (EMP) and Web Card installed in the UPS. The
battery cabinet ambient temperature is used via the Web Card for Battery
Temperature Compensation.
The compensation temperature range is from 0C to 50C; the voltage per cell is
decreased 3 mV per each C. The default setup values are the voltage levels at
25C.
The charger values use the following algorithm:
Value(T) = setup_value - 3mV x (T-25C) [where T is battery temperature.]
Under 0C, value (0C) is used. Above 50C, value (50C) is used.
Example: Using default values for the settings, the voltage values at some
temperatures are shown in the following chart:

Voltage Values Charging voltage per cell

0º C 10º C 25º C 40º C 50º C

ABM Float Voltage 2.380 2.350 2.305 2.260 2.230

Batt. Charge Voltage = ABM Float Voltage + 0.03VPC 2.410 2.380 2.335 2.290 2.260
Batt. Charge Ref. Volt. = ABM Float Voltage + 0.08VPC 2.460 2.430 2.385 2.340 2.310
Battery Continuing Float Voltage 2.345 2.315 2.270 2.225 2.195

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Functional Descriptions 9390 Service Manual

2.500 VPC
ABM Float V
Batt . Chrg V
Batt . Chrg Ref . V
2.400 VPC Cont . Float V

2.300 VPC

2.200 VPC

2.100 VPC
0 C 10 C 20 C 30 C 40 C 50 C

Figure 4-8 Battery Charger Voltages per Temperature

The Environmental Monitoring Probe temperature can be seen on the XCP

Service Tool Meter tab.
On XCP Service Tool Version 3.01 and higher, the X-Slot and Battery
Temperature Compensation are selected on the Battery Options tab.

4.3.7 Battery Test

4.3.7.1 Introduction
This section describes the operation of ABM and battery test in the 9390.
4.3.7.2 Battery Test Run Time
The run time calculation uses voltage load and battery information to give a
prediction of battery run time.

4.3.7.3 Battery Test Operation

Battery testing occurs periodically and every time that the unit performs an ABM
charging cycle. The test starts at a fixed time after ABM begins. The time
relative to the start of the ABM float charge cycle is programmable but is
typically set to half of the float time.

4.3.7.4 Battery Test 1

The Battery Test begins with Test 1. Test 1 is typically set for 20% load for a 7%
discharge of the battery. At the end of the test, the voltage and power level are
recorded.

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9390 Service Manual Functional Descriptions

If the required discharge load is less than the output load, the rectifier will
backfeed the line with the excess power. The test will abort if the utility is lost, if
the battery voltage falls below a preset level, or if a charger malfunction occurs.

4.3.7.5 Battery Test 2

The Battery Test ends with Test 2. Test 2 is set for 50% load for 45 seconds. At
the end of the test, the voltage and power level are recorded.
If the required discharge load is less than the output load, the rectifier will
backfeed the line with the excess power. The test will abort if the utility is lost,
battery voltage falls below a preset level, or a charger malfunction occurs.

4.3.7.6 Battery Test Calculations

The following parameters are recorded during the battery test.
• Date and Time
• Status
• Test 1 - End voltage
• Test 1 - Power level
• Test 2 - End voltage
• Test 2 - Power level
From the previous data, the Battery Open Circuit voltage, battery resistance and
battery health are calculated. The data is then used to alter the Battery Time
Remaining (BTR) algorithm.

Table 4-1 Battery Setup Data

Name Effects Description

Charger
Battery Setup Setup Bit word for the battery
ABM

Num Cells String Calcs Number of cells in a single battery string

Num Strings String Calcs Number of battery Strings

Battery DCOV Alarm Battery DCOV level

Charger The level that is used to charge the batteries for the
Battery Equalize
ABM Battery Float Time, typically 48 hours

The target voltage level at the beginning of an ABM

Charger
Battery Charge charge cycle. This voltage is higher than Battery
ABM
Equalize.

Lower than Battery Charge; the level that ends

Battery is Charged Level Charger ABM
regulation to Battery Charge.

Charger Level to regulate to, if ABM is set to continuous

Battery Float Level
Float float.

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Functional Descriptions 9390 Service Manual

Table 4-1 Battery Setup Data (Continued)

Name Effects Description

If the battery voltage falls below this level within the

ABM
Battery Not Charged rest fail time, a “Check Battery” alarm is
ALARM
annunciated; otherwise an ABM cycle is started.

ABM
The level that triggers the low Battery
BTR
Battery DCUV shutdown alarm. The system will shutdown in the
ALARM
programmed Battery DCUV Time.
OPER.

BATTERY DCUV Shutdown BTR Time in seconds before shutdown if the Battery
Time OPER voltage falls below Battery DCUV.

If the Battery Voltage falls below this level, the

Absolute Battery DCUV OPER
system is shutdown within a few seconds.

The power supply is disabled if the battery was

Battery DCUV for Logic
OPER discharged and the battery voltage falls below this
Power Off
level after string voltage recovers.

Battery Temperature Battery charging voltage is compensated

OPER
Compensation according to battery temperature.

Battery Charge Current Limit Charger Level at which the battery charge current is limited.

Battery Charge Current Limit

Nothing Place holder for future applications
On Generator

Hours, When ABM enters float, the Battery test

Support Test Time Batt Test
runs after float charging the Battery for this time.

Hours, ABM must reach equalize voltage before

Battery Charge Time Max ABM
this time or a “Check Battery” alarm triggered

Hours, ABM float charges the battery for this time

Battery Float Time ABM
during each ABM Charge cycle.

Hours, If the battery voltage falls below a preset

Battery Rest Fail Time ABM level before this time, a “Check Battery” alarm is
triggered.

Hours, the time before an ABM charge cycle is

Max Rest Time ABM
initiated.

Maximum Battery Discharge Seconds, if the unit drops on battery for greater
ABM
Time before Charge than this time an ABM charge cycle is initiated.

Battery Run Time at Battery Tenth minutes, Run Time at Battery Watts, typically
BTR
Watts full load run time

Battery Watts BTR Watts/cell, Battery watts at Battery Run Time

Batt test
Battery Open Cell Voltage Volts/cell, used only until commission test occurs
BTR

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9390 Service Manual Functional Descriptions

Table 4-1 Battery Setup Data (Continued)

Name Effects Description

Volts/cell, Used by BTR to determine the state of

Battery Start charge BTR
charge on the battery while resting or charging.

Q15, milliohms, used by BTR until the

Battery Resistance BTR
commissioning test runs

Volts/cell, Used by BTR until the commissioning

Battery Test 1 voltage BTR
test runs.

On Battery Delay ALARM Delay time before queuing “ON Battery”

Number of tenth amps below which the battery

Battery Current Meter Zero Meter
current meter is zeroed

Battery Number of hours to subtract off of battery life for a

Battery Discharge Coeff.
Lifetime given discharge

Battery Number of hours before replacement of battery is

Expected Battery Lifetime
Lifetime recommended.

Battery Life Number of hours the battery currently has left

Battery Lifetime Left
Time before replacement is needed

Batt Test
Battery Test 1 Power Tenth KW, Total KW for Battery Test 1
BTR

Seconds, Time Battery test 1 runs at Battery Test 1

Battery Test 1 Time Batt test
Power

Battery Test 2 Power Batt Test Tenth KW, Total KW for Battery Test 2

Seconds, Time Battery test 2 runs at Battery Test 2

Battery Test 2 Time Batt Test
Power

If the battery voltage falls below this level during

Battery Test Min Voltage Batt Test battery test, the test is aborted and a “Check
Battery” alarm is triggered.

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Functional Descriptions 9390 Service Manual

4.3.8 User Interface to Battery Test Information

4.3.8.1 Battery Test Queue Printing
The battery test queue can be viewed in TERMINAL mode by entering “ESC B”
at any serial port.
The commissioning test and the contents of the battery test log are printed. The
printout is shown below.
• Battery Test Number
• Date and Time of the battery test
• If the test failed, the reason Battery Test Status
• Test 1 results, voltage per cell and power
• Test 2 results, voltage per cell and power
• Calculated open circuit voltage
• Calculated Battery Resistance in Milliohms V/P not V2/P
• Calculated Battery Health (percentage health)

4.3.8.2 Battery Test Information via XCP

The Battery Test information is transmitted in the XCP Battery Test data block.

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9390 Service Manual Functional Descriptions

4.4 NiCd Batteries

4.4.1 Overview
Beginning in Q4 2008 the 9390 is approved to support wet NiCd batteries
designed for use in float voltage applications. There are presently two
manufacturers authorized to provide NiCd batteries for use in the 9390.
To configure a unit for NiCd batteries, correctly enter the CTO number for NiCd
batteries and use the XCP Service Tool to perform a PCB Setup. The correct
ABM defaults for NiCd batteries will be written to the machine. Open the XCP
Service Tool Battery Startup Tab and select Battery Setup Complete. Do not
change any values. These settings are established by the XCP Service Tool in
accordance with the CTO.

4.4.2 Charge Cycle

The NiCd battery charge cycle will be a simple three stage charger. After an
initial constant current state of around 15 hours, the batteries are floated at a
slightly higher level than the third stage long-term float level. The cycle will be
much longer than the traditional ABM 28 day cycle. More information will be
forthcoming concerning the specific parameters; however, these parameters are
all engineering established defaults and must not be adjusted without
engineering’s approval.

4.4.3 Battery Information

• Two manufacturers:
a. Enersys: RH-185 Battery; 370 cells
b. Saft: SPH100 Battery; 380 cells
• The number of cells is fixed and must NEVER be changed
• Different size batteries from these manufacturers may be used
with prior engineering approval
• ABM is disabled - continuous float mode only
• BTR will be less accurate because the NiCd discharge curve
varies from that of the VRLA battery

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Functional Descriptions 9390 Service Manual

4.5 POWER MODULE - INVERTER

4.5.1 Introduction
Reference Documents:
• 110720506 80kVA, LV (208V) Top Print
• 110720507 80kVA, HV (480V) Top Print

4.5.2 Description and Operation

See Figure 4-9, Inverter Functional Diagram.
See Figure 4-10, AC Voltage Sensing Channels Wave Form.
The inverter consists of three Isolated Gate Bipolar Transistors (IGBT) located
on the Power Module Assembly. The function of the inverter is to re-create a
three-phase AC output from the unit’s internally created DC source. The inverter
is provided regulated and balanced DC power from the rectifier during normal
unit operation on utility or from battery during utility outages.
The inverter output is connected to the line side of inductors L5, L6, L7, L8, L9,
and L10. The load sides of these inductors connect to the inverter output filter
capacitor assembly then on to the line side of the inverter output contactor K3.
Inverter output voltage sensing is obtained from the load sides of the inductors
and sent on J8 from the Power Board to J27 on the Interface Board through J11
on the Control Board for inverter regulation and control. Inverter output current
sensing is obtained from the outputs of the LEMs Q3, Q4, and Q5 and sent on
J7 from the Power Board to J31 on the Interface Board through J11 on the
Control Board for inverter regulation and control.

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TB3--7

L7 / 8
Q4
F7
K3 E9
TB3--8 OUTPUT
L4
Q2 Q5 TB3--9 F8 E10
L9 / 10 208 VAC
Q3 TB3--10
F9 E11 3 Phase
L3

L5 / 6
Input EMI
Filter Caps
TB3--5 Caps
E12
E11
Neutral
208V Neutral Regulator & Inverter
TB3--7

L8 L7 Q4 F7
K3 E9
TB3--8 OUTPUT
L10 L9
L3 L4 Q5 TB3--9 F8 E10 480 VAC
Q2 L6 L5 Q3 TB3--10 F9 E11 3 Phase
EMI
Caps Input
Filter
TB3--5 Caps
E12
TB3--11
Neutral
480V Neutral Regulator & Inverter

Figure 4-9 Inverter Functional Diagram

Inverter operation is monitored and controlled by the Digital Signal Processor

(DSP) on the Control Board, which uses Pulse Width Modulation (PWM) to
produce the three-phase AC output.
The raw inverter output PWM current (measured by Q3, Q4, Q5) is fed back to
the DSP on the Control Board.

0o 120o 240o

Phase Phase Phase

Sample of Unfiltered Single Phase PWM A B C

Figure 4-10 AC Voltage Sensing Channels Wave Form.

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4.5.3 Neutral Regulator

The inverter employs an active PWM neutral. A 50% duty cycle modulation
scheme on this leg places the neutral at the mid point between the two rails. A
minimum DC may be better obtained by modulating it with a signal that
represents 1/3 the sum of the modulation values of the other three legs.
Simulation and measurement has shown that this scheme reduces the switching
harmonic content 30% or more and the switching current in the bulk DC
capacitor by more than 50%. This results in significantly reduced cost in the DC
and AC filters.
Employing an active neutral allows modulation in such a way that the required
DC voltage may be reduced. IGBT switching loss calculations show that overall
system efficiency may be improved nearly a full 1% (10% reduction in losses) by
taking advantage of this ability. The DC voltage space must be able to
simultaneously contain voltage space to write each of the input three-phase
lines and each of the output three-phase lines. When the input and output three-
phase is in sync, the required minimum DC may be reduced approximately 15%
by modulating the neutral with a tripling harmonic at 1/6 the amplitude. This
modulation signal must be a zero sequence added to all input and output phase
legs. If, however, the input and output are not in phase, the minimum DC may
have to be raised to accommodate all the phase voltages.

4.5.4 Inverter Regulation and Sync Control

There is little more to the Inverter regulation than what is described above. As
stated earlier, the gain of the PWM block is proportional to the DC voltage. To
keep this gain constant, DC feed forward is employed where the actual DC is
divided out of a constant in this block. There is also an outer loop where the
rectified summed average is regulated and this becomes the reference to the
sine wave look-up table for each of the three phases.
The bypass frequency limits set the limits for the inverter operation. If the
bypass is within these limits and is within voltage limits, the inverter will sync to
bypass. If bypass sync information is not properly available, then the inverter will
sync to the input if it is within inverter frequency limits.

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4.6 POWER MODULE -SMART GATE DRIVE BOARD-

OLD (101073650-001)
4.6.1 Introduction
Reference Documents:
110720510 Smart Gate Drive Board Schematic
The Smart Gate Drive Board (SGDB) is a PCB containing resistors, capacitors,
diodes, and transformers. It is mounted directly to the outside of the Power
Module Board and is connected through a series of pin-outs on the back of the
board. It is connected to the Interface Board by a ribbon cable. This board
provides gating signals from the Control Board via the Interface Board to the
IGBTs on each Power Module assembly.
There is one interface ribbon harness for the inverter power module(s) and one
for the rectifier power module(s). The ribbon cable is daisy chained from one
module to the other module on the same side, allowing the two modules to work
in parallel with each other as a rectifier or inverter.
Inputs/Outputs:
• CAN Network (Controller Area Network)
• Gate Drive signals from Control Board (PWM_Pos and Neg)
• Gate Enable signal
• +5 Vdc Sensing
• +15 Vdc
• Board ID
• Gate Drive to IGBTs

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Functional Descriptions 9390 Service Manual

Figure 4-11 Smart Gate Drive Board

4.6.2 Description and Operation

Each SGDB contains a Micro Controller which is connected through the CAN
network to the Control Board. This circuit controls the enable circuit and
provides the gate power clock signal to the gate drives.
Each gate drive channel contains several resistors, a dual MOSFET driver,
transformer, an IGBT gate drive opto-coupler, and power transistors to drive
either the positive or the negative gate signals. The output of each channel
contains a circuit comprising transient absorption zener diodes and two
capacitors which are used to impedance match the gate drive circuit and the
IGBT device. This matching is useful when a common gate drive circuit is used
to drive IGBT devices in parallel. This type of “Impedance match” ensures that
both parallel devices turn on and off at the same time, reducing pre and post
IGBT firing which reduces IGBT overshoot, IGBT fatigue, and high frequency
noise on both the DC input and the AC output of each inverter heat sink
assembly.
The drive board also contains the temperature sensor interface from the power
module temperature sensors to the SGDB Micro Processor. This circuit contains
a timer that varies pulse width and frequency based on the temperature,
controlling the opto-coupler transistor that sends the over temp signal to the
Micro Processor. When the temperature falls back into normal operating
parameters, the opto-coupler is turned off and the over temperature signal
clears. The circuit output is an averaged 0-5 Vdc square wave for the HS_Temp
sensing. The chart below lists the temperature relationship to the duty cycle and
voltage.

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Table 4-2 Temperature vs. Duty Cycle and Voltage

duty duty duty Vout
C K NTC
(nom) (min) (max) (nom)

25 298 5000 45.5% 45.2% 45.7% 2.73

30 303 4148 44.6% 44.3% 44.9% 2.77

35 308 3463 43.7% 43.3% 44.0% 2.814

40 313 2907 42.7% 42.3% 43.0% 2.864

45 318 2454 41.5% 41.1% 41.9% 2.925

50 323 2083 40.3% 39.8% 40.8% 2.982

55 328 1776 39.0% 38.5% 39.5% 3.049

60 333 1522 37.6% 37.1% 38.2% 3.116

65 338 1311 36.2% 35.6% 36.8% 3.191

70 343 1133 34.7% 34.0% 35.3% 3.266

75 348 984 33.2% 32.5% 33.8% 3.343

80 353 858 31.6% 30.9% 32.3% 3.421

85 358 751 30.0% 29.3% 30.7% 3.499

90 363 659 28.4% 27.7% 29.2% 3.577

95 368 581 26.9% 26.1% 27.6% 3.656

100 373 514 25.3% 24.6% 26.1% 3.733

105 378 456 23.8% 23.1% 24.6% 3.808

110 383 406 22.4% 21.6% 23.1% 3.881

115 388 362 21.0% 20.3% 21.7% 3.951

120 393 324 19.7% 18.9% 20.4% 4.017

125 398 291 18.4% 17.7% 19.1% 4.081

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Functional Descriptions 9390 Service Manual

4.7 POWER MODULE-SMART GATE DRIVE BOARD-

NEW (101073679-001)
4.7.1 Introduction
Reference Documents:
110720568 Smart Gate Drive Board Schematic
The Smart Gate Drive Board (SGDB) is mounted directly to the outside of the
Power Module Board through a series of pin-outs on the back of the board. The
SGDB is connected to the power Interface Board by a ribbon cable. This board
provides gating signals from the Control Board via the Interface Board to the
IGBTs on each power module assembly.
There is one interface ribbon harness for the inverter power module(s) and one
for the rectifier power module(s). The ribbon cable is daisy-chained from one
module to the other module on the same side, allowing the two modules to work
in parallel with each other as a rectifier or inverter.
Inputs/Outputs:
• CAN Network
• Gate Drive signals from Control Board (PWM_Pos and Neg)
• Gate Enable signal
• +5 Vdc Sensing
• +15 Vdc
• Gate_Enable
• ID
• Gate Drive to IGBTs
• Gate Drive Power levels for IGBT modules back to Control Board via CAN
Network.

4.7.2 Description and Operation

Each SGDB contains a Micro-Controller with a CAN BUS interface through the
Interface Board to the Control Board. The Gate Enable signal comes from the
Control Board is validated by this local Micro-Controller and enables (or
disables) all gate drives to the IGBTs driven by the SGDB.
A single common DC/DC converter powers 5 transformers, each with dual
secondaries, to provide isolated floating supplies to support the 10 gate drivers.
Optically coupled gate drivers (5 high side and 5 low side) drive the gates of the
IGBTs through individual gate drive resistors (on the Power Module board) to
each of the paralleled IGBTs.

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Gate drive power is derived by sensing the current feeding each of the five
transformers. Neutral and Battery converter gate power are added together
while phase A, B, and C are sensed separately. These 4 gate power levels are
fed into A/D input ports of the local Micro-Controller and can be monitored.
The SGDB also contains one temperature sensing circuit. The thermistor inside
one IGBT module is used to vary the duty cycle of a 555 oscillator which drives
through an opto-coupler to produce an averaged voltage (Vout). Vout varies
with the temperature inside the IGBT module.
This temperature dependent voltage is input into an A/D port on the local Micro-
Controller and, along with the ambient temperature and current levels can be
used to get an idea of whether that IGBT module is producing the expected heat
and, indirectly, if it is operating properly.

Typical IGBT Temp Sense

6000 4.5

4.0
5000
3.5

4000 3.0
NTC ohms
2.5
Ohms

Vout
3000
2.0 Linear (Vout)

2000 1.5

1.0

1000
0.5

0 0.0
25 45 65 85 105 125
Deg C

Figure 4-12 AC Voltage Sensing Channels Wave Form

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Functional Descriptions 9390 Service Manual

4.8 BYPASS
4.8.1 Introduction
Reference Documents:
• 110720506 80kVA, LV (208V) Top Print
• 110720507 80kVA, HV (480V) Top Print
• 110720513 Static Switch Control Board Schematic
The 9390 is equipped with an internal bypass full duty Static Switch Module
Assembly. The purposes of the Static Switch power circuits are to support
connected loads:
1. At startup,
2. During and after a unit failure, or
3. During unit maintenance and service.

4.8.2 Description and Operation

4.8.2.1 Internal Static Switch Bypass
See Figure 4-13, Internal Static Switch Bypass Functional Block Diagram.
The internal UPS Bypass consists primarily of a backfeed contactor (K5) and a
static switch consisting of six silicon-controlled rectifiers (SCRs), fuses, fan(s),
ACCTs, and the Static Switch Board. The Static Switch Board is located on the
Static Switch Module Assembly at the bottom-left corner of the unit. On the
208V model, K5 is located behind the input/output terminal connections. On the
480V model, K5 is located on a panel to the left of the input/output terminal
connections. All components of the internal bypass are sized and rated to
continuously support 110% of the unit’s rated load.

Static Switch
K5 F4
E6 E9

CT1

Bypass E7 F5 E10 UPS

Input Output
CT2

E8 F6 E11

CT3 E12

Inverter
Output
Figure 4-13 Internal Static Switch Bypass Functional Block Diagram

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9390 Service Manual Functional Descriptions

An external Maintenance Bypass is provided by an optional IDC cabinet or by

custom configurations. The general function of each should be the same (refer
to the 9390 IDC Cabinet for more details or installation drawings for other
vendor’s wrap-around hardware \ switchgear equipment).
The internal UPS Bypass can be energized manually by the operator or
automatically by the unit, if the unit is operating in the Normal mode of operation.
Monitoring and control of the internal UPS Bypass components (K5 and the
static switch SCRs) is the responsibility of the DSP processor assisted by a
static switch Control Board.
Power flow through the UPS Bypass originates from the bypass input terminal
block to the backfeed contactor K5 through the Static Switch Module assembly
(static switch), to the output terminal block.
See Figure 4-14, AC Power Flow Through Bypass SCRs.
Two (2) SCR devices are required on each phase, one to conduct on the
positive half cycle and the other to conduct on the negative half cycle of the
utility bypass input. As each SCR conducts, bypass power is allowed to flow
from backfeed protection contactor (K5), through the static switch to the output
of the module.

Figure 4-14 AC Power Flow Through Bypass SCRs

An R-C “snubber” network located on the Static Switch Control Board is

connected from the line side and the load side of each SCR to the system
neutral, preventing an SCR from falsely turning on when voltage transients enter
the bypass input of the module.
Gate phase control is normally not required on the static switch since the device
acts literally like a power switch in either an ON or OFF state. When needed, the
Static Switch Control Board gates all six SCRs on.

4.8.2.2 Backfeed Protection Contactor (K5) Operation

The backfeed protection contactor (K5) is opened during utility power outages to
prevent static switch leakage voltage from entering the utility feed from the UPS
critical bus output. See section 4.11.3.13, Contactor Control for K5 closure
requirements.

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Functional Descriptions 9390 Service Manual

If Bypass On with Normal Command is not enabled in the XCP Options Tab:
• When bypass power is applied, backfeed protection contactor (K5) is
closed if the microprocessor senses that bypass input is in limits. When the
operator selects "Normal," the UPM will enter "DC Starting" state, but the
bypass SCRs will not be gated. If the operator selects "Bypass" at startup,
(K5) is already closed, so the SSW board microcontroller gates the static
switch to support the critical load on bypass. The unit will only gate the
static switch on startup if "Bypass" is selected from the front panel.
If Bypass On with Normal Command is enabled in the XCP Option Tab:
• When bypass power is applied, backfeed protection contactor (K5) is
closed if the microprocessor senses that bypass input is in limits. When the
operator selects "Normal," the UPM energizes the critical bus on bypass
while the UPS Power Modules complete the precharge and startup routine.
The unit gates the static switch on startup if either "Normal" or "Bypass" is
selected from the controls screen on the front panel.

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9390 Service Manual Functional Descriptions

4.9 LOGIC POWER SUPPLIES

Reference Documents:
110720506 80kVA, LV (208V) Top Print
110720507 80kVA, HV (480V) Top Print
110720512 Power Supply Schematic
The Power Supply contains the following hardware circuits:
• AC/DC Input Power
• Utility and Bypass Input Voltage Sensing Pass Through
• Precharge Circuit
• 48 Vdc ELV
• +15 Vdc SELV
• Fan Fail Detect Circuit

4.9.1 Description and Operation

See Figure 4-17 Logic Power Supply Functional Block Diagram.

4.9.1.1 AC / DC Input Power

Each power supply creates 48 Vdc ELV or +15 Vdc SELV for use by all PCBs,
contactors, system fans, REPO, and external battery disconnects. The power
supplies are supplied by Bypass input AC voltage or DC Link voltage.
At start up, AC voltage enters each power supply from bypass input terminals
through a fifteen-pin connector P5 connected directly to each power supply
board. The input power harness is daisy-chained to all P/S boards. Each of the
AC/DC power supplies has three full-wave rectifier bridges for converting phase-
to-phase AC voltage (208 or 480 volts) to DC voltage. This DC voltage is used
for the precharge and for making 48 Vdc ELV (125W) and 15 Vdc SELV (40W)
system power.
Once precharge is complete, K1 closes and the rectifier starts. The DC Link will
become the input power source for both power supplies as soon as the rectifier
starts. Relays K1, K2, and K3 on both power supply boards energize in the open
position removing the Bypass AC input voltage to the full wave rectifier bridges.
The DC Link is now the input source for the power supplies.
Power fail signals on both power supply boards are passed through the
Interface PCB on J1 to the Control Board on J10. Both power supplies contain
an “output present” green LED. The 15 and 48 volt power failure circuits are
combined for one power supply failure alarm. The LEDs on the power supply
boards are used to determine which voltage has initiated the alarm.

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Bypass 3--phase AC input

Relays
(Closed prior to rectifier start up)

Rectification
(Full Wave Bridge Rectifiers)

48VDC and Pre--Charge

15VDC Power Circuits
Supply Circuits
Diode

48V
15V

DC Link

DC Capacitors

Figure 4-15 Logic Power Supply Functional Block Diagram

4.9.1.2 Rectifier and Bypass Input Voltage Sensing Pass-through

Rectifier and Bypass input single phase (phase “B”) voltage sensing “dropping
resistors” are on the P/S board limiting the current of the sensing path. The P/S
board acts only as a pass through to the Interface Board / Control Board. These
two single-phase sensing paths are used by the DSP to determine if voltage is
present before closing K1 or K5.

4.9.1.3 Fan Tach Signal

The tach signal from each fan can be measured on the power supplies. The tach
signal is a 10V square wave at 140Hz. It can be measured at the connectors to
the fan tray below the power modules.

4.9.1.4 Precharge Circuit

On start up, the voltage produced on the DC Link from the three full-wave bridge
rectifiers provides the input to the precharge circuit. The input voltage for a 208V
system will be approximately 264 Vdc, for a 400V system will be approximately
510 Vdc, and for a 480V system it will be approximately 635 Vdc. The only

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purpose of the precharge circuit is to charge the DC bus capacitors to an

acceptable level so that when the input contactor closes the inrush through the
body diodes of the IGBTs does not destroy them. The rectifier cannot do any
testing off of the precharge circuit. The precharge shuts off when the DC caps
have reached approximately 90% of the rectified input voltage, or 0.9 * VinL-L
rms * √2. If the link doesn’t reach this 90% level within 2 minutes, then an alarm
goes active and the precharge circuit will turn off.

4.9.1.5 48 Vdc ELV

The 48VDC ELV is paralleled from both power supply boards and is used for
Contactor power. PS1 provides power for three fans on P1 of the fan assembly
and PS2 provides the power for the remaining three fans on P2 of the fan
assembly. Power to the Static Switch fan is supplied to the SSB Fan Speed
Control circuit on the static switch board from the power supply boards.

4.9.1.6 +15 Vdc SELV

The +15 Vdc SELV on PS1 is sent to the Interface Board, which distributes it to
the Control Board, Display Board, X-Slots, Gate Drive Boards, CAN
connections, and CSB connection. PS2 and PS1 supply +15 Vdc SELV to the
Static Switch on a different connection than the one going to the Interface
Board.

4.9.1.7 Fan Fail Detection Circuit

Each power supply powers with 48 Vdc and monitors via tachometer circuits
three fans. Each fan tachometer signal drives an LED. Tachometer signals from
each fan pass through a resistor divider network and are sent to two
comparators referenced between 4 and 8 Vdc. The output of the comparator
during a fan fail will cause the associated LED to extinguish and a fan fail signal
to be passed to the Control Board via the Interface Board. The fan fail initiated
by the Control Board does not distinguish which fan failed. The technician must
look at the power supply board LEDs to determine the failed fan. The “Fan Fail”
from the Static Switch fan is tied into the same lines to the Interface Board and
does not have an LED associated with it. Therefore, if all LEDs are lit and you
have a fan fail alarm, check the static switch fan.

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4.10 CONTROL CIRCUIT BOARD

Reference Documents (Prints Chapter):
Schematic 10 21 280 Old Control Circuit Board
Schematic 10 24 459 New Control Circuit Board

4.10.1 Introduction
This section describes the operation of the Machine Control Firmware for the
9390 Machine Control. This firmware is executed by a TI TMS320F2812
Embedded Single Chip Micro-controller. If the Control Board is used in a unit
with a CSB, the unit can be flashed to 5.XX code. If not included (indidcated in
the CTO), firmware 5.2 or higher must be purchased by the customer. See the
Parts chapter for upgrade kits. If the Control Board is used in a unit without the
CSB, it must be flashed to 2.12 or newer 2.XX code.
Note:
Rectifier / Charger control is handled with separate machine states.

Figure 4-16 9390 Control Circuit Board

4.10.2 New vs. Old Control Boards

In 2008, Eaton released both a new common Control Board and new common
Interface Board. The following units use the common Control Board: the 9395
ISBM and UPM, 9390, and all 9x55 product lines. The 9395 ISBM and the 9390
both use the common Interface Board.
The standardized Interface and Control Boards are installed in all 9390 systems
in production after January 2008 beginning with the serial numbers greater than
EB05xxxxx. The new standardized boards must be installed as a pair. They
cannot be installed in conjunction with old boards in the same unit. Individual
units in a parallel system can contain old and new board sets and still work
together. The old Control Board is no longer available from CPO.

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The standardized Interface Board is shipped with plug P4 installed. P4 identifies

the board to the XCP Service Tool as a 9395 component. When using the
standardized Interface Board in the 9390, the P4 plug must be removed.

4.10.3 Operational Commands

The operational commands listed below are received from the CAN Network.
These commands typically come from the Front Panel Display, Building alarm
Inputs, or Serial Communications.
User Commands
• BYPASS COMMAND
• NORMAL COMMAND
• LOAD OFF COMMAND
Service Commands
• UPS ON COMMAND (PM ON)
• UPS OFF COMMAND (PM OFF)

4.10.3.1 Bypass Command

When the UPS is not online, the Bypass SCRs are enabled. The backfeed
contactor (K5) closed when valid input power was sensed. When the UPS is
online (Normal Mode), the load is safely transferred to bypass. Latched Alarm
and Notices are cleared when this command is issued.
If the unit is configured as a parallel, the Bypass command is sent three times
on the ECAN to all units.
Other parallel units will ignore the ECAN Bypass Command if their Load Off
Commands are active.

4.10.3.2 Normal Command

The UPS is automatically ramped and put online. If the load is off and Bypass is
available, Bypass is first enabled before the UPS goes online; otherwise the
UPS will energize the Output with the Inverter. Latched Alarm and Notices are
cleared when this command is issued. The AUTO Mode is enabled if the
NORMAL command is received.
If the unit is configured as a parallel unit the normal command is sent one time
on the ECAN to all units. Also, if the unit is configured to go to bypass with the
Normal Command the Bypass Command is sent three times on the ECAN to all
units.
Other parallel units will ignore the ECAN Normal Command if their Load Off
Commands are active.

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4.10.3.3 Load Off Command

The Bypass and UPS are turned off and shutdown. Note that if the system is on
Maintenance Bypass, the load is not de-energized. Auto restart is cleared.
In a parallel configuration, the Load Off command will only operate if the system
is redundant. Otherwise, the unit must be transferred to bypass first before the
load off command will operate.

4.10.3.4 UPS On Command (PM On)

The UPS is automatically ramped. The UPS will not assume the load until the
Normal command is received. Latched Alarm and Notices are cleared when this
command is issued.

4.10.3.5 UPS Off Command (PM Off)

If the UPS is NOT online, all components of the UPS are turned off and
shutdown.
If the UPS is online (Normal Mode) and bypass is available, the load is first
safely transferred to Bypass. After a second PM Off Command, the power
modules will shut down.
If the UPS is online and the bypass is NOT available, UPS stays online.
In a parallel configuration with the unit online, the PM off command will not
cause a transfer to bypass. The PM off will command the unit to the syncing
state as long as the system is redundant, otherwise the command will do
nothing. If in the syncing state and PM off is commanded, the unit will transfer to
the shutdown state.

4.10.4 Machine States

DC Inverter Inverter Inverter

Initial. Shutdown Starting Starting Syncing On--Line
State State State State State State

(Power Up)

Figure 4-17 Machine State Transitions

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4.10.4.1 Initialization State to Shutdown State

FROM TO CONDITION ACTION
Held for three seconds at power up to
allow system to level off
Initializing Shutdown
Power Up
State State
Checks for an Auto Restart (If True
Auto Mode is enabled)

4.10.4.2 Bypass Operation for All States

(Shutdown, DC Starting, Inverter Starting, Inverter Syncing, Inverter Online)
CONDITION ACTION
If all of the following:
Bypass in limits *
Output K3 is not closed
Bypass Command or Parallel Bypass Command
(via the ECAN is received) or Normal Command or
Auto Mode

Note: For the Normal Command or Auto Mode the

K5 is written closed
unit must be configure to go to bypass with the
Normal Command
Note: The backfeed contactor is limited to three
attempts (to close) over a ten-minute period.
Or all of the following:
Bypass Available **
Output K3 closed

Or all of the following:

Bypass in limits *
Output K3 not closed
Inverter on
If any of the following are True for 10 seconds: K5 is written open
Load Off Command
Bypass 25% below nominal Bypass SCRs are turned Off
If all of the following:
Load Off Command is Not Active
Bypass Command or Parallel Bypass Connected in Parallel:
Command via the ECAN is received or Normal/ Three ECAN Close Bypass Commands are sent
Auto Mode Command (Unit Setup must have this
enabled) After 2.5 seconds the Bypass SCRs are turned On
Bypass in limits *
The Bypass SCRs are Off Not Connected in Parallel:
Not Going Online. After 2.5 seconds the Bypass SCRs are turned On
This Unit is not attempting to close K3 to assume a
dead output bus. Note: The delay of 2.5 seconds is for checking
phase rotation after the backfeed contactor has
Note: A Normal Command or Auto Mode being closed.
active will not cause the bypass SCRs on when
other units are online (In a parallel configuration)

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CONDITION ACTION
If any of the following:
Load Off Command Active
Bypass Below 25% of nominal Bypass SCRs are turned off
Remote Emergency Power Off and the unit is not
configured to go to bypass with a REPO
Each UPM will shut off its Bypass SCRs (every 10
If all of the following: sec.) and look for a bypass UV. If a bypass UV
In parallel occurs, the SCRs will remain off, otherwise they
Bypass SCRs are on will be turned back on. The SCRs will also be
Not currently performing a bypass detect test turned back on if an output UV occurs. (This
Other UPM on bypass feature is a UL requirement – prevents
backfeeding the bypass input).
* - Bypass In Limits
• Bypass ACOV/ACUV not active.
• Bypass Phase Rotation not active (latched).
** - Bypass Available
• Bypass ACOV/ACUV/UFOF not active.
• Bypass Phase Rotation not active (latched).
• The inverter is phase locked to the bypass.
• Bypass contactor (K5) failure is not active.
• Bypass static switch short is not active.
• Bypass failure is not active (loss of communication with the bypass
board).
• Force bypass not available is not active.
• Remote sync is not active.

4.10.4.3 Shutdown Alarms

Shutdown Alarms are checked to determine if the system should be Shutdown.
These alarms will also prevent the inverter from bleeding the DC link in the
shutdown state.

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4.10.4.4 System Shutdown Alarms

(DC Starting, Inverter Starting, Inverter Syncing, Inverter Online)

CONDITION ACTION

Shutdown alarms are alarms that cause the MCU

to transfer to the Shutdown State.
Emergency Power Off is active (and not Online)
These alarms cause the Inverter to shutdown and
Heat Sink OT
the machine state to transfer to the Shutdown
K3 will not open is active
State. It also cancels the Auto Mode.
Three Attempts to ramp DC and AC on the
Inverter in Ten Minutes.
Note: If the machine state is not DC Starting, the
machine state is transferred to the DC Starting
state and then the shutdown state.

4.10.4.5 Three Attempt Alarms

See Section 1.4.4, Bypass Mode - Parallel for examples of the attempts.

4.10.4.6 UPS Shutdown

The system could be on Bypass. The Inverter is Off. A command is required
from an external source to start the UPS. The Indicator Lamp and System Level
status conditions are determined as shown in the following two tables.

SYSTEM LEVEL STATUS CONDITION

On Bypass The Static Switch is On
UPS Off The Static Switch is Off

INDICATOR LAMP CONDITION

Normal Off
Bypass On if the Static Switch is on
Battery Off
Alarm Off

During the Shutdown State, the components of the UPS are controlled as
described in the table below.

UPS COMPONENT OPERATION

See section above: Bypass Operation for All
Bypass, Static Switch, Backfeed Contactor
States
Inverter Contactor (K3) Open
Inverter Frequency NA
Inverter Voltage Off
Rectifier Off

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On DC Link if > 250V, otherwise on Bypass AC

Power Supply Relay
Input
OK to Flash (DSP) If DC Link < 200

4.10.4.7 Machine State Transitions during the Shutdown State

Shutdown State to DC Starting State
FROM TO CONDITION ACTION
All of the following:
NORMAL command
OR
PM ON command
OR
Auto Mode is enabled
OR
Normal Command via the
ECAN is received
AND Attempts for 10 seconds to go to the
Shutdown DC Starting
Inverter is shutdown DC Starting State before remaining in
State State
AND the Shutdown State
Current limit is not active
AND
Rectifier is shutdown
AND
EPO is not active
AND
K3 is open
AND
Load Off is not active

4.10.4.8 DC Starting State

Any time that the UPS trips, this state is entered. The Indicator Lamp and
System Level status conditions are determined as shown in the following two
tables.
SYSTEM LEVEL STATUS CONDITION
On Bypass, DC Starting The Static Switch is On
UPS Off, DC Starting The Static Switch is Off

INDICATOR LAMP CONDITION

Normal Flashing
Bypass On if the Static Switch is on
Battery Off
Alarm Off

During the DC Starting State, the components of the UPS are controlled as
described in the table below.
UPS COMPONENT OPERATION

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See section above: Bypass Operation for All

Bypass, Static Switch, Backfeed Contactor
States
Inverter Contactor (K3) Open
Inverter Frequency NA
Inverter Voltage Off
Rectifier On
On DC Link if Rectifier on Normal, otherwise on
Power Supply Relay
Bypass AC Input
OK to Flash (DSP) False
If the Inverter is on for any reason, the Inverter is shutdown.

4.10.4.9 Transfers from the DC Starting State

DC Starting State to Shutdown State
FROM TO CONDITION ACTION
Any of the following:
1. Any System Shutdown
Alarms occur
OR
For conditions 1. thru 3. the inverter
DC Starting Shutdown 2. Rectifier Fails
bleed will be prevented in the
State State OR
Shutdown state
3. Precharge on for more than
2 minutes
OR
Load Off or PM Off Command
DC Starting State to Inverter Starting State
FROM TO CONDITION ACTION
Inverter Rectifier on AC and the DC
DC Starting The machine state is set to Inverter
Starting voltage is between InvDCUV
State Starting.
State and InvDCOV for 1 second
Inverter Starting State
During the inverter starting state, the inverter is commanded to ramp to full
voltage. The Indicator Lamp and System Level status conditions are determined
as shown in the following two tables.
SYSTEM LEVEL STATUS CONDITION
Bypass Off, Inverter Starting The Static Switch is Off
On Bypass, Inverter Starting The Static Switch is On

INDICATOR LAMP CONDITION

Normal Flashing
Bypass On if the Static Switch is on
Battery Off
Alarm Off

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During the Inverter Starting State, the components of the UPS are controlled as
described in the table below.
UPS COMPONENT OPERATION
See section above: Bypass Operation for All
Bypass, Static Switch, Backfeed Contactor
States
Inverter Contactor (K3) Open
Inverter Frequency See section below: Inverter Sync
Inverter Voltage Ramping
Rectifier On
On DC Link if Rectifier on Normal, otherwise on
Power Supply Relay
Bypass AC Input
OK to Flash (DSP) False

4.10.4.10 Transfers from the Inverter Starting State

Inverter Starting State Trips to DC Starting State
FROM TO CONDITION ACTION
Any of the following:
The state is transferred to the DC
Inverter doesn’t start within
Starting State.
Inverter twenty seconds of being
DC Starting
Starting requested on.
State Note: The unit will not allow more than
State OR
three attempts for the inverter to start
Any System Shutdown
over a ten-minute period.
Alarms occur
Inverter Starting State to Inverter Syncing State
FROM TO CONDITION ACTION
The Inverter is running
Inverter Inverter normally and the DC voltage
The machine state is set to Inverter
Starting Syncing is between Inverter DCUV
Syncing.
State State and Inverter DCOV for 5
seconds

4.10.4.11 Inverter Syncing State

During this state, the UPS prepares to go online. If the Bypass static switch is
on, the Inverter voltage and frequency are matched to the output. The UPS goes
online whenever auto mode is enabled. The Indicator Lamp and System Level
status conditions are determined as shown in the following two tables.
SYSTEM LEVEL STATUS CONDITION
Bypass Off, UPS Ready The Static Switch is Off, Ready to go On-Line
Bypass Off, UPS Not Ready The Static Switch is Off, Not Ready to go On-Line
On Bypass, UPS Ready The Static Switch is On
On Bypass, UPS Not Ready The Static Switch is On

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INDICATOR LAMP CONDITION

Normal Flashing
Bypass On if the Static Switch is on
Battery Off
Alarm Off

During the Inverter Syncing State, the components of the UPS are controlled as
described in the table below:
UPS COMPONENT OPERATION
See section above: Bypass Operation for All
Bypass, Static Switch, Backfeed Contactor
States
Inverter Contactor (K3) Open
See Section 4.9.3.13 below: Determining “Ready”
Inverter Frequency
in the Inverter Syncing State
Inverter Voltage Matches output if not UV, otherwise it is Nominal
Rectifier On
On DC Link if Rectifier on Normal, otherwise on
Power Supply Relay
Bypass AC Input
OK to Flash (DSP) False

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4.10.4.12 Determining “Ready” in the Inverter Syncing State

Determining “Ready” when the Output is Energized

CONDITION ACTION

Output ACUV = FALSE

AND
For one second all of the following are true:
READY is a term used to denote that the UPS is
The state has been Inverter Syncing for 1 second ready to close K3 and Go online if Auto Mode is
AND Active.
Inverter is Phase Locked to the output.
AND When all of these conditions are true, the Display
Output Phase Rotation Alarm is false. indicates READY.
AND
Output Voltage and Frequency is within specified When all of the Conditions are true the UPS is
limits. READY TO GO online.
AND
Overloads are clear and the load is below 100% of Note: If Output ACUV is not active, the Inverter
the specified level. Voltage is regulated to match the output voltage.
AND
The Inverter has not tripped or failed and a trip is
not occurring.

Determining “Ready” when the Output is Not Energized

CONDITION ACTION

OUTPUT ACUV = TRUE

AND
When all of these conditions are true, the Display
For one second all of the following are true:
indicates READY.
The state has been Inverter Syncing for 2 seconds
When all of the Conditions are true the UPS is
AND
READY TO GO ONLINE. See Transfers from the
Not On Bypass
Inverter Syncing State.
AND
Output Voltage is less than 25% of Nominal.
The ECAN Network is used to determine if another
AND
UPM is assuming a dead output bus. To do this
Overloads are clear
UPMs skew when K3 is closed based on their
AND
UPM Number. A module will transmit that it is
The Inverter has not tripped or failed and a trip is
assuming a dead bus one second before closing,
not occurring.
but not close K3 for (UPM Number * 300 Msecs +
AND
One Second) before closing.
If connected in Parallel, another UPM is not
reporting that it is online or assuming the load.

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4.10.4.13 Transfers from the Inverter Syncing State

Inverter Syncing to Online with Output Energized

FROM TO CONDITION ACTION

The Inverter voltage regulator is

disabled

K3 is written closed.

Ten Milliseconds after K3 closes

(using a direct read of the K3 AUX - 10
passes @160us), the Bypass SCRs
are turned off.
When the Output Bus is
If connected in Parallel, three
energized and all of the
“ASSUME LOAD” commands are sent
following:
to all UPMs in the System via the
The UPS is READY to Go
ECAN Network.
online.
AND
If connected in Parallel, three “OPEN
Auto Mode is active
BYPASS” commands are sent to all
(Activated by the Normal
UPMs in the System via the ECAN
Command) or the Assume
Network.
Load Command is received
via ECAN from another UPS
Inverter If the Inverter cannot get online within
AND
Syncing Online State 120 Milliseconds, the transition is
In parallel, the number of units
State aborted and the UPS is tripped.
required to go online is less
than or equal to the number
A transfer to the Online State occurs
ready or if another unit is
when K3 is closed.
already online
AND
Note: Bypass is Available for one
Battery breaker is closed or
second after writing K3 Closed, if
the unit is configured to go
assuming load from Bypass.
online without battery. (This
can be bypassed by the
Note: When Connected In Parallel, a
Normal Command when in
UPS is Ready to parallel bypass when
the Ready state)
Bypass is closed and Auto Mode is
active (Normal Key was pushed on
any unit).

Note: When a unit is Ready and Auto

Mode is active, Inverter Voltage
regulation (RMS) is disabled. If the
unit remains in this state for over 120
milliseconds, the Inverter Regulator is
re-enabled.

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4.10.4.14 Inverter Syncing to On-Line with Output De-Energized

FROM TO CONDITION ACTION

When the Output Bus is

energized and all of the
following:
The UPS is READY to Go The Inverter voltage regulator is
Online. disabled
AND
Auto Mode is active K3 is written closed ten milliseconds
(Activated by the Normal after K3 closes
Inverter
Command) or the Assume
Syncing Online State
Load Command is received If the Inverter cannot get online within
State
via ECAN from another UPS 120 Milliseconds, the transition is
AND aborted and the UPS is tripped.
Battery breaker is closed or
the unit is configured to go A transfer to the Online State occurs
online without battery. (This when K3 is closed.
can be bypassed by the
Normal Command when in
the Ready state)

4.10.4.15 Inverter Syncing State Trips to DC Starting State

FROM TO CONDITION ACTION

Inverter goes off.

OR
The state is transferred to the DC
Any System Shutdown
Starting State.
Inverter Alarms occur
DC Starting
Syncing OR
State Resulting in:
State Emergency Transfer to
Inverter Shutdown
Bypass.
K3 is written Open
OR
PM Off Command

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4.10.4.16 UPS Online State

During this state, the inverter is connected to the output. The Indicator Lamp
and System Level status conditions are determined as shown in the following
two tables.
SYSTEM LEVEL STATUS CONDITION
The Static Switch is Off, Output K3 closed:
Load Protected
“Inverter Online”

INDICATOR LAMP CONDITION

Normal On
Bypass Off
Battery On if on Battery
Alarm Off

During the On-Line State, the components of the UPS are controlled as
described in the table below.
UPS COMPONENT OPERATION
See section above: Bypass Operation for All
Bypass, Static Switch, Backfeed Contactor
States
Inverter Contactor (K3) Closed
See Section 4.9.3.13: Determining “Ready” in the
Inverter Frequency
Inverter Syncing State
Inverter Voltage Nominal
Rectifier On
On DC Link if Rectifier on Normal, otherwise on
Power Supply Relay
Bypass AC Input
OK to Flash (DSP) False

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4.10.4.17 Transfers from the Online State

Manual Transfers to Bypass

FROM TO CONDITION ACTION

If Connected in Parallel, the ECAN
Manual Bypass Command is sent
three times if this module is initiating
the transfer to bypass, otherwise it is
sent once.

From T= 0 until T= One Second: The

Inverter regulates its voltage to match
the bypass RMS. For parallel this is
accomplished by the using the ECAN
to transmit the percent difference
between the bypass and the inverter.
The highest percent is used to adjust
the voltage regulation of all parallel
units.
Bypass Command is active.
OR
From T= 1 Second until T= Two
PM Off Command
Seconds: The Inverter stops
OR
regulating the RMS voltage of the
Load Off Command
Inverter.
OR
Inverter
Connected in Parallel and the
Online State Syncing At the instance that Inverter is Phase
ECAN “Command” MANUAL
State locked to Bypass, the Bypass is
TRANSFER TO BYPASS is
enabled. The Bypass SCRs are
received.
turned on.
OR
Pull chain is active
K3 is written Open (When bypass has
AND
closed).
Bypass is Available
If the output (K3) doesn’t open within
250ms the transfer to bypass is
aborted.

Once K3 opens, a transfer to Inverter

Syncing occurs.

If parallel and pull chain is active,

ECAN must be down to transfer to
bypass.

Note: The transfer to Bypass is

cancelled if, at any time, Bypass
becomes unavailable

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4.10.4.18 Transfer Offline, Do Not Energize Bypass

FROM TO CONDITION ACTION

K3 is opened
All of the following:
Load Off Command
Once K3 Opens, the machine state is
Inverter AND
transferred to Inverter Syncing.
Online State Syncing Bypass Unavailable
State OR
If parallel, Load off and PM off only
PM Off Command & System
shutdown the unit if system is
is Parallel
redundant.

Emergency Transfers to Bypass

FROM TO CONDITION ACTION

All of the Following:

Bypass Available
AND
Load Off Command is (Actions taken when UPS Trips and
Inactive Bypass is available)
AND
EPO is Inactive or EPO The Bypass is turned on K3 is written
transfer to bypass is active Open.

AND Any of the Following Inverter Shutdown

Output ACUV
OR If “In Parallel” and a module starts the
Output ACOV emergency transfer due to an internal
Online State OR alarm, the Bypass is turned on only if
OR Inverter Trips for any reason an Output ACUV (Very Fast) occurs
Inverter OR within one second of the start of the
DC Starting
Syncing Transferring to Bypass and Emergency transfer to Bypass. When
State
State and K3 fails to open in 250ms. the Bypass is turned on.
Going OR
Online Inverter DCUV / DCOV Three “Emergency Transfer to
OR Bypass” Commands are also sent to
Selective Trip all other UPS so that all UPS will
OR perform an emergency transfer.
Heat sink over temperature
OR Emergency Transfer Notes:
Charger inverter shutdown When transferring the load from
request Bypass, Bypass is always Available
OR as soon as the unit writes K3 closed to
Parallel and a ETB is received Go Online and for one second after
over the ECAN. the unit has gone online.
OR
Any of the three second trips
(listed below) are active.

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Three Second Trips

FROM TO CONDITION ACTION

Any of the Following for three

seconds:
Selective Trip detected. (Actions taken when UPS Trips and
OR Bypass is Not available)
Inverter goes off.
OR The system is tripped in the same
DC Starting
Online State Output Overload goes active manner as an emergency transfer to
State
OR bypass except the load may not be
Output ACOV transferred to bypass. That is, if
OR Bypass is not available the load would
Output ACUV. be de-energized.
OR
Output (K3) will not close

4.10.5 Inverter Sync

The Inverter phase locks to following sources (in order of priority):

4.10.5.1 Offline
1. Output – Single Phase B
2. Bypass – Three Phase (Backfeed Contactor Closed)
3. Bypass – Single Phase B (Backfeed Contactor Open)
4. Packet (Parallel)
5. Input – Single Phase B
6. Base Freq.

4.10.5.2 Online
1. Bypass – Three Phase (Backfeed Contactor Closed)
2. Bypass – Single Phase B (Backfeed Contactor Open)
3. Packet (Parallel)
4. Input – Single Phase B
5. Base Freq.

4.10.6 Auto Mode

When the Inverter is offline, Auto Mode is enabled if the NORMAL COMMAND
is received. Auto Mode is disabled if the PM ON COMMAND, BYPASS ON
COMMAND, PM OFF or LOAD OFF COMMAND is received as well as trips
described above.

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4.10.7 Auto Restart Operation

When “Auto Restart” and “Enable Retry on Load Dump” are selected on the
XCP Service Tool Options Tab, the 9390 will restart after a battery DCUV or a
power outage. Selecting Enable Retry on Load Dump ensures the unit will
restart after battery DCUV, and selecting Auto Restart ensures the unit will
restart after logic power has been lost. Think of an auto restart as the operator
pressing the To Normal command at the front panel controls screen. Bypass will
only turn on if the Bypass ON with Normal Command is selected on the Options
Tab.
Additionally, the unit will not come to Normal unless the battery breaker is
closed or the “Batt Brkr Not Required” option is selected on the Battery Options
Tab. If this option is selected, be aware that the unit will come to Normal, but will
not have a battery power source until an operator closes the battery breaker.
To test auto restart in the 9390, refer to FSB 624A.
The chart below provides a description of possible unit setups and the resulting
operation without operator intervention. Be aware that if the battery breaker trips
during an outage, the customer will not have battery backup following an auto
restart unless the battery breaker is manually closed.

Table 4-3 Auto Restart Operation with “Enable Retry On Load Dump” selected.

Conditions Effects
To Bypass Batt Brkr Batt. brkr. SSW State Final Battery K3 State
with Normal Not Req tripped on During Machine Breaker
Command Set? discharge? Startup State State
Set

Yes Off Ready Open Open

No Off Normal Closed Closed

Yes Yes Off Normal Open Closed

Yes No Off Normal Closed Closed

Yes Yes On Ready Open Open

Yes No On Normal Closed Closed

Yes Yes Yes On Normal Open Closed

Yes Yes No On Normal Closed Closed

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4.11 Interface Circuit Board

Reference Documents:
110720511 Interface Circuit Board
The description contained in this section pertains only to the hardware found on
the Interface Board. The Interface Board used in the 9390 serves primarily as an
interface with the PCBAS Control Board and the rest of the system. The
Interface Board has no microprocessor and limited controlling circuitry that are
controlled by the DSP on the PCBAS Control Board.

Figure 4-18 9390 Interface Circuit Board (Old Version)

4.11.1 New vs. Old Interface Boards

In 2008, Eaton released both a new common Control Board and new common
Interface Board. The following units use the common Control Board: the 9395
ISBM and UPM, 9390, and all 9x55 product lines. The 9395 ISBM and the 9390
both use the common Interface Board.
The standardized Interface and Control Boards are installed in all 9390 systems
in production after January 2008 beginning with the serial numbers greater than
EB05xxxxx. The new standardized boards must be installed as a pair. They
cannot be installed in conjunction with old boards in the same unit. Individual
units in a parallel system can contain old and new board sets and still work
together. The old Control Board is no longer available from CPO.
The standardized Interface Board is shipped with plug P4 installed. P4 identifies
the board to the XCP Service Tool as a 9395 component. When using the
standardized Interface Board in the 9390, the P4 plug must be removed.

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4.11.2 Introduction
The Interface Board contains the following hardware circuits:
• Power Supplies
• Alarm Relay (NO/NC)
• Rectifier and Inverter Gate Drive Circuits
• CAN Network
• Rectifier Input Voltage Sensing
• Rectifier Current Sensing
• Bypass Voltage Interface
• Bypass Current Interface
• Static Switch / Inverter Interface
• Contactor Control
• Inverter Voltage Sensing
• Inverter Current Sensing
• X-Slots
• Building Alarms
• COM Port (RS-232)
• Control Board Interface
• Display Board Interface
• Fan Fail Circuit
• EPO Circuit

4.11.3 Description and Operation

4.11.3.1 Power Supplies
The Interface Board receives +15 Vdc SELV from the power supplies through
J1. The +15 Vdc SELV provides power to:
• F1 for power to the PCBAS Control Board.
• F3 for X-Slot-1.
• F4 for X-Slot-2.
• F5 for U1 on the +12 Vdc supply.
• F6 for U16 on the +5 Vdc supply.
• F7 for PWM gate drive circuits to the rectifier and inverter power modules.
• +15V_FUSED for the Display interface and CSB interface.

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• U5 and T1 on the Isolated Power Supplies.

4.11.3.2 +12 Vdc Supply

This supply powers the green LED indicating the +12 Vdc power supply is
functioning. It provides power for the Alarm Relay circuit, F2 for power to the
PCBAS Control Board, U28 for the 2.5 Vdc reference voltage for the current op.
amps, and the +5 Vdc power supply. The +5 Vdc provides power to the
contactor control circuit, the Static Switch interface, the RS-232 interface, Fan
Control Circuit and the Clock Supervisor.

4.11.3.3 +5 Vdc Supply

+15 Vdc SELV is the source for this power supply. It supplies +5V_CURR
voltage to F9 for the +5V_FUSED voltages to the Display interface and the CSB
interface.

4.11.3.4 Isolated Power Supplies

The isolated power supplies are designed to isolate potential harmful voltages
from backfeeding into the +15 Vdc SELV power supply. The voltages produced
by the isolated power supplies are -10VDC_ISO, +10VDC_ISO, and
+12VDC_ISO.
The board receives +48 Vdc ELV power through J1 on the Interface Board. The
+48 Vdc ELV is tapped off prior to F8 for a +48 Vdc source and after F8 for a
+48V_FUSED source that provides power to:
• Contactor Control
• Fan Fail Circuit
• EPO Circuit

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4.11.3.5 Interface Board Power Fuses

Figure 4-19 Interface Board Fuses

F1 +15 Vdc SELV to PCBAS Control Board

F2 +12 Vdc to PCBAS Control Board
F3 +15 Vdc SELV to X-Slot-1
F4 +15 Vdc SELV to X-Slot-2
F5 +15 Vdc SELV to +12 Vdc Power Supply
F6 +15 Vdc SELV to +5 Vdc Power Supply
F7 +15 Vdc SELV to +15V_GD to Gate Drive Circuits
F8 +48 Vdc to +48V_FUSED
F9 +5 Vdc
F10 +15 Vdc SELV to +15V_FUSED

4.11.3.6 Alarm Relay (NO / NC)

The Interface Board contains a relay (K7) providing a single set of Form C
contacts (Normally Open (NO), Normally Closed (NC), Common (C)). Relay
contacts are rated: NO = 40A at 240 Vac/14 Vdc and NC = 30A at 240 Vac / 14
Vdc. The relay is connected to the +12 Vdc power supply (+12 Vdc coil) and
receives a signal return from the PCBAS Control Board FET, PLD D44.

4.11.3.7 Rectifier & Inverter Gate Drive Circuits

The gate drive circuits located on the Interface Board contain resistors and
amplifiers to increase the PWM gate drive signals from the PCBAS Control
Board to Smart Gate Drive boards.

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4.11.3.8 CAN Network

The Interface Board connects the PCBAS Control Board to the Display Board,
Rectifier Power Module, Inverter Power Module, CSB, Bypass Control, and both
X-Slots on the CAN Network.

4.11.3.9 Rectifier Input, Inverter Output & Bypass Voltage Sensing

The rectifier, inverter, and bypass voltage sensing pass through current
reducing resistors on the Interface Board prior to connecting to the PCBAS
Control Board.

4.11.3.10 Rectifier & Inverter Current Sensing

The currents sensed on the rectifier and inverter outputs are passed through a
quad operational amplifier referenced at 2.5 Vdc and with a feedback loop that
reduces the gain but increases the stability of the signal. The output of the
amplifier is then sent to the PCBAS Control Board for processing.

4.11.3.11 Bypass Interface & Output Voltage Sensing

The Static Switch input voltage (bypass voltage), current, and output phase “B”
voltage is passed through the Interface Board on J2 and sent directly to the
PCBAS Control Board for processing.

4.11.3.12 Static Switch Interface

The interface between the Interface Board and the Static Switch board utilizes
differential line receivers, comparator amps, and resistors to communicate the
various conditions between the Static Switch board and the PCBAS Control
Board via the Interface Board. There are four separate signals that are
transmitted between the boards. Bypass Avail, Inv. Online, Bypass Ready, and
Bypass Inhibit (I/O Good on STSW Bd).
The Bypass Avail and Inv. Online signals originate on the PCBAS Control Board
and are passed through the Interface Board to the STSW Board. The Bypass
Ready originates on the STSW Board and is passed through the Interface
Board to the PCBAS Control Board. The Bypass Inhibit (I/O Good) is derived
from the Clock Supervisor circuit on the Interface Board. The inputs to the Clock
Supervisor circuit come from the PCBAS Control Board. The following is a brief
description of each signal:
1. Bypass Avail
• If the PCBAS Control Board determines that bypass is within
specifications and available for transfer.
2. Bypass Ready
• The micro-processor on the STSW board has completed a self
check and is ready to gate the static switch to assume the load.
3. Inv. Online

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• The PCBAS Control Board is notifying the STSW board that the
load is supported by the inverter and the system is in Normal Mode
(don’t gate the static switch).
4. Bypass Inhibit (I/O Good)
• The PCBAS Control Board issues the gating commands to the
rectifier and inverter during normal operations. When the gating is
enabled a signal to the Clock Supervisor circuit activating the
clock_good signal. The clock_good signal is a direct line to a
comparator amp to the I/O Good on the Static Switch board. If the
gating signal fails the static switch will gate and the load will be
supported on bypass.

4.11.3.13 Contactor Control

The close command is issued by the PCBAS Control Board to the contactor
control circuits located on the Interface Board. Each contactor has a control
circuit containing two transistors, a MOSFET, diodes, and resistors. The
purpose of the circuit is to provide the active low to energize the coil and close
the contactor. Auxiliary contacts on the contactor are monitored through the
Interface Board to the PCBAS Control Board.

4.11.3.14 X-Slot
The X-Slot connectivity on the Interface Board consists of a pass through to the
PCBAS Control Board, the X-Slot serial buffer, the +15 Vdc fused for the X-Slot
card power, and X-Slot contactor control buffers.

4.11.3.15 Building Alarms

The Interface Board contains the isolation circuits to prevent any external
building alarm from damaging the PCBAS Control Board. The building alarm
circuit contains resistors, diodes, a buffer, and an opto-coupler circuit. When the
dry contacts of the building alarm are connected it completes the circuit and puts
a low on the buffer which causes the opto-coupler circuit to conduct. This
initiates an active alarm condition to the PCBAS Control Board.

4.11.3.16 Control Board Interface

The interface with the PCBAS Control Board consists of two connectors with
three rows of contacts to which the Control Board mates.

4.11.3.17 Fan Circuits

The Fan Fail circuit consists of an opto-coupler circuit that electrically isolates
the fan fail signal from the power supply boards to the PCBAS Control Board.
The Fan Control circuit consists of a transistor, resistors, and an opto-coupler
circuit to simply turn the fans on or off as directed by the PCBAS Control Board
and provide electrical isolation from the fans.

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4.11.3.18 EPO Circuit

Utilizing the same opto-coupler circuitry to electrically isolate the REPO inputs
from the PCBAS Control Board, the REPO circuit when active will shut down the
system and cause a load dump to occur. The remote EPO has two options: A
normal open connection and a normally closed connection. If the normally
closed connect is not used a jumper must be installed on TB-1 to prevent the
system from being in a constant state of EPO. The EPO circuit contains four
opto-coupler circuits for the EPO action utilizing the +48V_Fused power and for
notifying the PCBAS Control Board that a remote EPO has been initiated. The
EPO circuits +48V_EPO opens K3 and K2 (battery breaker UVR is removed).
When the PCBAS Control Board receives the EPO command, it commands the
inverter and rectifier to shut down and opens K1 and K5 contactors.

4.11.3.19 RS-232
The communication RS232 port connects the technician to the DSP on the
PCBAS Control Board. Because the serial connection provides another external
path to the PCBAS Control Board, high speed TTL opto-coupler devices are
used to electrically isolate the connection. The RS-232 connector is mounted
directly to the Interface Board.
The RS-232 connection toggles with X-Slot 2 circuits to the PCBAS Control
Board. When connected to the RS-232 port, X-Slot 2 is disconnected. After 30
minutes of inactivity, the serial port X-Slot 2 will reactivate.

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4.12 STATIC SWITCH BOARD

4.12.1 Introduction
Reference Documents:
110720513 Static Switch Board Schematic
See Figure 4-21, Static Switch Board Block Diagram.
This description pertains to the physical hardware located on the Static Switch
Board (SSB). This board contains no firmware therefore no firmware functional
descriptions exist for this particular board.
The SSB contains the following hardware circuits:
• Power Path from Bypass Input to System Output (via SCRs)
• Static Switch SCR Gate Drives
• Micro-controller and Control Interface
• Output Voltage Sensing Pass-through
• Bypass Input Current Sensing
• Bypass Input Voltage Sensing Pass-through
• Redundant Contactor Hold-in
• Static Switch Fan Speed Control
• Static Switch Fan Tach Circuit
• Parallel Bypass Relay

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Figure 4-20 Static Switch Board (SSB)

4.12.2 Description and Operation

4.12.2.1 Power Path from Bypass Input to System Output (via SCRs)
Three-phase utility bypass power enters the SSB from the K5 contactor through
fuses F4, F5, & F6. Power is then provided to each of the static switch SCRs in
each phase. Since both the positive and negative half cycles of the utility must
pass through the switch, utility is provided to the anode side of one SCR and the
cathode of the other SCR in the same phase. When the SCR receives a gating
signal from the Static Switch Board (SSB) the SCRs begin conducting energy
from the bypass input to the output. Gating signals are connected from the SSB
to the SCR devices. In this function, the SCR is an electronic switch, controlled
by logic, which is many times faster than any mechanical device (like contactor
or breaker). Utility power leaving the SCRs is then delivered to E9, E10, & E11,
the output of the module.

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4.12.2.2 Static Switch SCR Gate Drives

There are six individual gate drive channels used to drive the static switch SCRs
(one for each half cycle of the utility). These channels receive their gating power
from the + 15V SELV input to the SSB from the power supply boards and are
isolated with on-board gate transformers T-1 through T-6. The gating signal
comes from the micro-controller U5 onboard the SSB at a pulse 20% duty cycle
of 25 kHZ.

4.12.2.3 Micro-controller and Control Interface

The Control Interface comprises three dedicated control signals, Inverter online
(input), Bypass Available (input), I/O GOOD (input), and Bypass Ready (output).
The Inverter uses the first two control signals to tell the Bypass Control Board
the ”State” of the system. The Bypass Control uses these signals (Inverter on
Line and Bypass Ready) to transition from state to state. The Bypass Control
uses I/O GOOD (input) to insure that the system does not drop the load if there
is a logic failure on the Control Board. The Bypass Control uses the third control
signal to tell the Inverter Control the state of the Bypass Control.
The micro-controller also controls the SSB LED in various states. The follow are
the states and condition of the LED.
State LED Condition
Idle Off
Ready Toggle every ½ second
Fire On
Initialization Off

RJ--45 Connector

Inverter Online PIC 16F630

Enable Fire
IO Good RS422
Receivers

Byp Avail SCR Gate

Drives

Bypass Ready RS422

Driver

To SCRs

Figure 4-21 Static Switch Board Block Diagram

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4.12.2.4 Output Voltage Sensing Pass Through

Phase “B” output voltage is sensed on the cathode of the SCR and passes
through resistors R18, R67, & R81 to J4 pin 4, output to the Interface Board.
The PCBAS Control Board determines whether the module is supporting loads
from utility bypass or from the inverter output. While “On Bypass” (K3 open,
Static Switch ON), this voltage is provided by utility via the static switch SCRs.
While “On Line” (K3 closed, Static Switch OFF), this voltage is provided by the
inverter output.

4.12.2.5 Bypass Input Current Sensing

Bypass input current is sensed on the SSB between the input of the static switch
SCRs and input fuses F4, F5, & F6. Bypass input current sensing leaves the
SSB through the CT Burden resistors to the Interface Board.

4.12.2.6 Input Bypass Voltage Sensing Pass Through

Input voltage is sensed on the SSB on the input of the SCRs and passed
through the input voltage resistors to J-4 Pins 1, 2, & 3 to the Interface Board.

4.12.2.7 Redundant Contactor Hold In

I/O GOOD ensures the UPS doesn’t come off of Bypass and drop the load if the
Control Board or the Interface Board logic power fails. It makes sure that Bypass
is available by utilizing the redundant contactor hold in circuit. When the system
is on bypass, the Control Board via the Interface Board closes K5. The
Redundant Contactor Hold In provides a redundant signal path from the SSB to
K5 P2 pin 1 to keep K5 closed. The circuit is reset when the microprocessor
reset occurs for any of the following reasons: SSB Logic Power Reset, From the
Logic Power Fail State, Watchdog Time-out, or a Static Switch malfunction.

4.12.2.8 Static Switch Fan Speed Control

The static switch fan is defaulted to a reduced speed when the static switch is
not gating. It transitions to full speed when the static switch is on with no
firmware intervention.

4.12.2.9 Static Switch Fan Tach Circuit

The tach circuit monitors the speed of the fan and will issue a fan-failed signal to
the Control Board via the Interface Board.

4.12.2.10 Parallel Bypass Relay

The parallel bypass relay is used with parallel operations to prevent one unit
being on bypass and the other unit(s) being on inverter. When a UPM is
commanded to bypass the coil of K-1 energizes and provides a completed
signal path on TB2 pins 7 & 8 for use with the other parallel unit(s). This relay,
also called the “pull-chain relay,” will only affect the unit operation if the ECAN
has failed.

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The relay’s max rating is 277 Vac / 30A, the MTA header/connector on the PCB
has a max current rating of 7A, and the traces on the board are sized for 5A max
(steady state). The terminal strip International Electrotechnical Commission
(IEC) rating is 250V/10A.

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4.13 COMMUNICATIONS SERVER BOARD (CSB)

Reference Documents: 110720534 -CSB Schematic

4.13.1 CSB
The 9390 was originally released with the CSB as an option. A CSB is required
for f/w 5.XX. Upgrade kits are available in the Parts Chapter.

4.13.2 Mandatory CSB

The 9390 was originally released with the CSB as a customer purchased option.
Beginning in 2008, all 9390s are manufactured with a mandatory CSB.
Requiring the CSB allowed engineering to free memory for the DSP on the
Control Board. In 9390 units with the CSB, code 5.XX must be used.

Figure 4-22 CSB Card

The standard CSB offers several advantages:

• Standard real-time clock
• Reduces burden on the DSP memory
• Enhanced performance of communication channels

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• Increases history log entries from 128 to 512

• Increases number of building alarms from 2 to 5
• No need to flash to change languages
• Communication, Modem, and Alarm Setups will now only be stored on the
CSB, not duplicated on the Control Board.
Refer to Section 4.14, DISPLAY MODULE , for descriptions of the
Communications Server Board (CSB).
Verify that the CAT-5 cable is connected to the RJ-45 at J3 and power is
connected at J4. See Figure 4-22, CSB Card.

NOTICE
Note:

Flash all UPM firmware to the latest versions. Following the proper flash
procedures, review the Field Service Bulletins (FSBs) for any updates relevant
to the CSB installation and operation prior to installing.

4.13.2.1 DSP Functionality Changes

Unless otherwise stated, the functionality of the DSP will be the same as in the
original 9390. The following functionality is removed from the DSP.
• The DSP will no longer drive the LCD display screens
• All serial communication, except for the service connection, will be
removed.

4.13.3 Features with and without CSB

See Table 5-1, X-Slot Connectivity Device Options, for the 80 kVA and 160 kVA
Retrofit Kits. Kits contain the Installation Procedure, Part Number 164700575.
A CSB board installed in the 9390 adds the following features to the UPS:

Feature 9390 without CSB 9390 with CSB

X-Slots One shared, one dedicated One shared, three dedicated

Setup for X-Slot 1 and 2 only - Serial

X-Slot related Port parameters, Full setup of all X-Slots available
Setup using LCD Modems, Default Password Levels, from Front Panel.
etc.

Relays (Outputs) 1 + 8 (2 X-Slots) = 9 total 1 + 16 (4-X-Slots) = 17 Total

Building alarms (Inputs) 2 2+4 = 6 total

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Fourteen languages possible.

Standard: English, Finnish,
Spanish, French, German, Italian,
Russian.
Languages English plus one other. Flash: Hungarian, Polish, Czech,
Romanian, Swedish, Korean,
Mandarin.
Korean and Mandarin require
newer display board.

Non-Volatile Real-time clock

The clock time is lost when logic
Real-Time Clock functional, programmed via XCP
power fails.
and front panel.

History Queue Size 128 Entries 512 Entries

All alarms available using XCP

Limited to 32 customized alarms using
Configurable Alarms Service Tool Version 3.00 or
the XCP Service Tool.
newer.

Battery statistics are available on

Battery Logging Not Available
the Front Display.

4.13.4 CSB Logging Functions

The battery discharge log, KW demand log, and the maximum current log are
described in the 9390 Installation and Operation Manual.

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4.14 DISPLAY MODULE

4.14.1 Overview
See Figure 4-23, Display Module.
This section describes the user interface for the 9390. The user interface is
defined as all indicators, horns, switches, and displays located on the front of
the unit as well as serial ports, X-Slots, relay outputs, and building alarm inputs.
This display is CAN bus connected and has up to eight lines with some graphics
capability.

Figure 4-23 Display Module

See Figure 4-24, Display CAN Interface.

The user interface consists of two components, a User Interface Controller
(CSB or DSP Control Board) and a Display Module (LCD). The CSB is the
interface controller when firmware 5.00 and higher is installed. The User
Interface Controller determines the contents and operation of the LCD screens
and also the state of the LEDs (indicators) on the Display Module. The Display
Module operates similar to a terminal and has some graphic capabilities.
The Display Module displays data that it receives from the CAN bus. It reports
user push button presses on the CAN bus. It is also re-programmed via the CAN
bus. In the 9390, the User Interface Controller is either the UPS DSP Controller
or, if installed, the CSB.
The Display Module consists of an LCD display, four push buttons, four
indicators, and a buzzer. The UPS communicates to the display via the CAN
Bus. The +5V power supply is supplied in the same cable with the CAN Bus.

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Display
CAN bus
Module
User Interface
Controller

Figure 4-24 Display CAN Interface

4.14.2 Specifications
4.14.2.1 Communications
The data (LCD, button state, LED control, buzzer control) is transferred using
the CAN Bus between the display module and UPS (User Interface Controller).
The message “Communication Lost” is displayed and the alarm indicator is
illuminated if the display module does not receive data on the CAN bus for more
than thirty seconds.
Microcontroller

CAN bus
Power Supply
Graphical LCD

LEDs
Buzzer
Pushbuttons

Figure 4-25 Display Communications

4.14.2.2 Push Buttons (S1-S4)

The button state is read by the micro-controller in the display module. The state
of the buttons is sent to the UPS via CAN Communications. When a button is
pressed, the micro-controller detects a low “0” at the input pin.

4.14.2.3 LEDs (V12-V15)

The LEDs are controlled by the micro-controller according to data incoming on
the CAN bus. An LED is on when the micro-controller output pin is high.
Four LEDs are located on the right side of the LCD in the following order.
• V12, green, UPS/Output ON (top)
• V13, yellow LED, on Battery

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• V14, yellow LED, on Bypass

• V15, red, alarm (bottom)
An LED override signal also drives the On Bypass and Alarm LED for when the
UPS has failed.

4.14.2.4 Buzzer (B1)

The buzzer is on/off controlled by V16 by the micro-controller according to the
data coming from the CAN bus.

4.14.2.5 LCD Display

A graphical LCD display is driven by the micro-controller. The display is
approximately 240 pixels across by 64 pixels down. In the character mode, the
display will accommodate 8 lines by 40 characters.

4.14.2.6 Micro-controller (D2)

A micro-controller with re-programmable flash memory and CAN
communications support, the LCD, LEDs, and buzzer and reads the push button
states.

4.14.2.7 Languages
The LCD display will provide the means for storing special alphanumeric
characters for non-English languages. It will also provide a means for storing
graphics for non-alphanumeric languages.
Changing languages may require firmware flashing. Low cost 9390 systems (no
CSB) have limited memory. The units are provided with two languages (English-
Spanish, English-French, etc.)

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4.15 User Interface Controller

This section describes the operation of the user interface for the 9390. The User
Interface Controller drives the contents of the LCD Display and determines the
state of the Display module LEDs and buzzer. The Display Module acts as a
dumb graphic terminal.
Display module push button and status data is received from the CAN bus.
Outgoing CAN data is transmitted to the display module to drive the LCD
display, indicator lamps, and the horn. In addition, the User Interface Control
can coordinate re-programming of the Display Module.

4.15.1 User Interface Control Processor

In a system without the CSB, the Display Module is controlled by the DSP on the
Control Board. The CSB is an additional Control Board. If a system has a CSB
with 5.XX code flashed to it, the UPS Control detects its presence and stops
driving the Display Module. The CSB takes over.
Without the CSB, items such as text messaging and user setup from the LCD
are limited. The table below lists the differences between systems with and
without a CSB.

UPS Control & Display

Feature CSB & Display Module
Module

Up to 128 Text Messages,

Alarm and Status Text Others shown as numbers
Up to 512 Text Messages
Messaging such as ALARM 44, STATUS
22, etc.

English plus one other, see Fourteen languages, see the

Languages
languages below section on languages below.

Serial Ports, Set Clock, Enable

See LCD Setup with CSB
User Setup using LCD Shutdown, Contrast Adjust,
below
Passwords fixed

Not Shown, the clock time is RTC is shown on LCD, RTC is

Real Time Clock lost when logic power fails. non-volatile. Time resolution 1
Time resolution 5 milliseconds. Millisecond

History Size 128 Entries 512 Entries

2+4 = 6 total (four building

Building alarms (Inputs) 2
alarms located on the CSB)

Relays (Outputs) 1 + 8 (2-X-slots) = 9 total 1 + 16 (4-X-slots) = 17 Total

Programmable Building Alarm

Not Available 6
Messages

Programmable Relay closure Available using Service Tool Using LCD

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UPS Control & Display

Feature CSB & Display Module
Module

Based on relative time, 16

Based on Real Time Clock, 32
Battery Test entries
Entries, shown on LCD
Not shown on LCD

UPS Statistics Not Available Available if needed

UPS Load Profile Not Available Available if needed

UPS Watt Hour Meter Not Available Available if needed

Phone Number Available 1 4

Configurable Alarms 8 All

Power Factor Meter with Lead/

Yes Yes
Lag

X-slots One shared, one dedicated One Shared, three dedicated

AS400 with Serial Available, takes an X-slot Available, takes an X-slot

Web Server Available, takes an X-slot Available, takes an X-slot

Remote Monitor (New) Available, takes an X-slot Available, takes an X-slot

Modem Available, takes an X-slot Available, takes an X-slot

SNMP Adapter Available, takes an X-slot Available, takes an X-slot

Hot Sync Interface (CAN

Available, takes an X-slot Available, takes an X-slot
Bridge)

Relay Card Available, takes an X-slot Available, takes an X-slot

Mod-bus Available, takes an X-slot Available, takes an X-slot

4.15.2 Languages
The User Interface Control supports multiple languages. Languages are handled
differently when a CSB is installed in the unit. The differences are described in the
sections below. The following languages are supported.

• English
• Finnish
• Spanish
• German
• French
• Italian
• Hungarian

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• Polish
• Czech
• Romanian
• Swedish
• Chinese Mandarin (Must have a new Display Board processor.)
• Korean
• Russian

4.15.2.1 Languages without CSB

When the CSB is not in the unit only two languages will be available. The two
languages are English and an alternate language. The alternate language is
selected by flashing the UPS Control.

4.15.2.2 Languages with CSB

In systems with a CSB, all alphanumeric languages are available. Re-
programming is not required.

4.15.2.3 Non-alphanumeric Languages

Non-alphanumeric languages such as Chinese (Mandarin), Korean, and
Russian will require that the unit be re-programmed with the code package that
implements English and the respective language. Chinese and Korean require a
different display part number. The types of LCD display screens will be the
same, but the contents will be slightly different.

4.15.3 LCD Setup with CSB

The following additional LCD Display based setup features become available
when the CSB is installed in a system.
• Building Alarm Names & Actions
• Relay Outputs
• Language choice
• Battery Test, Battery Test Setup, Battery Lifetime
• Serial Ports
• Modem Telephone Number, Initialization String, and Out-Call
• Input Voltage/Frequency
• Output Voltage/Frequency
• Bypass Voltage/Frequency
• Remote Control Enable
• Set/Change Passwords

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• Reset Statistics
• Reset Load Profile
• Unit Name

4.15.4 Graphics
See Figure 4-26, Display Graphics.
Some graphic capability is available on the display. The example below
illustrates the contents of the Mimic screen for an alphanumeric language.

UPS Normal No Alarms Batt Time: 15.1 Mins

Normal

Output
INPUT
UPS Battery

Bypass
Batt
Charger STSW
Alarm

Control Events Meters Setup

Figure 4-26 Display Graphics

4.15.4.1 Mimic Screen Header Information

When the LCD is displaying the mimic screen (level 1), the header will alternate
as follows.
• Unit Name
• Date and Time (If CSB drives the display)
• Display Active Alarms
• Load percent and Battery Time

4.15.4.2 Display Screens

Refer to the Operation Section in the Installation and Operation Manual for a
complete description of each screen available on the LCD Display.

4.15.5 Serial Ports & X-slots

See Figure 4-27, X-Slot #1 and Figure 4-28, X-Slot #2.

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4.15.5.1 Standard Systems

In the 9390 system with no CSB, there are two serial ports. One connects to an
X-Slot; the other is shared by an X-Slot and DB9 type RS-232. Service will use
the DB9 port.

TX, RX

UPS 4--Outputs, DTR X--Slot

Micro #1
Via PLD CAN Bus

Figure 4-27 X-Slot #1

X-Slot #1 connects directly to the serial port; X-Slot #2 is multiplexed and shared
with the DB9. If the DB9 connects, the TX, RX signals are automatically
disabled for X-Slot #2. When the DB9 is disconnected, the TX, RX signals are
re-routed to X-Slot #2.

RS232 DB9
Multiplexer

TX, RX TX, RX

UPS 4--Outputs, DTR X--Slot

Micro #2
Via PLD

CAN Bus

Figure 4-28 X-Slot #2

4.15.5.2 Parallel Systems

One of the two X-Slots is lost in a Parallel System. The Parallel CAN Bridge X-
Slot card must be added in either X-Slot.
• X-Slot #2 is preferred for the CAN Bridge Board as it is not affected by the
XCP Service Tool.

4.15.5.3 Systems with CSB

When a CSB is added, X-Slots #3 and #4 are added as shown below.

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CAN Bus

TX, RX X-Slot
Opto
Isolation 4-Outputs, DTR #3

Mini-CSB
Micro TX, RX
X-Slot
4-Outputs, DTR
#4

Figure 4-29 X-Slots #3 & 4

4.15.6 Output Relays

4.15.6.1 Standard Systems
There is one stand-alone relay in the standard system. A relay card can be
installed in either or both standard X-Slots (#1, #2, #3, #4). Each relay card adds
four relays. The standard system could have up to seventeen relays. These
relays can be configured through the XCP Service Tool.

4.15.6.2 Systems with CSB

The CSB adds two X-Slots; therefore, up to eight additional relays can be added
by adding X-Slot relay cards. Relays can be configured using the LCD Panel
when a CSB is installed.

4.15.7 Building Alarm Inputs

4.15.7.1 Standard Systems
Two building alarm inputs are available in the standard system.

4.15.7.2 Parallel Systems

In a parallel system, building alarm #2 is used. The Parallel CAN Bridge X-Slot
card adds an additional building alarm input, so the net is two.

4.15.7.3 Systems with CSB

The CSB adds an additional four programmable building alarms. It also adds the
capability to configure the building alarms using the LCD Panel.

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4.15.8 Remote Monitor Panel

The remote monitor panel is driven via a twisted pair of wires through the CAN
bridge board. The remote monitor panel is fed by 120 Vac from the critical bus
power.

4.15.9 Parallel System Communications

The Parallel CAN Bridge X-Slot card must be added when a unit is configured
as a parallel system. One CAN Bridge Card per module is required for a parallel
system.
Along with the CAN Bridge Card, a pull-chain to bypass back-up is installed in
TB1 pins 2 and 3 and jumped to TB2 pins 7 and 8.
Refer to Figure 3-12, Pull chain Wiring Diagram with OLD Terminal Blocks and
Figure 3-13, Pull chain Wiring Diagram with NEW Terminal Blocks.

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4.16 ESM Mode

A basic overview of ESM Mode is provided in Chapter 1, System Overview.
Below is more detailed information about this customer purchased option.
Note: Use of energy saver mode on older (pre-refresh) units requires CTO,
firmware, and, often, hardware modifications. Please see “ESM Upgrade Kits”
on page 30 of the parts chapter for the upgrade kit part numbers. The
procedure is included with the kit.

4.16.1 ESM Operation

On Generator: The system will return to Normal mode if it senses a generator
input.
Forward Transfers: All forward transfers go to Battery mode before returning to
Normal mode.
High Alert Mode (Storm Detection): If the 9390 experiences three power line
disturbances that force it to Normal mode in one hour, it will remain in Normal
mode for one-hour. This state is known as High-Alert mode. The unit can be
commanded to ESM via the front panel during this one-hour period.
Battery Test: When a scheduled battery test is to be run, the unit will switch
from ESM mode to Normal mode before running the test. When the test is
complete the system will transfer back to ESM mode.
Fans: While in ESM the system fans will be off unless a power converter
(rectifier, DC converter, inverter) is switching.
Fault Detection: The system is able to distinguish between load and source
faults.
• Load Fault: the unit remains in ESM for one cycle to try to clear the fault
before forward transferring to online mode.
• Source Fault: the unit will complete an immediate forward transfer.
Overloads: If the load exceeds ESM load capability the unit will transfer to
Bypass mode. The system will use the same overloads as the bypass static
switch in Bypass mode. Level 1 overload will remain in ESM for 10 minutes,
Level 2 for 1 minute, and level 3 for 10 seconds.
SSW Short: If the system detects a shorted static switch, it will remain in
Normal mode and not return to ESM. The SSW will be checked for a short
whenever the unit transfers to Normal mode.
ESM Battery Cycle and Neutral Toggling: When in ESM, the DC link is
maintained through the IGBT protection diodes. If the DC Link voltage is lower
than the battery voltage, the UPS enables neutral toggling to avoid discharging
the batteries. The 400 volt models may use the rectifier and/or neutral toggling
to maintain the DC link. The DC link may drop below battery voltage in 400 volt
models.

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Building Alarms: Two new building alarms are available.

• ESM Mode - this building alarm will command the system to ESM or
Normal mode.
• High Alert Mode - this building alarm will command the system to High Alert
Mode. The system will remain in High Alert for one hour.

4.16.2 Parallel ESM Operation

A parallel 9390 system can operate in ESM mode. Commanding one parallel
UPS to ESM will cause all UPMs to transfer to ESM mode. All UPMs in the
system will transfer between ESM, Normal, and Bypass modes at the same
time. The following lists define common reasons for transfers.
1. Parallel Transfers from ESM to Normal
For parallel configurations the system will transfer out of Energy
Saver mode (back to Normal Mode) for any of the following
conditions:
• Power line disturbance on the systems bypass or output.
• Any parallel unit requires a battery test or requires the batteries to
be charged.
• Any parallel unit is off or being serviced.
• Any new unit is ramping online.
• Any user command to Normal or High Alert. User commands will
be sent via CAN to other parallel units.
• Exceeds parallel system kVA rating.
• One or more MOB's are detected open and system is redundant.
2. Parallel Transfers from ESM to Bypass
For parallel configurations, the system will transfer out of Energy
Saver mode to Bypass for any of the following conditions:
• System overload or unit overload.
• One or more MOB's are detected open and system is non-
redundant.
• User command to bypass.
3. Parallel ESM Abnormal Conditions
For a parallel system in Energy Saver Mode, the system will have the
following responses to parallel system abnormal parameters:
• External CAN failure - Distributed Bypass will return to the normal
online state (ignore the pull-chain for 10 seconds during the
transfer back to online mode). Units will use individual bypass sync
source during this mode. ESM will become unavailable.

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• Static switch failure "Shorted" - The system will remain in ESM until
the system attempts to go online. If at that time, any unit
determines that the unit's STSW has failed shorted, the system will
match bypass until the failed unit's backfeed contactor opens
(remaining online). Bypass/ESM will become unavailable.
• Static switch failure "Open" - system will perform an immediate
forward transfer to Normal mode. Bypass/ESM will become
unavailable.
• Selective trips will be disabled while in ESM mode (gating of IGBTs
is disabled). In the event of a forward transfer, the selective trip
feature will be re-enabled and function the same as Normal mode.

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4.17 ECT (Easy Capacity Test)

Easy Capacity Test (ECT) is a feature that allows testing of a UPS power train
under full load stress without the requirement of any external load. This
technology was developed by Eaton in a continued effort to produce products
and services that are environmentally friendly and deliver cost effective
solutions to customers.
ECT is a method by which the UPS can recycle load energy for the purposes of
test and validation of the power handling components in a UPS system. This
allows the UPS to be calibrated, tested, and characterized for performance.
Customers who buy UPS products are paying for reliability, and require 100%
uptime. So it makes sense that many customers choose to perform on-site
commission tests of their new UPS products before placing them in service
powering critical loads.

4.17.1 Testing Capabilities of Easy Capacity Test

ECT has the ability to test all of the power handling components within the UPS
including: rectifier, inverter, contactors, fuses, power buses, cabling, battery,
bypass (static switch), magnetics, and filter capacitors. It also has the ability to
test upstream Bypass Input Breakers (BIB) and Rectifier Input Breakers (RIB),
and all of the intervening electrical cable. Figure 4-30, Current Flow During ECT
shows current flow during ECT.

BYPASS

AC/DC DC/AC
Rectifier Inverter
Utility

BATTERY

Figure 4-30 Current Flow During ECT

4.17.2 Easy Capacity Test Basics

Understanding the technology behind ECT begins with a simple illustration of
how energy is transferred between two AC sources. The schematic below
shows two AC sources connected by some inductance. The circuit below was
simulated, and the two AC sources have the same voltage but have a phase
difference of 10°.

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Figure 4-31 Two (2) AC Sources Connected by the Same Inductance

The result is a current flow through the inductor. Since the current is in phase
with the voltage, it represents power transfer. Figure 4-31, Two (2) AC Sources
Connected by the Same Inductance shows the voltage of the AC sources and
the resulting current. The current waveform is the smallest of the three. It is
important to note that power is being transferred from one AC system to another
but there is no net consumption of energy within the system.
In Figure 4-30 the utility source is connected to the inverter by way of the
bypass. Using digital control techniques the inverter is able to regulate power
back through the bypass by changing this phase relationship. The arrows show
the direction of current flow in the system. As the inverter transfers power from
the DC Bus the rectifier naturally responds by drawing power in and transferring
it to the DC bus. The power transferred by the rectifier is equal to the power
delivered by the inverter plus efficiency losses within the UPS. The efficiency
losses are represented by the 5% of power that is coming in from the utility.
The question always arises, where does all the energy go? The energy doesn’t
go anywhere. Remember that the UPS was not designed to consume energy; it
is designed to transport energy. The child’s game of Hot Potato is a fairly good
analogy. The inverter, bypass, and rectifier are simply passing the energy
around in the same way they would if they were powering a real load.
Full battery discharge is accomplished by opening RIB. The UPS will sense the
loss of input voltage and engage the battery for discharge. See Figure 4-32,
ECT Full Battery Discharge.

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BIB BYPASS

105% 100%
DC/AC
Inverter
9390

FACILITY

Figure 4-32 ECT Full Battery Discharge

In most cases the energy that is fed back is absorbed by the other electrical
loads within the building or facility. In cases where the facility does not require
that amount of power, the excess power will be returned to the utility grid to be
consumed by another customer. In such cases, local regulations should be
considered before performing the full battery discharge.

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 5
Connectivity & Communication
This chapter provides information about X-Slot options and communication,
service software connection and interpretation, and procedures related to the
configuration of X-Slot cards and Service Tool functions.

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5.1 9390 XCP Service Tool Overview

5.1.1 The CTO Tab
The CTO Tab of the XCP Service Tool is displayed when the XCP program is
initially started, see Figure 5-1, The XCP Tool CTO Tab. The first three lines of
information, labeled “Product,” “CTO/CAA,” and “SN,” are received from the
UPS.
• “Product” is based on UPS machine code. Each UPS type has its own
unique machine code (for example, 9155HV = 400, 9355HV = 401,
9155LV = 402, 9355LV = 403, 9390 = 410, 9395 = 480, and so on).
• “CTO/CAA” is the CTO number received from the UPS. This number is
used to identify the XCP Tool configuration of the unit, such as:
– number of batteries,
– single vs. parallel,
– I/P and O/P voltages and frequencies.
• “S/N” is the unique serial number of the UPS.

Figure 5-1 The XCP Tool CTO Tab

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The information in bottom half of the tab, “Configuration Type,” “kVA,” and etc.,
is generated by the XCP Service Tool and is used for information purposes only.
The information is loaded from the CTO file of the XCP Service Tool. If the CTO
number received from the unit doesn’t match one of those specified in the CTO
file for that product, an “Invalid CTO” window will appear and the correct CTO
number is requested. Once entered, the correct CTO number will be written to
the UPS.

5.1.2 The Meters Tab

The Meters Tab for the shows the meter values of the UPS. See Figure 5-2.

Figure 5-2 Unit and Display Meters

Column one:
• “Input B-PH” - the phase B AC input to K1.
• “Va Input”, “Vb”, and “Vc” - 3-phase voltage sensing between the input
contactor, K1, and the rectifier input.
• “Freq” - the average rectifier input frequency of the three phases.
• “Ia,” “Ib,” and “Ic” - the 3-phase rectifier input current sensing.
• “kVA,” “KW,” and “PF” - the rectifier input kVA, KW, and Power Factor.
• “CAN Errors” - increments by 1 each time there is a packet error in the
UPS’s communications.
• “% CPU Idle” - the CPU load displayed as percent of maximum processing
capacity
Column two:

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• “Vdc Link” and “Idc Link” - the measured DC Link voltage and current.
• “Vdc Batt” and “Idc Batt” - the battery charger voltage and current.
• “BTR(t)” - an estimate of the battery time remaining based on load and
battery charge.
• “Batt%Cap” - the remaining battery capacity calculated from the results of
the battery tests.
• “Batt%Life” - the percent of life remaining for the battery. The system can
also be configured to display hours remaining. Five years is the default.
• “EMP Temp.” - provides temperature monitoring if the unit has an SNMP/
Web Card and the EMP probe connected.
• “Neutral V” - neutral voltage displayed as a representation of current
Column three:
• “Output B-PH” - the output phase B voltage measured at the output side of
K3, the inverter output contactor
• “Va Inverter,” “Vb,” and “Vc” - 3-phase inverter voltage sensing, used to
calibrate/adjust inverter output
• “Freq” - the average frequency of the three inverter output phases
• “Ia,” “Ib,” and “Ic” - the inverter current sensing.
• “kVA,” “KW,” and “PF” - the rectifier input kVA, KW, and Power Factor
• Va Inv LCD, Vb, Vc - used to calibrate the LCD display inverter output
voltage line to neutral readings.
Column four:
• “Bypass B-PH” - input phase B AC voltage prior to K5
• “Va Bypass,” “Vb,’ and “Vc” - bypass input 3-phase voltage at the input to
the bypass SCRs
• “Freq” - an average frequency of the three bypass input phases
• “Ia Bypass,” “Ib,” and “Ic” - bypass current
• Vab Inv LCD, Vbc, Vca - used calibrate the LCD display inverter output
voltage line to line readings.

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Figure 5-3 Gate Power and Temperature Meters

The gate power and temperature screen is used primarily for diagnostics. This
screen is only populated when used with DSP Firmware 5.XX. See 9.1.2 for a
description.
• “X TempX” - Module IGBT Temperatures are provided. If the unit has fewer
than four rectifier power modules, the unused spaces will read 0.
• The remaining blocks indicate gate power for the IGBTs used for phase A,
B, C, battery, and neutral.

5.1.3 The Modem Tab

The MODEM Tab, see Figure 5-4, is used to configure the X-Slot modem for
remote monitoring. See modem / remote monitoring setup instructions later in
this chapter.

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Figure 5-4 The Modem Tab

Changing the Customer Name and Unit Type fields on the modem page will
change the front panel display. Ask the customer before changing these fields.

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5.1.4 The EEPROM Tab

The EEPROM tab is used to access UPS EEPROMs. From the Select field each
programmable board can be chosen. The address field specifies the EEP
address and the new value is entered to EEPROM in the “Write Value” field
window, see Figure 5-5.

CAUTION
The system does not evaluate user entries; wrong values may cause a failure
CAUTION

to the unit.

Figure 5-5 The EEPROM Tab

You may use the Windows Calculator button for binary / decimal conversion and
other calculations.
“Change kVA Rating” is used to upgrade the UPS kVA rating. The Upgrade
code is required when changing UPS output kVA to a higher value. See 9.4
“9390 kVA CONFIGURATION PROCEDURE” on page 20
“Save Board EEPs” will save an EEP Map of the selected board(s).

5.1.5 The PCB Tab

The PCB tab is used for Automated PCB Programming (that is, to set UPS
parameters to default values). The default values are specified in the CTO file of
the XCP Service Tool. Before performing any PCB setup, make sure the unit
CTO number (CTO Tab or unit display) is correct.
Note:
The default values defined in the XCP Service Tool are based on certain

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firmware version(s) of the UPS. The version of the XCP Service Tool and UPS
firmware needs to match (see the firmware flashing instructions). If the latest
XCP Service Tool version is used, and UPS firmware version(s) are updated to
latest prior to PCB setup, no problems should occur.
The “Perform Script” button may be used to send special configurations to a
unit. Generally, this feature is used with custom products where actual UPS
configuration is not supported by available CTO combinations.

Figure 5-6 PCB Tab

5.1.6 Battery Startup Tab

The “Battery Startup” tab is used to configure the batteries during
commissioning, see Figure 5-7.

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Figure 5-7 Battery Startup Tab

5.1.6.1 Battery Startup

In the main menu the following items are present:
• “Cells/string” - the number of series connected cells in one battery string.
240 cells is equivalent to forty (40) 12V batteries (default value).
• “Strings” - the number of parallel connected battery strings.
• “Watts/Cell @ 15 Minutes” - the constant power discharge rating of the
battery (see datasheet) to ~1.75VPC end voltage at normal ambient
temperature.
• “Battery Life (yrs)” - a counter that reduces indicated battery life over time.
It has no effect on unit behavior.

5.1.6.2 Enable Battery Commissioning Test at startup or when installing

a new string of batteries
When selected, the first (next) battery test will be used as a reference for future
tests to evaluate battery health. Click “Battery Setup Complete” after
programming settings.

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5.1.7 The Options Tab

The Options tab is used to enable and disable different features of the UPS, see
Figure 5-8.

Figure 5-8 The Options Tab

• Disable Horn - disables the horn.

• Auto Restart - the UPS can restart automatically to online mode after full
battery discharge (or other shutdown). See 4.10.7 “Auto Restart Operation”
on page 57
• Bypass ON with Normal Command - the UPS will go to bypass when the
Normal command is given via display (or remotely).
• Immediate Transfer to Bypass - unit transfers to bypass immediately if an
overload occurs. When not used, the unit transfers to bypass when the
timer expires (refer to product technical specification in the User’s Guide
for times and loads).
• Bypass Not Installed - A frequency converter is a typical example of usage.
The UPS disables some bypass related alarms and does not try to use the
bypass line.
• Enable Retry on Load Dump - allows unit to restart after load loss because
of battery DCUV prior to logic power loss. Used with Auto Restart.
• Display Meters Line-to-Line - changes front panel display from line-to-
neutral to line-to-line display.
• Enable Protected Bypass - If set and UPS in on bypass while bypass is
under- or overvoltage, or if under or over frequency occurs the UPS will

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dump the load. If not set, the UPS doesn’t care about bypass voltages
while on bypass.
• Enable Site Wiring Fault Detection – when used, the UPS will monitor for
voltage between Neutral and Ground. If the above is the specified level, the
site wiring fault alarm will appear and transfer to bypass is inhibited.
• EPO to Bypass (No Load Dump) - the UPS transfers to bypass and shuts
down the UPM(s) when EPO is active. By default the load is disconnected,
and the UPS shuts down completely.
• Enable Output Transformer Line Compensation - Sets unit to compensate
for voltage loss through an output transformer.
• DC Fuse Sensing (160kVA) - enables fuse sensing in 160 kVA units.
• Single Ph. Outage Detect. Enabled - when not set the unit will continue to
try to support the load using the rectifier with one phase missing
• Disable Bypass with Internal MBS - unit will not transfer to bypass if it
senses MBS close.
• Disable current meter zeroing - When current is near zero, the unit will
display zero to minimize operator confusion. Selecting this option disables
the force to zero feature.
• RMP, SCM, RIM Installed - tells the unit that one of these options is
connected to the unit via the CAN Bridge Adapter. The UPS expects to
detect the CAN Bridge Adapter in one of the X-Slots.
• Enable 2nd Lang. - enables 2nd language with no CSB.
• Euro date format - changes date to day/month/year from month/day/year.
• Load Sync Control-Building Alarm 1 - used if load sync control is installed.
• No Logo on Display - no logo will be displayed.
• Cold Start Hardware installed - an option on Helsinki manufactured units to
allow the unit to start from battery.
• FAA allow high inrush load current - option used with some FAA
installations.

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5.1.8 Reports

Figure 5-9 The Reports Tab

The Reports tab, see Figure 5-9, is used to access the Hyper Terminal program,
download the UPS History Log and a Node Bit Map, and to run reports. When
the HYPERTERMINAL button is pressed, the XCP tool will release the serial
port for Hyper Terminal and open Hyper Terminal with the correct settings for
the UPS, see 5.7 “9390 HYPERTERMINAL COMMUNICATIONS ” on page 58.
Running the Configuration Report creates an Excel spreadsheet that contains
UPS configurations, such as voltages, building alarms, battery, and so on.
Running the Meters Report creates a summary of the UPS measurements
created on an Excel sheet.
Note: Excel macro security settings may need to be adjusted for the Report
functions to work properly.

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5.1.9 The Flash Tab

Figure 5-10 The Flash Tab

In Flash tab you can see the firmware versions of the UPS. By double clicking
the appropriate box, you may start the firmware update of that processor.
If a firmware update is needed, follow the instructions provided in manuals and
on the appropriate website(s). The latest firmware is available for downloading
from the Global Techsupport BBS and from the Serviceweb EMEA.

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5.1.10 The Building Tab

Figure 5-11 The Building Tab

The Building tab, see Figure 5-11, is used to configure the building alarms (the
signal inputs of the UPS). Using the Building Alarm Number menu, choose
which building alarm to configure. You must select the correct contact type for
the building alarm (Normally OPEN or Normally CLOSED). In the Message field
you can customise the event text for the building alarm. You may choose to
have the building alarm log a message in the unit events log or you may choose
to have the alarm logged and one of the following actions occur:
• GOTO Bypass - A request for UPS to transfer to bypass if bypass is in
limits and the inverter is in sync; it works the same as when selecting GO
TO BYPASS via the front panel.
• GOTO Normal - A request for UPS to go to normal mode if possible; it
works the same way as when selecting GO TO NORMAL via the front
panel.
• Turn-Off Pwr - Turns off the power modules.
• RedInpCurr OnGen - Used to tell the UPS that a genset is feeding the unit.
When active, a reduced input kVA (current) limit will be used. Also the sync
to bypass and rectifier input can be disabled and transfers to bypass
inhibited. Current (kVA) limit needs to be configured separately (Battery
Options) as well as disabling the syncs, transfers (EEP860 Unit_Setup5).
The automatic battery test will be disabled when On Generator is active.
• ATS Pre-Transfer - sends unit to battery during the transfer to generator.

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• No Sync To Bypass - forces the unit to sync to base when the generator
doesn’t interface well with the UPS.
• TBD
• SEE OPTIONS TAB
• ON Maint Byp - Unit will transfer to bypass if on inverter when this alarm is
active.
• Battery Charger Off - When active, batteries will be placed in rest mode;
however, if mains failure occurs, the UPS will operate as normally.
Typically used to turn off the charger when the battery room ventilation fails
so that hydrogen is not produced.
• GOTO ESM - When active, the unit will transfer to energy saver mode.
• ESM High Alert - When active, the unit will enter energy saver mode high
alert mode.

5.1.11 The Events Alarm

Figure 5-12 The Events Tab

Use this tab to configure (customize) UPS events and to program relays. For X-
Slots you may choose the correct configuration for relay signal via the pull down
menus. Custom means that X-Slot relays are controlled by individual events, but
none of the events will operate X-Slot relays by default. The ER AS/400
configuration is used with the normal (LV) X-Slot relay adapter, P/N 1019. Logic
power must be cycled for some of the change son this page to take effect.

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5.1.12 Battery Options Tab

Figure 5-13 The Battery Options Tab

5.1.12.1 Battery Options

Use the Battery/BTR/ABM Options tab to customize ABM functionality. See
section 4.3.5 “Advanced Battery Management (ABM)” on page 9
• ABM Cycle Setup - allows manipulation of the ABM cycle parameters.
• Continuous Float Mode - disables ABM rest mode and charges the
batteries continuously. See Figure 5-14, Continuous Float Setting.
• Auto Battery Equalize - the UPS will equalize batteries during every
charging period for a specified amount of time with the specified voltage,
which is normally done after an automatic battery test (unless disabled).
See Figure 5-15, Auto Battery Equalize.
• Battery Brkr Not Required - the unit goes to normal mode without the
battery breaker being closed. By default, battery breaker needs to be
closed before the unit will transfer online.
• Battery Fuse Sensing - 100-160 kVA units have battery fuse sensing.
• Skip Batt Detection - skips detection for the standard 192, 216, or 240 cell
string. Set if using non-standard string.
• Disable Battery Test - the UPS will not perform automatic battery tests.
• Batt Temperature Comp - enables battery temperature compensation.
EMP must be used for this option to be enabled. See Figure 5-16, Battery
Temperature Compensation.

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• On Gen Current Limit - allows generator current limit to be set. See Figure
5-17, On Generator Current Limit.
• Temp Battery Cells - allows temporary use of a non-standard battery string.
See Figure 5-18, Temporary Battery Cell Option.

Figure 5-14 Continuous Float Setting

Use this page to set battery parameters in accordance with the battery
manufacturer’s specifications. Note that the ABM Float Voltage is the float
voltage prior to the battery tests, and the Cont. Float VPC is the float voltage
during the 28 day ABM cycle.

CAUTION
See FSB 672 prior to changing a UPS to continuous float mode.

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Figure 5-15 Auto Battery Equalize

Only use battery equalize with wet cell batteries. Consult engineering and the
battery manufacturer’s specifications to ensure proper setup.

Figure 5-16 Battery Temperature Compensation

Use this page to set X-Slot being used for the Environmental Monitor Probe,
allowing correct battery temperature compensation function.

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Figure 5-17 On Generator Current Limit

Use this page to set the generator current limit.

Figure 5-18 Temporary Battery Cell Option

This page is used to configure the 9390 to temporarily operate with a reduced
number of battery cells. Refer to FSB 613 and 613A before changing the value
on this page.

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5.1.13 The Distributed Bypass Tab

The Distributed Bypass Tab allows the unit to be configured for distributed
bypass parallel operation.

Figure 5-19 Distributed Bypass Setup Tab

In addition to allowing basic parallel system setup, several options are available.
• Enable Sync to Base with PCAN Loss - If a unit loses Parallel CAN
communication it will synchronize its inverter to the processor’s base
frequency.
• Module Output Brk Installed - A Module Output Breaker with auxiliaries has
been installed.
• Disable Sync to Input (Par Dual Source) – when used, the inverter is not
allowed to synchronize to rectifier input.
• Disable Parallel 1 Ph Volt Regulation - disables regulation using single
phase sensing.
• Auto Restart - the UPS can restart automatically to online mode after full
battery discharge (or other shutdown). See 4.10.7 “Auto Restart Operation”
on page 57
• Bypass ON with Normal Command - the UPS will go to bypass when the
Normal command is given via display (or remotely).
• Immediate Transfer to Bypass - unit transfers to bypass immediately if an
overload occurs. When not used, the unit transfers to bypass when the
timer expires (refer to product technical specification (IO Manual) for times
and loads).

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• Bypass Not Installed - A frequency converter is a typical example of usage.

The UPS disables some bypass related alarms and does not try to use the
bypass line.

5.1.14 The ECT Tab

The Easy Capacity Test tab allows you to program the UPS to load itself for
testing and calibration purposes. This feature is only available with f/w 5.2 and
above. Refer to “Basic Easy Capacity Testing” on page 12 of Chapter 3 or the
Extended Commissioning Test procedure provided with the service ticket.

Figure 5-20 Basic Easy Capacity Test

• Test Category - Select either Basic Capacity or Extended Commissioning.

Extended Commissioning requires a service ticket number.
• Power Modules to Test - Always choose UPM 1.
• Requested kW - Enter a kW between 10% and 100% of UPS capacity.
• Test Duration - Enter a value between 1 and 120 minutes.
• Abort Test - This button will immediately end the test.
• Start Test - This button will begin the test.

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Figure 5-21 ECT Extended Commissioning Test

• Test Category - Select either Basic Capacity or Extended Commissioning.

Extended Commissioning requires a service ticket number.
• Test Type - Choose either Automatic Load Level Test, Battery Discharge
Test, or Extended Burn-In Test. Battery Discharge Test allows you to
select the load level and expected run time of the battery. Extended Burn-
In Test allows you to select a longer test duration.
• Power Modules to Test - Always choose UPM 1.
• Battery Test Enabled - Choose this option to include an ECT battery test as
part of the commissioning test. Note: for battery test first verify that
backfeeding of utility is allowed or the customer has an upstream load to
use the output power. See the extended commissioning test procedure.
• UPM Power During Battery Test (%) - Select the percent kW for the battery
portion of the commissioning test. Note: If the customer has a low aH
battery, choose an appropriate kW rating to avoid stress to the battery.
• Abort Test - This button will immediately end the test.
• Start Test - This button will begin the test.

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5.1.15 The Configuration Tab

The configuration tab provides information about the default parameters for the
system such as voltage, frequency, and overload settings. ABB contactor
installed option allows the paralleling of Cutler Hammer breaker K3 units with
ABB breaker K3 units. This tab simplifies the implementation of custom
engineering approved configurations, eliminating the need for EEPROM data to
be released. Do not adjust these settings without engineering approval.

Figure 5-22 Normal Configuration Settings

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Figure 5-23 Configuration Limits

CAUTION
Only change configuration limits when directed by engineering.

Figure 5-24 Configuration Overloads

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CAUTION
Only change configuration overloads when specifically directed by
engineering.

Figure 5-25 Configuration ABB/C-H Parallel Contactors

Use this page to set the ABB contactor delay when paralleling units with Cutler
Hammer and SBB contactors. Refer to FSB 620A for setup information.

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5.1.16 The About Tab

Figure 5-26 The About Tab

The About tab displays the XCP Service Tool version and the supported
products.

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5.2 Summary Alarm Relay Configuration

The summary alarm relay energizes whenever an alarm is present in the
machine. In some instances a customer will want to use this alarm to energize
when specific messages are present, in order to signal a building management
system or some other piece of equipment. Note that in addition to the TB1 or
summary alarm relay, you can set the type of horn, modem call, and X-Slot relay
behavior from this screen as well. Simply choose the appropriate configuration
and select Save Custom. See Table 5-2, Relay Interface Card Translation
Table, for details.

5.2.1 Customizing an event

Note: The customer’s load must be transferred to maintenance bypass or shut
down to complete this procedure.
1. Connect the XCP Service Tool to the UPS.
2. Select the Events Tab.
3. Access Node Bit 229 and disable the TB1 Relay. Failure to complete
this step will result in all alarms plus any customized events triggering
the alarm relay.
4. Choose the event you would like to customize using the node bit
number or the text message label. See Figure 5-27.

Figure 5-27 XCP Service Tool Events Tab

5. When the event to be customized appears, choose TB1 Relay.

6. Select Save Custom.

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7. Verify that the node bit number appears in the Customized Node #s
box in the bottom right corner of the screen.
8. Verify that the customer’s load is secure and that the UPS can be shut
down.
9. Cycle logic power by completely shutting down the unit.
10. Restart the unit and verify that the Summary Alarm on TB1 changes
state when the programmed event has been activated.

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5.3 9390 X-SLOT CONNECTIVITY DEVICES

The 9390 supports a variety of connectivity devices from additional RS-232 and
RS-485 serial ports to SNMP (Simple Network Management Protocol) network
and web adapters. To accommodate these devices, the 9390 supports two (2)
X-Slots which house these devices. X-Slots 1 and 2 can be used for any of the
available cards. See Figure 5-28 and Table 5-1.

NOTICE
Note:

The Modem Card can not be used in X-Slot 2.

Two additional X-Slots may be added by an optional Communication Server
Board known as the Mini-CSB. All X-Slot cards are “Hot Swappable,” meaning
that the UPS does not have to be shut down or transferred to BYPASS for the
card to be installed or removed.
For additional information and specific details pertaining to the setup and
configuration of each connectivity device, refer to sales brochures and product
manuals. RoHS Compliant means that the unit is free of hazardous materials,
such as lead, cadmium, chromium, or mercury.

Table 5-1 X-Slot Connectivity Device Options

PART NUMBER DESCRIPTION

103 004 336 X-Slot, “Hot Sync” CAN Bridge Card (Field Kit)

X-Slot, ConnectUPS SNMP / Web / Hub 10/100 (Field Kit),

116750221-001
(RoHS Compliant) p/n was 0514 6288-5501
10 18 460 X-Slot, Low Voltage (LV) Relay Interface (Field Kit)
103 003 055 X-Slot, High Voltage (HV) Industrial Relay / RMP Interface (Field Kit)

103005425-5591 X-Slot, MODBUS (Field Kit) (RoHS Compliant)

10 19 017 X-Slot, Modem Card (Generic) (Field Kit)
10 19 018 X-Slot, Modem Card (New Zealand, Australia) (Field Kit)

103 004 409 Mini-CSB for 20-80 kVA (Field Kit)

103 004 410 Mini-CSB for 100-160 kVA (Field Kit)
103 004 336 CAN Bridge Card

103 004 221 Relay Interface Module (RIM II) (Also requires 103 004 336)
103 004 222 Supervisory Contact Module (SCM II) (Also requires 103 004 336)
103 004 223 Remote Monitor Panel (RMP II) (Also requires 103 004 336)

103 004 409 80 kVA Mini-CSB Retrofit Installation Kits

103 004 410 160 kVA Mini-CSB Retrofit Installation Kits

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Table 5-1 X-Slot Connectivity Device Options

PART NUMBER DESCRIPTION

164 700 575 80 and 160 kVA Mini-CSB Installation Procedure

See Chapter 10, Parts, for other spares, kits, accessories, circuit boards, and
subassemblies.

5.3.1 Basic Serial Communication

Two serial ports are available with a standard unit. One of the serial ports is
dedicated to an X-Slot. The other port is shared between an X-Slot and a local
DB9 RS-232 port. The second port (X-Slot/DB9) can be used by either service
or the customer.
The unit can be ordered with a mini-Communication Server Board (CSB) and
two more X-Slots. Units that use the 5.XX firmware must have the CSB option.

Figure 5-28 X-Slot Locations

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5.3.2 Relay Signaling

One general-purpose relay on the Interface Board, with Safety Extra-Low
Voltage (SELV) compliant contacts, is available for output signaling. The default
set-up for this relay will be “Alarm” and is accessed on the Customer Terminal
Blocks, TB1 and TB2. This relay can be customized via the Events tab in the
XCP Service Tool.
See Figure 3-11, Old and New Terminal Blocks, TB1 and Figure 3-12, Old and
New Terminal Blocks, TB2.
See Section 4.11, Interface Circuit Board, for functional description.

5.3.3 Building Alarm Inputs

The unit has two configurable, galvanic-isolated (SELV) “building alarm” inputs.
The CSB option adds four building alarms.

5.3.4 Additional Connectivity & Software

The UPS supports the XCP protocol, allowing communication with the following:
• LanSafe
• PowerVision
• Foreseer
• Modem-based Remote Notify
• Power Strategy Command
• XCP-based service tools
UPS Firmware “flashing” will be accommodated through the XCP Service Tool.

5.3.5 Low Voltage (LV) Relay Interface Card

Figure 5-29 Low Voltage Relay Interface Card

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This card provides true FORM C relay contacts (NC and NO) through two
methods: a single 15-point terminal block, and a single, two row DB-15 male
connector. Note: The Relay Card setup can be performed using the ‘Events’ Tab
on the XCP Service Software Tool.

5.3.5.1 Relay Card Setup

See Drawing 1018345, X-Slot LV Relay Interface Board, in Chapter 11, Prints.
Each of the X-Slot relays functions in one of four modes:
1. AS400 Mode: An industry standard, the relays indicate the following
conditions:
• Utility Failure
• Unit on Bypass
• Low Battery
2. European AS400:
• Utility Failure
• Unit on Bypass
• Low Battery
• UPS Alarm
3. Remote Monitor Mode (RMP): This mode mimics the Remote Monitor
Panel, with four signals active:
• Unit is Normal
• Unit is on Battery
• Unit is on Bypass
• Unit has an Active Alarm
4. Custom Node Bit Mode: This mode allows the operator to customize
the alarm or notice that activates a relay. The XCP Service Tool is
required to set up the node bits.
a. Connect the XCP Service Tool to the unit.
b. Open the Events Tab.
c. When customizing the Relay Interface Card, use the chart below
to determine which XCP node bit selection is required to actuate
the correct relay on the card.
Note: The information in Table 5-2 was verified with DSP 2.12 and DSP 5.0 in a
unit with a mini-CSB. K4 energizes as soon as power is applied. When
customizing this relay think of its contacts as inverse of the others.

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Table 5-2 Relay Interface Card Translation Table

XCP Relay Selection Relay Card Relay

K1 K1

K2 K4
K3 K2
K4 K3

5.3.6 High Voltage (HV) Industrial Relay

Figure 5-30 High Voltage Industrial Relay Card

This card provides four sets of Form C relay contacts serving as a Relay
Interface Module (RIM). The Remote Monitoring Panel (RMP) signals and relay
status contacts can be used simultaneously but cannot be programmed
separately.
RMP Signal Interface: J1 (6 total positions, 2 plugs, 3 positions each)
Relay Contact Interface: J2 (12 total positions, 4 plugs, 3 positions each)
5.2.2.1Relay Card Setup
See Drawing 110720413, X-Slot HV Industrial Relay Board, in Chapter 11,
Prints.
Note:
The Relay Card configuration can be performed using the ‘Events’ Tab on the
XCP Service Software Tool.
Each of the X-slot relays function in one of four modes:
1. AS400 Mode: An industry standard, the relays indicate the following
conditions:

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• Utility Failure
• Unit on Bypass
• Low Battery
2. European AS400:
• Utility Failure
• Unit on Bypass
• Low Battery
• UPS Alarm
3. Remote Monitor Mode: This mode mimics the Remote Monitor Panel,
with 4 signals active:
• Unit is Normal
• Unit is on Battery
• Unit is on Bypass
• Unit has an Active Alarm
4. Custom Node Bit Mode: This mode allows the operator to customize
what alarm or notice activates a relay. The XCP Service Tool is
required to set up the node bits.

5.3.7 10/100 MB SNMP/Web/Hub Card Adapter

This RoHS Compliant device provides UPS data to one or more computers over
an Ethernet network. Board connections include:
• Four RJ-45 Ethernet network connectors
• One RJ-45 Serial Communication Configuration Port

Figure 5-31 10/100 Megabyte SNMP/Web/Hub

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Figure 5-32 SNMP/Web/Hub Card Components

5.3.8 MODBUS Communications Card

Figure 5-33 MODBUS Communications Card

The MODBUS card provides both RS-232 and RS-485 serial data to a
customer’s Building Management System (BMS). See Figure 5-33, MODBUS
Communications Card and Table 5-3, MODBUS Communications Card
Connector Pins.
Board connections include:
• RS-232 and RS-485 Communications
• RS-485 Hard Wire Terminal Block, or RS-485 DB-9 MOD Bus Port
• RS-232 DB-9 MOD Bus Port
• RS-232 DB-9 Configuration Port

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Figure 5-34 MODBUS Communications Card Components

Table 5-3 MODBUS Communications Card Connector Pins

RS-232 (DB- RS-485 (DB- RS-485
SIGNAL
9F) 9F) (TB)

TxD (+) 2 2 1

RxD (+) 3 1 2
TxD (-) - 7 3
RxD (-) - 6 4

Signal
5 5 5
Ground

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5.3.9 Modem Card

Figure 5-35 Modem Card

The X-Slot Modem is made for UPS remote monitoring purposes. The modem
card allows the unit to be connected to remote computers via a standard phone
line connection. It offers one RJ-11 phone-jack connector for telephone network
connection and four LEDs to indicate its status on its face plate.
The four indicator LEDs (R13 - R16, V1 - V4) show modem status: Sending
(TX), Data Terminal Ready (DTR), Receiving (RX), and Data Carrier Detect (off-
hook) (DCD). DTR indicates modem is ready and is nearly always lit.

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5.3.10 CAN Bridge Card

DB-9 Connector

See Table 5-4 for

Terminal J-3
Descriptions
Figure 5-36 CAN Bridge Card with DB-9 Connections

A CAN Bridge Card is connected between two different CAN networks denoted
the ICAN and ECAN. The CAN Bridge receives messages that are addressed to
it and re-transmits these messages on the other network. Figure 5-36 shows the
CAN Bridge Card with the DB-9 Connector. Figure 5-38 shows the CAN Bridge
Card with RJ-45 Phone Connectors. The function of the CAN Bridge Card is to
provide a translation interface between the internal CAN bus and the external
CAN. One CAN Bridge Card per module is required for a 9390 parallel system.
The bridge card also controls one relay, one building alarm, and an RS-232
serial port.

NOTICE
Note:

X-Slots 1 and 2 can be used for any of the available cards. However, the
Modem Card must be in X-Slot 1. Although the CAN Bridge Card could be used
in either slot, it is recommended that it be inserted into Slot 2 for all parallel
hookups, leaving X-Slot 1 open for the Modem Card when needed.

5.3.10.1 Serial Port

The RS-232 serial port on the bridge card in Figure 5-36 is a pass-through X-
Slot serial interface; however, the RS-232 serial port is not available on the CAN
Bridge card with the RJ-45 connectors.

5.3.10.2 Remote Monitor

The Remote monitor panel has a two-wire connection. The breakdown of the
connections are in Table 5-4, Table 5-5, Figure 5-37, and Figure 5-38.

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Table 5-4 CAN Bridge Card Remote Monitor Connections

CAN Bridge J3 RMP TB1

__
6 TX 5

7 TX 4

Figure 5-37 CAN Bridge Card J3 Terminals

Table 5-5 Terminal J-3 Descriptions

Terminal J-3 Name Description

Programmable UPS alarm. Activated by a remote dry

1 Alarm
contact closure.

2 Alarm Rtn
3 Alarm Relay NC Not used on 9X55

4 Alarm Relay COM Not used on 9X55

5 Alarm Relay NO Not used on 9X55

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Table 5-5 Terminal J-3 Descriptions (Continued)

Terminal J-3 Name Description

Remote Monitor Panel (RMP), Relay Interface Module

___
6 (RIM), or Supervisory Contact Module (SCM)
TX
Connections.

Terminal J-3 Name Description

Remote Monitor Panel (RMP), Relay Interface Module

7 TX (RIM), or Supervisory Contact Module (SCM)
Connections.
Computer Area Network (CAN) Input for parallel
8 CAN L
operation.

9 CAN H
10 Shield

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Figure 5-38 CAN Bridge Card with RJ-45 CAN Connections

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5.4 MODEM Setup, ACTIVE RESPONSE

MONITORING TO CRC-single module
NOTICE
Note:

This procedure applies to V03.05.00 and higher of the XCP Service Software
Tool.
The 9390 DSP Revision MUST be at Version 2.00 or higher.
If the Mini-CSB is used, then Mini-CSB must be Version 1.10 or higher.
For UPS units that do not have a Mini-CSB, XCP Service Tool V3.05 does not
support Eaton Monitoring. (This will be supported in the next XCP Service Tool
release.) Call Tech Support for setup information without Mini-CSB.
Remote Notify for Customer Paging is supported. See Section 5.6, Setup for
9390 REMOTE NOTIFY, CUSTOMER PAGING -single module for more
details.

5.4.1 Scope
This document provides instructions necessary to setup a single module, 9390
for the EatonPW Active Response Monitoring Service. This procedure does not
apply to multi-module parallel systems unless each module is being configured
independently with each unit having its own modem and phone line.

5.4.2 General Notes

This procedure must only be performed by personnel trained and authorized by
Global Services for conducting service on this model UPS.
Prior to site visit, review all Field Service Bulletins (FSB) or other engineering
notifications so they may be completed during the same visit (if appropriate).
Prior to performing any operations, read the entire setup procedure, including
the data sheets, to become familiar with the procedure and to ensure the
procedure is applicable to the system in which monitoring will be performed.

5.4.3 Requirements

NOTICE
Note:

The modems used for Monitoring have been tested and proven to work
specifically with the 9390. Therefore, the modem used for this service, must be
either supplied by Eaton Corporation or approved at the discretion of Eaton
Corporation.

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5.4.3.1 Site Requirements:

Record the dedicated modem telephone numbers for this UPS on this sheet.
This line will be used for both incoming and outgoing UPS calls. It must be
known if a “9” or “8” is required in the dial string for the UPS to obtain an outside
line:
Modem telephone number (____) (__________)
Is a “9” -or- an “8” required for outgoing calls? YES___ NO___
Record on this sheet the Customer 24-Hour number that will be used to notify
the customer that the UPS has called for service.
Customer 24-Hour telephone number (____) (__________)

5.4.3.2 CSE Equipment & Software Requirements:

Ensure that the XCP Service Tool Software is V03.05.00 or newer and has been
authorized for the laptop from which this procedure will be performed.
• X-Slot Modem Card. See Table 5-1, X-Slot Connectivity Device Options,.
• DSP Revision 2.00 or higher
• Mini-CSB 1.10, if used. Note: For setup on Unit without Mini-CSB, call Tech
Support.
• Use the Customer information Form. See Section 5.5, CUSTOMER
INFORMATION FORM , for the electronic version and the e-mail
procedure.

CAUTION
USE ONLY THE XCP SERVICE TOOL SOFTWARE V03.05 REFERENCED IN
THIS PROCEDURE. DO NOT USE ANY OTHER PROGRAMS OR PRIOR
VERSIONS TO PERFORM THIS MONITORING SETUP PROCEDURE.

NOTICE
Note:

This procedure must be followed exactly as written. Do not skip any steps for
any reason. For questions or assistance contact Technical Support before
proceeding.

5.4.4 UPS Setup Procedure

5.4.4.1 Introduction
The 9390 is shipped from the factory with Modem (Outcall) notification disabled.
The following steps provides details necessary to configure the 9390 to initiate
an automatic call to Eaton’s Call Center (CRC).

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Connectivity & Communication 9390 Service Manual

5.4.4.2 Modem Setup

1. Unpack the X-Slot modem.
2. Plug the Modem Card into an empty X-Slot: 1, 3, or 4 only.
See Section 5.3.9, Modem Card.
Note:
When powered up, only Data Terminal Ready (DTR) LED on the modem is lit.
3. Connect the phone line to the modem.
4. Clean up any loose wiring using tie wraps as necessary.

5.4.4.3 Modem (Outcall) Setup

1. To perform Setup using the XCP Service Tool:
a. Connect the laptop to the dedicated service port behind the top
dead front.
b. Using an authorized laptop computer, start the XCP Service Tool
Software (V3.05 or greater) and select the Modem (Outcall)
function tab. The software will begin communicating to the UPS
and displaying unit default data in the fields shown below. See
Figure 5-39, Modem Setup Screen .

Figure 5-39 Modem Setup Screen

c. Select the COM port the X-Slot modem is plugged into.

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9390 Service Manual Connectivity & Communication

– COM port = X-Slot, for example COM1 = X-Slot 1

d. Enter the Customer’s Name.
e. If UPS Type is blank, enter the UPS Type (9390)
f. If Modem Initialization String is blank, enter
AT&FE0V0X0&K0&D0&Q5S0=1T&W0&Y0
g. Enter the dedicated phone number for the UPS.
h. For Eaton Monitoring, select XCP for Phone 1 only. (Can not use
Phone 2.)
i. On the Phone Number Setup Area, select “Phone Number 1”
and enter:
– “ATD” and CRC phone number in Phone 1:
Phone No. (_888_) (_870-4192_)
Note:Remember to use a “9” or “8” and comma(s) if needed. See Figure 5-44,
Modem Setup Screen.
• Example: ATD9,18888704192, or ATD18888704192
j. If the site requires a 9 or 8 to be dialed enter a “9” or “8” (nine
comma or eight comma) before the number.

5.4.5 Programming UPS for EatonPW Monitoring

Note:
XCP Service Tool V3.05 does not support monitoring programming via the
Power Monitoring button on UPS units without Mini-CSB. Call Tech Support for
information.
XCP Service Tool V3.06 will soon be available to support UPS units without
Mini-CSB.
1. Go to the Events Tab and select the ‘Power Monitoring’ button. See
Figure 5-40, Alarm/Event Configuration .
Note:
Any previous custom nodes will be overwritten. They can be re-programmed
after this procedure.

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Connectivity & Communication 9390 Service Manual

Figure 5-40 Alarm/Event Configuration

2. A ‘Confirm’ message box appears in Figure 5-41 indicating a choice

asking you to continue. Select ‘Yes.’

Figure 5-41 Confirm Message Box

3. Programming occurs in the background and a ‘Writing Node’ box

appears in the lower-right part of the XCP Event Configuration
Screen. See Figure 5-40.
4. When completed, an ‘Events Configuration’ message box appears.
See Figure 5-42, Events Configuration Message Box.

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9390 Service Manual Connectivity & Communication

Figure 5-42 Events Configuration Message Box

5.4.6 Test Procedure

5.4.6.1 Preparation for Field Test
The system is now ready to be tested. The Eaton Call Center (CRC) must be
notified at this time that the system is now active. This test verifies that the
system is working. Confirm with them that you will be doing a test.
5.4.6.2 Field Test
1. With the XCP Service Tool, program Building Alarm 1 Node Bit #19 to
call out on Phone No. 1.
Note:
Building Alarm 2 can be substituted if Building Alarm 1 is being used.
2. Short Building Alarm 1 and verify it indicates active on the Front
Display.
3. The Front Display should indicate that the modem is attempting to call
out.
Note:
When modem is connected to the CRC, the Data Carrier Detect (DCD) LCD is
lit. The X-Slot Modem card illuminates, then the RX and TX will flicker.
4. Verify that the Eaton Call Center (CRC) received the proper
information from the call. Failure to verify may result in your Customer
not being properly monitored.
5. Deselect the modem call out for the Building Alarm and restore the
unit to its normal condition.
Note:Viewing Active Events from the Front Panel Display screen will abort the
current Modem (Outcall) function.
If having Modem (Outcall) problems, you may need to secure the Load and
Cycle Logic Power on the UPS and retry the test.

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5.5 CUSTOMER INFORMATION FORM

For the Customer to be properly monitored and receive their monthly reports,
the Customer Information Form must be completed and sent using the form’s
instructions.
The form is available on the Tech Support, Documentation, and Training web
site at: http://gstechsup.powerware.com/
In the web site, go to: Site Links/Download/CSE Laptop Support/. The Customer
Information Form file name is “EPW Mon CustInfo Form.dot.”
Download the form, fill it out, and e-mail it to: [email protected]
Note:
You must e-mail the Customer Information Form. Failure to do so may cause
the Customer site NOT to be monitored.
An example of the Eaton UPS Monitoring Customer Information Form is shown
on the next page in Figure 5-43.

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Figure 5-43 Example of Customer Information Form

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Connectivity & Communication 9390 Service Manual

5.6 Setup for 9390 REMOTE NOTIFY, CUSTOMER

PAGING -single module
NOTICE
Note:

This procedure applies to V03.05.00 and higher of the XCP Service Software
Tool.
The 9390 DSP Revision MUST be at Version 2.00 or higher.
If the Mini-CSB is used, then Mini-CSB must be Version 1.10 or higher.
Remote Notify for Customer Paging is supported. See Section 5.5 for the
Active Response Monitoring to CRC procedure.
Call Tech Support if you need more setup information help.

5.6.1 Scope
This document provides instructions necessary to setup a single module, 9390
for the Remote Notify, Customer Paging Service. This procedure does not apply
to multi-module parallel systems unless each module is being configured
independently with each unit having its own modem and phone line. Setup can
be done by using either the Front Panel or the XCP Service Tool. See Section
5.6.4.3, Outcall Setup.

5.6.2 General Notes

This procedure must only be performed by personnel trained and authorized by
Global Services for conducting service on this model UPS.
Prior to site visit, review all Field Service Bulletins (FSB) or other engineering
notifications so they may be completed during the same visit (if appropriate).
Prior to performing any operations, read the entire setup procedure, including
the data sheets, to become familiar with the procedure and to ensure the
procedure is applicable to the system in which monitoring will be performed.

5.6.3 Requirements

NOTICE
Note:

The modems used for Monitoring have been tested and proven to work
specifically with the 9390. Therefore, the modem used for this service, must be
either supplied by Eaton Corporation or approved at the discretion of Eaton
Corporation.

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5.6.3.1 Site Requirements:

Record the dedicated modem telephone numbers for this UPS on this sheet.
This line will be used for both incoming and outgoing UPS calls. It must be
known if a “9” or “8” is required in the dial string for the UPS to obtain an outside
line:
Modem telephone number (____) (__________)
Is a “9” -or- an “8” required for outgoing calls?YES___ NO___
Record on this sheet the Customer 24-Hour number that will be used to notify
the customer that the UPS has called for service.
Customer 24-Hour telephone number (____) (__________)

5.6.3.2 CSE Equipment & Software Requirements:

Ensure that the XCP Service Tool Software is V03.05.00 or newer and has been
authorized for the laptop from which this procedure will be performed.
• X-Slot Modem Card. See Table 5-1, X-Slot Connectivity Device Options in
Section 5.3.
• DSP Revision 2.00 or higher
• Mini-CSB 1.10, if used.
Note:
For setup on unit without Mini-CSB, call Tech Support. See Section 5.4.

CAUTION
USE ONLY THE XCP SERVICE TOOL SOFTWARE REFERENCED IN THIS
PROCEDURE. DO NOT USE ANY OTHER PROGRAMS OR PRIOR VERSIONS
TO PERFORM THIS MONITORING SETUP PROCEDURE.

NOTICE
Note:

This procedure must be followed exactly as written. Do not skip any steps for
any reason. For questions or assistance contact Technical Support before
proceeding.

5.6.4 UPS Setup Procedure

5.6.4.1 Introduction
The 9390 is shipped from the factory with Modem (Outcall) notification disabled.
The following steps provides details necessary to configure the 9390 to initiate
an automatic call to a Customer Pager.

5.6.4.2 Modem Setup

1. Unpack the X-Slot modem.

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Connectivity & Communication 9390 Service Manual

2. Plug the Modem Card into an empty X-Slot: 1, 3, or 4 only.

See Section 5.3.9, Modem Card.
Note:
When powered, only Data Terminal Ready (DTR) LED on the modem is lit.
3. Connect the phone line to the modem.
4. Clean up any loose wiring using tie wraps as necessary.

NOTICE
Note:

For more details on the Customer Paging Setup procedure 9390 Remote
Notify, Single Module, call Tech Support.

5.6.4.3 Outcall Setup

1. Customers can perform setup using the Front Panel:
a. On the Front Display panel select the “Setup” menu.
b. Enter the Service password.
c. Select “Modem Setup”
d. Select “Modem X Slot Setup. Select the X-Slot that the modem is
plugged into. (Highlight over selection and press “Select”).
e. In the Modem Setup Menu Select “Modem Init String” and enter
AT&FE0V0X0&K0&D0&Q5S0=1T&W0&Y0
f. In the Modem Setup Menu select “Unit Phone Number” and
enter the UPS phone number.
g. In the Modem Setup Menu select “Outcall Setup.”
h. In the Outcall Setup Menu select “Outcall Phone Number” and
enter:
– “ATD” along with the phone number in Phone 1: Customer
Pager Phone No. (____) (__________) plus desired Out Page
Number.
– “ATD” along with the phone number in Phone 2: Customer
Pager Phone No. (____) (__________) or another phone
number plus desired Out Page Number, if Pager is used.
– Remember to use a “9” or “8” and a comma if needed.
Example: ATD9,18005551212 or ATD5551212
Note:
Some pager numbers may require delays in the Outcall number to achieve
desired paging results (one or more commas can be used for delay purposes).
i. In the Outcall Setup Menu, select “Outcall Phone Type” and
select “Remote Notify.”

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9390 Service Manual Connectivity & Communication

Note:
The customer’s pager will only display the number programmed in the
Phone 1 or Phone 2 display or XCP Service Tool.
j. The modem is now set up. However the UPS is defaulted not to
call out so the Node Bits must be customized to activate the
modem.
– See Section 5.6.5, Customizing Node Bits for Remote Notify
with Mini-CSB Installed and Section 5.6.6, Customizing Node
Bits for Remote Notify without Mini-CSB Installed .
2. CSEs can perform setup using the XCP Service Tool:
a. Connect the laptop to the dedicated service port, a DB-9
Connector, behind the top dead front on the UPS above the
Power Modules.
b. Using an authorized laptop computer, start the XCP Service Tool
Software (V03.05 or greater) and select the MODEM function
tab. The software will begin communicating to the UPS and
displaying unit default data in the fields shown below. See Figure
5-44, Modem Setup Screen.

Figure 5-44 Modem Setup Screen

c. Select the COM port the X-Slot modem is plugged into

– COM port = X-Slot, for example COM1 = X-Slot 1

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Connectivity & Communication 9390 Service Manual

d. Enter the Customer’s Name

e. If UPS Type is blank, enter the UPS Type (9390)
f. If Modem Initialization String is blank, enter
AT&FE0V0X0&K0&D0&Q5S0=1T&W0&Y0
g. Enter the dedicated phone number for the UPS.
h. For Remote Notify select ASCII for Phone 1
i. On the MODEM Tab select “Phone #1” and enter:
– “ATD” along with the phone number in Phone 1: Customer
Pager Phone No. (____) (__________) plus desired Out Page
Number.
– Or select Phone #2
– “ATD” along with the phone number in Phone 2: Customer
Pager Phone No. (____) (__________) or another phone
number plus desired Out Page Number, if Pager is used.
Note:
Remember to use a “9” or “8” and comma(s) if needed.
See Figure 5-44, Modem Setup Screen.
– Example: ATD9,18005551212, or ATD5551212
Note:
Some pager numbers may require delays in the Outcall number to achieve
desired paging results (one or more commas can be used for delay purposes.)
j. If the site requires a 9 or an 8 to be dialed, enter a “9,” or “8,”
(nine comma or eight comma) before the number.

5.6.5 Customizing Node Bits for Remote Notify with Mini-

CSB Installed
1. Go to the Alarm/Events Tab and select the node bit that needs to be
set up to call out. See Figure 5-45, Alarm / Event Configuration
Screen .
2. Select which phone number is to be called when that node bit
becomes active. See Figure 5-46, Selection of Node Bit to Customize.
See Figure 5-45, Alarm / Event Configuration Screen .
Note:
With the Mini-CSB installed, all node bits can be configured to call out on either
or both phone numbers.

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Figure 5-45 Alarm / Event Configuration Screen

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Connectivity & Communication 9390 Service Manual

Figure 5-46 Selection of Node Bit to Customize

5.6.6 Customizing Node Bits for Remote Notify without Mini-

CSB Installed
With XCP Tool Version 3.05, or greater, a maximum of 32 node bits can be
customized. The Alarm/Event tab on the XCP Service Tool will operate similar to
the Alarm/Event tab with a Mini CSB with a configuration limit of 32 node bits.
See Section 5.6.5, Customizing Node Bits for Remote Notify with Mini-CSB
Installed. See Figure 5-47, Select Modem Phone Number 1, 2, or Both
(WithOUT Mini-CSB).
Note:
Without the Mini-CSB installed, only 32 node bits can be configured to call out
on either or both phone numbers.

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9390 Service Manual Connectivity & Communication

Figure 5-47 Select Modem Phone Number 1, 2, or Both (WithOUT Mini-CSB)

5.6.7 Test Procedure

5.6.7.1 Preparation for Live Field Test
The system is now ready for a live test. The customer must be notified at this
time that the system is now active. This test verifies that the system is working.

5.6.7.2 Field Test

1. With the XCP Service Tool, program Building Alarm 1 Node Bit #19 to
call out on one or both phone numbers.
Note:
Building Alarm 2 can be substituted if Building Alarm 1 is being used.
2. Short Building Alarm 1 and verify it indicates active on the Front
Display.
3. The Front Display should indicate the modem is attempting to call out.
4. Verify the customer received a page/phone call.
5. Deselect the modem call out for the Building Alarm and restore the
unit to its normal condition.
Note:
Viewing Active Events from the Front panel Display screen will abort the
current Modem (Outcall) function.
If you are having Modem (Outcall) problems, you may need to secure the Load
and Cycle Power on the UPS and re-try the test.

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Connectivity & Communication 9390 Service Manual

5.7 9390 HYPERTERMINAL COMMUNICATIONS

5.7.1 Basic Serial Communications
Hyper Terminal can be accessed through the XCP Service Tool reports tab.
This procedure may be useful if your XCP tool is not available.
Two serial ports, COM1 and COM2, are available with the standard unit. One of
the serial ports will be dedicated to an X-Slot. The other port is shared between
an X-Slot and (or exclusive) a local DB9 RS-232 port. The second X-Slot or DB9
can be used by either CSE service or the customer. See Section 5.3.10, CAN
Bridge Card for more details about Serial Ports.

NOTICE
Note:

For purposes of the following screens, some figures show 9355 UPS.
However, the UPS number 9390, would be entered into the Hyper Terminal
‘Connection Description’ screen instead. See Figure 5-23. The following
screens also show 9390: See Figure 5-50; and Figure 5-26, Properties and
Hyper Terminal.

5.7.2 Hyper Terminal Emulation Configuration for 9390 UPS

Click on the Start Button/Programs/Accessories/Communications/Click on
Hyper Terminal. See Figure 5-22.

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9390 Service Manual Connectivity & Communication

Figure 5-48 Path to Hyper Terminal Application

Click on HyperTerminal.exe.
Enter the file name, 9390, for the emulation and select an icon. When complete,
select OK. See Figure 5-23.

Figure 5-49 Hyper Terminal Opening Screen Selections

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Connectivity & Communication 9390 Service Manual

The Connect To window comes up. The screen says: ‘Connect To 9390.’
Connect using: COM1 or COM2. Select COM1 or COM2 from the active serial
port from the drop-down menu, and then click OK. See Figure 5-50, Select
COM1 or COM2 from Drop-Down Menu.

Figure 5-50 Select COM1 or COM2 from Drop-Down Menu

The COM1 or COM2 Properties window comes up. See Figure 5-25. Make the
following selections on the screen:
Table 5-6 Hyper Terminal Setup
Parameter Setting

Bits per Second 19200

Data Bits 8
Parity None

Stop Bits 1
Flow Control None

When complete, select OK.

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9390 Service Manual Connectivity & Communication

Figure 5-51 Port Parameter Setup

Go to the File menu on the Menu bar, click on Properties. The Properties screen
pops up. See Figure 5-26.

Figure 5-52 File, Properties Menu Options, Settings Tab, Emulation Drop-Down

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Connectivity & Communication 9390 Service Manual

The 9390 Properties window comes up. Click on the Tab labeled Settings.
In the window click on the Emulation pull down menu and select ANSI.
Go to the View menu on the Menu bar, click on Font, and ensure that the Font
selected is Terminal. See Figure 5-27.

Figure 5-53 Font Settings Menu

When you have completed the previous instructions – don’t forget to save your
new emulation. Go to File and select Save.
The following functions are available for the 9390 Terminal Emulation:
• ESC A - Current Active Events
• ESC B – Battery Test Queue
• ESC V - Video Mode
• ESC H – Set to Print out the History Log
• ESC L – Prints any new event (Real Time)
• ESC N – Prints Node Bit Setup
Note:
These buttons should be pressed sequentially, not simultaneously. Failure to
follow this procedure may cause communications to lock-up.
Entering Video Mode Example: Press and release the ESC key, wait 2 seconds,
and then press the V (Video Mode) key.

5.7.3 Hyper Terminal Log Capture Procedure

Use the following procedure to capture and save event logs, battery test logs,
and such, on your laptop. See Figures 5-28, 5-29, 5-30, 5-31, and 5-32 to follow
the screens and procedure step-by-step.
From the main Hyper Terminal screen, select Transfer and click on Capture
Text in the drop down menu.

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9390 Service Manual Connectivity & Communication

Figure 5-54 Hyper Terminal Capture Text

The next screen will allow you to select where you want to save the captured
file. In this example the file will be saved to the desktop.

Figure 5-55 Hyper Terminal Capture Text

After selecting the file location, click start.

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Connectivity & Communication 9390 Service Manual

Figure 5-56 Hyper Terminal Capture Text Start Capture

For a 9390, press ESC H to capture the History log.

After completing the capture, select Transfer, Capture Text, Stop.

Figure 5-57 Hyper Terminal Capture Text Stop Capture

Minimize Hyper Terminal and you will find a text (.TXT) file on your desktop.

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Figure 5-58 Hyper Terminal Capture Text File on Desktop

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5.8 9390 COMMUNICATION ACCESS LEVELS

Ctrl. Svc.
Super Rem.
Default User Ctrl. with Eng.
User Ctrl.
Load Only

FUNCTION NAME L0 L1 L2 L3 L4 L5 L6

Change Password X X X X
Enter Password X X X X X X
Log Out X X X X X X

Contrast X X X X X X
Versions X X X X X X
Unit Type X X X X X X

Date & Time X X X X X

COM Port Setup X X X X X
Unit Name X X X X

Change User Password X X X X

Voltage Adjust X
Building Alarms X X X X

Modem Setup/Configuration - - - -
1. Modem Setup X X X X
2. Phone Number X X X X

Battery Test Setup X

Remote Control (XCP) X

COM Port Access Levels X X X

Controls X X X
Clear History X

Default Access Levels X X X

Load On/Off X X
Run Battery Test X

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X Available Function

Function Not Available

NOT for Customers;
Customer Service Engineer
only

5.8.1 Default Passwords

Level Access Password

0 Default -

1 User L1
2 Super User SUP
Remote
3 REM
Control

4 Control CTR
Control with
5 CTL
Load

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This page was left blank intentionally.

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 6
Options & Accessories
6.1 EATON® 9390 UPS Internal Options
For additional information and specific details pertaining to the setup and
configuration of each option, refer to sales brochures and product manuals in
the CD version or on the World Wide Web at: www.powerware.com.

6.1.1 Single or Dual-Feed Input

All 9390s are shipped as single-feed units. Refer to the following Installation &
Operation manuals:
• 80 kVA UPS with ABB Breakers, 164201535
• 80 kVA UPS with Cutler-Hammer Breakers, 164201603
• 160 kVA UPS with ABB Breakers, 164201554
• 160 kVA UPS with Cutler-Hammer Breakers, 164201604
In the field, single-feed jumpers can be removed to make the unit dual feed. If a
‘Sidecar’ is attached to the UPS, see “Parallel Tie / Maintenance Bypass
“Sidecar” Cabinet” on page 16.
The dual input feed option will contain an additional disconnect device (for
backfeed protection) and an additional set of terminals for landing the
customer’s cables. This option will be configured at assembly but may be a sold
upgrade by field service. Refer to the 9390 ‘Sidecar’ Installation & Operation
manual, 164201586.

6.1.2 Internal Maintenance Bypass Switch (400V Units Only)

See Figure 6-1, Internal Maintenance Bypass (MBP) Block Diagram.
An internal maintenance bypass switch will be an option on the 20 kVA and 80
kVA 400 V models.
Position Number “1” (BYPASS)
Position Number “2” (NORMAL)

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Options & Accessories 9390 Service Manual

OPTIONAL INTERNAL
MAINTENANCE BYPASS SWITCH
(MBS) BYPASS
POSITION (1)

Static
Bypass

Rectifier Inverter
NORMAL
POSITION (2)

Figure 6-1 Internal Maintenance Bypass (MBP) Block Diagram

6.1.3 Internal Service / Bypass Switch (ISS / ISB)

See information in Chapter 1, System Overview, Section 1.3.4, BYPASS Mode
with Internal Service Switch Option. See Figure 6-2, 80 kVA Terminal Block
TB3, ISB Contactor and Snubber.

Figure 6-2 80 kVA Terminal Block TB3, ISB Contactor and Snubber

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9390 Service Manual Options & Accessories

The original Internal Service Switch design required removal of the dead fronts
to access the switch (see Figure 6-2). The more recent design includes a handle
that extends through the UPS front cover, behind the door, allowing the
customer to use the ISS (see Figure 6-3). Functionality remains identical.
If the optional Internal Service Switch (ISS) is installed, the CSE (or customer
with the new configuration) has the ability to put the load in Bypass, shut down
the Power Modules, and secure the Logic Power. Power supply connectors
have extensions on them, providing an accessible plug to disconnect securing
input power to the power supplies while maintaining customer load with a
bypass wrap-around in the UPS. See Figure 6-4, ISS Depiction.
An Anderson connector is used between the output and the Static Switch to
allow disconnecting power from backfeeding to the Static Switch. This allows
removal of the Static Switch while continuing to support the load. This is a ‘Make
Before Break’ procedure to ensure Customer’s load is supported. Transfer the
ISS to bypass to make, then disconnect the Anderson to break.
Before restarting the UPS, unplug the in-line Anderson connector(s) in the
cabinet bottom. This disconnects the Static Switch output from the actual UPS
output, which is still hot through the ISS. Then command the unit to Bypass.
With the UPS in Bypass, connect the Anderson connector, connecting the Static
Switch to the output. It will carry some of the critical load current. The ISS
carries most of the critical load because it has a lower impedance than the static
switch SCRs. The Anderson connectors are disconnected as the last step of the
process.
The limitations with this line up are that no maintenance can be performed on
any contactors. Dangerous voltages still exist near the Static Switch and
Anderson connectors. Use caution when connecting and disconnecting.

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Options & Accessories 9390 Service Manual

Figure 6-3 208 Vac Internal Service Switch with Handle

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9390 Service Manual Options & Accessories

ISS
STATIC SWITCH

K5 ANDERSON
CONNECTOR

RECTIFIER INVERTER

K1 K3
RECTIFIER INVERTER

External
Disconnect
Internal
Service
BATTERY Switch

Figure 6-4 ISS Depiction

6.1.4 Sync Control

Connections for an external sync control module are provided as an option. This
will be a “configure-at-assembly” option but may be an upgrade sold by field
service.

6.1.5 Seismic Capability

Seismic stands will be provided as necessary. A non-operating seismic test will
derive test methods from NEBS GR-63-CORE, ANSI T1 329, or EN 60068-2 as
appropriate.

6.1.6 Power Conditioner Mode

Power Conditioner Mode means no batteries are required.
Power Conditioner Mode disables battery converter operation and alarms
associated with the battery. In this mode the unit is intended to run without a
battery and has been tested to withstand voltage sags and brownouts.

6.1.7 Convert an RT to Power Conditioner Mode

Use XCP Service Tool 3.04, or newer.

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Options & Accessories 9390 Service Manual

1. Click on Battery Options Tab. Enable Power Conditioner Mode. See

Figure 6-5.

Figure 6-5 Battery Options Tab, Enable Power Conditioner Mode

2. Go to the CTO Tab. Enter the CTO number from the unit label,
replacing digit #5 with the number “4”. If the CTO number is valid, go
to Step 3.

NOTICE
Note:

However, if the CTO number is invalid, the XCP Service Tool does not have a
Setup File available. In this situation, use the previous CTO number. See
Figure 6-6.

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9390 Service Manual Options & Accessories

Figure 6-6 CTO Tab, Invalid CTO

3. The unit is now setup for Power Conditioner Mode, even if you did not
change the CTO number.
4. If you want to return to an RT setup, perform these same Steps 1.
through 3. However, deselect the Power Conditioner Mode (Figure 6-
5) and change the CTO number (Figure 6-6).

NOTICE
Note:

When the UPS unit is configured as a power conditioner, disregard all of the
battery setup requirements. See Section 3.1.2, Electrical Inspection, for more
details.

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Options & Accessories 9390 Service Manual

6.2 NEUTRAL-FORMING TRANSFORMER FIELD

KITS
The neutral-forming transformer field kit is available as a factory-installed or a
field-installed kit for the 80 kVA and 160 kVA 9390. These kits can only be
installed on an 80 kVA or 160 kVA 480-volt, single feed 9390.

NOTICE
Note:

Do not install this kit on any dual-feed setup.

These kits must not be used when any load is connected phase-to-neutral. The
entire UPS load must be phase-to-phase. Remove any neutral-to-ground
bonding wire when this kit is installed. The only external connection to UPS
neutral bus (E12) is the wire from this kit.

Figure 6-7 Neutral-Forming Transformer

See Chapter 10, Spare Parts, Table 10-47 for assembly and part numbers.
See Chapter 11, Prints, for Assembly drawing details. See Drawing 106711188
for 80 kVA and 106711191 for 160 kVA UPSs.

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6.3 Frequency Converter / Voltage Converter

The XCP Service Tool now supports these two options using the XCP Service
Tools Option Tab to enable these options.
The following are conditions for the frequency converter option:
• The UPM is always rated at 0.8 pF.
• Transfers to bypass are disabled.

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Options & Accessories 9390 Service Manual

6.4 Energy Saver Mode

Energy saver mode is a service option. The unit CTO number determines ESM
functionality. ESM function is described in Chapters 1 and 4. Chapter 10
contains ESM upgrade kits. The kit will include all of the appropriate hardware
and instructions.
The following kits are available:
• US 400/480 MODEL 40 with any digit 8 and ALL OTHER MODELS WITH
DIGIT 8 OF THE SERIAL # = "B" OR HIGHER
For any unit except the Model 40, 400/480 volt, with digit 8 of the serial number
less than B:
• 208V MODELS 40 & 80 AND US 400/480V MODELS 120 & 160
• 9390 ESM UPGRADE KIT FOR 208V MODELS 120 & 160
• 9390 ESM UPGRADE KIT FOR US 400/480V MODEL 80

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6.5 ECT Extended Commissioning Test

The extended commissioning test is a service option for the customer. Contact a
senior field technician or sales representative to determine how to sell this
service to the customer. The extended commissioning test uses easy capacity
test to load the unit at various levels and generate reports that will be provided
to the customer.
A service ticket and scope of work is required for this test to be performed.

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Options & Accessories 9390 Service Manual

6.6 9390 Battery Options

The 9390 can be ordered with the optional internal battery configuration,
external VRLA batteries, or wet cell batteries.

6.6.1 9390 IT Internal Battery

The 9390 IT can have one to three battery strings installed. The battery trays are
connected red to black within the string and black to black or red to red between
strings. The battery string wires will have tie wrap tags on them to distinguish
them from the tray to tray connections.

Figure 6-8 9390 IT

6.6.2 VRLA Battery Cabinets

See Figure 6-9, 570mm & 1085mm Battery Cabinets.
Batteries will be offered in 570mm and 1085mm “Line-Up-and-Match” cabinets
in the following configurations:
• 192-cell battery cabinets

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9390 Service Manual Options & Accessories

• 216-cell battery cabinets

• 240-cell battery cabinets

Figure 6-9 570mm & 1085mm Battery Cabinets

6.6.3 Wet Cell Battery

Below is a sample wet cell battery configuration. The parameters used to
configure wet cells with the 9390 vary based upon the battery used. Consult
engineering prior to completing a wet cell installation. The battery vendor will
provide specifications used in the procedure below. This setup changes the
default settings for 9390 battery charging to accommodate flooded battery
characteristics.

Battery: EnerSys CX-13M

Specs: 1.215 S.G.; 586 W/cell (15 min);
Other values: 195AH (8hr); equalize 2.30VPC for 18 hours every 6 months;
charge 2.25VPC

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Configuration: 240 cell; single string

Note: The data for float, charge, and equalize are based on prior information
from EnerSys.
Note: The "initial freshening charge" of the wet cell batteries is not covered in
this document and is solely the responsibility of the battery supplier. This
should be done prior to battery installation.
The procedure below enables float mode, enables and schedules time based
equalize (180 day intervals), and disables the battery test. The XCP Service
Tool is required to change the battery charging setup on the 9390. The Battery
Options tab shows several boxes, each with a selection button. To select the
function, click over the button area and make sure it fills in.
1. Select Auto Battery Equalize. See Figure 6-10, XCP Service Tool
Battery Options Tab. Enter the following values on this page:
• Equalize Volt = 2.30 (Equalize VPC)
• Start Equal Time = 72 (Auto Equalize delay (hours))
• Equalize Duration = 18 (Auto Equalize duration (hours))

Figure 6-10 XCP Service Tool Battery Options Tab

2. Select Continuous Float Mode. See Figure 6-10, XCP Service Tool
Battery Options Tab. Enter the following values on this page:
• ABM Float Volt = 2.25(Normal charge mode VPC)
• Cont Float = 2.23(Continuous Float VPC)
• Cont Float Time = 4220(Continuous Float mode duration (hours))
Note this will generate an outside limits error (red box); ignore this.

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3. Select Disable Battery Test. (If the battery test is left enabled (default),
it will occur just before the Equalize Charge cycle. This is disruptive to
wet cell batteries.)
4. Select the Battery Startup tab. See Figure 6-11, XCP Service Tool
Battery Startup Tab. Confirm Cells = 240 and String = 1. Enter the
following value:
• Watt/Cell = 586 (Battery capacity in W/cell)

Figure 6-11 XCP Service Tool Battery Startup Tab

5. Select the EEPROM tab. Enter the following value:

• 314 = 195 aH rating for this battery

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Options & Accessories 9390 Service Manual

6.7 9390 EXTERNAL ACCESSORIES

For additional information and specific details pertaining to the setup and
configuration of each option, refer to sales brochures and product manuals in
chapter 10 of the CD version or on the World Wide Web at:
www.powerware.com.

6.7.1 Parallel Tie / Maintenance Bypass “Sidecar” Cabinet

In Figure 6-12, the Sidecar Cabinet attaches to the side of the UPS cabinet. The
Sidecar houses Parallel Tie equipment for the 80kVA 208 & 480 volt units as
well as the 160kVA 480 volt units. The Sidecar also houses the 2, 3, or 4
breaker Maintenance Bypass. The Maintenance Bypass breakers are available
as a high KAIC type.
• See Sidecar drawing numbers 9390INST-001GE and 9390INST-002GE in
Chapter 11, Prints.
• Refer to the 9390 Sidecar Installation and Operation manual, 164201586.

Figure 6-12 9390 With Attached Sidecar Cabinet

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6.7.2 External Maintenance Bypass (MBP)

See Figure 6-13, External Maintenance Bypass (MBP) Block Diagram.
An external maintenance bypass (provided by Eaton® or others) can be applied
to the system. There may be several different arrangements, but the function of
each is generally the same.
In most cases, some type of interlock is included with an MBP system. On TB2
pins 9 and 10, the 9390 provides a closed auxiliary contact when the output
contactor K3 is open. A building alarm is also available on TB1 pins 1 and 2 that
can be configured for UPS GOTO BYPASS when the MBP breaker is closed,
providing MBP auxiliary contacts are available.
Refer to the 9390 Installation and Operations manuals for more specific details
and installation drawings. Refer to vendor / customer drawings if the wrap
around hardware \ switchgear has been provided by others.

MBP
MAINTENANCE BYPASS

BYPASS MIS

RECTIFIER UPS CUSTOMER

LOAD

Externally Applied
Maintenance Wrap--Arounds
(2 Breaker Configuration)

MAINTENANCE BYPASS

BIB MBP
BYPASS

MIS
CUSTOMER
RECTIFIER UPS LOAD

Externally Applied
Maintenance Wrap--Arounds
(3 Breaker Configuration)

Figure 6-13 External Maintenance Bypass (MBP) Block Diagram

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6.7.3 Remote Emergency Power Off (REPO)

The REPO station contains a red push-button latching-type switch to open the
breakers and contactors and de-energize the critical load. A key is required to
reset the push-button. The REPO station is approximately 4.5 inches square
overall and may be flush or surface wall mounted. Maximum distance from the
UPS is 500 feet. Multiple REPO stations may be used with a single UPS. The
contacts must be wired in parallel.

6.7.4 Environmental Monitoring Probe (EMP)

Refer to Chapter 10 on the CD version of the manual for installation and
additional information. Also refer to Advanced Battery Management in Chapter
4, Section 4.3.5 and Section 4.3.6.7 for Battery Temperature Compensation
information.

6.7.5 Integrated Accessory Cabinet (IAC)

The IAC houses Parallel Tie equipment for the 160 kVA 208 volt units. The IAC
is also capable of housing an output distribution panel.

Figure 6-14 9390 Integrated Accessory Cabinet (Internal View)

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9390 Service Manual Options & Accessories

6.7.6 Thinline PDU (PCDU)

The power conditioning and distribution unit (PCDU) basic component is a high
performance three-phase insulated and shielded isolation transformer
manufactured by Teal Corporation. This option provides protection against
common-mode noise and spikes (neutral-ground potentials). It can also provide
the inrush and peak currents required by disk drives and modern switch mode
power supplies in today’s computer systems. The PCDUs are available in 75
kVA & 90 kVA models.
Refer to product manuals in chapter 10 of the CD version of this manual or at
www.powerware.com.

Figure 6-15 9390 with attached Thinline PDU.

6.7.7 Wall Mounted Maintenance Wrap-around

A Cutler-Hammer® wall-mounted manually-operated maintenance wrap-around
bypass is available. The addition of one or two switches for the bypass input
and/or rectifier input are available.

6.7.8 Remote Monitoring Panel (RMP II)

The Remote Monitor Panel (RMP II) provides remote indications of the UPS
status through eight back-lit LED indicator lamps. An audible horn (with silence
button) is also sounded with any of the alarm conditions. See Figure 6-16.

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Options & Accessories 9390 Service Manual

To test the indicator lamps and horn, depress and hold the horn button for 3
seconds. All lamps should light, and the horn will sound continuously until the
button is released.
The remote monitor panel is driven via a twisted pair of wires through the CAN
Bridge board. The remote monitor panel is fed by 120 Vac from the critical bus
power.

SYSTEM
NORMAL

Figure 6-16 Remote Monitor Panel II.

6.7.9 Relay Interface Module (RIM II)

An optional Relay Interface Module (RIM II) uses relay contact closures to
indicate the operating status and alarm condition of the UPS system. Up to two
optional accessories (RMPs or RIMs) can be installed. The RIM II has four 15–
pin connectors labeled J1 through J4.

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Figure 6-17 Relay Interface Module II.

6.7.10 Supervisory Contact Module (SCM II)

The Supervisory Contact Module (SCM II) provides remote indications of the
UPS status through eight, normally open (N.O.) or normally closed (N.C.), dry
relay contacts. This panel mimics the same general alarms as the UPS panel
and the RMP. Communication between the UPS and the contact module is
accomplished through a four-wire RS-485 serial connection. The contact
module can be placed anywhere in the facility within 500 feet maximum of the
UPS. The contact module can be flush mounted or surface mounted to a
desktop, console, or wall.

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Options & Accessories 9390 Service Manual

Figure 6-18 Supervisory Contact Module II.

6.7.11 Integrated Distribution Cabinets (IDC)

Figure 6-19 shows the 160 kVA 9390 Integrated Distribution Cabinet. Figure 6-
20 and Figure 6-21 show the 80 kVA and 160 kVA IDC cabinets in UPS Mode.
The Integrated Distribution Cabinet (IDC) can be installed as an adjacent or
remote stand alone unit; it is configurable and contains three main options:
• Maintenance Bypass (MBP)
• Transformers
• Distribution

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9390 Service Manual Options & Accessories

Figure 6-19 9390 Integrated Distribution Cabinet. (160 kVA)

Figure 6-20 and Figure 6-21 show all the available options installed in one
cabinet. For a more complete explanation of the IDC installation and operation,
refer to the IDC Installation & Operation manuals. These manuals are listed
in the Supporting Documents bookmark on the interactive CD of this
Service Manual:
• 164201546, 80 kVA IDC
• 164201560, 160 kVA IDC

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Options & Accessories 9390 Service Manual

AC INPUT AC INPUT
TO UPS TO BYPASS

RIB
(Optional)

TO UPS RECTIFIER
INPUT
BIB
(Optional)

TO UPS BYPASS
INPUT

MBP
Maintenance Isolation Switch

FROM UPS OUTPUT

Transformer

Output Distribution
Breaker (Optional)
OUTPUT TO LOAD OR OTHER
DISTRIBUTION PANELS

OUTPUT TO LOAD OR Output Lugs

DISTRIBUTION PANELS
42 Pole Panelboard
(Optional)

OUTPUT TO LOADS

PanelBoard
Input Circuit
Breaker

MAIN POWER FLOW IN UPS MODE

Figure 6-20 9390 Integrated Distribution Cabinet (80 kVA UPS Mode)

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Figure 6-21 9390 Integrated Distribution Cabinet (160 kVA UPS Mode)

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Options & Accessories 9390 Service Manual

6.8 Vycon Flywheel

The 9390 UPS is able to work with flywheel systems from several
manufacturers. Do not complete startup of a 9390 with flywheel attached without
training. The information below is meant only as an overview of system
connections and a brief discussion of flywheel and UPS interaction. Always refer
to the most recent documentation from the flywheel manufacturer and consult
Eaton UPS engineering for assistance.

6.8.1 9390 RT EEP Setup (without mini CSB) for 1 or more

Vycon Flywheels
Also see Chapter 11, Prints, for more information.

6.8.1.1 Configuration Requirements and Notes:

• The flywheel cabinet should arrive with an optional 48 UVR installed. It is
part number 9700011-00.
• The flywheel cabinet should also have an optional External Interface PCB
part # 22-00016-00.
• The 9390 UPS CTO digit 11 must specify 480V battery voltage (240 cell)
This digit should be V.
Note: UPS running at full rated load may not have sufficient power to recharge
the flywheel in a reasonable time. If the UPS input voltage is lower than
nominal (but still within normal limits), there will be limited power available to
recharge the flywheel.
• Clear the UPS Battery Setup Required bit, but do not set Battery
Commissioning Test. The BTR value will always indicate 2 minutes and
cannot be corrected.
• The UPS DSP code should be 2.12 or 5.0 or greater

6.8.1.2 Flywheel setup requirements:

The only setup requirement is to use the Vycon firmware that is appropriate for
the 9390 UPS.

Table 6-1 9390 Vycon Setup w/o CSB

EEP Value Comment

211 Bit 5 = 1 Set Bit 5 to enable rectifier to transition into out of phase input voltage waveform

262 1 Walk-in load time

This is a Bit word. These bits disable Battery test, Battery detection, ABM charge
310 7
mode, and enable Continuous Float mode. No other bits should be set.
325 231 Sets “Continuous” float voltage to 554 volts.

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Table 6-1 9390 Vycon Setup w/o CSB

Sets Battery UV per cell to 528V, which is above flywheel discharge voltage. Note:
332 220 this will generate a Shutdown Imminent warning as soon as flywheel starts
discharging.
334 3600 DCUV Time. This extends time to 1 hour to prevent early UPS shutdown.

348 672 Continuous Float Mode duration: 87 days

The following are EEP values that are related and important, but do not change for flywheel operation.
These should be confirmed during setup to assure proper operation.

312 240 This should be set already, but if CTO is wrong then override.
322 231 Sets “ABM” float voltage to 554 volts.
336 156 Absolute DCUV shutdown voltage. This is normal value of 374V.

206 bit 6 = 0 This disables Auto Battery Equalize: should already be 0

340 kVA set Battery Charge Current limit. Will be set according to kVA rating. Do not change.

6.8.2 9390 RT EEP Setup (with mini CSB) for 1 or more

Vycon Flywheels
Also see Chapter 11, Prints, for more information.

6.8.2.1 Configuration Requirements and Notes:

• The flywheel cabinet should arrive with an optional 48 UVR installed. It is
part number 9700011-00.
• The flywheel cabinet should also have an optional External Interface PCB
part # 22-00016-00.
• The 9390 UPS CTO digit 11 must specify 480V battery voltage (240 cell)
This digit should be V.
Note: UPS running at full rated load may not have sufficient power to recharge
the flywheel in a reasonable time. If the UPS input voltage is lower than
nominal (but still within normal limits), there will be limited power available to
recharge the flywheel.
• Clear the UPS Battery Setup Required bit, but do not set Battery
Commissioning Test. The BTR value will always indicate 2 minutes and
cannot be corrected.
• The UPS DSP code should be 2.12 or 5.0 or greater.

6.8.2.2 Flywheel setup requirements:

The only setup requirement is to use the Vycon firmware that is appropriate for
the 9390 UPS.

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Options & Accessories 9390 Service Manual

Table 6-2 9390 Vycon Setup w/o CSB

EEP Value Comment

211 Bit 5 = 1 Set Bit 5 to enable rectifier to transition into out of phase input voltage
waveform

262 1 Walk-in load time

310 7 This is a Bit word. These bits disable Battery test, Battery detection, ABM
charge mode, and enable Continuous Float mode. No other bits should be
set.

325 231 Sets “Continuous” float voltage to 554 volts.

332 220 Sets Battery UV per cell to 528V, which is above flywheel discharge voltage.
Note: this will generate a Shutdown Imminent warning as soon as flywheel
starts discharging.

334 3600 DCUV Time. This extends time to 1 hour to prevent early UPS shutdown.

348 672 Continuous Float Mode duration: 87 days

The following are EEP values that are related and important, but do not change for flywheel
operation. These should be confirmed during setup to assure proper operation.

312 240 This should be set already, but if CTO is wrong then override.

322 231 Sets “ABM” float voltage to 554 volts.

336 156 Absolute DCUV shutdown voltage. This is normal value of 374V.

206 bit 6 = 0 This disables Auto Battery Equalize: should already be 0

340 kVA set Battery Charge Current limit. Will be set according to kVA rating. Do not
change.

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6.9 LOAD SYNC CONTROL PROCEDURE

Each UPS (UPS-A and UPS-B) must be fully operational before this procedure
can be conducted. For new UPS installations, refer to the appropriate startup
procedure before attempting this procedure.
The Load Sync Control requires that each individual UPS be equipped with
Customer Terminal Block, TB6, and the harness configured for Load Sync
Control operation. If the Load Sync Control panel is being applied to UPS
equipment previously installed, or the Load Sync Terminal Block and harness
were not installed in the factory, a field installation kit must be obtained from the
parts center and installed.
Refer to the Upgrade Field Kits:
• P/N 103005705 (80 kVA 480V Only)
• P/N 103005706 (80 kVA 208V and 160 kVA 208V & 480V)

WARNING
Load Sync Control can only be applied to systems where the Bypass Input
and the Critical Bus Output of each UPS are of the same phase and voltage.

NOTICE
Note:

For Customer sites where the Load Sync is pre-installed, refer to the
“9390 Sync Control Installation and Operation Manual,”
Document No. 164201571. This I & O manual is included in the Interactive CD,
under “Supporting Documents.”
For Customer sites where Load Sync is being retrofitted, refer to “9390 Load
Sync Control Procedure,” Document No. 164700613, which is posted on the
Tech Support Web site. To download, go to: http://gstechsup.powerware.com.
Under “Site Links,” click “Downloads,” then “9390.”

6.9.1 Confirm Installation and Setup Software

1. Ensure the Sync Control harness is installed and connected within
both UPSs.
• See Figure 6-22, Load Sync Control TB-6 Wiring Diagram.
• See Figure 6-23, 9390 TB1 & TB2 and Load Sync Control TB1
Wiring Diagram.

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Options & Accessories 9390 Service Manual

To each additional
power supply

For 160 KVA

P5--7 E6 K5 -- 1L1

P5--1 E7 K5 -- 3L2

P5--3 E8 K5 -- 5L3
Power
Supply
Board
P--100 --1 --2 --3

No Load
Sync
Control:
Jumper --1 --2 --3
Installed J--100

TB--6
1

3
Phase ”A”

Phase ”B”

Neutral
} Bypass Voltage

Output Bus
} E9

E10

E11
4

7
Phase ”A”

Phase ”B”

Neutral
} Output Voltage

Neutral E12

9 Phase ”B” RTN

10

Figure 6-22 Load Sync Control TB-6 Wiring Diagram

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UPS System A
}
UPS System B
}
NEW TB2 1
2
1 BLDG Alarm 2
3
1 2 RETURN 4
2
5
3 ON Bypass (NO)
3
4 ON Bypass COM
4
5 1
5 Alarm Relay (NC) 2
3
6 6 Alarm Relay COM 4
5
7 7 Alarm Relay (NO) 6
7
8 8
8 Alarm Relay COM 9
9 10
11
10 9 On Inverter K3 AUX (NC) 12
13

10 On Inverter K3 AUX COM 14

15
16
17
18
19 19
20
20 21
21 22
} 23
UPS System A 22 24
23 25

UPS System B
} 24 26
27
25 28
26 29
30
31
32
33
34
NEW TB1 35
36
1 Remote EPO NC 37
38
39
1 2 Return 40
2 41
3 Remote EPO NO 42
3 43 D4
4 Return
44
45 D5
4
5 5 Batt Brkr [AUX]
6 6 Return
7 7 Batt Brkr +48 VDC, 1A
8 Batt Brkr Control
8
9
BLDG Alarm 1
Load Sync
10 9
10
Return Control
TB1

Figure 6-23 9390 TB1 & TB2 and Load Sync Control TB1 Wiring Diagram

2. Verify that the configuration jumper on TB1 (40-41) in the Load Sync
Control Panel is installed.

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3. Apply power to the input and bypass of UPS-A only, leaving UPS-B
completely off.
4. Place UPS-A on bypass with the Inverter Power Module off.
5. Setup UPS for Load Sync Control by enabling Remote Sync Control
as follows:
• Using the XCP Service Tool, V3.04 or newer, go to the Options
Tab and enable Load Sync Control.

6.9.2 Electrically Verify Hardware and Software Setups

1. Ensure the Load Sync Control System has been properly installed
using the procedure in the previous Section 3.4.1, Confirm Installation
and Software Setup.
2. Apply input and bypass power to both UPS-A and UPS-B.
• Ensure Load Sync Control panel is disabled (no light).
• Place Preferred Source Selector switch to the UPS-A position.
3. Start both UPS-A and UPS-B placing each UPS online in System
Normal
• No alarms or notices should be active
4. With both UPS-A and UPS-B in System Normal, disable transfer on
each UPS by placing a shorting jumper on TB1 in the Load Sync
Control Panel.
• UPS-A, short TB1-22, 23
• UPS-B, short TB1-24, 25
• Verify “Building Alarm 1” and “Bypass Source Out of Tolerance”
are active in the active alarms listing.
5. On one UPS at a time, place the Mode Switch to BYPASS and verify
UPSs do not transfer to bypass.
6. Remove shorting jumpers when finished.
Note:
If either UPS transfers to bypass, See Section 6.9.1, Confirm Installation and
Setup Software, for proper UPS logic setup.
The following sections are used to verify Sync Control Operation with UPS-A
and UPS-B:
• Section 3.4.3, Verify UPS-B with Load Sync S1 in A position
• Section 3.4.4, Verify UPS-A with Load Sync S1 in A position
• Section 3.4.5, Verify UPS-B with Load Sync S1 in B position
• Section 3.4.6, Verify UPS-A with Load Sync S1 in B position

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6.9.3 Verify Sync Control Operation from UPS-B with

S1=UPS-A
1. Enable the Load Sync Control panel by pressing Load Sync Enable
button on the Load Sync Panel.
• The pushbutton lamp should come on.
• UPS-A should have Active Master Source lamp lit.
• No other lamps should be lit.
2. Transfer UPS-B to battery to simulate a loss of sync source for UPS-
B. Verify Load Sync Control Panel.
• K5 in Control Panel pulls in.
• UPS-A should have Active Master Source lamp lit.
• UPS-B should have Synchronized to Load-A lamp lit.
Verify UPSs. UPS-A should be in System NORMAL. The front panel display on
UPS-B should read:
• “Input ACUV”
• “Building Alarm 1”
• “Utility Out of Tolerance”
• “Bypass Source Out of Tolerance”
• “UPS On Battery”
Using an oscilloscope, verify that both UPS-A and UPS-B outputs are in sync
with each other and with the utility bypass.

Ch 1: UPS-A Load V
Ch 2: UPS-B Load V
Ch 3: UPS-A Bypass V
Ch 4: UPS-B Bypass V

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3. Apply utility input voltage to UPS-B to simulate the return of the sync
source for UPS-B.
• K5 in control panel drops out.
• Both UPS-A and UPS-B should return to normal operation.
• Sync Control panel has UPS-A as Master Source.
4. With both UPSs in normal, and the Sync Control enabled, Transfer
UPS-B to BYPASS. Verify Load Sync Control Panel.
• K4, K5 do not pull in.
• UPS-B should become the Active Master Source (regardless of the
source selector switch position)
Verify UPSs. UPS-B is in BYPASS. UPS-A is in System NORMAL, no alarms.
5. Transfer UPS-B to System NORMAL
– Verify both UPS-A and UPS-B are operating in System
NORMAL with no alarms.
– UPS-A regains Active Master Source status.

6.9.4 Verify Sync Control Operation from UPS-A with

S1=UPS-A
1. Ensure that both UPS-A and UPS-B are operating in system normal
with no alarms.
• The Sync Control panel should have the Preferred Source Selector
in position UPS-A.
• Verify Sync Control panel has UPS-A as Active Master Source.
2. Transfer UPS-A to battery to simulate a loss of sync source for UPS-
A. Verify Load Sync Control Panel.
• K5 in Control Panel pulls in.
• UPS-A should have Active Master Source lamp lit.
• UPS-B should have Synchronized to Load-A lamp lit.
Verify UPSs. UPS-A has active alarms.
• “Bypass ACUV”
• “Input ACUV”
• "Utility Out of Limits”
• “Bypass Source Out of Tolerance”
• “UPS On Battery”
UPS-B has active alarms.
• “Building Alarm 1”
• “Bypass Source Out of Tolerance”

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Using an oscilloscope, verify both UPS-A and UPS-B outputs are in sync (no
sync with utility bypass).

Ch 1: UPS-A Load V
Ch 2: UPS-B Load V
Ch 3: UPS-A Bypass V
Ch 4: UPS-B Bypass V
3. Apply utility input voltage to UPS-A to simulate the return of sync
source for UPS-A.
• K5 in Control Panel drops out.
• Both UPS-A and UPS-B should return to normal operation.
• Sync Control panel has UPS-A as Master Source.
4. With both UPSs in NORMAL, and the Sync Control enabled, Transfer
UPS-A to BYPASS. Verify Load Sync Control Panel.
• K4, K5 do not pull in.
• UPS-A maintains Active Master Source status.
Verify UPSs. UPS-A is in BYPASS. UPS-B is in System NORMAL, no alarms
5. Transfer UPS-A to System NORMAL
• Verify both UPS-A and UPS-B are operating in System NORMAL
with no alarms.
• UPS-A maintains Active Master Source status.

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Options & Accessories 9390 Service Manual

6.9.5 Verify Sync Control Operation from UPS-B with

S1=UPS-B
1. Ensure both UPS-A and UPS-B are operating in System NORMAL
with no alarms.
• Place Preferred Source Selector switch to the UPS-B position.
• Verify the Sync Control panel has UPS-B as the Active Master
Source.
2. Transfer UPS-B to battery to simulate a loss of sync source for UPS-
B. Verify Load Sync Control Panel.
• K4 in control panel closes.
• UPS-B should have Active Master Source lamp lit.
• UPS-A should have Synchronized to Load-B lamp lit.
Verify UPSs. UPS-A with active building alarm.
• “Building Alarm 1”
• “Bypass Source Out of Tolerance”
UPS-B has Bypass Not Available alarm active.
• “Bypass ACUV”
• “Input ACUV”
• “Utility Out of Limits”
• “Bypass Source Out of Tolerance”
• “UPS On Battery”
Using an oscilloscope, verify both UPS-A and UPS-B outputs are in sync (no
sync with utility bypass).

6–36 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Options & Accessories

Ch 1: UPS-A Load V
Ch 2: UPS-B Load V
Ch 3: UPS-A Bypass V
Ch 4: UPS-B Bypass V
3. Apply utility input voltage to UPS-B to simulate the return of sync
source for UPS-B.
• K4 in Control Panel opens.
• Both UPS-A and UPS-B should return to normal operation.
• Sync Control panel has UPS-B as Master Source.
4. With both UPSs in NORMAL, and the Sync Control enabled, transfer
UPS-B to BYPASS. Verify Load Sync Control Panel.
• K4, K5 do not close.
• UPS-B maintains Active Master Source status.
Verify UPSs. UPS-B is in BYPASS. UPS-A is in System NORMAL, no alarms.
5. Transfer UPS-B to System NORMAL
• Verify both UPS-A and UPS-B are operating in System NORMAL
with no alarms.
• UPS-B maintains Active Master Source status.

© 2009 Eaton Corporation. Company Confidential. 6–37

Options & Accessories 9390 Service Manual

6.9.6 Verify Sync Control Operation from UPS-A with

S1=UPS-B
1. Ensure both UPS-A and UPS-B are operating in System NORMAL
with no alarms.
• Sync Control panel should have the Preferred Source Selector in
position UPS-B.
• Verify the Sync Control panel has UPS-B as the Active Master
Source.
2. Transfer UPS-A to battery to simulate a loss of sync source for UPS-
A. Verify Load Sync Control Panel.
• K4 in control panel closes.
• UPS-B should have Active Master Source lamp lit.
• UPS-A should have Synchronized to Load-B lamp lit.
Verify UPSs. UPS-A is with active alarms.
• “Bypass ACUV”
• “Input ACUV”
• “Utility Out of Limits”
• “Bypass Source Out of Tolerance”
• “UPS On Battery”
UPS-B is in System NORMAL.
Using an oscilloscope, verify both UPS-A and UPS-B outputs are in sync with
each other and with utility bypass.

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9390 Service Manual Options & Accessories

Ch 1: UPS-A Load V
Ch 2: UPS-B Load V
Ch 3: UPS-A Bypass V
Ch 4: UPS-B Bypass V
3. Apply utility input voltage to UPS-A to simulate the return of sync
source for UPS-A.
a. K4 in control panel opens.
b. Both UPS-A and UPS-B should return to normal operation.
c. Sync Control panel has UPS-B as Master Source.
4. With both UPSs in NORMAL, and the Sync Control enabled, Transfer
UPS-A to BYPASS. Verify Load Sync Control Panel.
• K4, K5 do not close.
• UPS-A should become the Active Master Source (regardless of the
source selector switch position).
Verify UPSs. UPS-A is in BYPASS. UPS-B is in System NORMAL, no alarms.
5. Transfer UPS-A to System NORMAL
• Verify both UPS-A and UPS-B are operating in System NORMAL
with no alarms.
• UPS-B regains Active Master Source status.

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This page was left blank intentionally.

6–40 © 2009 Eaton Corporation. Company Confidential.

 7
Removal / Replacement
7.1 Eaton® 9390 UPS Required Tools
[] 10mm Wrench and / or Adjustable Wrench
[] 1/2” Wrench and / or Adjustable Wrench
[] 10mm Nut Driver
[] 7/16” Nut Driver
[] 5/16” Nut Driver
[] 3/8” Ratchet
[] 4” 3/8” Extension
[] 10mm 3/8” Socket
[] 1/2” 3/8” Socket
[] 7/16” 3/8” Socket
[] 5/16” 3/8” Socket
[] HEX Socket Set with 3-4” lengths
[] 5/32” Hex Wrench
[] 6mm Hex Wrench 12” or longer
[] 12” 1/4” Flat Screwdriver
[] 12” #2 Phillips Screwdriver
[] 6” #2 Phillips Screwdriver
[] 6” Diagonal Cutters
[] 6” Tie Wraps
[] 4” Tie Wraps

© 2009 Eaton Corporation. Company Confidential. 7–1

Removal / Replacement 9390 Service Manual

WARNING
Two customer service engineers may be required to perform the removal
and replacement procedure for the smart gate drive board and the power
modules. The modules are heavy, cumbersome, prone to fall, and require
careful alignment during replacement.

CAUTION
After any type of power component/power module failure, all components
downstream of the output voltage sensing must be checked with an
ohmmeter prior to the first transfer attempt of the Inverter online
(particularly F7, F8, and F9). K3 may not be testable prior to a transfer
attempt, but should be considered as a first replacement component if
output voltage related symptoms exist after the fuses have been ruled
out.

7.2 SMART GATE DRIVE BOARD

7.2.1 Preparation

NOTICE
Note:

Prior to performing any maintenance, download the EEP Map and the Event
History Log.
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available, the
customer’s load must be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Software Tool, disable “AUTORESTART.”
7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

7–2 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

WARNING
If an ISS is used, logic power must be removed by disconnecting the
input power to the power supplies. In this situation, the lower section of
the UPS will still have dangerous voltages present.

8. Remove the screws on the control panel door (12 screws) and swing
open (door should open 180°). Care should be taken with harnesses
going to PCBs on the control panel assembly.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

7.2.2 Removal
1. Remove air filter and dead front on lower half of unit.
Note:
Some screws need only to be loosened to remove the lower dead front.
2. Remove upper dead front cover.
Note:
Some screws need only to be loosened to remove the upper dead front.
3. With NO ISS, verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
4. With an ISS, unplug power to the power supplies.
See Figure 7-1, Power Module Retaining Bracket.
5. Remove power module retaining bracket at top center of modules.

© 2009 Eaton Corporation. Company Confidential. 7–3

Removal / Replacement 9390 Service Manual

Figure 7-1 Power Module Retaining Bracket

See Figure 7-2, Double Wires Removed.

6. When replacing an SGDB on a front module, remove all lower back
wires connected to TB3 from contactors. Cut tie wraps as required.
7. When replacing an SGDB on a back module, first perform Step 6.
Also remove the color-coded wires to both modules on the side where
the board is located.
Note:
Wires are color coded; leaving the single wires on Terminal Block 3 (TB3) will
be a guide for reinstallation.

NOTICE
Note:

Black and White wires from both rectifier and inverter power modules are
combined on TB3. Gray and white wires look nearly alike under low lighting
conditions.

7–4 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

Figure 7-2 Double Wires Removed

See Figure 7-3, Power Module Tray Screw.

8. Remove the two side screws that secure the power module assembly
tray.

Figure 7-3 Power Module Tray Screw

See Figure 7-4, Fan Plugs FPP1 and FPP2.

9. Remove Fan Plugs FPP1 and FPP2 from FPJ1 and FPJ2.

© 2009 Eaton Corporation. Company Confidential. 7–5

Removal / Replacement 9390 Service Manual

Figure 7-4 Fan Plugs FPP1 and FPP2

10. After removing the required wires from TB3, the tray screws, and
unplugging the fans, relocate any power module wires to the sides so
they don’t interfere with power module assembly tray removal.
See Figure 7-5, Power Module Ribbon and CAT5 Cables (FRONT -->).
11. Cut tie wraps on front of power modules and unplug the ribbon and
CAT5 cables from the smart gate drive board on the SGDB being
replaced. Ensure each cable’s position is marked for reinstallation.
Carefully move cables clear of SGDB for removal.

7–6 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

Figure 7-5 Power Module Ribbon and CAT5 Cables (FRONT -->)

Note:
Black trays were used on older units; white trays are used on newer units.

Figure 7-6 Smart Gate Drive Board

CAUTION
Only pull the power module assembly tray out enough to access the first
module. Pulling the power module assembly tray out further may cause
the unit to tip forward and crush the technician. If the module to be

© 2009 Eaton Corporation. Company Confidential. 7–7

Removal / Replacement 9390 Service Manual

removed is in the back of the unit, both front modules must be removed
first.
12. Pull the power module assembly tray half way out of the unit along
with the Cap Pan Tray. Make sure the cables that were across the
front of the module are lifted up to allow the module to pass under.
13. When replacing either front power module smart gate drive board
(SGDB), the tray will slide out far enough to provide ample space to
replace it without removing the power module. See Figure 7-5, Power
Module Ribbon and CAT5 Cables (FRONT -->) and Figure 7-6, Smart
Gate Drive Board. If replacing only a front Power Module SGDB, skip
to Step 19.
See Figure 7-7, Removing (or Attaching) Black Module Clip.
14. When removing a rear SGDB, remove the black module clips located
on the top of the module. This clip insulates and supports the rectifier
and inverter modules.

Figure 7-7 Removing (or Attaching) Black Module Clip

Note:
Before packaging and returning older power modules to the Parts Center,
transfer the wire tie clips from the older power modules to the newer power
modules.

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9390 Service Manual Removal / Replacement

15. If the SGDB on the rear power module needs to be replaced, first
remove both front power modules from the unit. Then the back power
modules can be slid forward on the tray to access the rear SGDB.
16. Only remove tie wraps on the first group of cables on the side of the
module. (These cables go to the other module and must be removed
from the front module’s tray in order to remove the front module.)
See Figure 7-8, “Unlocking” the Power Module Assembly.
17. After removing the other module’s wires, move the wires out of the
way. Notice the black (or white) tray edge under the module to be
removed. Lift up on black (or white) tray edge to unlock the power
module from the power module assembly tray and pull slightly
outward. A flat-head screwdriver may come in handy.
Note:
Black trays were used on older units; white trays are used on newer units.

Figure 7-8 “Unlocking” the Power Module Assembly

18. Lift module out of power module assembly tray and place on work
bench.

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Removal / Replacement 9390 Service Manual

CAUTION
Be careful not to damage the power module circuit boards when
removing. The Smart Gate Drive Board is mounted on the outside of the
power module circuit board.
See Figure 7-9, Smart Gate Drive Board, Side View.
19. Removing the SGDB.
• Disconnect all plugs required to separate the SGDB from the
Power Module.
• While maintaining a 90° angle between the SGDB and the Power
Module, slowly remove the SGDB, ensuring that all 10 plastic
shrouds (small black cubes), stay intact on the inside of the Power
Module.

Figure 7-9 Smart Gate Drive Board, Side View

7–10 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

7.2.3 Replacement
See Figure 7-9, Smart Gate Drive Board, Side View.
1. Slowly insert the new SGDB into place, maintaining a 90° angle with
respect to the power module.
• After insertion, verify that all ten plastic shrouds (small black
cubes) stay intact on the inside of the power module. Also, ensure
that their corresponding pins are not bent.
See Figure 7-10, Power Module Assembly “Lock”.
2. If a power module was removed, lift the new module into the power
module assembly tray approximately 1-2 inches from center and slide
inward. You should hear a click as the black tray locks in on the
bottom (Be careful that the wires from the other module aren’t in the
way). Replace rear modules first, then the front ones.

Figure 7-10 Power Module Assembly “Lock”

© 2009 Eaton Corporation. Company Confidential. 7–11

Removal / Replacement 9390 Service Manual

Note:
Black trays were used on older units; white trays are used on newer units.
3. Re-attach black module clips at top of modules. See Figure 7-7,
Removing (or Attaching) Black Module Clip.
See Figure 7-11, Power Module Wire Routing and Tie Wrapping.
4. Arrange wires from rear module along the side of the front power
module tray and tie wrap to other wires to allow tray to slide back into
unit without damaging the wires.

Figure 7-11 Power Module Wire Routing and Tie Wrapping

5. Connect the CAT5 cable from other power module and the ribbon
cables. Slide the power module assembly tray in to finish making all
connections.
6. Install tie wraps on CAT5 cable and ribbon cable that come across the
front of the power module assemblies, securing them to the front of
the modules.
7. Install the two side screws that secure the power module assembly.
8. Reconnect Fan plugs P1 and P2 into fan assembly.
See Figure 7-12, TB3 Power Module Wiring and Tie Wrapping.

7–12 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

NOTICE
Note:

Use a torque value of 30 inch-pounds when tightening all connections on the

TB3 terminal board for power modules and capacitors.
9. Connect the power module wires to TB3. Bundle power module wiring
neatly across the front of the module with tie wraps as you reconnect
the wires to TB3. (The bundling and tie wrapping of the wires is critical
to closing the control panel door. If the wires are bunched up it will
prevent the door from closing properly.)

Figure 7-12 TB3 Power Module Wiring and Tie Wrapping

Note:
Gray and white wires look nearly alike under low lighting conditions.
10. Install module top retaining bracket.
11. Install top dead front.
12. Install bottom dead front and filter.
13. Close control panel door; check that all wires are situated in such a
manner as to not be pinched or broken in the door hinge.
14. Install outer skin door.

© 2009 Eaton Corporation. Company Confidential. 7–13

Removal / Replacement 9390 Service Manual

7.2.4 Recommissioning
1. Apply utility and bypass power to the UPS.
• Verify that the only alarm present is ‘Output ACUV.’
2. Verify firmware version of the new display. Flash to the latest version
if required.
3. Step through all display screens and verify that everything functions
properly.
4. Transfer load from Maintenance Bypass or Internal Service Switch
(ISS) and restore unit to Normal mode. Use the startup procedures in
Chapter 3, Installation and Startup.
5. Cycle unit between modes and verify that the unit transfers with no
problems.
6. Enable “AUTORESTART” if disabled earlier.

7–14 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

7.3 POWER MODULE (20-80 kVA)

7.3.1 Preparation

NOTICE
Note:

Prior to performing any maintenance, download the EEP Map and the Event
History Log.
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass or an ISS is not available, the
customer’s load must be shut down.
4. Remove outer skin door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Software Tool, disable “AUTORESTART.”
7. Following normal shutdown procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

8. Remove the screws on the control panel door (12 screws) and swing
open (door should open 180°). Care should be taken with harnesses
going to PCBs on the control panel assembly.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

7.3.2 Removal
1. Remove air filter and dead front on lower half of unit (ten screws).
Note:
Some screws need only to be loosened to remove the lower dead front.
2. Remove upper dead front cover (five screws).

© 2009 Eaton Corporation. Company Confidential. 7–15

Removal / Replacement 9390 Service Manual

Note:
Some screws need only to be loosened to remove the upper dead front.
3. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
See Figure 7-13, Power Module Retaining Bracket.
4. Remove power module retaining bracket at top center of modules.

Figure 7-13 Power Module Retaining Bracket

See Figure 7-2, Double Wires Removed.

5. Remove all double connected wires going to TB3 from power
modules. Cut tie wraps as required.
Note:
If only one power module is being replaced, remove all the lower black wires
from TB3 and the capacitor pan right-side screw. Pull capacitor tray out with
the Power Module tray. This limits the small power board wires to be removed.

NOTICE
Note:

Single wires on TB3 and lower power wires do not have to be removed. Wires
are color coded; leaving the single wires on TB3 will be a guide for
reinstallation. Black and White wires from rectifier and inverter power modules
are combined on TB3. Gray and white wires look nearly alike under low lighting
conditions.

7–16 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

Figure 7-14 Double Wires Removed

See Figure 7-15, Power Module Tray Screw.

6. Remove the two side screws that secure the power module assembly
tray.

Figure 7-15 Power Module Tray Screw

See Figure 7-4, Fan Plugs FPP1 and FPP2.

7. Remove Fan Plugs FPP1 and FPP2 from FPJ1 and FPJ2.

© 2009 Eaton Corporation. Company Confidential. 7–17

Removal / Replacement 9390 Service Manual

Figure 7-16 Fan Plugs FPP1 and FPP2

8. After removing all wires from TB3, the tray screws, and unplugging
the fans, relocate all power module wires to the sides so they don’t
interfere with power module assembly tray removal.
See Figure 7-17, Power Module Ribbon & CAT5 Cables (FRONT -->). Figure 7-
18, 9390 CAN Network 80 kVA CAT5 Cables, with Mini-CSB shows a schematic
of the 80 kVA CAN Network red rectifier cables and blue inverter cables with
their respective part numbers and Mini-CSB option.
Note:
Section 7.5 Subassembly Part Number 103003853 shows four CAT5 Control
Harness Cables in PRMS.
9. Cut tie wraps on front of power modules. Unplug the ribbon and CAT5
cables from the smart gate drive board on the module being replaced.
Unplug all cables from the Interface Board to the Power Modules.
Ensure each cable connection is marked. Carefully move cables clear
of SGDB for removal.

7–18 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

Figure 7-17 Power Module Ribbon & CAT5 Cables (FRONT -->)

Note:
Black tray edges are on older units, white tray edges are on newer units.

CAUTION
Only pull the power module assembly tray out enough to access the first
module. Pulling the power module assembly tray out further may cause
the unit to tip over forward. If the module to be removed is in the back of
the unit, both front modules must be removed first to prevent the unit
from tipping forward.

© 2009 Eaton Corporation. Company Confidential. 7–19

Removal / Replacement 9390 Service Manual

RECTIFIER 2 RECTIFIER 1

J14 J13
SMART GATE DRIVE BOARDS
Gate Drive Gate Drive
101073679--001 101073679--001
SMART GATE DRIVE BOARDS
Rect 2 INV 2
LOGIC CONTROL ID 2 ID 10
Temp 2 Temp 2
101073676--001 Jumper
152601536

J13 J14
Note: Always verify
part numbers on
PRMS before
ordering parts. 152601473--001
Red 152601473--002
Blue

REC
J38
J14 J13

Gate Drive Gate Drive

INTERFACE BD
101073651--001 101073679--001 101073679--001
152601473--003
Red Rect 1 INV 1
ID 1 ID 9
INV Temp 1 Temp 1
J39

J37
J14
J13

152601785--002
Jumper (If
Mini--CSB
not installed)
152601536 J3
Mini CSB 152601473--005
101073662--001 Blue
(option)

Figure 7-18 9390 CAN Network 80 kVA CAT5 Cables, with Mini-CSB

10. Pull power module assembly tray half way out of unit. Make sure the
cables that were across the front of the module are lifted up to allow
the module to pass under.
See Figure 7-18, 9390 CAN Network 80 kVA CAT5 Cables, with Mini-CSB.
11. Remove the black module clips located on the top of the module. Clip
holds the rectifier and inverter module together.

7–20 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

Figure 7-19 Removing (or Attaching) Module Clip

Note:
Before re-packaging and returning older Power Modules to the Parts Center,
transfer the Wire Tie Clips from the older Power Modules to the newer Power
Modules.
12. Only remove tie wraps on the first group of cables on side of module.
(These cables go to the other module and must be removed from the
front module’s tray in order to remove the front module.)
See Figure 7-8, “Unlocking” the Power Module Assembly.
13. After removing the other module’s wires, move the wires out of the
way. Notice the black (or white) tray under the module to be removed.
Lift up on black (or white) tray edge to unlock the power module from
the power module assembly tray and pull slightly outward.

© 2009 Eaton Corporation. Company Confidential. 7–21

Removal / Replacement 9390 Service Manual

Figure 7-20 “Unlocking” the Power Module Assembly

Note:
Black tray edges are on older units, white tray edges are on newer units.
14. Lift module out of power module assembly tray and place on work
bench.

CAUTION
Be careful of the circuit boards on the power module when removing. The
smart gate drive board is mounted on the outside of the power module
circuit board.
15. Follow the same removal procedure for each module to be replaced.

7–22 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

7.3.3 Replacement
See Figure 7-20, “Unlocking” the Power Module Assembly .
1. Lift new module into power module assembly tray approximately 1-2
inches from center and slide inward. You should hear a click as the
black tray locks in on the bottom. (Be careful that the wires from the
other module aren’t in the way.) Replace rear modules first, then the
front ones.

Figure 7-21 Power Module Assembly “Lock”

Note:
Black tray edges are on older units, white tray edges are on newer units.
2. Attach black module clips at top of modules.
See Figure 7-11, Power Module Wire Routing and Tie Wrapping.
3. Arrange wires from rear module along the side of the front power
module tray and tie wrap to other wires to allow tray to slide back into
unit without damaging the wires.

© 2009 Eaton Corporation. Company Confidential. 7–23

Removal / Replacement 9390 Service Manual

Figure 7-22 Power Module Wire Routing and Tie Wrapping

4. Connect CAT5 cable from other power module and ribbon cables; you
will have to push the power module assembly tray in to finish making
all of the connections.
5. Install tie wraps on CAT5 cable and ribbon cable that come across the
front of the power module assemblies, securing them to the front of
the modules.
6. Install the two side screws that secure the power module assembly.
7. Reconnect Fan plugs P1 and P2 into fan assembly.
See Figure 7-12, TB3 Power Module Wiring and Tie Wrapping.
8. Connect power module wires to TB3. Bundle power module wiring
neatly across the front of the module with tie wraps as you reconnect
the wires to TB3 (The bundling and tie wrapping of the wires is critical
to closing the control panel door. If the wires are bunched up it will
prevent the door from closing properly).

7–24 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

Figure 7-23 TB3 Power Module Wiring and Tie Wrapping

NOTICE
Note:

Use a torque value of 30 inch-pounds when tightening all connections on the

TB3 terminal board for power modules and capacitors.
Note: Gray and white wires look nearly alike under low lighting conditions.
9. Install module top retaining bracket.
10. Install top dead front.
11. Install bottom dead front and filter.
12. Close control panel door; make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
13. Install outer skin door.

7.3.4 Recommissioning
1. Check all unit fuses after replacing a failed power module.
2. Apply utility and bypass (if dual feed) power to UPS.
3. Verify firmware version of new display. Flash to latest version if
required.
4. Step through all display screens, verify everything functions properly.

© 2009 Eaton Corporation. Company Confidential. 7–25

Removal / Replacement 9390 Service Manual

5. Transfer load back from Maintenance Bypass, or ISS, and restore unit
back to NORMAL. Use the startup procedures in Chapter 3,
Installation and Startup.
6. Enable “AUTORESTART.”

7–26 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

7.4 POWER MODULE (100-160kVA)

7.4.1 Preparation

NOTICE
Note:

Prior to performing any maintenance, download the EEP Map and the Event
History Log.
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available, the
customer’s load must be shut down.
4. Remove outer skin door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Software Tool, disable “AUTORESTART.”
7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. In this situation, the lower section of
the UPS will still have dangerous voltages present.

8. Remove the screws on the control panel door and swing open (door
should open 180°). Care should be taken with harnesses connected
to the PCBs on the control panel assembly. See Figure 7-24, 100-160
kVA Power Modules and Power Supplies 3 and 4.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

7.4.2 Removal
1. Remove air filter and dead front on lower half of unit.
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Remove upper dead front cover.

© 2009 Eaton Corporation. Company Confidential. 7–27

Removal / Replacement 9390 Service Manual

Note:
The dead front panel screw holes are slotted, allowing easier removal.

Figure 7-24 100-160 kVA Power Modules and Power Supplies 3 and 4

3. Remove the right side dead front; use caution not to damage the
power supplies behind the dead front when removing it.
4. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery and DC Link TB3-5, TB3-6, and TB3-7.
• Bypass input E6, E7, and E8.
5. Remove power module retaining bracket at top center of modules.
6. Remove all double-connected wires going to TB3 from power
modules. Cut tie wraps as required.

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9390 Service Manual Removal / Replacement

NOTICE
Note:

Single wires on TB3 and lower power wires do not have to be removed.
Wires are color coded; leaving the single wires on TB3 will be a guide for
reinstallation.
Black and White wires from rectifier and inverter power modules are combined
on TB3.
7. If you are NOT removing Power Modules from right side of unit, skip
to Step 10.
8. Unplug the fans on the right side of the UPS going to Power Supplies
3 and 4.
9. Loosen, do not remove, the four screws holding the power supply
assembly to the sides. Once the screws are loosened, the whole
assembly can be lifted off the screws and set on the top of the unit.
See Figure 7-25, Power Supply Assembly Mounting Screws.

© 2009 Eaton Corporation. Company Confidential. 7–29

Removal / Replacement 9390 Service Manual

Figure 7-25 Power Supply Assembly Mounting Screws

10. Loosen the side screws that secure the power module assembly tray.
11. Remove Fan plugs P1 and P2 if removing the left side Power
Modules.

7–30 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

12. After removing all wires from TB3, the tray screws, and unplugging
the fans, relocate all power module wires to the sides so they don’t
interfere with power module assembly tray removal.
13. Cut tie wraps on front of power modules and unplug the ribbon and
CAT5 cables from the Interface Board on the control panel door.
14. Figure 7-26, 9390 CAN Network 160 kVA CAT5 Cables, with Mini-
CSB shows a schematic of the 160 kVA CAN Network red rectifier
cables and blue inverter cables with their respective part numbers and
Mini-CSB option.
Note: Section 7.5 Subassembly Part Numbers 103004206 and 103004514
contain six CAT5 Control Harness Cables.
15. Also unplug ribbon cables from the inter-cabinet pass through
connector. Move cables clear of module for removal.

CAUTION
Only pull the power module assembly tray out enough to access the first
module. Use caution with the location of the wires so they don’t get
pinched or cut during removal. If the module to be removed is in the back
of the unit, both front modules must be removed first to prevent the unit
from tipping forward.
16. Pull the power module assembly tray half way out of the unit.
17. Remove the black module clips located on the top of the module. The
clip holds the rectifier and inverter module together.
18. Only remove tie wraps on the first group of cables on side of module.
(These cables go to the other module and must be removed from the
front modules tray in order to remove the front module.)

© 2009 Eaton Corporation. Company Confidential. 7–31

Removal / Replacement 9390 Service Manual

152601473--005
152601473--002 Blue
Blue

J13

J14

J13

J14
Gate Drive INV 4
Gate Drive INV 3
101073679--001 ID 12 ID 11
Temp 4 101073679--001 Temp 3

Gate Drive Rect 4 Gate Drive Rect 3

INV
J41
ID 4 ID 3
101073679--001 101073679--001
J14 Temp 4 Temp 3

J13

J14

J13

INV
J39
FEED--
Jumper 152601473--001 THRU
Red Bd

REC
152601536 152601473--003

J40
152601473--009 Red
Blue
152601473--002
Blue

REC
J38
J13

J14

J13

J14
101073682--001

Gate Drive INV 2 Gate Drive INV 1

101073679--001 ID 10 ID 9
Temp 2 101073679--001 Temp 1

152601473--005 Note: Always verify part

Blue
numbers on PRMS before
Rect 2 Rect 1 ordering parts.
Gate Drive Gate Drive
ID 2 ID 1
101073679--001 Temp 2 101073679--001 Temp 1
J14

J13

J14

J13
152601473--001
Red
152601473--003 Red
152601473--008 Jumper (If
Red
Mini--CSB
not installed)
152601536
REC

INV
J39
J38

Mini CSB
LOGIC CONTROL J37 J3 101073662--001
INTERFACE BD
101073676--001 (option)
101073651--001

Figure 7-26 9390 CAN Network 160 kVA CAT5 Cables, with Mini-CSB

19. After removing the other modules wires, remove the wires from the
connectors on the power module being removed.
20. Notice the black (or white) tray under the module to be removed. Lift
up on black (or white) tray edge to unlock the power module from the
power module assembly tray and pull slightly outward.
21. Lift module out of power module assembly tray and place on work
bench.

CAUTION
Avoid damaging the smart gate drive board on the power module when
removing. The smart gate drive board is mounted on the outside of the
power module circuit board.
22. Follow the same removal procedure for each module to be replaced.

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9390 Service Manual Removal / Replacement

7.4.3 Replacement
1. Lift new module into power module assembly tray approximately 1-2
inches from center and slide inward. You should hear a click as the
black (or white) tray locks in on the bottom. (Be careful that the wires
from the other module aren’t in the way.) Replace modules in the rear
first then front.
2. Attach black module clips at top of module.
3. Arrange wires from rear module along the side of the front power
module tray and tie wrap to other wires to allow the tray to slide back
into the unit without damaging the wires.
4. Connect CAT5 cable from other power module and ribbon cables; you
will have to push the power module assembly tray in to finish making
all connections.
5. Install tie wraps on CAT5 cable and ribbon cable that come across the
front of the power module assemblies, securing them to the front of
the modules; reconnect all wires to the Interface Board and the inter-
cabinet pass through connector.
6. Install the side screw that secures the power module assembly.

NOTICE
Note:

If the right side modules were removed, reinstall the power supply assembly
and tighten side screws.
7. Reconnect Fan plugs into fan assembly that was removed.

NOTICE
Note:

Use a torque value of 30 inch-pounds when tightening all connections on the

TB3 terminal board for power modules and capacitors.
8. Connect power module wires to TB3. Bundle power module wiring
neatly across the front of the module with tie wraps as you reconnect
the wires to TB3. (The bundling and tie wrapping of the wires is critical
to closing the control panel door. If the wires are bunched up it will
prevent the door from closing properly.)
9. Install module top retaining bracket.
10. Install top dead front.
11. Install bottom dead front and dead front covering power supplies 3
and 4.
12. Close control panel door; make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.

© 2009 Eaton Corporation. Company Confidential. 7–33

Removal / Replacement 9390 Service Manual

13. Install outer skin door but don’t close it.

14. Remove Terminal board access panel.

7.4.4 Recommissioning
1. Apply utility and bypass (if dual feed) power to UPS.
2. Verify firmware version of the new display. Flash to the latest version
if required.
3. Step through all display screens and verify that everything functions
properly.
4. Transfer load back from Maintenance Bypass, or ISS, and restore unit
back to NORMAL. Use the startup procedures in Chapter 3,
Installation and Startup.
5. Enable “AUTORESTART.”

7–34 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

7.5 STATIC SWITCH ASSEMBLY (20-80kVA)

7.5.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available,
customer’s load must be shut down.
4. Remove outer skin door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Software Tool, disable “AUTORESTART.”
7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an Internal Service Switch is used, logic power must be removed by
disconnecting the input power to the power supplies. The lower section
of the UPS will still have dangerous voltages present.

8. Remove the screws on the control panel door (12 screws) and swing
open (door should open 180°). Care should be taken with harnesses
going to PCBs on the control panel assembly.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

7.5.2 Removal
1. Remove air filter and dead front on lower half of unit (10 screws).
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
See Figure 7-27, K5 Contactor Wiring, 208V & 480V Units.
3. Remove wires 2T1, 4T2, & 6T3 from bottom side of K5 contactor.

© 2009 Eaton Corporation. Company Confidential. 7–35

Removal / Replacement 9390 Service Manual

Figure 7-27 K5 Contactor Wiring, 208V & 480V Units

See Figure 7-28, E9, E10, & E11 Wiring, 208V & 480V Units.
4. Remove static switch output wires from E9, E10, and E11.

7–36 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

Figure 7-28 E9, E10, & E11 Wiring, 208V & 480V Units

5. Unplug P3, P8, and SP1 (GND) from the Static Switch board.
See Figure 7-29, Static Switch Hold-down Screws.
6. Loosen, do not remove, the two hold down screws located on left and
right of the static switch fan.
7. Slide static switch forward to clear screws, then lift slightly and pull out
using caution not to harm the plugs or harnesses located on the back
of the static switch board.

© 2009 Eaton Corporation. Company Confidential. 7–37

Removal / Replacement 9390 Service Manual

Figure 7-29 Static Switch Hold-down Screws

See Figure 7-30, Static Switch Plugs P2 & P4.

8. When the rear plugs are clear, unplug P2 and P4 from the Static
Switch board.

Figure 7-30 Static Switch Plugs P2 & P4

9. Remove static switch assembly from unit and set on table.

7–38 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

7.5.3 Replacement
1. Position the static switch in the bottom of the unit and plug in P2 and
P4.
See Figure 7-31, Static Switch Insertion (Rear View).
2. Tip the static switch assembly as you push it into the unit so the back
of the assembly clears the sheet metal above it and the insert slides
into the bottom slot.

Figure 7-31 Static Switch Insertion (Rear View)

3. Once the assembly is in position, lock it in under the screws on both

sides of the fan. Tighten down screws to secure the assembly.
4. Plug in P3, P8, and SP1 (GND) to the static switch board.
5. Attach output wires to E9, E10, and E11. Verify output wire installation
phase rotation.
6. Attach wires 2T1, 4T2, and 6T3 into bottom side of K5 contactor.
Verify output wire installation phase rotation.

7.5.4 Recommissioning
1. Install bottom dead front and filter.
2. Close control panel door; make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
3. Install outer skin door.
4. Apply utility and bypass (if dual feed) power to UPS.

© 2009 Eaton Corporation. Company Confidential. 7–39

Removal / Replacement 9390 Service Manual

5. Start UPS in BYPASS and verify K5 closed and the static switch is
gating.
6. Verify output on meter screen and front panel indicates the unit is in
BYPASS mode.
7. Transfer the unit to NORMAL and then back to BYPASS, verifying the
static switch is transferring normally.
8. Verify firmware version of the new display. Flash to the latest version
if required.
9. Step through all display screens and verify that everything functions
properly.
10. Transfer load back from Maintenance Bypass, or ISS, and restore unit
back to NORMAL. Use the startup procedures in Chapter 3,
Installation and Startup.
11. Enable “AUTORESTART.”

7–40 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

7.6 STATIC SWITCH ASSEMBLY (100-160kVA)

7.6.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available, the
customer’s load must be shut down.
4. Remove outer skin door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Software Tool, disable “AUTORESTART.”
7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. In this situation, the lower section of
the UPS will still have dangerous voltages present.

8. Remove the screws on the control panel door and swing open (door
should open 180°). Care should be taken with harnesses going to
PCBs on the control panel assembly.
• Tie wraps may have to be cut to provide the maximum opening of
the door.

7.6.2 Removal
1. Remove air filter and dead front on lower half of unit.
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
3. Remove wires from fuses on the static switch (mark for correct phase
rotation on reinstallation).

© 2009 Eaton Corporation. Company Confidential. 7–41

Removal / Replacement 9390 Service Manual

4. Unplug P3, P8, and SP1 (GRD) from bypass Control Board.
See Figure 7-29, Static Switch Hold-down Screws.
5. Loosen, but do not remove, the two hold down screws located on left
and right of the static switch fan.
6. Slide static switch forward to clear screws and then lift slightly and pull
out. Use caution not to harm the plugs or harnesses located on the
back of the bypass Control Board.
See Figure 7-30, Static Switch Plugs P2 & P4.
7. When the rear plugs are clear, unplug P2 and P4 from the bypass
Control Board.
8. Remove the wires from output terminals E9, E10, and E11 (mark
wires for reassembly with correct phase rotation). Push the wires
through the access hole in the sheet metal into the back of the unit.
9. Remove static switch assembly from unit with output wires attached
and set on table.

7.6.3 Replacement
1. Position the static switch in the bottom of the unit, allowing access to
fish the output wires back through the access hole and reconnect to
output terminals E9, E10, and E11. Ensure correct phase rotation.
2. Reconnect plugs P2 and P4
See Figure 7-31, Static Switch Insertion (Rear View).
3. Tip the static switch assembly as you push it into the unit so the back
of the assembly clears the sheet metal above it and the insert slides
into the bottom slot.
4. Once the assembly is in position, pull it forward to lock it in under the
screws on both sides of the fan. Tighten down screws to secure the
assembly.
5. Plug in P3, P8, and SP1 (GRD) to the bypass Control Board.
6. Reattach wires to fuses. Make sure you have them in the right
position or you will have a phase rotation problem.

7.6.4 Recommissioning
1. Install bottom dead front and filter.
2. Close control panel door, make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
3. Install outer skin door.
4. Apply utility and bypass (if dual feed) power to UPS.

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9390 Service Manual Removal / Replacement

5. Start UPS in BYPASS and verify K5 closed and the static switch is
gating.
6. Verify output on meter screen and front panel indicates the unit is in
BYPASS mode.
7. Transfer the unit to NORMAL and then back to BYPASS, verifying the
static switch is transferring normally.
8. Verify the firmware version of the new display. Flash to the latest
version if required.
9. Step through all display screens and verify that everything functions
properly.
10. Transfer load back from Maintenance Bypass, or ISS, and restore unit
back to NORMAL. Use the startup procedures in Chapter 3,
Installation and Startup.
11. Enable “AUTORESTART.”

© 2009 Eaton Corporation. Company Confidential. 7–43

Removal / Replacement 9390 Service Manual

7.7 STATIC SWITCH BOARD PCB (20-80kVA)

7.7.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available, the
customer’s load must be shut down.
4. Remove outer skin door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”
7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. In this situation, the lower section of
the UPS will still have dangerous voltages present.

8. Remove the screws on the control panel door (12 screws) and swing
open (door should open 180°). Care should be taken with harnesses
going to PCBs on the control panel assembly.
• Tie wraps may have to be cut to provide the maximum opening of
the door.

WARNING
Use ESD strap when replacing any Printed Circuit Board (PCB).

7.7.2 Removal
1. Remove air filter and dead front on lower half of unit (10 screws).
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.

7–44 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

• Bypass input E6, E7, and E8.

See Figure 7-27, K5 Contactor Wiring, 208V & 480V Units.
3. Remove wires 2T1, 4T2, & 6T3 from bottom side of K5 contactor.
See Figure 7-28, E9, E10, & E11 Wiring, 208V & 480V Units.
4. Remove static switch output wires from E9, E10, & E11.
5. Unplug P3, P8, and SP1 (GND) from static switch board.
See Figure 7-29, Static Switch Hold-down Screws.
6. Loosen the two hold down screws located on left and right of the static
switch fan.
7. Slide static switch forward to clear screws and then lift slightly and pull
out. Use caution not to harm the plugs or harnesses located on the
back of the static switch board.
See Figure 7-32, Static Switch SCR Gating Leads.
8. When the rear plugs are clear, unplug P2 and P4 from static switch
board.
9. Remove static switch assembly from unit and set on table.
10. Remove P5, P6, P7, and P10.
See Figure 7-32, Static Switch SCR Gating Leads.
11. Remove SCR gating leads.

Figure 7-32 Static Switch SCR Gating Leads

See Figure 7-33, Static Switch SCR Bus Bar Screws.

12. Remove SCR bus bar screws.

© 2009 Eaton Corporation. Company Confidential. 7–45

Removal / Replacement 9390 Service Manual

Figure 7-33 Static Switch SCR Bus Bar Screws

13. Remove static switch board from standoffs.

7.7.3 Replacement
See Figure 7-34, Static Switch PCB Fan Sensing Jumper J9 (Close-up).
1. Ensure jumper J9 is set correctly for the UPM in which it is being
installed.
• J9 On or Shorted for 80kVA (all voltages) & 400/480V 160kVA
UPMs
• J9 Off or Open for 208V 160kVA UPMs only
Note:
If Jumper J9 is set incorrectly, it will cause a false Fan Fail Alarm.

7–46 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

Figure 7-34 Static Switch PCB Fan Sensing Jumper J9 (Close-up)

2. Install new static switch board on standoffs.

See Figure 7-35, Static Switch SCR Gating Leads (Close-up).
3. Reconnect SCR gating leads. The wiring sequence is the same for all
three phases.

Figure 7-35 Static Switch SCR Gating Leads (Close-up)

4. Reinsert SCR bus bar screws.

5. Plug P5, P6, P7, and P10.

© 2009 Eaton Corporation. Company Confidential. 7–47

Removal / Replacement 9390 Service Manual

6. Position the static switch in the bottom of the unit and connect P2 and
P4.
See Figure 7-31, Static Switch Insertion (Rear View).
7. Tip the static switch assembly as you push it into the unit so the back
of the assembly clears the sheet metal above it and the insert slides
into the bottom slot.
8. Once the assembly is in position, lock it in under the screws on both
sides of the fan. Tighten down screws to secure the assembly
9. Plug in P3, P8, and SP1 (GND) to the static switch board.
10. Attach output wires to E9, E10, & E11. Make sure you have them in
the right position or you will have a phase rotation problem.
11. Attach wires 2T1, 4T2, & 6T3 into bottom side of K5 contactor. Make
sure you have them in the right position or you will have a phase
rotation problem.

7.7.4 Recommissioning
1. Install bottom dead front and filter.
2. Close control panel door; make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
3. Install outer skin door.
4. Apply utility and bypass (if dual feed) power to UPS.
5. Start UPS in BYPASS and verify K5 closed and the static switch is
gating.
6. Verify output on meter screen and front panel indicates the unit is in
BYPASS mode.
7. Transfer the unit to NORMAL and then back to BYPASS, verifying the
static switch is transferring normally.
8. Verify firmware version of the new display. Flash to the latest version
if required.
9. Step through all display screens and verify that everything functions
properly.
10. Transfer load back from Maintenance Bypass, or ISS, and restore unit
back to NORMAL. Use the startup procedures in Chapter 3,
Installation and Startup.
11. Enable “AUTORESTART.”

7–48 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Removal / Replacement

7.8 STATIC SWITCH BOARD PCB (100-160kVA)

7.8.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available, the
customer’s load must be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”
7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. In this situation, the lower section of
the UPS will still have dangerous voltages present.

8. Remove the screws on the control panel door and swing open (door
should open 180°). Care should be taken with harnesses going to
PCBs on the control panel assembly.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

WARNING
Use ESD strap when replacing any Printed Circuit Board (PCB).

7.8.2 Removal
1. Remove air filter and dead front on lower half of unit.
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.

© 2009 Eaton Corporation. Company Confidential. 7–49

Removal / Replacement 9390 Service Manual

• Bypass input E6, E7, and E8.

3. Remove wires from fuses on the static switch (mark for correct phase
rotation on reinstallation).
4. Unplug P3, P8, and SP1 (GND) from bypass Control Board.
See Figure 7-29, Static Switch Hold-down Screws.
5. Loosen, but do not remove, the two hold down screws located on left
and right of the static switch fan.
6. Slide static switch forward to clear screws and then lift slightly and pull
out. Use caution not to harm the plugs or harnesses located on the
back of the bypass Control Board.
See Figure 7-30, Static Switch Plugs P2 & P4.
7. When the rear plugs are clear, unplug J2 and P4 from the bypass
Control Board.
8. Remove the wires from output terminals E9, E10, and E11 (mark
wires for assembly with correct phase rotation). Push the wires
through the access hole in the sheet metal into the back of the unit.
9. Remove static switch assembly from unit with output wires attached.
10. Remove SCR gate leads (mark wires for reassembly).
11. Remove SCR bus bar screws.
12. Remove bypass Control Board from standoffs.
13. If replacing an SCR, remove the bus bar and output wire from the
SCR.

7.8.3 Replacement
1. Install new SCR, output wire, and bus bar if previously removed.
2. Install new bypass Control Board on standoffs.
3. Reinsert SCR bus bar screws.
4. Plug in SCR gate leads.
5. Position the static switch in the bottom of the unit, allowing access to
pull the output wires back through the access hole and reconnect to
output terminals E9, E10, and E11. Verify correct phase rotation.
6. Reconnect plugs J2 and P4.
See Figure 7-31, Static Switch Insertion (Rear View).
7. Tip the static switch assembly as you push it into the unit so the back
of the assembly clears the sheet metal above it and the insert slides
into the bottom slot.

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9390 Service Manual Removal / Replacement

8. Once the assembly is in position, pull it forward to lock it in under the

screws on both sides of the fan. Tighten down screws to secure the
assembly.
9. Plug in P3, P8, and SP1 (GRD) to the bypass Control Board.
10. Reattach wires to fuses. Make sure you have them in the correct
position or you will have a phase rotation problem.

7.8.4 Recommissioning
1. Install bottom dead front and filter.
2. Close control panel door; make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
3. Install outer skin door.
4. Apply utility and bypass (if dual feed) power to UPS.
5. Start UPS in BYPASS and verify K5 closed and the static switch is
gating.
6. Verify output on meter screen and front panel indicates the unit is in
BYPASS mode.
7. Transfer the unit to NORMAL and then back to BYPASS, verifying the
static switch is transferring normally.
8. Verify firmware versions. Flash to the latest version if required.
9. Step through all display screens and verify that everything functions
properly.
10. Transfer load back from Maintenance Bypass, or ISS, and restore unit
back to NORMAL. Use the startup procedures in Chapter 3,
Installation and Startup.
11. Enable “AUTORESTART.”

© 2009 Eaton Corporation. Company Confidential. 7–51

Removal / Replacement 9390 Service Manual

7.9 POWER SUPPLY BOARD PCB (20-80 & 100-

160kVA)
7.9.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass or an ISS is not available, the
customer’s load must be shut down.
4. Remove outer skin door by lifting up and away from hinge.
5. Remove secondary outer skin on 160kVA UPM.
6. Remove terminal board access plate for access to the DB9
connection.
7. Utilizing the XCP Service Tool, disable “AUTORESTART.”
8. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

9. Remove the screws on the control panel door and swing open (door
should open 180°). Care should be taken with harnesses going to
PCBs on the control panel assembly.
Note:
Tie wraps may be cut to provide maximum opening of door.

WARNING
Use ESD strap when replacing any Printed Circuit Board (PCB).

7.9.2 Removal
1. Verify all input power from utility, bypass, and battery has been
removed.
See Figure 7-36, Power Supply Cover.

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2. Lift black cover off front of Power Supply boards. Cut tie wrap on white
mylar cover over power supplies 3 and 4 in the 100-160 kVA version.

Figure 7-36 Power Supply Cover

3. On Power Supply Board, remove P1, P2, P3, P4, P5, and P6.
4. Remove power supply board from standoffs.

7.9.3 Replacement
1. Insert new power supply board on Control Board assembly standoffs.
2. Plug in P1, P2, P3, P4, P5, and P6.
Note:
J1 (from the Interface Board) gets plugged into PS1 on the 160kVA UPM and
PS2 on the 80kVA UPM.

7.9.4 Recommissioning
1. Install bottom dead front and filter.
2. Place black cover over power supply boards and slide onto standoffs.
• Black cover on PS1 & PS2 only
3. Apply utility and bypass (if dual feed) power to UPS.

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CAUTION
Dangerous voltages exist when power supply board black cover is
removed.See Figure 7-37, Power Supply LEDs D5 & D8 Lit.
4. Verify green LEDs D5 and D8 are lit on both boards and Display
board energizes.

Figure 7-37 Power Supply LEDs D5 & D8 Lit

5. Turn off utility and bypass (if dual feed) power to UPS.
6. Close control panel door so wires are not pinched at door hinge.
7. Install outer skin door.
8. Apply utility and bypass (if dual feed) power to UPS.
9. Restore unit back to normal conditions.
10. Verify firmware version of new display. Flash to latest version if
required.
11. Step through all display screens and verify that everything functions
properly.
12. Transfer load back from Maintenance Bypass, or ISS, and restore unit
back to NORMAL. Use the startup procedures in Chapter 3,
Installation and Startup.
13. Enable “AUTORESTART”.

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7.10 Interface & Control Board PCBs (20-80kVA)

7.10.1 Preparation

NOTICE
Note:

If the original Control Board is of an older firmware version than the new
replacement Control Board, all firmware versions within the module need to be
checked. Refer to the latest “Firmware Flashing Procedure,” on the Tech
Support Web site, and follow the steps up to, but NOT including flashing the
DSP Boot Loader, PLD and DSP, prior to removing the original Control Board.
Refer to the Tech Support Web site to see all the latest firmware, versions, and
downloads. Go to: http://gstechsup.powerware.com/. Under “Site Links,” click
on “Firmware.” Scroll down to “9390 Field Firmware and Flashing Procedure,
Part Number 164700603.”

NOTICE
Note:

In 2008, EATON released both a new common Control Board and new
common Interface Board. The following units use the common Control Board:
the 9395 ISBM and UPM, 9390, and all 9x55 product lines. The 9395 ISBM and
the 9390 both use the common Interface Board.
The standardized Interface Board is installed in all 9390 UPS systems in
production after January 2008 beginning with the serial numbers greater than
EB05xxxxx. The new standardized boards must be installed as a pair. They
cannot be installed in conjunction with old boards in the same unit. Individual
units in a parallel system can contain old and new board sets and still work
together. The old Control Board is no longer available from CPO.
The standardized Interface Board is shipped with plug P4 installed. P4
identifies the board to the XCP Service Tool as a 9395 component. When using
the standardized Interface Board in the 9390, the P4 plug must be removed.

7.10.2 Procedure
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an optional Internal Service Switch (ISS) is installed, transfer
the load to the internal maintenance wrap. See Section 1.3.4,
BYPASS Mode with Internal Service Switch Option.
Note:
If you are troubleshooting a 208 or 480V UPS that has the Internal Service
Switch (ISS), you will not be able to start the unit because power is sensed on

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the output. To overcome this and bring the unit online without dropping the
customer’s load, disconnect the Anderson connectors between the Static
Switch and the output. The connector(s) are located in the bottom of the
cabinet and may not unplug easily. Then command the unit to Bypass. After
the UPS goes to Bypass, connect the Anderson connectors. This connects the
Static Switch to the output, and it will now be carrying some portion of the
critical load current. The ISS should be carrying most of the critical load current,
since it is a lower impedance, until it is opened as the last step of the process.

WARNING
Extremely dangerous voltages exist, so adhere to all safety requirements.
This step disconnects the Static Switch output from the actual UPS
output, which still has hot voltages through the ISS.

3. If external maintenance bypass, or an ISS, is not available,

customer’s load must be shut down.
4. Remove outer skin door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Software Tool, disable “AUTORESTART”.
7. If possible, before removing the original Control Board, download all
the board EEPROMs, including the calibration EEPs from the original
Control Board so they can be entered on the new Control Board as a
starting point for calibrations. Do this for EEPs 3002 through 3029.
Also, note all of the settings on the XCP Service Tool Battery Options,
Battery Startup, Options, and Building tabs.
8. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

9. Remove the screws on the control panel door and swing open (door
should open 180°). Care should be taken with harnesses going to
PCBs on the control panel assembly.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

WARNING
Use ESD strap when replacing any Printed Circuit Board (PCB).

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7.10.3 Removal
1. Verify all input power from utility, bypass, and battery has been
removed.
See Figure 7-38, Interface Board & Control Board .
2. On the Interface Board, unplug: P1, P2, P3, P5, P6, P7, P8, P12, P15,
P19, P21, P22, P25, P27, P30, P31, P36, P37, P38, P39.

Figure 7-38 Interface Board & Control Board

3. Lift both the Interface and Control Boards off the standoffs together.
4. Using ESD handling procedures, separate the Control Board from the
Interface Board.

7.10.4 Replacement
1. Reconnect the new Control Board and/or Interface Board with the
other PCB.
2. Mount the Control Board and the Interface Board together on the
control door assembly standoffs.
3. If you have installed a new Interface Board, verify that plug P4 has
been removed (old Interface Board do not have pins in J4).

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4. Connect plugs P1, P2, P3, P5, P6, P7, P8, P12, P15, P19, P21, P22,
P25, P27, P30, P31, P36, P37, P38, P39 to the Interface Board.
5. Close Control Panel door, ensure all wires could not be pinched or
broken near door hinge.
6. Install outer skin door but don’t close it.
7. Remove Terminal board access panel.

7.10.5 Recommissioning
The new Control Board from the Parts Center should be defaulted with 9155HV
code. If the new Control Board is used (as in, it has been previously installed in
another system for troubleshooting), or for some other reason is not defaulted
with 9155HV code, a kVA upgrade may also need to be performed. If so, a kVA
Authorization (Magic) Number will be required which is explained in 9.4.1 “kVA
RECONFIGURATION (UPGRADE) INSTRUCTIONS”.
For the latest 9390 firmware, and “Firmware Flashing Procedure,” refer to the
Tech Support Web site. To see all the latest firmware, versions, and downloads,
go to: http://gstechsup.powerware.com/, the Eaton Global Services
Documentation, Technical Support, and Training Web site. Under “Site Links,”
click on “Firmware.” Scroll down to “9390 Field Firmware and Flashing
Procedure, Part Number 164700603.”
With the release of the mandatory CSB version of the 9390 in Q4 of 2008,
engineering has released two code packages for the 9390. Code version 2.12
will be used for units that do not contain a mini-CSB. All units that do contain a
mini-CSB must be flashed with 5.XX code.
When replacing only the Control Board:
1. When logic power is applied to the UPS, the display will ask what
values you would like to use: “Control Board” or “Interface Board.”
Select the “Interface Board” if replacing the Control Board, and the
system was running normal, copy setups from the Interface Board
when asked.
2. If replacing the Control Board, and the system was having issues,
copy the setups from the new Control Board.
3. When the setup is completed, cycle Logic Power.
4. With Logic Power only applied, connect the XCP Service Tool.
Note:
CTO, serial number, and custom settings will have to be reloaded - if setups
were downloaded from the Control Board.
Note:
At no time when flashing, should the unit be in Normal or Bypass Mode. The

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Customer load must be on Maintenance Bypass, Off, or on the optional Internal

Service Switch (ISS), if installed.
5. Use the “Flash Tab” on the XCP Service Tool. Verify that the latest
code on ALL boards is installed. If not, flash all boards to latest
released firmware version using the Flash Procedure.

WARNING
Do not perform any other functions until flashing is completed and the
reset is sent to the Digital Signal Processor (DSP).

6. Verify that DSP is at the latest firmware level; open the “PCB Tab,”
select the DSP, and click on “Start PCB Setup.”

WARNING
Do nothing else until the programming is completed.

7. Load Calibration EEP values from the previously removed Control

Board.
8. Perform the Calibration procedure in Section 6.3.
9. Transfer load back from Maintenance Bypass, or ISS, and perform a
Normal Startup using the Startup procedure in Chapter 3, Installation
and Startup. Verify calibrations and calibrate as required.
When replacing only the Interface Board:
With the release of the mandatory CSB version of the 9390 in Q4 of 2008,
engineering has released two code packages for the 9390. Code version 2.12
will be used for units that do not contain a mini-CSB. All units that do contain a
mini-CSB must be flashed with 5.XX code.
1. When logic power is applied to the UPS, the values are automatically
written to the mirror on the Interface Board. If the Interface Board was
previously used, then the display will ask which values to use, in this
case you would select “Control Board” for all requests.
2. Verify firmware version of the unit. Flash to the latest version if
required.
3. Step through all display screens and verify that everything functions
properly.
4. Transfer load back from Maintenance Bypass, or ISS, and perform a
start up procedure in accordance with the Service Manual Chapter 3,
including calibrations.
5. Use the startup procedures in Chapter 3, Installation and Startup.
6. Refer to the Calibration procedure in Section 6.3.

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7.10.6 Feedback from the Field

Tech Support has provided some helpful feedback from the field and new
information is being acquired and compiled regularly. Their knowledge may be
useful if you have had some problems with the recommissioning procedure, or
require further assistance.

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7.11 FAN ASSEMBLIES (20-80 & 100-160kVA)

7.11.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available, the
customer’s load must be shut down.
4. If FAN FAIL is the reason for this procedure, the Power Module (PM)
must remain on until verification of which fan has failed can be
ascertained from the LEDs on the power supply boards.
5. Remove outer door by lifting up and away from hinge.
6. Remove the right-hand door on 100-160kVA UPMs.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. In this situation, the lower section of
the UPS will still have dangerous voltages present.

7. Remove the screws on the control panel door and swing open (door
should open 180°). Care should be taken with harnesses going to
PCBs on the control panel assembly.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

CAUTION
Dangerous voltages exist when verifying LEDs
See Table 7-1, Fan LED Location Diagram; Figure 7-39, Power Supply Fan Fail
LEDs; and Figure 7-40, Fan Assembly and Numbering.
8. Using the LEDs on the power supply boards, verify which fan has
failed.

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• For the 160kVA UPM, the left fan assembly is fed from power
supplies 1 & 2; the right fan assembly is fed from power supplies 3
& 4.

Table 7-1 Fan LED Location Diagram

FAN POWER SUPPLY LED

1 PS-1 D-32
2 PS-1 D-31

3 PS-1 D-29
4 PS-2 D-32
5 PS-2 D-31

6 PS-2 D-29
1 PS-3 D-32
2 PS-3 D-31

3 PS-3 D-29
4 PS-4 D-32
5 PS-4 D-31

6 PS-4 D-29

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Figure 7-39 Power Supply Fan Fail LEDs

Figure 7-40 Fan Assembly and Numbering

9. Once the faulty fan has been identified, turn Power Module OFF. Shut
down UPS and secure all power to the unit.

7.11.2 Removal
1. Remove air filter and dead front on lower half of unit.

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Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
See Figure 7-41, Fan Plugs FPP1, FPP2, and Fan Assembly Screws.
3. Unplug FPP1 and FPP2 from fan assembly.
4. Remove the two screws holding in the fan assembly. See Figure 7-41
“Fan Plugs FPP1, FPP2, and Fan Assembly Screws”.

Figure 7-41 Fan Plugs FPP1, FPP2, and Fan Assembly Screws

5. Remove the fan assembly from the unit.

Note:
Fan assembly does not have the handle.
6. Turn the fan assembly over to access the fans.

7.11.3 Replacement
1. Remove failed fan and replace.
2. When reinserting the fan assembly, ensure it fits into the tray slides in
the unit.
3. Insert screws, the tray may need to be lifted to thread the screws in.
4. Connect in FPP1 and FPP2.
5. Install bottom dead front and filter.
6. Close control panel door; make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
7. Install outer skin door.

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8. Apply utility and bypass (if dual feed) power to UPS.

7.11.4 Recommissioning
1. Following start up procedures, start the unit in NORMAL.
2. Verify FAN FAIL alarm is cleared.
3. Verify tach signal on each fan. The tach signal from each fan can be
measured on the power supplies J2 Pin 3 to J3 Pin 2, J2 Pin 4 to J3
Pin 2, and J2 Pin 5 to J3 Pin 2. The tach. signal should be a 10V
square wave of approximately 130 Hz.
4. Verify firmware version of the new display. Flash to the latest version
if required.
5. Step through all display screens and verify that everything functions
properly.
6. If customer’s load is on External Maintenance Bypass, or ISS, place
unit in BYPASS and transfer the customer’s load back to UPS.
7. Restore system to NORMAL. Use the startup procedures in Chapter
3, Installation and Startup.
8. Enable “AUTORESTART.”

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7.12 HV & LV Capacitor Assembly (20-80 & 100

160kVA)
7.12.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available, the
customer’s load must be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”
7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

8. Remove the screws on the control panel door and swing open (door
should open 180°). Care should be taken with harnesses connected
to PCBs on the control panel assembly.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

7.12.2 Removal
1. Remove air filter and dead front on lower half of unit.
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
3. Remove all wires from TB3, except for single wire connections.

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• Remove power wires and DC fuse sensing (100-160 kVA units)

wires
4. Remove retaining nut & bolt on right side of tray.
See Figure 7-42, Capacitor Tray with EMI Capacitors and Figure 7-43,
Capacitor Tray with TB3.
5. Pull tray out with TB3 still attached to front.

Figure 7-42 Capacitor Tray with EMI Capacitors

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Figure 7-43 Capacitor Tray with TB3

See Figure 7-44, Capacitor Board Mounting Screw.

6. Remove capacitor board mounting screws.

Figure 7-44 Capacitor Board Mounting Screw

See Figure 7-45, Capacitor Board Spade Lug Connectors.

7. Remove capacitor board from capacitors.

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Figure 7-45 Capacitor Board Spade Lug Connectors

8. Flip tray on its side and remove cap retaining nuts.

9. Remove capacitors from tray.

7.12.3 Replacement
1. Install new capacitors and attach retaining nuts.
2. Flip tray upright, connect capacitor boards and install capacitor board
mounting screws.
3. Insert tray into unit
4. Connect DC fuse sensing (100-160 kVA units)
5. Install retaining nut & bolt on right side of tray.
6. Reconnect all wires to TB3; double-check all connections for location
and security.
7. Install dead front and filter.
8. Close control panel door, make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
9. Install outer skin door.
10. Apply utility and bypass (if dual feed) power to UPS.

7.12.4 Recommissioning
1. Following start up procedures, start the unit in NORMAL.
2. Verify < 2 Vac ripple on the DC link.
3. Verify firmware version of the new display. Flash to the latest version
if required.
4. Step through all display screens and verify everything functions
properly.

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5. If the customer’s load is on External Maintenance Bypass or ISS,

place unit in BYPASS and transfer the customer’s load back to UPS.
6. Restore the system to NORMAL. Use the startup procedures in
Chapter 3, Installation and Startup.
7. Enable “AUTORESTART.”

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7.13 DISPLAY ASSEMBLY (20-80 & 100-160kVA)

7.13.1 Preparation
1. Transfer the customer’s load to bypass. “Hot swapping” the display
can cause load loss.
2. If available, transfer the customer’s load to an external maintenance
bypass. Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass or an ISS is not available, the
customer’s load must be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”

WARNING
If an ISS is used, logic power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
Use ESD strap when replacing any Printed Circuit Board (PCB).

7.13.2 Removal
See Figure 7-46, Removing Display Assembly.
1. Slide display assembly to the right slowly to clear the holding clips.
• Alternate removal: Pull display assembly down to clear the top
holding clips then lift out.

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Figure 7-46 Removing Display Assembly

See Figure 7-47, Display CAT-5 Cable.

WARNING
If working on equipment that has exposed live electric circuits, OBSERVE
the following precautions: Do not wear jewelry, chains, metal frame
eyeglasses, or other personal metal objects

2. Unplug CAT5 cable (green) from display circuit board.

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Figure 7-47 Display CAT-5 Cable

7.13.3 Replacement
1. Plug the CAT5 cable into new display circuit board.
2. Lay display assembly up against the control door assembly. Position
the CAT5 cable in slot on door.
3. Slide assembly plastic tabs under sheet metal clips.

7.13.4 Recommissioning
1. Install outer door.
2. Apply utility and bypass (if dual feed) power to UPS.
3. Verify display panel powers up and is functioning properly.
4. Verify firmware version of the new display. Flash to the latest version
if required.
5. Step through all display screens and verify that everything functions
properly.
6. Verify firmware version of the new display. Flash to the latest version
if required.
7. Verify all display screens function properly.
8. If customer’s load is on External Maintenance Bypass or ISS, place
unit in BYPASS and transfer the customer’s load back to UPS.

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9. Restore system to NORMAL. Use the startup procedures in Chapter

3, Installation and Startup.
10. Enable “AUTORESTART.”

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7.14 Mini-Communication Server Board (CSB)

Note: This procedure is for units with pre 5.XX code only.
To troubleshoot and verify a failed CSB, see section 9.1.3 Communication
Server Board (CSB).
NOTE: New CBS are shipped with 9390 v5.0 CSB code installed. This code
package is not compatible with control board DSP version 2.12. If the customer
wants to keep v2.12 on the unit, you will be required to flash the DSP up to v5.0,
flash the CSB down to v1.16, then flash the DSP back down to v.2.12. Refer to
the applicable portions of the flashing procedure available online.
If the CSB is programmed with 9395 code, it will automatically enter bootloader
mode to allow flashing the 9390 code on the board. After the board has been
flashed to the correct code version, select the PCB Tab “Perform Script” button.
Choose the filename “Convert_9395_CSB_to_9390.dat.” This script file will
configure the unit’s node bits.
Ask the customer’s permission to transfer the load to maintenance bypass or
shutdown the load. To replace the board:
1. Remove the UPS service access upper dead front.
2. Remove the logic power connection P4, the terminal block, and both
ribbon cables to the X-Slots. Do not remove the CAN connection at
this time.
3. Carefully pop the board off of the standoffs and allow it to hang over
the dead front by the CAN wire while you install the new board.
4. Install the new board verifying the correct jumper settings.
5. Install the X-Slot ribbon cables, terminal block, and power connection
P4.
6. Move the CAN connection from the old board and to the new board.
7. Once the board is replaced, several alarms may be present. If the
CSB has a 9395 code installed, it will enter bootloader mode to allow
flashing.
Note: For the complete flashing procedure, refer to the 9390 Flashing
Procedure available on the technical support web site. The steps below are an
abbreviated version.
8. Connect the XCP Service tool to the service port.
9. Go to the Flash tab on the service tool and flash the CSB: (If a “C9
Enablement Failed” pop-up appears, acknowledge it and continue.)
• 9390_BLD_CSB_###.ROM
• 9390_CSB_INT_###-###_intFlash.ROM
• 9390_CSB_EXT_###-###_extFlash.ROM

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10. After the board has been flashed to the correct code version, select
the XCP Service Tool PCB Tab “Perform Script” button. Choose the
file “Convert_9395_CSB_to_9390.dat.” This script file will configure
the unit’s node bits.
11. Wait for the boards to sync. After they sync, cycle logic power.
12. Start the unit in bypass and verify the front display is functioning
properly.
13. Start the unit to Normal mode and perform transfers between bypass
and normal, verifying the front display and CSB operate correctly.

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7.15 DC LINK FUSES (100-160 kVA)

7.15.1 Preparation

NOTICE
Note:

Prior to performing any maintenance, download the EEP Map and the Event
History Log.
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass or an ISS is not available, the
customer’s load must be shut down.
4. Remove outer skin door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Software Tool, disable “AUTORESTART.”
7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

WARNING
If an ISS is used, Logic Power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

8. Remove the screws on the control panel door (12 screws) and swing
open (door should open 180°). Care should be taken with harnesses
going to PCBs on the control panel assembly.
Note:
Tie wraps may have to be cut to provide the maximum opening of the door.

7.15.2 Removal
1. Remove air filter and dead front on lower half of unit (ten screws).
Note:
Some screws need only to be loosened to remove the lower dead front.
2. Remove upper dead front cover (five screws).

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Note:
Some screws need only to be loosened to remove the upper dead front.
3. Verify no AC or DC voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
• TB-3 pins 1-11.
4. Remove Filter Capacitor Tray retaining bolt. TB-4 uses two retaining
bolts. See Figure 7-48, DC Link Fuse Location.

Figure 7-48 DC Link Fuse Location

5. Slide capacitor tray forward far enough to access the DC Link Fuses.
6. Replace fuses with fuses of the same rating. See Chapter 10, Parts,
for fuse part numbers.

7.15.3 Replacement
1. Install retaining nut & bolt on right side of tray.
2. Install dead front and filter.
3. Close control panel door, make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
4. Install outer skin door.

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5. Apply utility and bypass (if dual feed) power to UPS.

7.15.4 Recommissioning
1. Following start up procedures, start the unit in NORMAL.
2. Verify < 2 Vac ripple on the DC link.
3. Verify firmware version of the new display. Flash to the latest version
if required.
4. Step through all display screens and verify everything functions
properly.
5. If the customer’s load is on External Maintenance Bypass or ISS,
place unit in BYPASS and transfer the customer’s load back to UPS.
6. Restore the system to NORMAL. Use the startup procedures in
Chapter 3, Installation and Startup.
7. Enable “AUTORESTART” if it was disabled previously.

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7.16 INPUT CONTACTOR K1 (20-80 & 100-160 kVA HV

UNITS)
7.16.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
3. If external maintenance bypass is not available, customer’s load must
be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Using the XCP Service Tool, disable “AUTORESTART.”

WARNING
If an ISS is used, logic power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

7.16.2 Removal
1. Remove air filter and dead front on lower half of unit (10 screws).
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
3. Remove contactor wires from TB3-1, TB3-2, and TB3-3.
4. Remove wires from input fuses F1-2, F2-2, and F3-2.
5. Remove fuse block assembly and set aside.
6. Remove contactor wires from E1, E2, and E3. Remove tie wraps from
wires.
7. Remove auxiliary contact wires K1A1/A2 using long shaft 1/4” flat
screwdriver.

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8. Remove the screws holding the contactor to the assembly and

maneuver it to access and remove auxiliary contacts K1A3/A4.
9. Remove contactor K1 from the unit.

7.16.3 Replacement
1. Remove wires from the old contactor and attach to new contactor.
2. Maneuver the new contactor into the unit and connect mounting
screws.
3. Attach auxiliary contacts K1A1/A2 and X13/X14.
4. Attach wires to E1, E2, and E3.
5. Install input fuse assembly.
6. Attach wires to F1-2, F2-2, and F3-2.
7. Attach wires to TB3-1, TB3-2, and TB3-3.

7.16.4 Recommissioning
1. With a DVM, verify wiring from E1 to K1 and from the output of the K1
Contactor to TB3-1, repeat for each phase.
2. Install bottom dead front and filter.
3. Close control panel door; make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
4. Install outer door.
5. Apply utility and bypass (if dual feed) power to UPS.
6. Start UPS in BYPASS.
7. Using the control panel, start Power Module (PM).
8. After pre-charge, verify K1 closes and rectifier starts with no phase
rotation alarms.
9. Verify firmware version of the new display. Flash to the latest version
if required.
10. Step through all display screens and verify that everything functions
properly.
11. Transfer load back from Maintenance Bypass and restore unit to
NORMAL mode. Use the startup procedures in Chapter 3, Installation
and Startup.
12. Enable “AUTORESTART.”

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7.17 INPUT CONTACTOR K1 (20-80 & 100-160 kVA LV

UNITS)
7.17.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
3. If external maintenance bypass is not available, customer’s load must
be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”

WARNING
If an ISS is used, logic power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

7.17.2 Removal
1. Remove air filter and dead front on lower half of unit (ten screws).
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
See Figure 7-49, Contactor Wires Removed from E1, E2, and E3.
3. Remove contactor input wires from E1, E2, and E3. For dual feed,
also remove contactor wires from E6, E7, and E8.
Note:
Mark wires for correct phase rotation when reinstalling.

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Figure 7-49 Contactor Wires Removed from E1, E2, and E3

4. Remove black wires from rectifier input TB3-1, 2, and 3; neutral, TB3-
4 and 11; battery input, TB3-5 and 7; and inverter output, TB3-8, 9,
and 10.
See Figure 7-50, Disconnecting Wires from E1, E2, and E3 to K1.
5. Remove 1/2” bolts from E1, E2, & E3 disconnecting wires to K1.

Figure 7-50 Disconnecting Wires from E1, E2, and E3 to K1

See Figure 7-51, View of Tie Wrap to Cut.

6. On left side of contactor assembly, cut tie-wrap holding aux. contact
wiring.

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Figure 7-51 View of Tie Wrap to Cut

See Figure 7-52, Contactor Mounting Screw Removal.

7. Remove the four contactor mounting screws.

Figure 7-52 Contactor Mounting Screw Removal

See Figure 7-53, Fuse Bracket Close-up.

8. Loosen, but do not remove, fuse bracket mounting screws and lift the
contactor off of the screws.

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Figure 7-53 Fuse Bracket Close-up

See Figure 7-54, Fuse Bracket Bolts.

9. Remove 10mm bolts from bracket on fuse assembly and remove fuse
bracket from unit.

Figure 7-54 Fuse Bracket Bolts

10. Slide contactor to the right slightly and remove aux. contact wiring
from A1 & A2 and remove wires from the right side of K1 1L1, 3L2,
and 5L3.

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11. Slide contactor to the left slightly and remove aux. contact wiring from
X14, slide further left and remove aux. wire from X13.
12. Slide contactor to the left and forward to remove from system.
See Figure 7-55, Fuse Assembly Mounting Bolts Close-up.
13. Remove fuse assembly from K1 2T1, 4T2, and 6T3.

Figure 7-55 Fuse Assembly Mounting Bolts Close-up

7.17.3 Replacement
1. Attach fuse assembly to K1 2T1, 4T2, and 6T3 on new contactor.
2. Insert new contactor and attach auxiliary contacts to X14 and X13
with contactor held slightly left.
3. Slide contactor to the right and install aux contacts A1 and A2.
4. Attach fuse bracket to fuse assembly using the 10mm bolts.
5. Connect previously removed wires to K1 1L1, 3L2, and 5L3.
Note:
Make sure you have the correct phase rotation. The wires have color coded
tape to identify each phase – orange, brown, and yellow.
6. Lift contactor slightly and install fuse bracket on screws.
7. Install contactor mounting screws.
8. Tighten the fuse bracket screws.
9. Rearrange aux wires and install new tie-wrap.
10. Attach wires from K1 to E1, E2, and E3.

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Note:
Make sure you have the correct phase rotation. The wires have color coded
tape to identify each phase – orange, brown, and yellow.
11. Re-attach wires to TB3.
12. Reconnect contactor input wires to E1, E2, and E3. For dual feed,
also connect E6, E7, and E8.

7.17.4 Recommissioning
1. With a DVM, verify wiring from E1 to K1 and from the output of the K1
contactor to TB3-1. Repeat for each phase.
2. Install bottom dead front and filter.
3. Close control panel door; Ensure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
4. Install outer door.
5. Apply utility and bypass (if dual feed) power to UPS.
6. Start UPS up in BYPASS.
7. Using the control panel, start Power Module (PM).
8. After pre-charge, verify K1 closes and rectifier starts with no phase
rotation alarms.
9. Verify firmware version of the new display. Flash to the latest version
if required.
10. Step through all display screens and verify that everything functions
properly.
11. Transfer load back from Maintenance Bypass and restore unit to
NORMAL mode. Use the startup procedures in Chapter 3, Installation
and Startup.
12. Enable “AUTORESTART.”

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Removal / Replacement 9390 Service Manual

7.18 OUTPUT CONTACTOR K3 (20-80 & 100-160kVA

HV UNITS)
7.18.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
3. If external maintenance bypass is not available, the customer’s load
must be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”

WARNING
If an ISS is used, logic power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

7. Following normal procedures, shut down the unit and remove all input
power from utility, bypass, and battery.

7.18.2 Removal
1. Remove air filter and dead front on lower half of unit (10 screws).
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
3. Remove wires from K3 1L1, 3L2, 5L3, 2T1, 4T2, and 6T3.
4. Remove aux contact wires K3 A1, A2, X13, and X14 using a long
shaft 1/4” flat screwdriver.
5. Remove the screws holding the contactor to the assembly and
remove it from the unit.

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7.18.3 Replacement
1. Maneuver the new contactor into the unit and reinstall mounting
screws.
2. Attach aux contacts K3 A1, A2, X13, and X14.
3. Reconnect wires to K3 1L1, 3L2, 5L3, 2T1, 4T2, and 6T3.
Note:
Verify correct wiring and phase rotation.

7.18.4 Recommissioning
1. With a DVM, verify wiring from E9 to K3 and from the output of the K3
Contactor to TB3-8, repeat for each phase.
2. Install bottom dead front and filter.
3. Close control panel door, make sure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
4. Install outer door.
5. Apply utility and bypass (if dual feed) power to UPS.
6. Start UPS up in BYPASS.
7. Using the control panel, start Power Module (PM).
8. After pre-charge, verify K1 closes and rectifier starts with no phase
rotation alarms.
9. Verify firmware version of the new display. Flash to the latest version
if required.
10. Step through all display screens and verify that everything functions
properly.
11. Transfer load back from Maintenance Bypass and restore unit to
NORMAL mode; verify K3 closes and unit indicates NORMAL. Use
the startup procedures in Chapter 3, Installation and Startup.
12. Enable “AUTORESTART.”

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7.19 OUTPUT CONTACTOR K3 (20-80 & 100-160kVA

LV UNITS)
7.19.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
3. If external maintenance bypass is not available, customer’s load must
be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”

WARNING
If an ISS is used, logic power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

7. Following normal shut down procedures, shut down the unit and
remove all input power from utility, bypass, and battery.

7.19.2 Removal
1. Remove air filter and dead front on lower half of unit (10 screws).
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
3. Remove contactor input wires from E9, E10, E11, and E12.
Note:
Mark wires for correct phase rotation when reinstalling.
4. Remove black wires from rectifier input TB3-1, 2, and 3; neutral, TB3-
4 and 11; battery input, TB3-5 and 7; and inverter output, TB3-8, 9,
and 10.
See Figure 7-56, Wires Disconnected from E9, E10, E11 and E12 to K3.

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5. Remove 1/2” bolts from E9, E10, & E11 disconnecting wires to K3.

Figure 7-56 Wires Disconnected from E9, E10, E11 and E12 to K3

See Figure 7-52, Contactor Mounting Screw Removal.

6. Remove the four contactor mounting screws.
See Figure 7-53, Fuse Bracket Close-up.
7. Loosen, but do not remove, fuse bracket mounting screws and lift
contactor off screws.
See Figure 7-54, Fuse Bracket Bolts.
8. Remove 10mm bolts from bracket on fuse assembly, and remove
fuse bracket from unit.
9. Slide contactor to the right slightly, and remove aux. contact wiring
from A1, A2 and power wires from the right side of K3 1L1, 3L2, and
5L3.
10. Slide contactor to the left slightly and remove aux. contact wiring from
X14. Slide further left and remove aux wire from X13.
11. Slide contactor to the left and remove from system.
See Figure 7-55, Fuse Assembly Mounting Bolts Close-up.
12. Remove fuse assembly from K3 2T1, 4T2, and 6T3.

7.19.3 Replacement
1. Attach fuse assembly to K3 2T1, 4T2, and 6T3 on new contactor.

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2. Insert new contactor and attach aux contacts to X14 and X13 with
contactor slightly left.
3. Slide contactor to the right and install aux contacts A1 and A2.
4. Attach fuse bracket to fuse assembly using the 10mm bolts.
5. Connect previously removed wires to K3 1L1, 3L2, and 5L3.
Note:
Make sure you have the correct phase rotation. The wires have color coded
tape to identify each phase – orange, brown, and yellow.
6. Lift contactor slightly and install fuse bracket on screws.
7. Install contactor mounting screws.
8. Tighten the fuse bracket screws.
9. Rearrange aux wires and install new tie-wraps.
10. Attach wires from K3 to E9, E10, & E11.
Note:
Make sure you have the correct phase rotation. The wires have color coded
tape to identify each phase – orange, brown, and yellow.
11. Re-attach wires to TB3.
12. Reconnect contactor input wires to E9, E10, E11, and E12.

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7.19.4 Recommissioning
1. With a DVM, verify wiring from E9 to K3 and from the output of the K3
contactor to TB3-8. Repeat for each phase.
2. Install bottom dead front and filter.
3. Close control panel door. Ensure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
4. Install outer door.
5. Apply utility and bypass (if dual feed) power to UPS.
6. Start UPS up in BYPASS.
7. Using the control panel, start Power Module (PM).
8. After pre-charge, verify K1 closes and the rectifier starts with no
phase rotation alarms.
9. Verify firmware version on the display. Flash to the latest version if
required.
10. Step through all display screens and verify unit function.
11. Transfer load back from Maintenance Bypass and restore unit to
NORMAL mode. Verify K3 closes and unit indicates NORMAL. Use
the startup procedures in Chapter 3, Installation and Startup.
12. Enable “AUTORESTART.”

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Removal / Replacement 9390 Service Manual

7.20 BACKFEED PROTECTION CONTACTOR K5 (20-

80 & 100-160kVA HV UNITS)
7.20.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
3. If external maintenance bypass is not available, the customer’s load
must be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”

WARNING
If an ISS is used, logic power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

7. Following normal procedures, shut down the unit and remove all input
power from utility, bypass, and battery.

7.20.2 Removal
1. Remove air filter and dead front on lower half of unit (10 screws).
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
3. Remove wires from K5 1L1, 3L2, 5L3, 2T1, 4T2, and 6T3.
4. Remove aux contact wires K5 A1, A2, X13, X14, and X16 using a long
shaft 1/4” flat screwdriver.
5. Remove the screws holding the contactor to the assembly and
remove it from the unit.

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7.20.3 Replacement
1. Maneuver the new contactor into the unit and reinstall mounting
screws.
2. Attach aux contacts K5 A1, A2, X13, X14, and X16.
3. Reconnect wires to K5 1L1, 3L2, 5L3, 2T1, 4T2, and 6T3.
Note: Verify correct wiring and phase rotation.

7.20.4 Recommissioning
1. With a DVM, verify wiring from E6 to K5 and from the output of the K5
contactor to static switch fuse F4. Verify for each phase.
2. Install bottom dead front and filter.
3. Close control panel door. Ensure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
4. Install outer door.
5. Apply utility and bypass (if dual feed) power to UPS.
6. Start UPS up in BYPASS.
7. Verify UPS indicates in BYPASS and output power is present on the
meter screen.
8. Using the control panel, start Power Module (PM).
9. After pre-charge, verify K1 closes and rectifier starts with no phase
rotation alarms.
10. Push NORMAL. Verify K3 closes and unit indicates it’s online.
11. Transfer to BYPASS and verify the unit transferred to BYPASS and
output power is still present on the meter screen.
12. Verify firmware version of the new display. Flash to the latest version
if required.
13. Step through all display screens and verify that everything functions
properly.
14. Transfer load back from Maintenance Bypass and restore unit to
NORMAL mode. Verify K3 closes and unit indicates NORMAL. Use
the startup procedures in Chapter 3, Installation and Startup.
15. Enable “AUTORESTART.”

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Removal / Replacement 9390 Service Manual

7.21 BACKFEED PROTECTION CONTACTOR K5

(20-80 & 100-160 kVA LV UNITS)
7.21.1 Preparation
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
3. If external maintenance bypass is not available, customer’s load must
be shut down.
4. Remove outer door by lifting up and away from hinge.
5. Remove terminal board access plate for access to the DB9
connection.
6. Utilizing the XCP Service Tool, disable “AUTORESTART.”

WARNING
If an ISS is used, logic power must be removed by disconnecting the
input power to the power supplies. The lower section of the UPS will still
have dangerous voltages present.

7. Following normal procedures, shut down the unit and remove all input
power from utility, bypass, and battery.

NOTICE
Note:

Contactor K1 MUST be removed first, prior to removing K5.

7.21.2 Removal
1. Remove air filter and dead front on lower half of unit (10 screws).
Note:
The dead front panel screw holes are slotted, allowing easier removal.
2. Verify no voltages are present on:
• Rectifier input E1, E2, and E3.
• Battery input TB3-5 and TB3-7.
• Bypass input E6, E7, and E8.
3. Remove Contactor K1. See section 7.16 “INPUT CONTACTOR K1
(20-80 & 100-160 kVA HV UNITS)”.

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4. Separate wires to get access to K5 1L1 and remove wire from

contactor. This will allow the wire to move enough to access 3L2,
remove wire on 3L2, move out of the way and remove wire on 5L3.
Note:
One or more contactor wires at E12 may also have to be removed to provide
access back to K5.
5. On left side of contactor assembly cut tie wraps holding aux contact
wiring.
6. Remove wires on K5 2T1, 4T2, and 6T3 on left side of contactor.
See Figure 7-52, Contactor Mounting Screw Removal.
7. Remove the four contactor mounting screws.
8. Slide contactor to the right slightly and remove aux. contact wiring
from A1, A2, and power wires from the right side of K3 1L1, 3L2, and
5L3.
9. Slide contactor to the left slightly and remove aux. contact wiring from
X14 and X16. Slide further left and remove aux wire from X13.
10. Slide contactor to the left and remove from system.

7.21.3 Replacement
1. Install new contactor and attach aux. contacts to X14, X16, and X13
with contactor slightly left.
2. Slide contactor to the right and install aux contacts A1 and A2.
3. Install contactor mounting screws.
4. Connect previously removed wires to K5 2T1, 4T2, and 6T3 on left
side of contactor.
5. Connect previously removed wires to K5 1L1, 3L2, and 5L3, start with
the bottom wire and work your way up.
Note:
Make sure you have the correct phase rotation. The wires have color coded
tape to identify each phase – orange, brown, and yellow.
6. Re-install contactor K1. See 7.16 “INPUT CONTACTOR K1 (20-80 &
100-160 kVA HV UNITS)”.
7. Install new tie-wraps.
8. Re-attach wires to TB3.
9. Reconnect contactor input wires to E1, E2, and E3. Reconnect E6,
E7, and E8 for dual feed.
Note:
Any contactor wires at E12 that may have been removed must be reconnected.

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7.21.4 Recommissioning
1. With a DVM, verify wiring from E6 to K5 and from the output of the K5
contactor to static switch fuse F4. Verify for each phase.
2. Install bottom dead front and filter.
3. Close control panel door. Ensure all wires are situated in such a
manner as to not be pinched or broken near door hinge.
4. Install outer door.
5. Apply utility and bypass (if dual feed) power to UPS.
6. Start UPS up in BYPASS.
7. Verify UPS indicates in BYPASS and output power is present on the
meter screen.
8. Using the control panel, start Power Module (PM).
9. After pre-charge, verify K1 closes and rectifier starts with no phase
rotation alarms.
10. Push NORMAL, verify K3 closes and unit indicates it’s online.
11. Transfer to BYPASS and verify the unit transferred to BYPASS and
output power is still present on the meter screen.
12. Verify firmware version of the new display. Flash to the latest version
if required.
13. Step through all display screens and verify that everything functions
properly.
14. Transfer load back from Maintenance Bypass and restore unit to
NORMAL mode, verify K3 closes and unit indicates NORMAL. Use
the startup procedures in Chapter 3, Installation and Startup.
15. Enable “AUTORESTART.”

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 8
Calibration
8.1 Tools Required
• Laptop computer with XCP Service Tool installed.
• DB-9 cable to connect the laptop to the UPS.
• Calibrated Digital Volt Meter with current clamp.
• Tools to remove unit front covers.

8.2 General Calibration Information

Please follow the guidelines below for calibration.
1. All systems:
• Use the same multimeter throughout the process (meters can vary
by several volts).
• Take your readings at the same location on all units (avoid
measuring on TB-3 because of possible noise issues).
2. Parallel systems:
• All parallel units must be calibrated on startup.
• When calibrating parallel unit inverter output voltage, shut down all
units, including logic power, except the one you are calibrating.
Simply isolating unit outputs will result in unsatisfactory results, as
the units continue to try to load share when communicating over
the CAN.
• Inverter output voltages of parallel units must all measure within .5
volts of each other and the target voltage.

8.3 Voltage Calibration

NOTICE
Note:

CSEs can now automatically and quickly perform calibration procedures using
the XCP Service Tool with Version 3.04 and newer.

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Calibration 9390 Service Manual

Calibration is the procedure to adjust a given parameter, based on known or

proven information or data, to make that parameter more accurate or realistic.
Calibration scripts are available in the XCP tool on the PCB Tab. Select the
Perform Scripts feature. Choose and run the script appropriate to the unit.
Default calibration values will be set in the machine. Scripts are available for the
9390 208-220 volt, 20-80kVA; the 208-220 100-160kVA; the 480 volt 20-80kVA;
and the 480 volt 100-160 kVA models. Scripts are useful after replacing
hardware or if calibrations are not successful.
Scalar limits must be assigned for each parameter. Table 8-1, Scalar Limits and
Calibration Sequence below shows the nominal limits and calibration sequence
used for 9390 systems test, but may vary slightly in a customer’s unit.

Table 8-1 Scalar Limits and Calibration Sequence

Sequence Meter name EEP # Low Limit Hi Limit

1 Neutral Calibration 3069 0 100

2 Calibrate Input Volts, Ph B 3024 9000 10500
3 Calibrate Output Volts, Ph B 3023 9000 10500

4 Calibrate Bypass Volts, Ph B 3022 9000 10500

5 Cal Bypass Input Volts, Ph A 3019 9000 10500
6 Cal Bypass Input Volts, Ph B 3020 9000 10500

7 Cal Bypass Input Volts, Ph C 3021 9000 10500

8 Cal Bypass Current, Ph A 3008 9000 11000
9 Cal Bypass Current, Ph B 3009 9000 11000

10 Cal Bypass Current, Ph C 3010 9000 11000

11 Cal Battery Volts 3025 9000 10500

12 Cal Rail DC Link Volts 3026 9000 10500

13 Cal Inverter AC Output Volts, Ph A 3016 9000 10500
14 Cal Inverter AC Output Volts, Ph B 3017 9000 10500

15 Cal Inverter AC Output Volts, Ph C 3018 9000 10500

16 Cal Inverter Output Current, Ph A 3005 8000 10500
17 Cal Inverter Output Current, Ph B 3006 8000 10500

18 Cal Inverter Output Current, Ph C 3007 7500 10000

19 Cal LCD Phase A line to neutral 3031
20 Cal LCD Phase B line to neutral 3032

21 Cal LCD Phase C line to neutral 3033

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9390 Service Manual Calibration

Table 8-1 Scalar Limits and Calibration Sequence (Continued)

Sequence Meter name EEP # Low Limit Hi Limit

22 Cal LCD Phase A to Phase B 3034

23 Cal LCD Phase B to Phase C 3035

24 Cal LCD Phase C to Phase A 3036
25 Cal Utility AC Input Volts, Ph A 3013 9000 10500

26 Cal Utility AC Input Volts, Ph B 3014 9000 10500

27 Cal Utility AC Input Volts, Ph C 3015 9000 10500
28 Cal Utility Input Current, Ph A 3002 8000 10500

29 Cal Utility Input Current, Ph B 3003 8000 10500

30 Cal Utility Input Current, Ph C 3004 7500 10000

3028
31 Cal Batt Current (discharging) 3029
3012 8000 10500

Note:
New Control Board settings are 9500 when flashed with 9390 code. Setting
defaults 10000 causes several alarms and the inability to start the UPS to
conduct calibrations. Set a new board to the same settings as the previous
Control Board if possible, then complete calibration. If not, you must change
Voltage Calibrations from 10000 to 9500 to start and calibrate the system.
If you change the Control Board but do not have a load bank or 80% load to
use, do only the voltage calibrations with XCP Service Tool. For current, use
the calibration values from the old Control Board. If old values are not
available, then the default of 10000 is better than miscalibration.
For all AC and DC voltage and current measurements and locations, see
“Measurements for 208 and 480-Volt Calibrations ” on page 21 and Figure 8-6,
TB3 Terminal Block for 208 and 480-Volt UPS Systems, and “Measurements
for 400-Volt Calibrations ” on page 24 and Figure 8-7, X5 or X6 Terminal
Blocks for 400-Volt UPSs for measurement locations.
The required tools for the voltage and current calibrations are:
• XCP Service Software Tool, V3.04 or newer
• Computer with software tool authorization
• Calibrated, True RMS Digital Volt Meter, DVM
• AMP Clamp (Clamp-on DCCT)

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Calibration 9390 Service Manual

8.3.1 Neutral Calibration

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
1. Begin with the unit in shutdown mode. Use neutral meter readings on
XCP Service Tool, V3.04 or newer, Meters Tab. See Figure 8-1, XCP
Service Tool, V3.04, Meters Screen.

Figure 8-1 XCP Service Tool, V3.04, Meters Screen

Note:
Do not use the meters on the front display. For 400V systems with a
Maintenance Bypass Switch installed, the MBS must be closed.
2. Disconnect the chassis SP1 cable from the Interface Board and
jumper the ground connection on the Interface Board to neutral. See
Figure 8-2, Interface Board Disconnect and Jumper.

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9390 Service Manual Calibration

Figure 8-2 Interface Board Disconnect and Jumper

3. Calibrate the Neutral

• Read EEP 3069
Note:
EEP values are in the tenths of a volt. For example: If an actual reading is 2.1
volts, you enter the resultant of 21 minus EEP 3069.
• Read the XCP Service Tool neutral meter
• New cal. value = EEP 3069 - neutral meter
• Write to EEP 3069 with the new calibration value
• Verify that XCP Service Tool ‘Neutral V’ meter is reading 0. If the
value is not 0, and is higher than before loading the new calibration
value, you are over adjusting EEP 3069. In this case, set EEP
3069=0 and repeat the rest of Step 3.
4. Remove the Jumper from the Interface Board ground connection and
replace the SP1 Cable.

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Calibration 9390 Service Manual

8.3.2 Calibrate Input Single Phase B Voltage

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
1. Begin with Logic Power only. Use the input Phase B meter readings
on the XCP Service Tool, V3.04 or newer, Meters Tab.
Note:
Do not use the meters on the Front Display.
2. Calibrate Input Single Phase B Voltage:
• Measure Input Single Ph B Voltage. See “Measurements for 208
and 480-Volt Calibrations ” on page 21 and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems, and
“Measurements for 400-Volt Calibrations ” on page 24 and Figure
8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs for measurement
locations.
• Double-click the _Input B-PH_ meter on XCP Service Tool, Meters
tab, to open the Calibration window. See Figure 8-3, Calibration
Voltage Input Screen.
• Enter measured value from DVM into ‘Volts’ field, and click ‘OK.’ If
you enter an out-of-range voltage, an ‘Error’ window opens.
3. Calibration Scalars are written to the EEPROM. Click OK.
4. Allow the meter to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 4.
5. Calibration is complete.

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9390 Service Manual Calibration

Figure 8-3 Calibration Voltage Input Screen

8.3.3 Calibrate Bypass Single Phase B Voltage

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
1. Begin with Logic Power only, use the bypass phase B meter readings
on the XCP Service Tool, Meters Tab.
Note:
Do not use the meters on the Front Display.
2. Calibrate Bypass Single Phase B Voltage:
• Measure bypass phase B voltage. See “Measurements for 208
and 480-Volt Calibrations ” on page 21 and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems, and
“Measurements for 400-Volt Calibrations ” on page 24 and Figure
8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs for measurement
locations.
• Double-click the _Bypass B-PH_ meter on the XCP Service Tool,
Meters tab. The Calibration window opens.

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Calibration 9390 Service Manual

• Enter the measured value from the DVM into the ‘Volts’ field and
click on ‘OK.’ If you enter an out-of-range voltage, an ‘Error’
window opens.
3. Calibration Scalars are written to the EEPROM. Click OK.
4. Allow the meter to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 4.
5. Calibration is complete.

8.3.4 Calibrate Bypass AC Input Voltage

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
1. Begin with PM OFF and Logic Power only. Use the bypass voltage
meter readings on the XCP Service Tool, Meters Tab.
Note:
Do not use the meters on the Front Display.
2. Calibrate the Bypass AC Input Voltage:
• Measure Bypass Phase A Input to Neutral. See “Measurements for
208 and 480-Volt Calibrations ” on page 21 and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems, and
“Measurements for 400-Volt Calibrations ” on page 24 and Figure
8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs for measurement
locations.
• Double-click the _Va Bypass_ meter on the XCP Service Tool,
Meters tab. The Calibration window opens.
• Enter the measured value from the DVM into the ‘Volts’ field and
click on ‘OK.’ If you enter an out-of-range voltage, an ‘Error’
window opens.
• Repeat the above steps for phases B and C.
3. Calibration Scalars are written to the EEPROM. Click OK.
4. Allow the meters to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 4.
5. Calibration is complete.

8.3.5 Calibrate Utility AC Input Voltage

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.

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9390 Service Manual Calibration

1. Begin with PM ON (Ready), Load on Bypass. Use the input voltage

meters on the XCP Service Tool, Meters Tab.
Note:
Do not use the meters on the Front Display.
2. Calibrate the Utility AC Input Voltage:
• Measure Utility AC Input Phase A to Neutral. See “Measurements
for 208 and 480-Volt Calibrations ” on page 21 and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems, and
“Measurements for 400-Volt Calibrations ” on page 24 and Figure
8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs for measurement
locations.
• Double-click the _Va Input _ meter on the XCP Service Tool,
Meters tab. The Calibration window opens.
• Enter the measured value from the DVM into the ‘Volts’ field, and
click on ‘OK.’
• Repeat for Utility AC Input Phase B, with the Vb meter, and Phase
C, with the Vc meter.
3. Calibration Scalars are written to the EEPROM. Click OK.
4. Allow the meters to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 4.
5. Calibration is complete.

8.3.6 Calibrate Output Single Phase B Voltage

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
1. Begin with PM ON (Ready), On Bypass, use the output Phase B
meter readings on the XCP Service Tool, Meters Tab.
Note:Do not use the meters on the Front Display.
2. Calibrate Output Single Phase B Voltage:
• Measure Output Single Phase B Voltage to Neutral. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations.
• Double-click the _Phase B Output _ meter on the XCP Service
Tool, Meters tab. The Calibration window opens.

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Calibration 9390 Service Manual

• Enter the measured value from the DVM into the ‘Volts’ field and
click on ‘OK.’ If you enter an out-of-range voltage, an ‘Error’
window opens.
3. Calibration Scalars are written to the EEPROM. Click OK.
4. Allow the meters to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 4.
5. Calibration is complete.

8.3.7 Calibrate Battery Voltage

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
The battery breaker(s) must be closed to calibrate battery voltage. The system
may have to be started to Normal mode to close the battery breaker. Once the
battery breaker is closed, the system can be returned to bypass mode. The
battery charger will need to be commanded OFF.
1. Begin with battery breaker closed, PM ON (Ready), and Battery
Charger Off, On Bypass. Use the VDC meter readings on the XCP
Service Tool, Meters Tab.
2. Calibrate the battery voltage:
• Measure the battery voltage. See “Measurements for 208 and 480-
Volt Calibrations ” on page 21 and Figure 8-6, TB3 Terminal Block
for 208 and 480-Volt UPS Systems, and “Measurements for 400-
Volt Calibrations ” on page 24 and Figure 8-7, X5 or X6 Terminal
Blocks for 400-Volt UPSs for measurement locations.
• Double-click the _Vdc Batt _ meter on the XCP Service Tool,
Meters tab. The Calibration window opens.
• Enter the measured value from the DVM into the ‘Volts’ field, and
click on ‘OK.’ If you enter an out-of-range voltage, an ‘Error’
window opens.
3. Calibration Scalars are written to the EEPROM. Click OK.
4. Calibration is complete; turn Battery Charger On.

8.3.8 Calibrate DC Link Voltage

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
1. Begin with PM ON (Ready), On Bypass. Use the VDC Link meter
readings on the XCP Service Tool, Meters Tab.
2. Calibrate the DC Link Voltage:

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9390 Service Manual Calibration

• Measure DC Link Voltage. See “Measurements for 208 and 480-

Volt Calibrations ” on page 21 and Figure 8-6, TB3 Terminal Block
for 208 and 480-Volt UPS Systems, and “Measurements for 400-
Volt Calibrations ” on page 24 and Figure 8-7, X5 or X6 Terminal
Blocks for 400-Volt UPSs for measurement locations.
• Double-click the _Vdc Link_ meter on the XCP Service Tool,
Meters tab. The Calibration window opens.
• Enter the measured value from the DVM into the ‘Volts’ field, and
click on ‘OK.’ If you enter an out-of-range voltage, an ‘Error’
window opens.
3. Calibration Scalars are written to the EEPROM. Click OK.
4. Allow the meters to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat step 2.
5. Calibration is complete.

8.3.9 Calibrate Inverter AC Output Voltage

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.

WARNING
If calibrating a UPM in a parallel system it is critical that all other UPMs
are completely shutdown, including logic power. Failure to do this will
result in improper load share.

When calibrating inverter AC output with the XCP service tool meter, the
calibration adjustment is not to match the measured voltage, but to
adjust the measured voltage for 277.1 volts for a 480-volt Unit, 120.1 volts
for a 208-volt unit, or 230.9 volts for a 400-volt unit.

See Table 8-2, Inverter Voltage Calibrations. When calibrating the

inverter, you are not adjusting meters, but inverter regulation. Do not use
the front display or XCP Tool meters to verify calibration. Instead, use the
DVM to confirm that the inverter output voltage matches target voltage.

Table 8-2 Inverter Voltage Calibrations

Inverter Output Voltage Calibrate To Nominal: Target

208 120.1 Volts

220 127.0 Volts
380 219.4 Volts

400 230.9 Volts

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Calibration 9390 Service Manual

Table 8-2 Inverter Voltage Calibrations

415 239.6 Volts
480 277.1 Volts

Note:
Enter Nominal (Target) voltage into XCP/Meters/Calibration/Target Value
field

Because of the closed loop operation of the inverter, the meters on the XCP
service tool will not change during, or after, the calibration.
1. Begin with PM ON (Online), online without load. Use the output meter
readings on the XCP Service Tool, Meters Tab.
Note:
Use PM ON (Ready) with load on External Maintenance Bypass without MBS
Auxiliaries. If External Maintenance Bypass is not available, then it is highly
recommended that the customer’s load is off.
2. Calibrate the Inverter AC Output Voltage:
• Double-click _Va Inverter_ meter on XCP Service Tool, Meters
tab. The Calibration window opens showing ‘Phase A to Neutral’
in the Measure field. Enter nominal voltage value from Table 8-2
into the ‘Target Value’ field. See Figure 8-4.
• Measure Inverter AC Output Phase A to Neutral. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations and enter the measured voltage
into ‘Volts’ field. Click OK. Measure field now shows ‘Phase B
to Neutral.’
• Repeat for Inverter AC Output Phase B to Neutral. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations and enter measured voltage into
‘Volts’ field. Click OK. Measure field now shows ‘Phase C to
Neutral.’
• Repeat for Inverter AC Output Phase C to Neutral. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt

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9390 Service Manual Calibration

UPSs for measurement locations and enter measured voltage into

‘Volts’ field. Click OK.
3. Calibration Scalars are written to the EEPROM. Click OK.
4. Allow the meter to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 4. For inverter
calibrations, the output meter values must match the reference setting
from the chart above, ±.5 Vac.
5. Calibration is complete.

Figure 8-4 Calibration Target Value Screen

8.3.10 Inverter Output Display Meter Calibration

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event. This procedure provides a means
of calibrating the LCD Display inverter output meters to match the measured
values. Both line to neutral and line to line calibrations must be completed.
1. Begin with the unit online.
2. Calibrate the inverter output display meters.

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Calibration 9390 Service Manual

• Double-click the _Va Inv LCD_ meter on XCP Service Tool, Meters
Tab. The Calibration window opens showing ‘Va Inv LCD to
Neutral’ in the Measure field.
• Measure Inverter AC Output Phase A to Neutral. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations and enter the measured voltage
into ‘Volts’ field. Click OK.
• The Calibration window opens showing ‘Vb Inv LCD to Neutral’
in the Measure field.
• Measure Inverter AC Output Phase B to Neutral. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations and enter the measured voltage
into ‘Volts’ field. Click OK.
• The Calibration window opens showing ‘Vc Inv LCD to Neutral’
in the Measure field.
• Measure Inverter AC Output Phase C to neutral. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations and enter the measured voltage
into ‘Volts’ field. Click OK.
3. Calibration Scalars are written to the EEPROM. Click OK.
• Double-click the _Vab Inv LCD_ meter on XCP Service Tool,
Meters Tab. The Calibration window opens showing ‘Va Inv LCD
to Vb’ in the Measure field.
• Measure Inverter AC Output Phase A to Phase B. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations and enter the measured voltage
into ‘Volts’ field. Click OK.
• The Calibration window opens showing ‘Vb Inv LCD to Vc’ in the
Measure field.
• Measure Inverter AC Output Phase B to Phase C. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21

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9390 Service Manual Calibration

and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations and enter the measured voltage
into ‘Volts’ field. Click OK.
• The Calibration window opens showing ‘Vc Inv LCD to Va’ in the
Measure field.
• Measure Inverter AC Output Phase C to Phase A. See
“Measurements for 208 and 480-Volt Calibrations ” on page 21
and Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS
Systems, and “Measurements for 400-Volt Calibrations ” on
page 24 and Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt
UPSs for measurement locations and enter the measured voltage
into ‘Volts’ field. Click OK.
4. Calibration Scalars are written to the EEPROM. Click OK.
5. Allow the meter to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 4.
6. Calibration is complete.

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Calibration 9390 Service Manual

8.4 Current Calibration

8.4.1 Calibrate Bypass Current
If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
1. Begin with PM ON (Online). Use at least 80% load from easy capacity
test, a load bank, or the customer’s load for all current calibrations.
Transfer the UPS to bypass. Use the bypass current meter readings
on XCP Service Tool, Meters Tab. Note: Do not use the meters on the
Front Display.
2. Calibrate Bypass Current:
• Double-click on _Bypass Ia_ on the XCP Service Tool Meters tab.
The Calibration window opens. See Figure 8-5, Calibration Current
Input Screen.

Figure 8-5 Calibration Current Input Screen

• Measure Bypass Phase A current. See “Measurements for 208

and 480-Volt Calibrations ” on page 21 and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems, and
“Measurements for 400-Volt Calibrations ” on page 24 and Figure

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9390 Service Manual Calibration

8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs for measurement

locations. Enter amps measured for Phase A.
• Measure Bypass Phase B current; enter amps measured for
Phase B.
• Measure Bypass Phase C current, then enter amps measured for
Phase C.
3. If you enter an out-of-range current, an ‘Error’ window opens.
4. Calibration Scalars are written to the EEPROM. Click OK.
5. Allow the meter to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 5.
6. Calibration is complete.

8.4.2 Calibrate Utility Current

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
1. Begin with PM ON (Online). Use at least 80% load from easy capacity
test, a load bank, or the customer’s load for all current calibrations.
Use the Input current meters on the XCP Service Tool, Meters Tab.
Note:
Do not use the meters on the Front Display.
2. Calibrate Utility Input Current:
• Double-click on _Input Ia_ and enter the following for each phase.
The ‘Utility Current Calibration’ window opens. See Figure 8-5,
Calibration Current Input Screenfor an example.
• Measure Utility Phase A input current. See “Measurements for 208
and 480-Volt Calibrations ” on page 21 and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems, and
“Measurements for 400-Volt Calibrations ” on page 24 and Figure
8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs for measurement
locations. Then enter amps measured for Phase A.
• Measure Utility Phase B input current, then enter amps measured
for Phase B.
• Measure Utility Phase C input current, then enter amps measured
for Phase C.
3. If you enter an out-of-range current, an ‘Error’ window opens.
4. Calibration Scalars are written to the EEPROM. Click OK.
5. Allow the meter to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 4.

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Calibration 9390 Service Manual

6. Calibration is complete.

8.4.3 Calibrate Battery Current

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.
This procedure requires that the battery be discharged for a short period of time
so the discharge current can be measured and calibrated.
To calibrate battery current the following, necessary steps must be performed in
the order listed. You may find it helpful to disable ABM prior to this procedure, or
simply turn the charger OFF. At the beginning of the procedure, the system
must be in NORMAL mode with Battery Breaker (CB-1) closed.
1. Put the system in Battery Mode by opening the utility input breaker.
2. Calibrate Battery Current, preferably with large battery current while
discharging.
Note:
Recommend at least an 80% load using easy capacity test, a load bank, or
customer’s load for all current calibrations. The 9390 displays on the XCP
Service Tool meter as a (+) positive value when discharging, and a (-) negative
value when charging.
• Double-click on _Idc Batt_. The ‘Battery Current Calibration’
window opens.
• Measure Battery Current while on battery. See “Measurements for
208 and 480-Volt Calibrations ” on page 21 and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems, and
“Measurements for 400-Volt Calibrations ” on page 24 and Figure
8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs for measurement
locations. Enter the amps measured into the calibration window.
3. If you enter an out-of-range current, an ‘Error’ window opens.
4. Restore utility input to the system. (System should automatically
return to NORMAL mode.)
5. Calibration Scalars are written to the EEPROM. Click OK.
6. Calibration is complete.
7. Re-enable ABM if you turned it off prior to the procedure.

8.4.4 Calibrate Inverter Current

If at any time during this procedure an alarm condition prevents the execution of
the following steps, see Table 9-4, Alarm Description and Definition to
determine and correct the cause of the event.

8–18 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Calibration

1. When calibrating parallel unit outputs, it is preferred that all other

UPMs be completely shutdown to ensure accurate calibration results.
2. Begin with PM ON (Online). Use at least 80% load from easy capacity
test, a load bank, or the customer’s load for all current calibrations.
Use the output meter readings on the XCP Service Tool, Meters Tab.
Note:
Do not use the meters on the Front Display.
3. Calibrate Inverter Output Current:
• Double-click on __Inverter Ia__. The ‘Inverter Current Calibration’
window opens. See Figure 8-5, Calibration Current Input Screen
for an example.
• Measure Inverter Phase A current. See “Measurements for 208
and 480-Volt Calibrations ” on page 21 and Figure 8-6, TB3
Terminal Block for 208 and 480-Volt UPS Systems, and
“Measurements for 400-Volt Calibrations ” on page 24 and Figure
8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs for measurement
locations. Enter amps measured for Phase A.
• Measure Inverter Phase B current. Enter amps measured for
Phase B.
• Measure Inverter Phase C current. Enter amps measured for
Phase C.
4. If you enter an out-of-range current, an ‘Error’ window opens.
5. Calibration Scalars are written to the EEPROM. Click OK.
6. Allow the meters to settle for 30 – 45 seconds and verify calibration. If
calibration is still needed, repeat steps 2 through 5.
7. Calibration is complete.

© 2009 Eaton Corporation. Company Confidential. 8–19

Calibration 9390 Service Manual

8.5 Parallel Calibration

Note:
Calibrate the individual UPMs, using the same meter, prior to Parallel Load
Share calibration.
See “General Calibration Information” on page 1 before continuing.

8.5.1 Parallel Load Share

NOTICE
Note:

If you perform all your calibrations correctly, including inverter output voltage
and currents, the modules should load share equally (within 1 volt).
If the system does not load share within 1 volt, repeat the procedure “Calibrate
Inverter AC Output Voltage” on page 11 for all units in the system.

WARNING
If calibrating a UPM in a parallel system it is critical that all other UPMs
are completely shutdown, including logic power. Failure to do this will
result in improper load share.

When calibrating inverter AC output with the XCP service tool meter, the
calibration adjustment is not to match the measured voltage, but to
adjust the measured voltage for 277.1 volts for a 480-volt Unit, 120.1 volts
for a 208-volt unit, or 230.9 volts for a 400-volt unit.

See Table 8-2, Inverter Voltage Calibrations. When calibrating the inverter,
you are not adjusting meters, but inverter regulation. Do not use the front
display or XCP Tool meters to verify calibration. Instead, use the DVM to
confirm that the inverter output voltage matches target voltage.

8–20 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Calibration

8.6 Measurements for 208 and 480-Volt Calibrations

See Figure 8-6, TB3 Terminal Block for 208 and 480-Volt UPS Systems

Table 8-3 AC Voltage Measurements

EEPROM Measurement Test Point (+) Reference (-)

3013 Utility Phase A to N TB3-1 to TB3-4, neutral

3014 Utility Phase B to N TB3-2 to TB3-4, neutral

3015 Utility Phase C to N TB3-3 to TB3-4, neutral

3019 Bypass Phase A to N E-6-A to E-12, neutral
3020 Bypass Phase B to N E-7-B to E-12, neutral

3021 Bypass Phase C to N E-8-C to E-12, neutral

3016 Inverter Phase A to N E-9 to E-12, neutral
3017 Inverter Phase B to N E-10 to E-12, neutral

3018 Inverter Phase C to N E-11 to E-12, neutral

3031 Inverter Phase A to N E-9 to E-12, neutral
3032 Inverter Phase B to N E-10 to E-12, neutral

3033 Inverter Phase C to N E-11 to E-12, neutral

3034 Inverter Phase A to B E-9 to E-10
3035 Inverter Phase B to C E-10 to E-11

3036 Inverter Phase C to A E-11 to E-9

3022 Bypass Single Phase B to N E-7-B to E-12, neutral

3023 Output Single Phase B to N E-10-B to E-12, neutral

3024 Input Single Phase B to N E-2-B to E-12, neutral

Table 8-4 DC Voltage Measurements

20 to 80 kVA 100 to 160 kVA
EEPROM Measure
Test Pt.(+) to Reference(-) Test Pt.(+) to Reference(-)

3025 Battery Plus TB3-5 to TB3-7 TB4-5 to TB4-7

3026 DC Link, Rail TB3-6 to TB3-7 TB4-6 to TB4-7

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Calibration 9390 Service Manual

Table 8-5 AC Current Measurements

20 to 80 kVA 100 to 160 kVA
EEPROM Measurement
Test Wire From/To Test Wire From/To

3002 Utility Current Phase A F1 to TB3-1 F1 to TB3-1 & TB4-1

3003 Utility Current Phase B F2 to TB3-2 F2 to TB3-2 & TB4-2

3004 Utility Current Phase C F3 to TB3-3 F3 to TB3-3 & TB4-3
3005 Inverter Current Phase A F7 to TB3-8 F7 to TB3-8 & TB4-8

3006 Inverter Current Phase B F8 to TB3-9 F8 to TB3-9 & TB4-9

3007 Inverter Current Phase C F9 to TB3-10 F9 to TB3-10 & TB4-10
3008 Bypass Current Phase A F4 to K5-2T1

3009 Bypass Current Phase B F5 to K5-4T2

3010 Bypass Current Phase C F6 to K5-6T3
E12 to TB3-4 or 11
3011 Neutral Current E12 to TB3-4 or 11
& TB4-4 or 11

Table 8-6 DC Current Measurements

20 to 80 kVA 100 to 160 kVA
EEPROM Measure
Test Wire From / To Test Wire From / To

Battery Current
3012 E4 to TB3-5 E4 to TB3-5 & TB4-5
Discharging

8–22 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Calibration

Figure 8-6 TB3 Terminal Block for 208 and 480-Volt UPS Systems

NOTICE
Note:

In the 20 to 80 kVA UPS units, a single terminal block, TB3, is used.

In the 100 to 160 kVA UPS units, an additional terminal block, TB4, is added
to the right of the TB3 Terminal Block.

© 2009 Eaton Corporation. Company Confidential. 8–23

Calibration 9390 Service Manual

8.7 Measurements for 400-Volt Calibrations

See Figure 8-7, X5 or X6 Terminal Blocks for 400-Volt UPSs

Table 8-7 AC Voltage Measurements

EEPROM Measurement Test Point (+) Reference (-)

3013 Utility Phase A to N X5-2 to X5-1, neutral

3014 Utility Phase B to N X5-3 to X5-1, neutral

3015 Utility Phase C to N X5-4 to X5-1, neutral

3019 Bypass Phase A to N X2-L1 to X2-N, neutral
3020 Bypass Phase B to N X2-L2 to X2-N, neutral

3021 Bypass Phase C to N X2-L3 to X2-N, neutral

3016 Inverter Phase A to N X5-9 to X2-N, neutral
3017 Inverter Phase B to N X5-10 to X2-N, neutral

3018 Inverter Phase C to N X5-11 to X2-N, neutral

3031 Inverter Phase A to N X5-9 to X2-N, neutral
3032 Inverter Phase B to N X5-10 to X2-N, neutral

3033 Inverter Phase C to N X5-11 to X2-N, neutral

3034 Inverter Phase A to B X5-9 to X5-10
3035 Inverter Phase B to C X5-10 to X5-11

3036 Inverter Phase C to A X5-11 to X5-9

3022 Bypass Single Phase B to N X2-L2 to X2-N, neutral

3023 Output Single Phase B to N X3-L2 to X3-N, neutral

3024 Input Single Phase B to N X1-L2 to X2-N, neutral

Table 8-8 DC Voltage Measurements

20 to 80 kVA 100 to 160 kVA

EEPROM Measure

Test Pt.(+) to Reference(-) Test Pt.(+) to Reference(-)

3025 Battery Plus X5-5 to X5-7 X6-5 to X6-7

3026 DC Link, Rail X5-6 to X5-7 X6-6 to X6-7

8–24 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Calibration

Table 8-9 AC Current Measurements

20 to 80 kVA 100 to 160 kVA
EEPROM Measurement
Test Wire From/To Test Wire From/To

3002 Utility Current Phase A X1-L1 to K1-L1 X1-L1 to K1-L1

3003 Utility Current Phase B X1-L2 to K1-L2 X1-L2 to K1-L2
3004 Utility Current Phase C X1-L3 to K1-L3 X1-L3 to K1-L3

3005 Inverter Current Phase A F7 to K3-L1 F7 to K3-L1

3006 Inverter Current Phase B F8 to K3-L2 F8 to K3-L2
3007 Inverter Current Phase C F9 to K3-L3 F9 to K3-L3

3008 Bypass Current Phase A F4 to K5-L1

3009 Bypass Current Phase B F5 to K5-L2
3010 Bypass Current Phase C F6 to K5-L3

3011 Neutral Current X5-8 to X3-N X3-N to X5-8 & X6-8

Table 8-10 DC Current Measurements

20 to 80 kVA 100 to 160 kVA

EEPROM Measure

Test Wire From / To Test Wire From / To

Battery Current
3012 X4+ to X5-5 X4+ to X5-5 & X6-5
Discharging

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Calibration 9390 Service Manual

Figure 8-7 X5 or X6 Terminal Blocks for 400-Volt UPSs

NOTICE
Note:

In the 20 to 80 kVA UPS units, a single terminal block, X5, is used.

In the 100 to 160 kVA UPS units, a second terminal block, X6, is added to the
right of the X5 Terminal Block.

8–26 © 2009 Eaton Corporation. Company Confidential.

 9
Troubleshooting and
Maintenance
9.1 Troubleshooting Procedures
9.1.1 Smart Gate Drive Board
Smart Gate Drive Boards have been known to cause Internal Communication
Failures, Faulty Overtemperature Alarms, Invalid Board ID, and DC Current
Imbalance faults. Improperly routed ribbon or RJ-45 cables have been known to
induce alarms. Before proceeding, verify that the cables are properly routed and
secured away from the power supplies on the unit door.
The following section lists some suggestions for troubleshooting various
symptoms. The first section describes how the boards are identified at startup.

9.1.1.1 Gate Drive Board Identification

See Figure 9-1, Gate Drive Board Identification Sequence
Gate drive boards in the Eaton® 9390 UPS have identical hardware and
firmware. When power is applied they differentiate themselves sequentially with
unique numbers.
Gate drive boards have an LED on the lower left corner. The state of this LED
can provide an indication of the board’s health.
• When power is first applied, the LED will flash rapidly for approximately 15
seconds while the board establishes communication with the control board.
• After 15 seconds the LED flashes one-half second on and one-half second
off, matching the DSP LED.
• If the LED flashes fast for the first minute after power is applied, replace the
board.
• After one minute the LED will flash half-second on and half-second off
regardless of the board’s condition.
Check these LEDs during the first minute after power application to verify a bad
board.

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Troubleshooting and Maintenance 9390 Service Manual

The boards identify themselves sequentially in the following order (160kVA):

• Rectifier 1
• Rectifier 2
• Rectifier 3
• Rectifier 4
• Inverter 9
• Inverter 10
• Inverter 11
• Inverter 12

The 80kVA uses the following ID sequence:

• Rectifier 1
• Rectifier 2
• Inverter 9
• Inverter 10

Inverter 12
Inverter 10
Rectifier 2

Rectifier 4

TOP VIEW
Inverter 11
Rectifier 1

Rectifier 3
Inverter 9

Front of Unit

Figure 9-1 Gate Drive Board Identification Sequence

Some alarms (and the Temperature data) may refer to Inverter 1, Inverter 2, etc.
In these cases, use the following translation:

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9390 Service Manual Troubleshooting and Maintenance

• Inverter 1 = Inverter 9
• Inverter 2 = Inverter 10
• Inverter 3 = Inverter 11
• Inverter 4 = Inverter 12

9.1.1.2 Internal Communication Failure with Gate Drives

Before you begin, determine if the communication failure occurs immediately
after power up (logic power) or while the unit is operating.
An Internal Comm Failure alarm can sporadically occur while the unit is running.
It should clear within a few seconds, without degradation of performance. The
active alarm should disappear and two entries in the event log, “Internal Comm
Failure #” and “Internal Comm failure OK” will remain.
Note:
Before replacing parts or troubleshooting internal comm. failures or over-
temperature alarms, ensure all firmware is at the latest version and the unit has
been updated with all applicable field service bulletins.
1. If you experience a communication failure while the unit is operating
that does not clear, the History queue will show “Internal Comm
Failure #”. Replace the board identified by that number.
2. If the communication failure occurs immediately after power up, the
History queue may not accurately identify the faulty gate drive board.
Follow the steps below to accurately locate the faulty board.
If the unit is 160kVA, an old version of gate drive code can cause this problem.
The boards must have V1.02 firmware or later to clear this problem.
1. Change EEP 212 to 1, then cycle logic power. The unit will only
identify Rectifier 1 and Inverter 9, possibly allowing the unit to report
the gate drive firmware version. Update the firmware if necessary. If
the problem persists, restore EEP 212 (which is 4 for a 160kVA) to its
original value and cycle logic power before continue on to the
following steps.
2. Use the temperature feedback from the gate drive boards to help
determine which are communicating. Each gate drive board will report
temperatures after identification on startup. Since they ID themselves
sequentially, Rectifier 1 will start providing valid temperatures first,
then Rectifier 2, and so on until it gets to the broken board. The faulty
board will continue to report 0° and will likely cause the other boards
after it to report 0° as well.
3. Replace the first board that continues to report 0°. Then power the
unit to see if the ‘Internal Comm Failure’ has cleared.

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Troubleshooting and Maintenance 9390 Service Manual

4. If the problem does not clear, there may be a faulty board that is
scrambling the ID sequence. In an 80kVA, replace the other board on
the side that is causing problems. In a 160kVA, there are 4 boards on
each side. Proceed to replace the remaining boards on the side that
has the problem. If you would like isolate the bad board further on the
160kVA, proceed with “Dividing the CAN” below.
5. If all else fails, replace all the gate drive boards to eliminate the
problem.
Dividing the CAN
1. With the power off, unplug from the feed-through board Rectifier J38
and Inverter J39. Terminate these cables with loop back plugs and
female-to-female connectors.
2. Set EEP 212 to 2 (will now be Internal Comm Fail 1, 2 = Rectifier and
Internal Comm Fail 9, 10 = Inverter) and turn on the power. If the UPM
comes up without any Alarms then the problem is in the Second PM
section (i.e. the set that is now disconnected on the right half of UPM).
If the Alarm still presents, check to see which temperature isn’t
reporting.
3. Once boards have been replaced, reconnect all cables and set EEP
212 back to 4. Power up and verify no Internal Comm Failure Alarms.

9.1.1.3 Heatsink Overtemperature / Check Temp Sensor Alarm

From the History queue, determine which gate drive is reporting a temperature
problem.
1. A faulty temperature sensor circuit will usually report a temperature of
189-190° and in some cases will report 0°.
2. Replace gate drive board reporting the error.
• In rare cases, the thermistor on the power module can cause the
Temperature circuit on the gate drive to behave as described
above. If you replace the gate drive and you still have Temperature
sensor problems, replace entire power module.

9.1.1.4 Invalid Board ID

Before you begin, determine if the Invalid Board ID occurs immediately after
power up (logic power) or while the unit is operating.
An “Invalid Board ID” alarm can occur sporadically while the unit is running. It
should clear within a few seconds, without degradation of performance. The
active alarm should disappear, and two entries remain in the event log, “Invalid
Board ID #” and “Invalid Board ID OK”.
1. If you experience continuous Invalid Board ID alarms while running,
the History queue will show “Invalid Board ID #”, where # is a gate

9–4 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Troubleshooting and Maintenance

drive board number that has the problem. In this case, simply replace
the board identified by that number.
2. If the Invalid Board ID occurs immediately after power up, it will
usually accompanied by an internal comm failure. Typically the Invalid
Board ID is the cause of the comm failure, but the internal comm
failure alarm should tell you which board has the problem. Use the
temperature feedback from the gate drive boards to help determine
which one is broken.
3. The XCP Service Tool meter screen provides temperature feedback.
Each gate drive board reports temperatures as soon as it gets an ID.
Since they ID themselves sequentially, Rectifier 1 will start providing
valid temperatures first, then Rectifier 2, and so on until it gets to the
broken board. The broken board will continue to report 0° and will
likely cause the other boards after it to report 0° as well. Replace the
first board that continues to report 0°, then power the unit to check for
proper operation.
4. If the preceding did not work and you still have an Invalid Board ID
during startup, replace all the rectifier or inverter gate drive boards.
With the unit off, remove the blue RJ-45 cable to the inverter modules
from the Interface Board. Power up the unit and check for the invalid
board ID. Note that this WILL cause an internal comm failure alarm,
but just ignore it during this test. If the invalid board ID alarm is gone,
then the bad board is on the inverter side. If it is still present, then the
bad board is on the rectifier side.

9.1.1.5 DC Current Imbalance

480V units are tested for proper sharing of battery converter legs during battery
operation. Battery converter operation is split among all power modules: each
power module has one IGBT half-bridge doing battery converter operation.
The object of this test is to verify all converters are more or less sharing the load.
While on battery mode at 80% load or more, inductor current flowing into each
battery converter leg is measured with a current meter. The unit successfully
passes the test if:
• No single leg has more than 33% of the sum of all currents going into the
power modules (in an 80 kVA)
• No inverter module has more than 57% of the sum of all the currents going
into inverter power modules (in an 80 kVA)
• No rectifier module has more than 57% of the sum of all the currents going
into rectifier power modules (in an 80 kVA)

Numbers for 160 kVA will be proportionally similar.

© 2009 Eaton Corporation. Company Confidential. 9–5

Troubleshooting and Maintenance 9390 Service Manual

If a unit fails this test, swap the gate drive boards on the side that had the
problem. This should clear the problem most of the time.

9.1.2 Gate Power (Firmware 5.00 and Newer)

NOTICE
Note:

Attempting to view the Gate Power Meters Screen with the XCP Service Tool in
units with firmware 2.12 and earlier will result in Nack of C9 errors and
unusable data. This feature will only work on 9390s with DSP 5.00 and newer
firmware.

9.1.2.1 Gate Power Sensing: Definition and Functional Description

It is possible for an IGBT to perform with a reduced kVA capability and not have
a catastrophic failure. However, if one (or more) of the individual IGBT chips
(which are paralleled) are not functioning properly it is - in some cases - possible
for the others to support operation. Here capability and reliability are
compromised and detection, alarm, and repair would be highly desirable.
If the gate is open or shorted, or if connection to the gate is marginal or
intermittent, or if the IGBT chip has shorted and subsequently blown wire bonds
open, etc., the power drawn by the gate driver will be significantly impacted.
Even if gate-to-emitter remains intact, the lack of collector-emitter voltage swing
will significantly impact gate power draw. The “plateau” of the gate voltage is a
result of the charge injected into the gate when the collector-emitter voltage
rises during turn-off. Upon thorough analysis, it can be shown that this plateau is
a significant contributor to total power drawn by the gate driver.
The current drawn through each current sense resistor is sensed, filtered and
level shifted by a differential op-amp circuit the output of which is sent to an A/D
input port of a micro-controller.
Faulty operation of one out of many paralleled IGBT chips can be sensed and
detected by the reflective impact on the gate power drawn thru the gate driver.
The SELV or low voltage side of the circuitry can provide this signal, without any
additional costly isolation. In effect, the detection scheme takes advantage of
the isolation already provided by the gate driver isolation transformers.
This technique is virtually independent of loading and can provide useful
diagnostic information even with the UPS on Bypass.
The detection scheme allows detection and identification of the faulty power
module and section of that power module. In addition, an alarm may be sent
through communications channels to advise service.

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9390 Service Manual Troubleshooting and Maintenance

The front end of the GatePower hardware consists of a current sense circuit.
This current represents the +15V current drawn by a particular power module in
the system and is a strong representation of the power module’s gate loading.
GatePower as a measured parameter is a current, and we assume that the gate
supply voltage is a constant +15Vdc. GatePower meters can be viewed using
the XCP Service Tool.
The components of the GatePower value are:
• IGBT gate load: the measurement representing energy delivered to the
IGBT gates.
• Gate drive power supply power dissipation: the measurement representing
the power losses associated with the regulation of the positive and
negative gate rails used by the IGBT gate drive.
• Gate drive control power dissipation: an incidental measurement
representing power losses associated with gate control components.

The sum of these components yields GatePower:

GatePower = IGBT gate load + Gate drive power supply power dissipation
+ Gate drive control power dissipation
Assuming that the gate drive power supply and control losses are constant, an
excessively high or excessively low GatePower indicates that something is
wrong with the IGBT gate load and, therefore, the IGBT itself.
GatePower can also indicate malfunctioning circuits and components other than
the IGBT. So it cannot be ruled out that an abnormal reading does not also
include possible problems with gate supply or gate control circuits or gate
cabling. The description below simplifies the problem of interpreting GatePower
readings by describing detections and interpretations. Abnormal GatePower
readings indicate a problem; isolating the exact cause may require the
assistance of technical support or engineering.

9.1.2.2 GatePower Sensing: Power Module Level Architecture

See Figure 9-2, Gate Power and Temperature Meters. Each power module
contains dedicated GatePower sense channels for Phase A, Phase B, Phase C,
Battery, and Neutral.
GatePower is measured for the following system level functions
* Rectifier phase legs A, B, and C
* Inverter phases legs A, B, and C
* Battery/Neutral

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Troubleshooting and Maintenance 9390 Service Manual

The Battery and Neutral leg readings are averaged. Turning off the battery
converter allows the Neutral GatePower to be read. Subtract this number from
the battery/neutral total to arrive at Battery GatePower. The DSP communicates
GatePower readings for each power module to the XCP Service Tool. Currently
there are no active events in the system firmware that are triggered by the
metered GatePower levels.

Figure 9-2 Gate Power and Temperature Meters

9.1.2.3 Detection and Interpretation

Under nominal conditions GatePower is a steady, unchanging reading. A
GatePower value that varies with fixed load conditions indicates a problem. A
healthy set of IGBTs being gated or switched at the nominal switching frequency
and at the nominal gate supply voltage would result in a GatePower level equal
to the values indicated in Table 9-1 and Table 9-2. An unhealthy set of IGBTs
(shorted or open gate) can drive GatePower levels above or below the nominal
level.
* A shorted gate will result in a higher than nominal GatePower.
* An open gate will result in a lower than nominal GatePower. It takes several
open IGBT gates to provide a strong enough signal change to indicate that
something is wrong.

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9390 Service Manual Troubleshooting and Maintenance

Note: The smallest number of “open” IGBT gates that can be detected with
reasonable accuracy needs to be determined (this development is currently
underway).
* A shorted or opened Battery or Neutral IGBT gate will result in abnormal
GatePower levels greater than or lower than the nominal value of about TBD.

9.1.2.4 Controlling IGBTs

GatePower readings should change with the ON or OFF state of power
modules. The GatePower reading should be lower in value when the power
module is off than when the power module is ON or switching. A GatePower
reading that does not follow or track the ON or OFF status of a power module
indicates a fault.

CAUTION

Switching of the IGBTs can be accomplished with PM On/Off commands

or Normal/Load Off. If the latter is used, be certain the customer’s load is
disconnected from the unit output.
By commanding the system to Normal and then quickly commanding it to Load
Off, the IGBTs on the power modules will be turned on to bleed the DC link.
While bleeding the link, all GatePower readings of phase legs should track and
remain equal or balanced; the lack of tracking or unequal readings indicates a
faulty module.
System level commands can be used to differentiate between the Battery and
Neutral functions. Command the Charger OFF to isolate the GatePower value of
the Neutral.

9.1.2.5 Typical “Normal” Operating Modes

Parameters
Model: 80Kva, 480V
DSP Code Version = 4.91.13 and newer
Gate Drive Code Version = 1.13
XCP Service Tool Version = 4.10 with special patch for gate power meters
Chart Column States
1 = Shutdown
2 = Normal mode (online) with no load, charger ON (Vbatt = 522 Vdc)
3 = On-battery with no load
4 = On-bypass and Charger ON

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-1 Rectifier Gate Power Normal Mode Readings

Rectifier Normal Operating Modes
Location
1 2 3 4

A .839 2.075 1.005 2.021

Rct
B 1.240 2.412 1.230 2.416
PM 1
C .878 2.050 1.000 2.070

Batt/Neutral Ave. .815 2.373 2.397 2.368

A .878 2.138 1.040 2.099
Rct
B 1.201 2.392 1.201 2.397
PM 2
C .898 2.084 1.030 2.114
Batt/Neutral Ave. .830 2.412 2.431 2.407

Table 9-2 Inverter Gate Power Normal Mode Readings

Inverter Normal Operating Modes
Location
1 2 3 4

Inv A .839 2.001 1.904 2.026

PM 3 B 1.201 2.338 2.241 2.290

(9) C .917 2.128 1.987 2.084
Batt/Neutral Ave. .800 2.387 2.407 2.387

Inv A .810 1.967 1.865 2.001

PM 4 B 1.210 2.275 2.182 2.280
(10) C .903 2.084 1.953 2.080
Batt/Neutral Ave. .830 2.363 2.373 2.358

9.1.2.6 GatePower: Some Tips and Methods

* Tip: Use GatePower for power train checking without high energy sources and
the closure of contactors.
Method: Apply logic power to the System and examine GatePower meters.
* Tip: Use GatePower to speed system failure analysis and debug.
Method: Examine GatePower meters to isolate failed power modules.
* Tip: Use GatePower to verify harness installation

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9390 Service Manual Troubleshooting and Maintenance

Method: Apply logic power to the unit and examine GatePower meters to detect
missing or unconnected PWM ribbon cables. Use GatePower meters in
combination with CAN related ID or lack there of to isolate problems with system
harnessing.
* Tip: Use GatePower to detect trends or shifts in system state of health
Method: Use XCP service tool to capture GatePower screen shots or meters
reports on every site visit and regularly comparing old and new screen shots to
monitor, and detect, shifts in system state of health.
* Tip: Use GatePower to confirm and capture system configurations
Method: Use XCP service tool to capture GatePower screen shots or meters
reports to confirm system configuration. Configurations can be confirmed before
energizing the system and before leaving the site.

9.1.3 Communication Server Board (CSB)

The CSB board controls the front panel display. If the CSB fails, the unit will
have limited operation. If the machine will not change modes, the CSB may
need to be replaced.
Troubleshooting steps:
1. Cycle logic power to the CSB by disconnecting the CSB P4 plug.
Attempt to control the unit.
2. Connect to the UPS using Hyper Terminal and attempt to control the
unit with the video mode function.
3. Use the remote “go to bypass with a building alarm” command via the
XCP Service Tool Building Alarm tab. This feature may not work if the
CSB has failed.
For CSB removal and replacement see section 7.14 Mini-Communication
Server Board (CSB).

9.1.4 Isolation and Troubleshooting, Parallel Modules

The purpose of this procedure is to isolate one 9390 module in a parallel
redundant system while maintaining the critical load on the remaining UPS
module.
• Module 2 is the UPS module to be isolated.
• Module 1 is the UPS module to remain online supporting the critical load.

This procedure also contains the troubleshooting steps required to isolate the
problem with Module 2, which is causing the symptoms of Internal Comm
Failure #11, Internal CAN Error, false alarms, and data displayed on the web
browser from Module 2.

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Troubleshooting and Maintenance 9390 Service Manual

See Section 3.2.3, Single Module with NO MOB AUX Contacts and Section
3.2.3.2, Parallel 9390 Units with MOB AUX Contacts.
Note:
Depending on the outcome of some steps, troubleshooting may be halted
temporarily to allow data to be reported to Raleigh Engineering and/or other
steps may be waived.
Ensure that your XCP Service Tool is Version 3.0 or higher.

CAUTION
Do not unplug the entire TB1 Connector. This would cause a REPO on that
unit and possibly the other UPM, resulting in a Customer load loss.

9.1.4.1 Module 2 Isolation Procedure

1. On Module 2 perform a PM Off twice. The first PM Off will open the
output contactor and the second will shut the module down.
2. With DSP firmware Version 1.24 AND auxiliary contacts for the
MOBs, connect XCP Service Tool and verify that the “Module Output
Brkr Installed” option is selected on the Options Tab. The pull chain
wires DO NOT need to be removed. Then go to Step 5.
3. With DSP firmware Version 1.22 and older, remove the Pull chain
wires from the Module 2 TB-1 and TB-2.
4. For DSP Version 1.22 and older, slide the Module 2 Can Bridge board
partly out of the card cage slot. An ‘External Communications Failure’
alarm and a ‘Loss of Redundancy’ alarm will appear on Module 1.
5. Open the Module 2 MOB breaker.
6. For DSP Version 1.22 and older, restart Module 2 but leave the MOB
open, pull chain wires removed, and the Can Bridge board pulled out.
7. Document the effect that these changes have made to Module 2’s
symptoms:

9.1.4.2 Module 2 Troubleshooting

1. Connect the laptop to the service port for Module 2 and use the XCP
Service Tool. Select the Meters Tab to view the CAN Errors.
Document the data viewed:

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2. Remove the Web and Relay X-Slot cards. Recheck the value of CAN
Errors and document the data viewed:

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Troubleshooting and Maintenance 9390 Service Manual

3. Swap the position of the Web and Relay X-Slot cards. Recheck the
value of CAN Errors and document the data viewed:

4. Remove the Modbus card from its X-slot. Recheck the value of CAN
Errors and document the data viewed:

5. Shut Down Module 2 by using the Load Off command. Remove the
bypass and rectifier input power to Module 2. Remove the required
dead fronts and panels to inspect the connectors on the Control
Board and all internal CAN connectors. Document any discrepancies
and problems found, then re-install any panels removed:

6. Reapply bypass and rectifier input power to Module 2. Recheck the

value of CAN Errors and document the data viewed:

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7. At this point a decision must be made to either:

a. Replace the Smart Gate Drive Board (SGDB) to Inverter No. 3
and/or the display board and retest for the same symptoms
under the exact same configuration, or
b. Leave the Modbus card disconnected (in both modules) and
recommission Module 2.
Document the decision made and why:

9.1.4.3 Restoring Module 2 On-line

1. Restore Bypass and Input power to Module 2.
2. On Module 2 display screen, ensure that no output voltage is
displayed. If so, perform Load Off.
3. Reinstall the Module 2 Can Bridge Board in the card cage slot if
removed previously.
4. Reinstall the Module 2 Pull chain wires on TB-1 and TB-2 if removed
previously.
5. Close the Module 2 MOB breaker.
6. Start Module 2 and close the battery breaker when prompted.
7. Transfer Module 2 online by pressing the Normal button.
8. Verify that there are no alarms on either Module and that they are
properly sharing load.

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Troubleshooting and Maintenance 9390 Service Manual

9.2 Maintenance
9.2.1 Temporary Reduced Battery String Operation
Note: Logic power must be cycled to complete the following changes. Notify the
customer that his load must be transferred to MBP or powered down for RT
and capacity systems or one parallel unit will need to be taken off line for
redundant systems.
It is possible to operate the 9390 with a reduced cell count battery for short
periods of time. Care must be used to remain within the parameters of this
section to prevent damage to the customer’s equipment. Carefully follow this
procedure if you must operate at a reduced cell count.
Note: The customer must have DSP firmware above 2.08 to implement this
provision. DSP 2.08 and earlier firmware only allows 192, 216, or 240 cells to
be set.
When DSP 2.10 or higher is installed, it is possible to run the unit with up to
twelve cells fewer than the standard string sizes.
1. Using the XCP Service Tool Battery Options Tab, select the Temp.
Battery Cells radio button to enable the reduced cells per string
feature. See 5.1.12, Battery Options Tab.
2. Enter the new number of cells in the numeric window that appears.
The minimum new cell number for the standard string sizes:
• 240 - 12 = 228
• 216 - 12 = 204
• 192 - 12 = 180

WARNING
The same number of cells must be removed in each string when paralleled
strings are configured

Cycle logic power, then restart the system and place back in normal mode.
Note: The battery test may fail if it is conducted while the lower number of cells
is being used. Use the battery configuration tab on the XCP Service Tool to
disable the battery test until the new cells are installed. Carefully annotate
these changes so you can restore full functionality when cells are replaced.
Remember to clear the XCP Service Tool Battery Options radio button and set
the correct number of cells when the replacement cells are installed.

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9390 Service Manual Troubleshooting and Maintenance

9.3 REVERSE TRANSFER & PARALLEL

CONVERSION PROCEDURES
This field retrofit procedure provides the necessary guidelines to convert a
Reverse Transfer (RT) or single module to one that operates in Parallel or multi-
module mode of operation. By reversing this process, a unit operating in a
Parallel system can be converted to operate as a Reverse Transfer.
One CAN Bridge Card Field Kit (103004336) is required per module.
Any unit to be operated in a parallel configuration must have the following
minimum firmware revisions or higher:
• DSP V1.14
• LCD V1.02
• PLD V4
• Gate-Drive V1.10
• Boot Loader V1.10
• Can-Bridge V1.02
• Bypass V1.00
Note:
All units in parallel must have matching DSP firmware. Also, upgrade all
firmware to the latest released versions.
1. Transfer the customer’s load to bypass.
2. If available, transfer the customer’s load to an external maintenance
bypass wrap around.
• Or, if an ISS is installed, transfer the load to the internal
maintenance wrap.
3. If external maintenance bypass, or an ISS, is not available,
customer’s load must be shut down.
If the module is no longer installed or supplied with input power, then Steps 4
through 11 may be completed after the mechanical configuration.
4. With UPM in bypass mode, prior to removing input power from the
UPM, use the XCP Service Software Tool (V02.05.00 or newer) to re-
configure the modules setup for multi-module operation.
5. Using the XCP Service Tool:
• Go to EEP 1012 and change it to 0 (zero).
6. Click back on the CTO tab in the tool.
• The tool will say that the CTO is invalid and ask you to enter a CTO
number.

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7. Enter the CTO number for a parallel configuration.

• The new CTO number will be the same as the old with digit 5
changed to a “2.”
• Example: Old CTO = TB0811300030010 New CTO=
TB0821300030010.
8. After the XCP Service Tool initializes with the new CTO number, go to
the “PCB Tab,” select the DSP, and click on “Start PCB Setup button.”
Verify that the settings in the windows are correct.
• At this point the tool will program the unit for parallel configuration.

NOTICE
Note:

During programming, do not select or close any windows. You may not have
any indication that the programming is in progress. The service tool will tell you
when the process is done. Programming may take several minutes, so don’t be
impatient.
9. Once the programming is completed, the red “parallel” light in the
XCP Tool should come on.
10. “External COMM Failure” alarm will be active until both units are
connected and running.
11. Click on the PCB tab and set up the total # of UPMs, # of UPMs
required & # of that UPM.
12. Repeat steps 4. through 11. for all subsequent units.

NOTICE
Note:

A complete module shutdown is required for initial wiring installation.

13. After the UPM has been programmed for parallel operations remove
logic power.
• If on external maintenance bypass remove all input power to UPM.
• If on internal maintenance bypass, or ISS, remove input power to
power supply boards, unplug AC power connectors.
• If no internal or external bypass is available, secure customers
load and remove all input power to the UPM.
14. Install all wiring and CAN Bridge Card (X-Slot-2 is the preferred slot.)
• Refer to appropriate 9390 Installation / Operations manual
164201535, 164201554, 164201603, or 164201604.
• Ensure CAN Bridge board wiring and pull chain wiring is correct in
accordance with Chapter 3 of the 9390 Service Manual.

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• Apply the new UL label or make a pen / ink change on the UPM
label where applicable.
15. Apply utility and bypass (if dual feed) power to UPS.
16. If the units software setup was not previously configured, once the
unit is installed in the parallel system, perform Steps 4. through 11. of
this procedure.
17. Perform the calibration procedures for parallel units before you
actually parallel the UPMs.

NOTICE
Note:

Parallel calibration in the start up procedure is critical to trouble free operation.

Ensure special attention is given to this part of the procedure.
After all the installation and start up procedures are complete (including
calibrations) the UPMs can be returned to normal operation. When paralleling
the UPMs, allow 10 minutes for the UPMs to stabilize and verify they share the
load equally. If load share is lopsided, perform the parallel calibration again.
(With smaller loads the system may not load share equally.)
18. After calibration, continue with the Parallel start up procedure in
Chapter 3.

9.3.1 FIELD PARALLEL CONVERSION PROCEDURE

Go to the Tech Support and the Eaton Intranet web sites for this procedure.
Note: Refer to “9390 Field Conversion Procedure” for these instructions:
• Single Module to Parallel Module
• Parallel Module to Single Module
The procedure is described in Document No. 164700589, which is posted on the
Tech Support Web site. Visit: http://gstechsup.powerware.com, “Site Links,”
select “Downloads,” then “9390.”
The procedure is also posted on the Intranet web site at: http://poweratwork/
usa.
Click on “EIS WebView” and enter “164700589.”

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Troubleshooting and Maintenance 9390 Service Manual

9.4 9390 kVA CONFIGURATION PROCEDURE

Note:
Refer to “9390 kVA Configuration Instructions” for this procedure. The
procedure includes part numbers, XCP Service Tool screen shots, UL/CTO
label, and the Upgrade Authorization form.
The procedure is described in Document No. 164700574, which is posted on the
Tech Support Web site. To see this downloadable, go to: http://
gstechsup.powerware.com. Under “Site Links,” click “Downloads,” then “9390.”
The procedure is also posted on the Intranet web site at: http://poweratwork/
usa.
Click on “EIS WebView” and enter “164700574.”
See Section 6.25, kVA Configuration (Upgrade) Instructions, to see the Call
Center flowchart and sample “Upgrade Request” and “Upgrade Authorization”
forms.
See the parts chapter for kVA Upgrade Kits for 208 and 480-volt UPS units.
See the parts chapter for kVA Upgrade Kits for 400-volt UPS units.

9.4.1 kVA RECONFIGURATION (UPGRADE) INSTRUCTIONS

This procedure outlines the detailed steps for all the principal persons and
locations to guide them through the power configuration process to upgrade the
9390. The involved persons include the customer, Call Center, the Field
Technician Customer Service Engineer, Logistics Center (Supply), and Depot
personnel.

9.4.2 Call Center, Logistics, and Depot Procedure

See Figure 9-3, Call Center kVA Upgrade Flowchart which outlines all the
necessary steps to authorize the upgrade before the CSE can begin the
reprogramming work at the customer site.

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9390 Service Manual Troubleshooting and Maintenance

Figure 9-3 Call Center kVA Upgrade Flowchart

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Troubleshooting and Maintenance 9390 Service Manual

EATON kVA Upgrade Authorization REQUEST Form

This “Upgrade Authorization REQUEST” form is filled out by Logistics Center

(Supply) personnel when the CSE Field Technician requests a kVA upgrade
authorization ‘magic’ number. Logistics Center (Supply) personnel enters all
required information, then the form is given to the Depot responsible for
generating the new CTO Label and Authorization (Magic) Number. Depot
personnel fills in the authorization number, provides upgrade instructions, and
makes the new CTO Label. The Depot sends this package back to the Logistics
Center (Supply) person whose name is listed on the Upgrade Authorization
REQUEST form.
The “Upgrade Authorization REQUEST” form can also be filled out by the CSE
Field Technician and sent or faxed to Logistics Center. When requesting a kVA
authorization number, the technician’s ticket should contain all the required
information.
If the CSE fill out the “Upgrade Authorization REQUEST” form, the CSE needs
to call: 1-800-843-9433, Option #7, Ext 6908 prior to faxing or sending the form.
Fax Number: (919) 431-6349 (call first X6446 or X6441)
E-mail Address: Obtain from the supply person contacted when calling.

_________________________________________________________
Technician’s Name
_________________________________________________________
Ticket Number or Request ID Number (RID)
_________________________________________________________
Serial Number of UPS
_________________________________________________________
Current CTO Number UPS
_________________________________________________________
Part Number of UPS (If available)
_________________________________________________________
kVA Part Number Ordering (see chart below)
_______________________________________________________
Name of Logistics Center (Supply) Person the form is to be returned to.
_________________________________________________________
Authorization (Magic) Number (to be supplied by Depot)

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EATON® 9390 UPS KVA UPGRADE AUTHORIZATION

FORM
This document verifies that system wiring for the UPS meets the new kVA rating
requirements and the UPS complies with both national and local electrical
codes.
From: ___________________ To: __________________________________
kVA Configuration Being Made (Old & New)
Input: ___________________ Output: _______________________________
Voltage Rating of UPS (Input & Output)
Input: ___________________ Output: _______________________________
AWG size of Customer Supplied Wiring (Input & Output)
Input: ___________________ Output: _______________________________
Rating of Customer Supplied Over-Current Protection (Input & Output)
______________________________________________________________
Serial Number of UPS
______________________________________________________________
Printed Name of Customer Date
______________________________________________________________
Authorized Customer Signature Title
______________________________________________________________
Customer Company Name and Address

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Troubleshooting and Maintenance 9390 Service Manual

6.26PERFORMANCE CHECKSHEET
9.4.3 Eaton® 9390, 20-160kVA UPS
Date: ____________________
Customer: _____________________________________________________
Site Contact: ___________________ Telephone: ( ) _____ - _______
UPS Model: ____________________ S/N: __________________________
UPS CTO No: ____________________ Order No. _____________________
UPS IP Address: ___________________ UPM No. ____________________

Historical Performance Evaluation ___ OK

Mechanical Evaluation (UPS & Battery)___ OK

Applicable Factory Modifications (FSBs)___ OK

System Operational Performance Evaluation ___ OK

Environmental Evaluation .............. ........___ OK

Performance Check Notes \ Recommendations:

______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
__________________________________________________________________

CUSTOMER ACCEPTANCE:

Service Representative: ______________________________Date: ___________

Customer Signature: _________________________________Date: ___________

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9390 Service Manual Troubleshooting and Maintenance

9.5 Preventive Maintenance Procedure Purpose

The preventive maintenance process is an important component in the overall
service level that we provide to our customers. Not only does it improve our
customer’s confidence in the equipment, it also allows the service organization
several opportunities to provide an increased level of support to our customers.
The primary goal of the PM process is to reduce emergency calls by:
• Identifying potential problems with the UPS and battery.
• Ensuring a clean environment and proper airflow through the unit.
• Addressing known issues through the implementation of FSBs.
• Addressing previously identified site issues in a less stressful setting.
• Establishing an up-to-date operating status and historical reference data.
The site visit with the customer is as important as the mechanical and technical
aspects of the PM. Building a strong relationship with your customer is important
for the success of the service business.
• Take the time to discuss any issues that are identified in the alarm history.
• Review the number of times the unit has protected the load or operated on
battery.
• Discuss any potential changes or upgrades that could be beneficial to the
customer
• Allow them to see that we are concerned for the site power quality and are
there to help them.
Establishing a positive tone during the PM helps to establish a better
relationship with the customer. After all, customer loyalty is the single most
valuable asset of a service organization.

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9.6 Preparing to Complete a PM

Prior to scheduling the site visit, review the customer’s service history and
check for any FSBs that need to be implemented. Completing this preliminary
work allows you time to prepare any procedures and parts that are necessary
and reduces or eliminates follow-up visits to address issues.
After the PM is complete, attach the unit downloads and complete notes to the
ticket/FAR upload. This practice ensures that there is an accessible record for
reference by technical support and other service personnel. This history will be
reviewed by the next technician to visit the site, enabling Eaton representatives
to make better decisions about what the customer needs.

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9.7 Preventive Maintenance Procedure

9.7.1 Required Materials
• Flash files to the latest version for each processor.
Note: If the unit does not have DSP firmware version 5.XX, only upgrade to the
newest 2.XX firmware. An upgrade kit to allow options available with 5.XX code
can be purchased by the customer. Also review the service manual and FSBs
for more information about the two code packages available for the 9390.
• XCP tool (latest version)
• Computer
• DB9 Male to DB9 female cable
• Printer with cables if required
• CSE Tool Kit
• Oscilloscope
• Hyper terminal
• Use the standard Preventive Maintenance Checksheet and PM
Worksheet from the Eaton 9390, 20−160 kVA UPS Service
Manual.

NOTICE
Note:NOTICE

If the unit to be inspected is equipped with remote monitoring, unplug the

modem’s phone line or network connection (Ethernet cable) to prevent false
outcall notifications. Pulling the web card from its internal connection will stop
any events created while performing the PM from being sent out after the
Ethernet connection is restored, and possibly prevent a load shutdown if the
customer has a shutdown client operating that monitors DC Voltage or the
battery breaker being opened.

9.7.2 Download and Save

• EEP Maps
• Use Hyper terminal to capture event history by entering ESC H
• Use Hyper terminal to capture node setup by entering ESC N
• Use Hyper terminal to capture battery test info by entering ESC B

9.7.3 Review Alarm / Event Queue / Unit Configuration with

Customer
• Note any alarm that is consistently viewed on the Alarm/Event
Queue.
• Note most reoccurring alarm(s).
• Does alarm occur at the same time of day or week?

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• Can the alarm(s) be correlated to the utility?

• Is the alarm(s) load related?
– If yes, what kind of equipment is the UPS supplying?
• Has any load been added to the UPS since installation?
– If load has been added, were there any problems? If yes,
explain on the PM forms.
• Does the UPS supply any motor loads?
– If yes, what kind?
• Did battery perform OK on last outage?
• Review unit configuration with the customer. Explain features that
are presently selected and not selected.
• Explain how E-notify works (EMP needs to be installed for proper
operation)

9.7.4 Customer Site and Unit Performance Discussion

The site and unit performance discussion allows the CSE to focus on problem
areas and probe for details.
• Discuss past visits to the site and any problems or concerns the
customer has regarding the UPS.
• Pay attention to any front panel meter discrepancies such as input
kW lower than output kW or negative battery current.
• Listen to the unit and get overall impression of unit health while
supporting the load.
• Pay attention to and document any reported anomalies in
performance or any comments/concerns from the customer.

9.7.4.1 Inventory Customer Spares

• Inventory the customer spare parts kit, if applicable, using site
inventory list or generic parts kit list in the service manual.
• Note missing parts to customer and order replacements if
applicable.
• Inspect the spare Control and Interface circuit board part numbers
and ensure they will be compatible in the future per FSB 652A.

9.7.5 Secure the Load

NOTICE
Note:

If the customer will not permit transferring the UPS back online without the
dead fronts, take IR temperature readings as quickly as possible after
removing the dead fronts. See 9.7.11 “Temperature Checks”.

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9390 Service Manual Troubleshooting and Maintenance

Before completing this section, ask the customer if you can transfer the load to
maintenance bypass, if available. If maintenance bypass is not available, the
load and the UPS will need to be shut down to complete the PM.

NOTICE
Note:

If the customer does not approve isolation of the UPS through MBP or shut
down, you can only complete the performance check portion of the PM.
Use the correct Installation and Operation Manual or Service Manual procedure
to secure the customer’s load before proceeding.
1. Transfer UPS to bypass
2. Turn the PMs off
3. Open the front doors and remove them from the UPS
4. On an 80 kVA frame
• Remove the screws or nuts from the top, sides and bottom of the
bottom dead front panel and carefully set the dead front out of the
way.
• Remove screws from the left top door panel.
5. On a 160 kVA frame
• Remove the screws or nuts from the top, sides and bottom of the
bottom dead front panel and carefully set the dead front out of the
way.
• Remove all screws from the left top door panel.
• Remove the screws from the right top dead front and carefully set
the dead front out of the way.
CAUTION
If the unit is on internal bypass then be aware that the following areas are
still powered in the unit and are not accessible without proper arc-flash
gear and safety measures.
– Customer connections
– Inverter contactor
– Any internal bypass breakers and circuits
– Harnessing associated with the above areas/components

9.7.6 Verify Modifications, Grounding, Field Service

Bulletins, and other options are terminated correctly.
• Verify applicable modifications or Field Service Bulletins (FSBs)
are completed or complete them now.

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Troubleshooting and Maintenance 9390 Service Manual

• Make note of any FSBs not completed that need to be performed

on the next PM.
• Update firmware to the latest revisions.
• Verify that they building alarm wiring is installed properly for
maintenance bypass and load sync options.
• Verify that the building alarms have been named properly.
• Verify that the E12 neutral connection is terminated per FSB 578.
ie; bonding jumper installed, neutral brought in with bypass, or
Neutral Forming Kit installed. If NFK is installed, inspect the
transformers for damage, overheating, or open connections.

9.7.7 Signs of Overheating

Inspect the unit for signs of overheating. Overheating can be caused by high
resistance connections, loose connections, or over-current situations.
• Look for darkened or charred areas around all connections (control
and power). Note all locations.
• Look for discoloration of control and power wire insulation at all
wiring connections, including all optional cabinets. Note locations
and wire numbers.

9.7.8 Fan Inspection

Fan failures can be anticipated by observing a slowing of the fan as the bearing
surface develops friction. The 9390 will log a fan failure when the fan slows to
75% or less of its nominal speed.
1. Does Alarm/Event queue indicate any fan failures?
2. Inspect the Power Module Fan Tray.
c. Remove the 2 screws holding the fan tray(s) in place remove the
electrical connector providing power to the tray. See the removal
and replacement chapter of the service manual for the
procedure.
d. Slide the tray(s) out, inspect and spin the fans by hand, checking
for vibration as the fan spins on its bearing.
e. Replace any bad or failed fans.
f. Install fan tray(s) and connector(s).
g. Verify that the Static Switch Fan is running if the unit is on
internal bypass.

9.7.9 Battery Inspection

This step may be performed by a battery customer service engineer.
1. Inspect all battery cabinet(s) and strings for signs of overheating.

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9390 Service Manual Troubleshooting and Maintenance

2. On battery strings look for:

• Swollen batteries.
• Corroded connections.
3. Inspect battery disconnect wiring for overheating.
4. If batteries are swollen, verify battery setups on the XCP Service Tool.
5. Note any deficiencies on the PM forms.
6. If ABM has been set to continuous float mode, verify that the ABM
float voltage has been reduced appropriately (usually 2.25 VPC).

9.7.10 Transfer Verification

WARNING
The following steps require that the unit be energized without the
protective deadfronts in place. Arc-flash safety practices must be
followed and appropriate safety gear must be worn. Use extreme caution
to ensure safety. Verify that the customer site safety procedures allow
you to run the UPS without the deadfronts in place.

1. Connect DVM and/or oscilloscope to the load bus to monitor Phase A

and Phase B voltages.
2. Set Oscilloscope on slow sweep.
3. With customer approval transfer back from maintenance bypass and
then from internal bypass to system normal.
4. Monitor transfer and view critical bus voltage when transferring online.
5. Repeat steps 1-4 for phase B to C and C to A.

9.7.11 Temperature Checks

1. Allow the system some time to reach operating temperature in Normal
mode. Measure temperatures using a handheld IR probe, following
the guidelines below to ensure accuracy:
• Select a distance away from your target that allows sensing the
complete target area. For measuring lugs or conductors, typically
hold the probe within 8” of the target. Read the instructions on the
probe or in the manual to determine the sensing area in relation to
distance from the target.
• When measuring multiple conductors or lugs common to a three-
phase device it is important to measure at the same point on each
phase. For example, measure the wire insulation at the junction of
lugs or 2” back from the lug on each phase to ensure an accurate
comparison between phases.

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Troubleshooting and Maintenance 9390 Service Manual

• The surface type will have an effect on the accuracy of the

readings. A highly reflective surface will not give as accurate a
reading as a dull or black surface. It is preferable to record the wire
insulation temperature next to a lug vs. a bolt or bus bar
temperature.
2. The visual inspection of the connections can reveal information about
past temperatures at that point. If the temperature readings are ok,
but there are any signs of discoloration or overheating, replace or
repair the connection.
3. When taking readings, consistency is the most important factor. If
measuring three lugs on a three-phase breaker or contactor and all
phases have equal current flow, then all phases should have the
same temperature reading. If readings are erratic or vary by more
than 10-15% then further investigation is needed.
4. Using a noncontact IR temperature probe, record the following
temperatures.
• Check all customer power connections and make sure all three
phases of input and output power connections measure within
20% of each other.
• Breaker lug temperatures should be balanced within 20%.
• Battery connections should match cabinet ambient temperature.
• Measure any readily accessible power connection or component
and make note of any discrepancies from surrounding or like
connections.

9.7.12 Metering Verification

The following checks are to verify the calibration of the 9390. If the unit is part of
a parallel system, each units inverter outputs must be calibrated to within 1 volt
of each other for proper load share.
• Ensure the option Phase to Phase meters is NOT selected in the
Options tab of the XCP Service Tool.
• Verify load current bar charts match measured currents.
• Ensure that all measured values match displayed and metered
values within 1%.
• Perform a calibration of any parameter that is not within 1%. For
parallel inverters, the inverter outputs must be within 1 volt for
proper load share.

9.7.13 Fan Tachometer Verification

Measure and record fan tach. signals. All should be approx. 110 – 160 Hz:
• Confirm signal is steady and not erratic.

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9390 Service Manual Troubleshooting and Maintenance

• Replace any fans which have tach signals which are below 75%
(95 Hz).
Return the system to Bypass mode and isolate the load on maintenance bypass
(if available) before continuing. If MBP is not available, the load will need to be
shut down. Check with the customer before turning off the UPS.

9.7.14 Generator and ATS verification (if applicable)

Note:
If UPS did not support load on battery during battery test, DO NOT perform
generator outage test.
1. Transfer system to generator operation
2. Verify stable generator frequency and voltage regulation
3. If the generator was not stable or did not support the system, the
following information may be needed to help resolve the issue:
– Generator Type: (Gas / Diesel / Other) and Manufacturer
– Generator Model Number and Serial Number
– Generator Size in kW, kVA, PF
– Generator governor type (Mech. / Elect / other)
– Transfer Switch type (Automatic / Manual / other)
– ATS Manufacturer
– ATS Model Number and Serial Number
– The total amount of load on the generator
– The amount of load on Generator without UPS (kW, kVA, PF)

9.7.15 Cleaning
• Vacuum unit and clean panels with mild detergent.
• Reattach the top dead front(s).
• Reattach the bottom dead front but make sure that you do not use
the screws along the top of this dead front as per FSB 653.
• Reattach outer doors.
• Verify cleanliness of air filters (change if necessary).
• Verify room ambient temperature and relative humidity.
• Verify adequate room ventilation.
• Verify room cleanliness.

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Troubleshooting and Maintenance 9390 Service Manual

9.8 Returning the unit to service

1. Transfer the UPS back online.
2. Verify that the unit displays the correct time and date.
3. Verify that the mimic panel reflects the proper system operation.
4. Reconnect the Ethernet network connection and or push the Web
card back into its slot if previously pulled forward. Verify all
connectivity options.
5. Verify that the Remote Monitor Panel is functional.
6. Complete all PM forms and paperwork.

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9390 Service Manual Troubleshooting and Maintenance

9.9 PREVENTIVE MAINTENANCE CHECKSHEET

9.9.1 Eaton® 9390, 20-160kVA UPS
Date: ____________________
Customer: _____________________________________________________
Site Contact: ___________________ Telephone: ( ) _____ - _______
UPS Model: ____________________ S/N: __________________________
UPS CTO No: ____________________ Order No. _____________________
UPS IP Address: ___________________ UPM No. ____________________

Historical Performance Evaluation ___ OK

Mechanical Evaluation (UPS & Battery)___ OK

Applicable Factory Modifications (FSBs)___ OK

System Operational Performance Evaluation ___ OK

Environmental Evaluation .............. ........___ OK

Preventive Maintenance Notes \ Recommendations:

______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
__________________________________________________________________

CUSTOMER ACCEPTANCE:

Service Representative: ______________________________Date: ___________

Customer Signature: _________________________________Date: ___________

© 2009 Eaton Corporation. Company Confidential. 9–35

Troubleshooting and Maintenance 9390 Service Manual

PREVENTIVE MAINTENANCE WORKSHEET

Eaton® 9390 (20 - 160 kVA) Single Module (RT) & Parallel Redundant /
Capacity
1. Verify all measurements and readings are within 1%
2. Make copies of this worksheet and fill one out for each UPM.
UPM# ______SN ___________________IP Address ________________

AC VOLTAGE MEASUREMENTS

Location Recorded Values

Measured XCP Tool LCD OK ( )

UPS AC Input A-B V V V

Phase-to-Phase or Phase-to-Neutral
depends on how the display is set up.
(Selectable with XCP Service Tool.)

B-C V V V

C-A V V V

A-N V V V

B-N V V V

C-N V V V

Bypass Input

Neutral to Ground N-G V V V

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9390 Service Manual Troubleshooting and Maintenance

AC VOLTAGE MEASUREMENTS

Location Recorded Values

Measured XCP Tool LCD OK ( )

Inverter AC Output A-B V V V

UPS must be in NORMAL mode or PM
ON, INV READY.

B-C V V V

C-A V V V

A-N V V V

B-N V V V

C-N V V V

AC CURRENT MEASUREMENTS

Location Recorded Values

Measured XCP Tool LCD 

ØA A A A

ØB A A A

ØC A A A

ØA A A A

ØB A A A

ØC A A A

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Troubleshooting and Maintenance 9390 Service Manual

FREQUENCY MEASUREMENTS

Location Recorde Values

d

Measure XCP LCD 

d Tool

Hz

Hz

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9390 Service Manual Troubleshooting and Maintenance

9.10 Troubleshooting Charts

9.10.1 Action Levels
Table 9-3, Alarm Action Levels, is provided to explain the various action levels
and what action should be taken for the 9390. This table is intended to be used
when determining a course of action when responding to a system event
generated by the web card or other monitoring software. See Section 9.2.2,
Alarms, Notices, and Status Definitions

Table 9-3 Alarm Action Levels

Mon.
Name of SW
Description of Action to be Taken Examples
Action Level Alert
Level

Building Alarm,
User should be aware that a condition exists which
Shutdown
Advisory does not threaten the protected equipment, but that Inform
Scheduled, Some
might need to be checked.
Events
The User should note the condition and may need to
Alarm Level 1
take immediate action. In some UPS products, the Check Modem,
(User Alarm -
message is displayed on the Active Alarm/Notice Battery Voltage Major
User action
Screen and the Alarm Lamp will light when the Low, etc.
required)
associated bit is active.

Alarm Level 2 Not defined.

This alarm condition indicates that shutdown of the
Alarm Level 3 UPS could occur. The shutdown could result in a load Load Over 100%,
(Shutdown is loss. In some UPS products, the message is displayed Over - Critical
Imminent) on the Active Alarm/Notice Screen and the Alarm Temperature, etc.
Lamp will light when the associated bit is active.

A condition in the UPS has been detected that requires

servicing but could be scheduled and does not require
Alarm Level 4 Check Battery,
immediate service. In some UPS products, the
(Schedule Redundant Fan Minor
message is displayed on the Active Alarm/Notice
Service) Failure, etc.
Screen and the Alarm Lamp will light when the
associated bit is active.
A technically oriented alarm condition. The user should Inverter Current
call for service to evaluate the condition. These Limit, Inverter
Alarm Level 5
conditions may clear but may indicate a pending Overload,
(Service Minor
problem. In some UPS products, the message is Rectifier Over
Information)
displayed on the Active Alarm/Notice Screen and the Voltage, DC Link
Alarm Lamp will light when the associated bit is active. Over Voltage

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-3 Alarm Action Levels (Continued)

Mon.
Name of SW
Description of Action to be Taken Examples
Action Level Alert
Level

Service of the UPS is required. In some UPS products,

Alarm Level 6
the message is displayed on the Active Alarm/Notice Inverter Failure,
(Service Major
Screen and the Alarm Lamp will light when the Fan Failure, etc.
Required)
associated bit is active.

UPS ON, UPS

Command UPS Control Commands Inform
OFF, etc.
Immediate A condition exists which can threaten the protected On Bypass, Fan
Major
Service equipment; it must be addressed today. Failure
Load Power The UPS is not providing power to the protected UPS Off by
Critical
Off equipment at this time. Command, DCUV

A condition exists in which the UPS may not be able to

Non-Critical
continue protecting all loads; non-critical equipment Major
Shutdown
should be shutdown at this time.
Normal None (Normal)
Notice conditions that are for information only. These
Notice Level Input AC Under
Notices require no action. In some UPS products, the
1 Voltage,
message is displayed on the Active Alarm/Notice Inform
(Information Equalizing
Screen and the Notice Lamp will light when the
Only) Battery, etc.
associated bit is active.

Notice Level Notice conditions that tell the User to do something. In

User is being told to
2 some UPS products, the message is displayed on the
close the Input Minor
(User Active Alarm/Notice Screen and the Notice Lamp will
Breaker.
Interaction) light when the associated bit is active.
Notice conditions that inform the User that the level of Bypass is Not
Notice Level
load protection has increased or decreased. In some Available, System
3
UPS products, the message is displayed on the Active Not Redundant, Minor
(Protection
Alarm/Notice Screen and the Notice Lamp will light System
Level)
when the associated bit is active. Redundant, etc.

Notice Level The user should investigate the UPS. In some UPS Building Alarms,
4 products, the message is displayed on the Active Emergency
Minor
(Investigate Alarm/Notice Screen and the Notice Lamp will light Transfer to
UPS) when the associated bit is active. Bypass
Notice Level
Not Defined.
5
Notice Level
Not Defined
6

Notification Simple Event Notification; no action req. Some Events Inform

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9390 Service Manual Troubleshooting and Maintenance

Table 9-3 Alarm Action Levels (Continued)

Mon.
Name of SW
Description of Action to be Taken Examples
Action Level Alert
Level

OFF An Indicator, LED, or Switch is OFF; no action required Front Panel LED Inform

ON An Indicator, LED, or Switch is ON; no action required Front Panel LED Inform
Safety A condition exists which may imperil personnel near Door Ajar with
Major
Hazard the UPS. Voltage Present
A condition exists which must be addressed by
Schedule PM Battery Health Low Minor
scheduling service for the UPS

Service
Status Inverter On, Input
Status conditions that are service oriented Inform
(Information Filter closed
Only)
The UPS can only provide power to the protected
Low Battery,
Shutdown equipment for less than the configured Low Battery
Shutdown Pending, Critical
Required Warning Time; all protected equipment should
Shutdown Imminent
commence shutdown procedures immediately.
User Status On Battery, Unit
(Information Status conditions that are User oriented. Normal, Input Inform
Only) Breaker Closed

User should be aware that a condition exists which

On Battery - Battery
does not currently threaten the protected equipment
Warning not charged, Output Minor
but that it indicates an underlying problem and may
Overload
lead to a situation that will.

9.10.2 Alarm, Notice, & Status Definitions

The following is a list of the various notices and alarms that can be displayed by
the 9390. Use this list with Table 9-3 to determine course of action. The node bit
number is also provided for programming notice/alarm events with the XCP
Service Tool. Node bits are address locations used to store events and
associated data. Knowing the node bit number enables you to quickly find the
correct alarm in the XCP Service Tool. The number also provides the most
reliable cross reference to this chart, as the actual displayed text may change.

© 2009 Eaton Corporation. Company Confidential. 9–41

Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

It has been detected

that the A/D converter
A/D Error 062 ALM
has performed
incorrectly.

The UPS has

detected an
inappropriate voltage
at its output before it
is providing output.
Abnormal For example: some
Output output voltage is
222 ALM
Voltage At detected before the
Startup UPS is supplying
output power; in a
parallel system, the
output voltage is not
in an acceptable
range.
An immediate-mode
interrupt has occurred
indicating that either
Absolute
the DC link voltage or
DCOV/ACOV 101 ALM
the UPS AC output
(Interrupt)
voltage has reached
a critically high over
voltage point.

The AC output has

been in an
AC Under
undervoltage state for
Voltage 115 ALM
a period long enough
Timeout
to invoke a critical
action handler.
A UPS test function
for verifying correct
Alarm Test
088 ALM operation has failed
Failure
to generate the
expected alarm.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

On systems with a
separate alternate
power source (e.g.,
Alternate
dual AC inputs), that
Power
230 ALM alternate power
Source Not
source is currently not
Available
available to support
the load if the primary
power source fails.

An ambient
temperature probe
Ambient Over
203 ALM has detected that the
Temperature
temperature is above
its upper limit.
An ambient
Ambient temperature probe
Under 202 ALM has detected that the
Temperature temperature is below
its lower limit.
Analog Board The analog voltage
A/D reference for an A/D
037 ALM
Reference converter is out of
Fail tolerance.

The analog-to-digital
Analog converter has failed
Processor 054 ALM (e.g. to complete a
Failure conversion within the
expected time frame.)
The UPS state is set
so that it will power up
Auto On
175 STS automatically when
Enabled
input power is
applied.

An attempt to
Auto-
automatically (re-)
calibration 219 ALM
calibrate the UPS has
Failed
failed.

© 2009 Eaton Corporation. Company Confidential. 9–43

Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

A condition exists in
the UPS which will
Unlike Shutdown Imminent (#55), due
lead to the loss of
to fault like Overload while On Battery.
Automatic power to the loads in
Note: This alarm is optional; however,
Shutdown 206 ALM less than the Low
if it is implemented, activating this
Pending Battery Warning
alarm will force monitoring software to
Time, unless the
do a panic OS shutdown.
condition is cleared/
removed.

The UPS has a

scheduled automatic
Automatic startup condition
Startup 210 ALM pending. The UPS
Pending could turn on at any
time without any
additional warning.
Backfeed The backfeed
Switchgear 255 STS contactor, breaker, or
Status switch is closed.
The UPS has
detected that (some
of) the Batteries are
Batteries
199 ALM not connected and
Disconnected
there is no or
seriously reduced
backup power.

Battery The battery is being

150 STS
Charging charged.
The battery is
Battery operating at
047 ALM
Current Limit maximum current
capability.

Battery The battery current

Current 045 ALM sensor has not been
Uncalibrated calibrated.
Battery Not The battery is not fully
151 ALM
Charged charged.
Battery
The battery contactor/
Switchgear 107 ALM
breaker is open.
Open

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Battery The battery contactor,

Switchgear 254 STS breaker or switch is
Status closed.

A battery test has

been executed and Active if Battery voltage goes below
Battery Test the results appear to EEP setting for min V/cell during
191 ALM
Failed indicate that the battery test. Cleared after any
battery has failed and command.
needs to be replaced.
Battery Test
256 STS
in Progress
The battery time
Battery Time
remaining calculation
Calculation 152 STS
and/or reporting has
Disabled
been disabled.

The battery has been

Battery
discharged to its
Totally 126 ALM
maximum discharged
Discharged
state.
Indicates that the
battery voltage has DCOV = EEP 320 * NumCells/100.
exceeded a 1. DCOV > 3 sec, Goto Rest
predetermined limit. 2. DCOV > 6 sec, Open Battery
Battery
068 ALM Operating with this 3. DCOV > EEP 3174 for 1 sec, open
Voltage High
alarm set will likely battery.
cause permanent NOTE THAT THESE ARE BINARY
battery and/or system ADDITIVE: 5 = 1 AND 4
damage.

Battery Undervoltage:
Indicates that the 1. Vb < (EEP332*#cells/100), Start 2
battery voltage and/or minute timeout until shutdown
Battery energy is below the 2. Load Dumped due to 2 minute
056 ALM
Voltage Low predetermined “low timeout
battery warning” 3. Vb < (EEP336*#cells/100),
level. Absolute BatUV, Load Loss
4. Unit in Logic Power Only Mode.
A dry contact closure
Building has been detected on
019 ALM
Alarm 1 the building alarm 1
input.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

A dry contact closure

Building has been detected on
018 ALM
Alarm 2 the building alarm 2
input.

A dry contact closure

Building has been detected on
017 ALM
Alarm 3 the building alarm 3
input.
A dry contact closure
Building has been detected on
016 ALM
Alarm 4 the building alarm 4
input.
A dry contact closure
Building has been detected on
015 ALM
Alarm 5 the building alarm 5
input.

A dry contact closure

Building has been detected on
014 ALM
Alarm 6 the building alarm 6
input.
Bypass input voltage
has exceeded the
Bypass AC
003 ALM upper voltage limit
Over Voltage
specification for
normal operation
Bypass input voltage
Bypass AC is less than the lower
To be used only on those UPSs that
Under 004 ALM voltage limit
have a separate bypass input.
Voltage specification for
normal operation
Bypass The bypass has been
Manual Turn 144 STS given a manual turn
Off off command.
On a multi-phase
Bypass
system, the bypass
Phase 119 ALM
input phases are out
Rotation
of sequence.

The bypass input has

Bypass insufficient power
142 ALM
Power Loss available to supply
the current load.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The bypass power

source is not
Bypass available for use. This For firmware versions 1.08 or below in
Source Out 105 ALM may be due to: over/ parallel, this alarm will occur if not
Of Tolerance under voltage, over/ enough UPMs are online.
under frequency, out
of phase lock.

Bypass
141 STS The bypass is on.
Status
Bypass
The bypass breaker
Switchgear 109 STS
is open.
Open
When true, indicates
Bypass
that the bypass
Switchgear 253 STS
contactor, breaker, or
Status
switch is closed.

The bypass input

Bypass
038 ALM voltage sensor has
Uncalibrated
not been calibrated.
Bypass input
Bypass frequency is outside
Under Or of either the upper or To be used only on those UPSs that
005 ALM
Over lower frequency limit have a separate bypass input.
Frequency specification for
normal operation
The door or cover of
Cabinet Door
204 ALM the UPS has been
Open
opened.
The door or cover of
Cabinet Door
the UPS has been
Open With
205 ALM opened, and
Voltage
dangerous voltages
Present
are present.
The Charger Off
Command was
Charger Off entered by the
236 STS
Command operator or a
communication
device.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The Charger On
Command was
Charger On entered by the
235 STS
Command operator or a
communication
device.

The battery charger

See 9.1.1.3 “Heatsink
Charger Over operating
021 ALM Overtemperature / Check Temp
Temperature temperature has
Sensor Alarm” on page 4
been exceeded.
The battery charger
Charger Over output is operating
Charger Current Limit
Voltage Or 023 ALM beyond either its
Current voltage limit or its
current limit.
Charger
140 STS The charger is on.
Status

The charger
Charger automatically tripped
022 ALM
Tripped off due to an alarm
condition.
An air filter may need
replacement and
must be checked.
Check Air
232 NTC This notice may be
Filter
simply a periodic
reminder from the
UPS.

Check Failure in the self-test

Analog Input 049 ALM for the analog inputs
Processor on a board.
The contactor or relay
designed to prevent
Check
voltage backfeeding
Backfeed 195 ALM
from the UPS output
Switchgear
appears to have
failed.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Check History Log for additional

A battery problem has information.
been detected. It may Fault Codes:
Check need to be replaced, 1. ABM detected Vbat < EEP329 in
149 ALM
Battery or its connections and less than 10 days of Rest Mode
fuses need to be (Verify EEP329 is set to 210)
checked. 2. UPS did not detect a battery
3. Battery is misconfigured (#cells?)

A leakage path
Check appears to exist
Battery 051 ALM between a battery
Ground connection and
ground.
Check The battery contactor
Battery 032 ALM or relay appears to
Switchgear have failed.
Check for a Bypass
failure, including
Check
188 ALM faults like static
Bypass
switch or bypass
breaker failure.

Check The bypass breaker

Bypass 033 ALM or relay appears to
Switchgear have failed.
The battery charger
Check
034 ALM appears to have
Charger
failed.

Power Module or Bypass fan problem

Verify the LEDs on the power supply
boards to rule out power module fans.
At least one fan in the
If the Static Switch fan is the cause,
Check Fan 193 ALM UPS appears to have
verify the harness isn’t damaged and
failed.
the jumper is installed on the Bypass
Control Board for a single fan (80kVA
and below).
A heatsink
Check temperature sensor
Heatsink at some unspecified 9.1.1.3 “Heatsink Overtemperature /
074 ALM
Temperature location in the UPS Check Temp Sensor Alarm” on page 4
Sensor appears to have
failed.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

-Input contactor closes and AUX

contacts indicate open
-or-
-Input contactor opens and AUX
The input or utility contacts indicate closed.
Check Input
217 ALM breaker appears to
Switchgear
have failed. -If not closed within 50 msec after
Command to close is issued.

-If Alarm latches, but unit is Normal,

push NORM again to clear alarm.

Check The inverter appears

031 ALM
Inverter to have failed.
Check The inverter breaker
Inverter 242 ALM or relay appears to On Power Board
Switchgear have failed.
Check The temperature
See 9.1.1.3 “Heatsink
Inverter sensor in the inverter
177 ALM Overtemperature / Check Temp
Temperature module appears to
Sensor Alarm” on page 4
Sensor have failed.

The primary logic

Check Logic
supply in the UPS Gate Drive +5 Volt Sense
Power 071 ALM
appears to have # in que = (Board id + 20)
Supply
failed.
A modem connected
to the UPS has failed
Check
211 ALM or is unable to
Modem
communicate with the
UPS.

An Output Breaker or
Check Output
157 STS Relay appears to
Switchgear
have failed.
The board used for
Check
paralleling control
Parallel 121 ALM
appears to have
Board
failed.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Bit from Power supply, does not

distinguish between 15 or 48 volt
One or more of the
supply. Verify the corner posts on the
control or logic power
Check Power power supply boards are connected.
070 ALM supplies in the UPS
Supply The corner posts are the ground paths
appears to have
for the power supplies. To verify which
failed.
power supply failed look at the LEDs
on the power supply boards.

The Precharge circuit

Check
244 ALM appears to have
Precharge
failed.
Check The rectifier appears
030 ALM
Rectifier to have failed
Check
A rectifier power
Rectifier
077 ALM capacitor appears to
Power
have failed.
Capacitors

Check The temperature

See 9.1.1.3 “Heatsink
Rectifier sensor in the rectifier
250 ALM Overtemperature / Check Temp
Temperature module appears to
Sensor Alarm” on page 4
Sensor have failed.
Check The secondary logic
Secondary supply in the UPS
072 ALM
Power appears to have
Supply failed.
#1. The static switch
appears to have
1. Look at History Log Alarm Message
failed.
for 1, 2, and/or 3 to see which leg
Check Static failed.
036 ALM #2. If unit is flashed
Switch 2. The load must be removed and
with newer firmware
logic power cycled to clear the alarm.
while load is on the
(1-3 = failed leg #)
static switch this
alarm will go active.
Primarily for parallel
Check
systems, the system
System
120 ALM Interface Board
Interface
appears to have
Board
failed.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The Battery contactor

or breaker is
Close Battery disconnected and
247 ALM
Switchgear there is no or
seriously reduced
backup power.

Set during UPS ramp

up when the UPS is
Close Bypass
185 STS ready for the user to
Switchgear
close the bypass
breaker.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Could be due to any one of the

following reasons: (check history log
for additional information):
-EEP 210 Bit 15 (32768) is set.
#30 - Old control board connected to
new interface board
#31 - New control board connected to
old interface board
#41 - EEP 220 seems misconfigured
(Output Voltage)
#42 - battery section has been
defaulted, and EEP 310 bit 15 is still
set.
#43 - Improper Battery Config. (check
#cells, Absolute DCUV)
Improper system
# 50 Unit sees output voltage when off
configuration has
but is not configured to be parallel
been detected. The
MyUpmNum = 0
reasons for this alarm
#51 Parallel Setup Error - UPS #1
Configuration are, for example:
224 ALM doesn’t exist but is sending data on
Error unmatched power
ECAN
rating data, config.
#52 Parallel Setup Error - UPS #2
data out of limits,
doesn’t exist but is sending data on
improper sub-unit
ECAN
identification, etc.
#53 Parallel Setup Error - UPS #3
doesn’t exist but is sending data on
ECAN
#54 Parallel Setup Error - UPS #4
doesn’t exist but is sending data on
ECAN
#59 Parallel Setup Error - Unit’s
MyUpmNum is greater than the
TotalNumUpms
#60 - Node Bit section of Mini CSB
NVRAM reset due to checksum error.
Check if plastic tab removed from
under battery or if battery is good.
#Other - The indicated EEP section
has been defaulted.
Control power has
been removed. This
alarm is either set
when the controls
Control
158 STS detect that they have
Power Off
lost or are about to
lose power. It is used
to record the date and
time of a power fail.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Control power has

been applied. This
status is set when the
controls first power
Control
138 STS up. It is used to
Power Status
record the date and
time of return of
power after a power
fail.

One of the Central

Processing Units
(CPU or control
microprocessor) has
erroneously entered
CPU ISR
146 ALM one of its Interrupt
Error
Service Routines
(ISR), implying that it
has received a
spurious interrupt
input.
In a double bridge
rectifier, the current
from the two bridges
Current
is unbalanced. This
Balance 231 ALM
may be due to a fault
Failure
in one of the rectifiers
or to incorrect
configuration.

DC Link
The DC link bleed-
Bleed 129 STS
down is complete.
Complete
Measured DC link
voltage has exceeded
DC Link Over
028 ALM the upper voltage limit
Voltage
spec for normal
operation
Measured DC link
DC Link voltage is less than
Under 029 ALM the lower voltage limit
Voltage specification for
normal operation

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The DC link has been

DC Over in an overvoltage
Voltage 125 ALM state for a period long
Timeout enough to invoke a
critical action handler.

The UPS has been

started on battery
when AC input power
DC Start
178 STS is not present. This
Occurred
alarm is used to
record the date and
time of this event.
The DC link has been
DC Under in an undervoltage
Voltage 114 ALM state for a period long
Timeout enough to invoke a
critical action handler.
The charger is unable
DC Under
to supply enough
Voltage
energy to raise the
While 116 ALM
DC link to its
Charger Is
minimum operating
Full On
level.

This is a warning that

DC Voltage the DC link voltage
042 ALM
Uncalibrated sensor has not been
calibrated.
DC/DC The DC/DC converter
Converter 112 ALM tripped off due to an
Tripped alarm condition.

An Emergency Power
Off (EPO) command
has been received to
Emergency shutdown the UPS
Shutdown 097 ALM immediately without
Command delay. This command
may come from a
local control panel or
from a remote source.
The load was
Emergency
automatically
Transfer To 186 ALM
transferred to bypass
Bypass
to protect the load.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

# 1 - #8 - UPM not responding - The

A non-recoverable UPM Number of the module that isn’t
External
error has occurred on responding.
Communica- 240 ALM
an external device # 9 - Check Pull chain - An error in the
tion Failure
network or node. pull chain wiring has been detected.
#10 - check CAN Bridge Board.

Indicates that the

“fast bypass”
command was issued
to the bypass control
Fast Bypass logic. “Fast bypass”
061 ALM
Command applies to those
systems that have a
static switch wrapped
around the bypass
breaker or contactor.
The system has gone
Firmware through a firmware
147 ALM
Restarted self-restart (i.e.,
warmboot)
A command has been
received to transfer
the load from bypass
From Bypass to the inverter. This
095 STS
Command command may come
from a local control
panel or from a
remote source.

The front panel or

Front Panel
communications
Self-Test 086 ALM
board has failed self-
Failure
test.
Indicates that the
battery charger is
constantly on. This
Full Time usually indicates that
060 ALM
Charging the battery was
severely discharged
or that the battery has
failed.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

(Active for 160kVA

only.)
At least one battery Replace defective fuse. Check fuse
Fuse Failure 192 ALM
fuse in the 160kVA sensing wiring.
UPS has failed and
needs to be replaced.

Heat sink fault: the

heat sink temperature
Heatsink at an unspecified See 9.1.1.3 “Heatsink
Over 073 ALM module exceeds the Overtemperature / Check Temp
Temperature upper temperature Sensor Alarm” on page 4
limit for normal
operation
1, 10 - Bypass ACUV
2, 11 - Bypass ACOV
3 - Bypass Unavailable
4 - Charger on Command
5 - Load Off Command
6 - Storm Detection
In High UPS is/is not 7 - Battery Test
Efficiency 227 STS operating in High 8 - On Gen.
Mode Efficiency Mode. 9 - Clear ESM Command
12 - Parallel - Command received
from other parallel unit
13 - Unbalanced bypass voltages
14 - Parallel - User command received
from other parallel unit
15 - Parallel - MOB open

The UPS is operating

In Parallel
179 STS in normal parallel
Operation
mode.
A modem connected
to the UPS has
Incoming
received an incoming
Modem Call 212 STS
call and has begun to
Started
negotiate a
connection.
Measured input
voltage has exceeded
Input AC
006 ALM the upper voltage limit
Over Voltage
specification for
normal operation

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Measured input
Input AC voltage is less than
Under 007 ALM the lower voltage limit
Voltage specification for
normal operation

Indicates that the

utility input power is
not within limits; This is very similar to alarm numbers
Input Line
067 ALM specifically that the 57 and 59 but specifically indicates
Voltage Loss
input voltage is below that the input voltage is out of range.
its minimum normal
range.
On a multi-phase
Input Phase system, the utility
118 ALM
Rotation input phases are out
of sequence.
Input Phase The input phases are
Rotation 090 ALM not in correct
Error sequence: L1, 2, 3.

This is a warning that

Input the rectifier/utility
039 ALM
Uncalibrated input voltage has not
been calibrated.
Measured utility input
frequency is outside
Input Under
of either upper or
Or Over 008 ALM
lower frequency limit
Frequency
specification for
normal operation

Check History Log.

A non-recoverable CAN Network ID
error has occurred on 0 or no #: CAN Bridge
an internal device
1-8: rectifier 1-8 (1=1st rect module)
Internal network or node. See
Communica- 063 ALM Section 6.1.2.1.1, 9-16: inverter 1-8 (9=1st inv module)
tion Failure Gate Drive Board See 9.1.1.2 “Internal Communication
Identification (unplug Failure with Gate Drives” on page 3
network cable to #30: Verify that the Control and
simulate this error). Interface Boards are compatible
versions.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

From any of the boards connected to

the CAN network. It usually
A system module or
annunciates when one of the boards
Invalid Board board has an invalid
241 ALM doesn’t ID itself correctly. Unit
ID hardware address,
operation shouldn’t be affected.
type, or node ID.
See 9.1.1.4 “Invalid Board ID” on
page 4

A system module or
Invalid
board has an invalid
Module 087 ALM
hardware/software
Configuration
configuration.
Inverter A/D One or more of the A/
Converter D converters on the
080 ALM
Self-Test inverter module failed
Failed self-test.
Measured inverter
output voltage has
exceeded the upper
Inverter AC
000 ALM voltage limit
Over Voltage
specification for
normal operation
(+10%)

An immediate-mode
interrupt has occurred
Inverter AC
indicating that the
Over Voltage 099 ALM
inverter output
(Interrupt)
voltage has exceeded
limit.
Inverter fault:
measured inverter
Inverter AC output voltage is less
Under 001 ALM than the lower voltage
Voltage limit specification for
normal operation (-
20%)

An immediate-mode
Inverter AC interrupt has occurred
Under indicating that the
100 ALM
Voltage inverter output
(Interrupt) voltage has dropped
below a set limit.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The inverter is being

Inverter
used to reduce the
Bleeding DC 145 STS
DC link voltage to a
Link Voltage
safe level.

Inverter The inverter module

Control has failed either its
079 ALM
Board Failed power up self test or
Self-Test continuous self test.
One or more of the
Inverter CPU
CPUs in the inverter
Self-Test 084 ALM
module failed self-
Failed
test.
Phase 1 of the UPS
Inverter L1
102 ALM output is in current Not in Vo.94
Current Limit
limit.

Phase 2 of the UPS

Inverter L2
103 ALM output is in current Not in Vo.94
Current Limit
limit.
Phase 3 of the UPS
Inverter L3
104 ALM output is in current Not in Vo.94
Current Limit
limit.
Inverter Low The inverter has
Level Test 136 ALM failed its low level self
Timeout test.

A command has been

received to turn the
Inverter Off inverter off: from
092 ALM Power Module Off
Command either a local control
panel or a remote
source.
A command has been
received to turn the
Inverter On inverter on: from
093 STS Power Module On
Command either a local control
panel or a remote
source.

The built-in delay

Inverter On
182 STS before starting the
Delay
inverter is running.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Indicates that the

Inverter On/ inverter has failed to
Off Status 046 ALM perform the
Failure requested function (to
turn on or off).

The inverter output

has failed and cannot
support the load. The # Reflects which module
Inverter reasons for this alarm Example: 80 kVA
Output 221 ALM are, for example: 2 = The Back Module
Failure inverter over/under Example: 160 kVA
voltage, over/under 3 = The Right Front Side Module
frequency, distorted
waveform, etc.
The measured
inverter output
Inverter
current exceeds the
Output Over 027 ALM
upper current limit
Current
specification for
normal operation.
Inverter fault:
measured inverter
temperature exceeds See 9.1.1.3 “Heatsink
Inverter Over
024 ALM the upper Overtemperature / Check Temp
Temperature
temperature limit Sensor Alarm” on page 4
specification for
normal operation

# Reflects which module

Example: 80 kVA
The inverter
2 = The Back Module
Inverter Over temperature has
Example: 160 kVA
Temperature 111 ALM exceeded its rated
3 = The Right Front Side Module
Trip operating
See 9.1.1.3 “Heatsink
temperature.
Overtemperature / Check Temp
Sensor Alarm” on page 4
The phase offset
Inverter component of the
Phase Bias 127 ALM inverter output
Error waveform is out of
controllable range.

Inverter The Inverter phases

Phase 238 ALM are rotated (on the
Rotation output).

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The inverter was

Inverter
commanded to start a
Ramp Up 091 ALM
ramp-up sequence
Test Failed
and it failed to start.

Inverter An attempt to start

Startup 048 ALM the Inverter module
Failure failed.
Inverter
139 STS The inverter is on.
Status
Inverter The inverter output
Opposite sense of #251 Inverter
Switchgear 108 ALM contactor/breaker is
Switchgear Status
Open open.

When true, indicates

Inverter
that the Inverter Opposite sense of #108 Inverter
Switchgear 251 STS
contactor, breaker, or Switchgear Open
Status
switch is closed.
The Inverter tripped
Inverter
110 ALM off due to an alarm
Tripped
condition.
This is a warning that
Inverter the inverter output
041 ALM
Uncalibrated voltage sensor has
not been calibrated.

Measured inverter
output frequency is
Inverter
outside of either the
Under Or
002 ALM upper or lower
Over
frequency limit
Frequency
specification for
normal operation
The DC component of
Inverter the inverter output
Voltage Bias 128 ALM waveform is too high.
Error (duplicate of alarm
#117)

Inverter The DC component of

Voltage Bias 117 ALM the inverter output
Error waveform is too high.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The feedback voltage

Inverter
used to regulate the
Voltage
113 ALM inverter output is at
Feedback
an unreasonable
Error
value.

During inverter ramp

Inverter
up, the inverter output
Voltage Too
131 ALM voltage has not
Low For
stayed within the
Ramp Level
expected limit band.
The load on this UPS
output phase (1)
exceeds the rated
current or power of
the UPS. If On
L1 Overload 159 ALM
Inverter, the UPS
may transfer to
Bypass or shutdown
after a timeout period
of some minutes.
The load on this UPS
output phase (1)
exceeds its rated
current or power by
an extreme amount.
L1 Overload The inverter cannot
(Extreme 165 ALM sustain this excessive
Level) overload and will shut
down immediately or
within seconds,
transferring the load
to bypass, if
available.
The load on this UPS
output phase (1)
exceeds its rated
current or power by a
substantial amount.
L1 Overload
162 ALM The inverter can only
(High Level)
sustain this overload
for a short time
(seconds) without
shutting down due to
overheating.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The load on this UPS

output phase (2)
exceeds the rated
current or power of
L2 Overload 160 ALM the UPS. If On
Inverter, the UPS
may transfer to
Bypass or shutdown
after a timeout period.

The load on this UPS

output phase (2)
exceeds its rated
current or power by
an extreme amount.
L2 Overload
The inverter cannot
(Extreme 166 ALM
sustain this excessive
Level)
overload and will shut
down immediately,
transferring the load
to bypass, if
available.
The load on this UPS
output phase (2)
exceeds its rated
current or power by a
substantial amount.
L2 Overload
163 ALM The inverter can only
(High Level)
sustain this overload
for a short time
(seconds) without
shutting down due to
overheating.

The load on this UPS

output phase (3)
exceeds the rated
current or power of
L3 Overload 161 ALM the UPS. If On
Inverter, the UPS
may transfer to
Bypass or shutdown
after a timeout period.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The load on this UPS

output phase (3)
exceeds its rated
current or power by
an extreme amount.
L3 Overload
The inverter cannot
(Extreme 167 ALM
sustain this excessive
Level)
overload and will shut
down immediately,
transferring the load
to bypass, if
available.

The load on this UPS

output phase (3)
exceeds its rated
current or power by a
substantial amount.
L3 Overload
164 ALM The inverter can only
(High Level)
sustain this overload
for a short time
(seconds) without
shutting down due to
overheating.
The input current to
Large
the charger is
Charger Input 130 ALM
unreasonably high for
Current
its state.
No power is being
Load provided to the load
Dumped (load loss). Used to
170 ALM
(Load Power record the date and
Off) time of a power off
event.
A LOAD OFF
Command, entered
by the operator or
communication
device, has been
Load Off
executed. The UPS
Command 189 ALM
will not turn On
Executed
automatically, but the
operator must use a
keyswitch or
command to restart
the unit.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

A load control
command to turn OFF
the/an output has
Load Off
been issued to the
Command 173 STS
UPS (may be with a
Received
delay). Used to
record the date and
time of this event.

The inverter is
supplying power to
the load. This may be
Load On
171 STS true even if the UPS
Inverter
is on battery or
bypass is not
available.
A LOAD ON
Command has been
entered by the
operator or
Load Power
communication
On 190 STS
device. The UPS or
Command
Output will turn On
automatically when
input power is
available.
A load control
command to turn ON
the/an output has
Load Power
been issued to the
On
172 STS UPS (may be with a
Command
delay). This alarm is
Received
used to record the
date and time of this
event.
In a phase-controlled
charger, the charger
is not synchronized to
Loss Of
135 ALM its input voltage. This
Charger Sync
implies that the
charger is not working
at this time.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

For parallel systems,

this indicates that this
Loss Of Load
UPS power module
Sharing 122 ALM
can no longer perform
Phase L1
load sharing on
phase A.

For parallel systems,

this indicates that this
Loss Of Load
UPS power module
Sharing 123 ALM
can no longer perform
Phase L2
load sharing on
phase B.
For parallel systems,
this indicates that this
Loss Of Load
UPS power module
Sharing 124 ALM
can no longer perform
Phase L3
load sharing on
phase C.
For an “n+1” parallel
system, the load is
Loss of
132 ALM supported, but the
Redundancy
system no longer has
redundant protection.

For a parallel system,

Loss Of Sync this module has
133 ALM
Bus detected that the sync
bus is not active.
Low battery capacity
Low Battery
174 ALM has caused a UPS
Shutdown
shutdown.

The load is supplied

Maintenance power through a
143 ALM
Bypass Mode maintenance bypass
switch.
Modem Call
263 STS
Aborted
The modem has
Modem Call successfully
Completed 215 STS completed a
Successfully transaction
sequence.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The modem has

Modem Call
failed to complete a
Completion 216 ALM
transaction
Failed
sequence.

The modem has

Modem established a
Connection 214 STS connection with a
Established remote modem or
paging service.
There have been no
packets received
from the network or Primarily applies to networks external
Network Not
085 ALM the heartbeat function to the UPS, but may apply to an
Responding
has detected that the internal UPS network.
network is not
connected.
The Neutral regulator
Neutral
246 ALM current exceeded the
Current Limit
internal limit.

Indicates that a non-

volatile memory
device (Flash,
Non-Volatile
EEPROM, or
Memory 053 ALM Queue Only. EEPROM failure
NVRAM) in the UPS
Failure
control or
communications logic
has failed.
A test of a data-
containing Flash,
EEPROM, or NVRAM
Nonvolatile has detected a
Data checksum failure.
082 ALM
Checksum The device either
Failure hasn’t been
programmed or now
contains suspect
data.

A command has been

received, from a local
control panel or from
Normal Mode
096 STS a remote source, to
Command
begin normal reverse
transfer UPS
operation.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

If there are enough UPMs, verify the

Parallel setup has
Parallel setup is correct with the XCP
Not Enough determined that there
262 STS Service Tool. If an external
UPMs are not enough UPMs
communication failure is also present,
to support the load.
check the Can Bridge Bd. or wiring.

On systems with dual

AC inputs, the power
On Alternate is currently being
226 ALM
AC Source supplied by the
Alternate (not the
Preferred) Source.
On a line-interactive
UPS, the input
voltage is too low for
the desired output
On Boost /
range so the
Voltage Step 197 STS
transformer tap has
Up
been changed to
raise the effective
input voltage to match
the output voltage.
On a line-interactive
UPS, the input
voltage is too high for
the desired output
On Buck /
range so the
Voltage 196 STS
transformer tap has
Reducer
been changed to
lower the effective
input voltage to match
the output voltage.
On a line-interactive
UPS, the input
voltage is extremely
low for the desired
On Double output range so the
Boost / transformer tap has
198 STS
Voltage Step been changed to
Up raise the effective
input voltage to the
maximum possible in
order to match the
output voltage.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

In a parallel system,
Other UPS this indicates that one
154 STS
On of the other UPSs in
currently on.

A modem connected
to the UPS has gone
Outgoing
off hook and has
Modem Call 213 STS
begun to either dial a
Started
number or negotiate a
connection.
Output voltage has
Output AC exceeded the upper
009 ALM
Over Voltage voltage limit for
normal operation
Output voltage is less
Output AC
than the lower voltage
Under 010 ALM
limit specification for
Voltage
normal operation

The system/critical
Output
output current sensor
Current 043 ALM
has not been
Uncalibrated
calibrated.
A DC output of the
UPS has been
Output DC
089 ALM detected to be greater
Over Voltage
than the limit for this
voltage.

The measured UPS

output current limit or
calculated or
Output
025 ALM measured power limit
Overload
has been exceeded
for the time allowed
by the internal limit.
The UPS has
detected an
Output Short
058 ALM abnormally low
Circuit
impedance placed on
its output.
Output The UPS output
Switchgear 137 ALM breaker or relay is
Open open.

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The system/critical
Output
040 ALM output voltage sensor
Uncalibrated
is uncalibrated.

The measured output

frequency is outside
Output Under
of either the upper or
Or Over 011 ALM
lower frequency limit
Frequency
specification for
normal operation
The UPS output
power limit, measured
Output Watts in Watts, has been
243 ALM
Overload exceeded for the time
allowed by the
internal time limit.
The DC busses are
Parallel DC 148 STS
operating in parallel.

Two or more inverters

Parallel Inv 155 STS are currently
operating in parallel.
The system/critical
Parallel
bus is has exceeded
System 050 ALM Parallel system is over 100%
100% of its current
Overload
output rating.
One or more of the
Power control or logic power
Supply Over 069 ALM supplies in the UPS is
Temperature operating beyond its
rated temperature.
A test of the
codespace has
detected a checksum
Program
or CRC error. The
Checksum 083 ALM
device’s operating
Failure
code is suspect and
should be replaced or
flashed.

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Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The control or
communication
firmware has
detected that the
Program
078 ALM internal program
Stack Error
stack has overflowed,
underflowed, or
otherwise been
corrupted.

RAM Device A RAM memory

Self-Test 081 ALM device has failed self-
Failure test.
The inverter failed to
ramp up its output to
Ramp Up
035 ALM its normally operating
Failed
point when
commanded.
Ramping The UPS is being
181 STS
UPS Up started.

The rectifier/charger
Rectifier
input or output current
Current Over 075 ALM
has exceeded 125%
125%
of its rating.
The rectifier/utility
Rectifier
input current sensor
Current 044 ALM
has not been
Uncalibrated
calibrated.

An EEPROM device
Rectifier contained within the
EEPROM 065 ALM rectifier module has
Failure been corrupted or
failed.
The device containing
Rectifier
the code for the
EPROM 066 ALM
rectifier module has
Failure
failed.
Rectifier
The rectifier/charger
Failed Self- 064 ALM
has failed self-test.
Test

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9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The measured
rectifier input current
Rectifier
exceeds the upper Rectifier may scale back charging to
Input Over 026 ALM
current limit stay within rated power.
Current
specification for
normal operation.

Rectifier L1 1: DCOV during test

259 STS
Current Limit 2: Utility outage during test
Rectifier L2 1: DCOV during test
260 STS
Current Limit 2: Utility outage during test
Rectifier L3 1: DCOV during test
261 STS
Current Limit 2: Utility outage during test

Differs from #249 Rectifier Over-

The temperature of a
Temperature Trip in that this may be
rectifier component
Rectifier Over just a warning.
223 ALM has exceeded its
Temperature See 9.1.1.3 “Heatsink
upper temperature
Overtemperature / Check Temp
limit.
Sensor Alarm” on page 4
Differs from #223 Rectifier Over
The rectifier has
Temperature this is a full alarm
exceeded its rated
Rectifier Over condition. Includes #1-16 to indicate
operating
Temperature 249 ALM module.
temperature and
Trip See 9.1.1.3 “Heatsink
automatically
Overtemperature / Check Temp
shutdown.
Sensor Alarm” on page 4
Rectifier The rectifier is
183 STS
Starting starting.
The Rectifier is On
Rectifier
245 STS and operating in
Status
normal mode.
Rectifier
The rectifier/charger
Switchgear 106 ALM
input breaker is open.
Open

Rectifier The rectifier input

Switchgear breaker has been
134 ALM
Shunt intentionally shunt
Tripped tripped.
Rectifier The rectifier
Switchgear 252 STS contactor, breaker, or
Status switch is closed.

© 2009 Eaton Corporation. Company Confidential. 9–73

Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Rectifier Tripped.
All Shutdown Rectifier.
1 = HW Amps Limit
2=DC over voltage
3 = Rect Failed to regulate, check
gate drive board and connections
4 = Rect Not Gating, check CTs
5 = Backfeed Overload, verify EEP
The rectifier tripped
Rectifier 3138 set at 55536
076 ALM due to an alarm
Tripped 6 = Neutral Amps Limit
condition.
7 = Utility L1 Outage
8 = Utility L2 Outage
9 = Utility L3 Outage
10=Excessive Backfeed Current;
Rectifier was backfeeding AND
Charger Hit Current Limit
12=ATS Detection Fast Mains
Transfer

The specified power

rating of an “n+1”
parallel system has
Redundancy been exceeded. The
Loss Due To 225 ALM load is supported, but
Overload the system lacks
redundant protection
while this overload
persists.
The UPS has
Remote
shutdown due to the
Emergency 012 ALM
activation of the
Power Off
remote EPO signal.

The Remote go-to-

bypass input to the
Remote Go unit is active. The
013 ALM
To Bypass UPS will remain on
bypass until this
signal is de-activated.
A UPS module has
been automatically
removed from a
Selective Trip
220 ALM parallel system,
Of Module
usually due to
improper load sharing
or other fault.

9–74 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Unique to the Series

7000, indicates unit is
Series 7000
153 STS a Series 7000
Enable
(Powerware 375
family member).

The setup switch has

been activated. The
Setup Switch UPS is currently in This alarm has been used in the past
098 ALM
Open setup mode instead to test the alarm functions of the UPS.
of in normal operating
mode.
Indicates that the
About to shut down due to overload or
UPS has entered a
battery discharge. Differs from
state where it may
Automatic Shutdown Pending (#206)
abruptly stop
in that it may not be a fault condition,
operating without
but rather a state like all Outlets have
further notice, in less
Shutdown shutdown countdowns in progress
055 ALM than the Low Battery
Imminent that will be completed in less than Low
Warning time.
Battery Warning Time. Note: This
However, it may
alarm is optional; however, if it is
continue to operate
implemented, activating it will force
indefinitely, even with
monitoring software to do an imminent
this alarm being
OS shutdown.
asserted.
There is a fault in the
input wiring, other
Site Wiring
194 ALM than Phase Rotation; Unsafe neutral voltage
Fault
e.g., Ground/Neutral
reversed.
0: not 9390 (thinks it’s 9155/9355)
1-16: gate drive board # with lowest
version (Flash gate drive boards with
In a multi-module
newest code.)
system or internally to
17: Non-9390 PLD code or Non-9390
a UPS with multiple
Software Interface Board
controllers, the
Incompatibili- 176 ALM 18: DSP code does not meet version
firmware versions in
ty Detected requirement for Mini-CSB
place are not
19: Mini-CSB External Flash does not
compatible with each
match version for Mini-CSB code
other.
20: PLD version is incompatible with
DSP version
21: Unknown Control Board Version

© 2009 Eaton Corporation. Company Confidential. 9–75

Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

User attempted to
start the UPS but the
system was unable to
Startup comply. It is most
Failed - likely that the EPO is
209 ALM
Check EPO being continuously
Reset asserted. The user
may need to activate
the EPO Reset button
to clear this condition.

The static switch

Static Switch
operating
Over 020 ALM
temperature has
Temperature
been exceeded.
Has the value of the action level of the
If non-zero, there is at most critical subsystem alarm that is
Subsystem least one alarm active currently active. Does not include
234 ALM
Alarm Active in a subsystem at this Notice alarms. Might not trigger the
time. System Alarm if the problem is
handled by other modules.
Has the value of the action level of the
Cautionary Alert: If
highest subsystem notice that is
non-zero, there is at
Subsystem currently active. Does not include
233 NTC least one notice
Notice Active critical alarms (i.e., those in the
active at a subsystem
Subsystem Alarm) and might not
level at this time.
trigger the System Notice.

The inverter output

waveform is being
Syncing To synchronized (phase
180 STS
Bypass and frequency
locked) to the bypass
source.
Used in parallel
systems, indicates
Syncing To that the local inverter
187 STS
Output is being phase locked
to the critical bus
waveform.

Critical Alert: If non-

Has the value of the action level of the
zero, there is at least
System highest critical alarm that is currently
229 ALM one severe alarm
Alarm Active active. Does not include Notice
active at the system
alarms.
level at this time.

9–76 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The UPS is
undergoing a startup
System delay caused by the
Initialization 218 STS necessity to initialize (e.g. ”Inverter EEP Loading”)
In Progress various internal
values, load code
modules, etc.

Cautionary Alert: If
non-zero, there is at
Has the value of the action level of the
System least one notice-level
228 NTC highest notice that is currently active.
Notice Active condition active at the
Does not include critical alarms
System level at this
time.
System Test
257 STS
in Progress
A fault has been
Tap-
detected in the relays
Switching 207 ALM
which switch
Relay Failure
transformer taps.

Test Aborted 258 STS

A command has been
received to transfer
the load from the
To Bypass inverter to bypass.
094 ALM
Command This command may
come from a local
control panel or from
a remote source.

An Input or Output
Transformer Transformer used by
Over 201 ALM the UPS has
Temperature exceeded its upper
temperature limit.
The charger circuit
determines this; may
Unable To
be due to bad
Charge 208 ALM
batteries or open
Batteries
circuit in connections
to the batteries.

© 2009 Eaton Corporation. Company Confidential. 9–77

Troubleshooting and Maintenance 9390 Service Manual

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

The temperature
UPS Cabinet inside the UPS
Over 200 ALM cabinet or enclosure
Temperature has exceeded upper
limit.

This UPS is in parallel

UPS In
156 STS operation with at least
Parallel
one other UPS.
This UPS module is
not supplying power
to the Load; if other
UPS Module
239 STS modules are
Off
available, they may
be providing load
power.
The UPS is in its
UPS Normal 237 STS normal operating
mode of operation.

The UPS is drawing

power from the
battery in order to
power the load. This
This alarm is Required (to support
UPS On alarm is not activated
168 ALM Shutdown). Activating this alarm will
Battery during non-alarming
eventually result in an OS shutdown.
On Battery events,
such as Quick Battery
Test or Tap
Switching.
The UPS is on
bypass. The critical
UPS On load does not have
169 ALM
Bypass protection against
power loss or
disturbances.

The power source for

UPS On
248 ALM the UPS is currently a
Generator
Generator.

9–78 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Troubleshooting and Maintenance

Table 9-4 Alarm Description and Definition (Continued)

Alarm Node Bit Event
Detailed Definition Remarks/Notes
Description Number Type

Indicates that the Differs from alarm #57 in that the

Utility Not
059 ALM utility input is not detected voltage is (near) zero in this
Present
present. case.

Utility input power is

This alarm is required (to support
not within
Shutdown). Activating this alarm will
predetermined limits.
Utility Out Of force monitoring software to do an
057 ALM This could be over
Limits imminent OS shutdown.
voltage, under
voltage, or over or
Not in v0.94
under frequency.
Indicates that the
phase-lock-loop on a
Waiting For
052 ALM phase-controlled
ChargerSync
battery charger/
rectifier is not in lock.
Used only when an
Auto Restart is
enabled. The UPS
Waiting For
184 ALM controls are powered,
Utility Input
but the UPS can not
start because input
power is not present.

Table 9-5 Symptom Troubleshooting Table

Symptom Event
Detailed Definition Remarks/Notes
Description Type

System transfers from

NORMAL, BYPASS
Normal to Bypass with no
& BATTERY LEDs
problems. Most probable cause is a bad display.
are illuminated but None
Cycling logic power does Replace the display assembly.
the system
not change the LED
functions normally
status.

NORMAL & The system is indicating Disable “Easy Capacity Test” option with
BYPASS LEDs are None that the “Easy Capacity the XCP Service Tool. This option
illuminated Test” option is enabled. should only be used for calibration.
1. Connect “On Generator” Bldg. Alarm.
Reduce input current when on Generator
Generator rated near the
Generator EEP 261.
ALM capacity of UPS. UPS
Instability with 9390 2. Adjust EEP 262 from 50 (5 sec) to 200
Setup issue.
(20 sec).
3. Replace with properly sized generator.

© 2009 Eaton Corporation. Company Confidential. 9–79

Troubleshooting and Maintenance 9390 Service Manual

This page was left blank intentionally.

9–80 © 2009 Eaton Corporation. Company Confidential.

 10
Parts
10.1 Information
10.1.1 Parts for EATON® 9390 UPS Units Built in Finland
For units built in Finland, there is a valuable web site for breaking down an
assembly part number to find a component part number. Here is the web site
along with the user name and password:
http://151.110.153.18/parts/
User Name: test
Password: test

10.1.2 RPO Parts Breakdown/Lookup Search Tool

10.1.3 U.S. Assembled 380/400/415 Volt Units

Some 400 volt model parts differ depending where the unit was assembled.
Refer to the CTO chart in the Prints chapter to determine where the unit you are
maintaining was assembled. This chapter contains parts for U.S. and Helsinki
manufactured 400 volt models. The U.S. version uses the 480 volt bottom. The
Helsinki model uses different power modules.

© 2009 Eaton Corporation. Company Confidential. 10–1

Parts 9390 Service Manual

10.2 9390 Spare Parts Listings, 208V and 480V

Table 10-1 9390 80kVA 208V “A” spares - 106 711 150
Part Number Description Qty.

101073704-001 INTERFACE BOARD 1

101073653-001 STATIC SWITCH BOARD 1

1024460 CONTROL BOARD 1
101073677-001 POWER SUPPLY BOARD 1

103003706 DISPLAY ASSY 1

103003708 TRAY, SIX FAN 1
103004379 208V POWER MODULE SPARE 2

128307025-002 FUSE 350A 700 Vac (Input) 3

128307025-007 FUSE 315A 700 Vac (Output) 3
128307025-008 FUSE 630A 600 Vac (SSW) 3

129101001-004 PAD THERMAL, 3.66 X 1.97 6

143321023 SCR 1600V 393A 3
151101079-001 FAN, 120 MM X 38 MM, 190 CF 1

151201040-001 AIR FILTER, 16 X 30 X 1 2

Table 10-2 9390 80kVA 480V “A” spares - 106 711 151
Part Number Description Qty.

101073704-001 INTERFACE BOARD 1

101073653-001 STATIC SWITCH BOARD 1

1024460 CONTROL BOARD 1
101073677-001 POWER SUPPLY BOARD 1

103003706 DISPLAY ASSY 1

103003708 TRAY, SIX FAN 1
103004381 480V POWER MODULE SPARE 2

128307025-002 FUSE 350A 700 Vac (SSW) 3

128307025-006 FUSE 160A 700 Vac (Input & Output) 3
129101002-002 THERMAL INTERFACE PAD 6

143318022 SCR, MODULE, DUAL, 142A, 1600V 3

10–2 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-2 9390 80kVA 480V “A” spares - 106 711 151 (Continued)
Part Number Description Qty.

151101079-001 FAN, 120 MM X 38 MM, 190 CF 1

151201040-001 AIR FILTER, 16 X 30 X 1 2

Table 10-3 9390 160kVA 208V “A” spares - 106 711 156
Part Number Description Qty.

101073704-001 INTERFACE BOARD 1

101073653-001 STATIC SWITCH BOARD 1

1024460 CONTROL BOARD II 1
101073677-001 POWER SUPPLY BOARD 1

103003706 DISPLAY ASSY 1

103003708 TRAY, SIX FAN 1
103004379 208V POWER MODULE SPARE 2

128307027-001 FUSE 700A 700 Vac (SSW) 3

128307027-002 FUSE 630A 700 Vac (Input) 3
128307027-004 FUSE 500A 700 Vac (Output) 3

129101001-006 PAD THERMAL, 4.88 X 2.36 6

143327009 -001 SCR 1600V 425A 3
151101079-001 FAN, 120 MM X 38 MM, 190 CF 1

151201040-001 AIR FILTER, 16 X 30 X 1 2

151201040-002 AIR FILTER, 12 X 30 X 1 2

Table 10-4 9390 160kVA 480V “A” spares - 106 711 157
Part Number Description Qty.

101073704-001 INTERFACE BOARD 1

101073653-001 STATIC SWITCH BOARD 1

1024460 CONTROL BOARD 1
101073677-001 POWER SUPPLY BOARD 1

103003706 DISPLAY ASSY 1

© 2009 Eaton Corporation. Company Confidential. 10–3

Parts 9390 Service Manual

Table 10-4 9390 160kVA 480V “A” spares - 106 711 157
Part Number Description Qty.

103003708 TRAY, SIX FAN 1

103004381 480V POWER MODULE SPARE 2
128307025-002 FUSE 350A 700 Vac (Input) 3
128307025-007 FUSE 315A 700 Vac (Output) 3

128307027-002 FUSE 630A 700 Vac (SSW) 3

129101001-004 THERMAL INTERFACE PAD 6
143321023 SCR, MODULE, DUAL, 393A, 1600V 3

151101079-001 FAN, 120 MM X 38 MM, 190 CF 1

151201040-001 AIR FILTER, 16 X 30 X 1 2
151201040-002 AIR FILTER, 12 X 30 X 1 2

Table 10-5 9390 80kVA 208V “B” spares - 106 711 164
Part Number Description Qty.

101073704-001 INTERFACE BOARD 1

101073653-001 STATIC SWITCH BOARD 1

1024460 CONTROL BOARD 1
101073677-001 POWER SUPPLY BOARD 1
101073679-001 SMART GATE DRIVE BOARD 2

103003706 DISPLAY ASSY 1

103003708 TRAY, SIX FAN 1
128307025-002 FUSE 350A 700 Vac (Input) 3
128307025-007 FUSE 315A 700 Vac (Output) 3

128307025-008 FUSE 630A 600 Vac (SSW) 3

129101001-004 PAD THERMAL, 3.66 X 1.97 6

143321023 SCR 1600V 393A 3

151101079-001 FAN, 120 MM X 38 MM, 190 CF 1
151201040-001 AIR FILTER, 16 X 30 X 1 2

10–4 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-6 9390 80kVA 480V “B” spares - 106 711 165
Part Number Description Qty.

101073704-001 INTERFACE BOARD 1

101073653-001 STATIC SWITCH BOARD 1

1024460 CONTROL BOARD 1
101073677-001 POWER SUPPLY BOARD 1

101073679-001 SMART GATE DRIVE BOARD 2

103003706 DISPLAY ASSY 1

103003708 TRAY, SIX FAN 1
128307025-002 FUSE 350A 700 Vac (SSW) 3

128307025-006 FUSE 160A 700 Vac (Input & Output) 3

129101002-002 THERMAL INTERFACE PAD 6
143318022 SCR, MODULE, DUAL, 142A, 1600V 3

151101079-001 FAN, 120 MM X 38 MM, 190 CF 1

151201040-001 AIR FILTER, 16 X 30 X 1 2

Table 10-7 9390 160kVA 208V “B” spares - 106 711 166
Part Number Description Qty.

101073704-001 INTERFACE BOARD 1

101073653-001 STATIC SWITCH BOARD 1

1024460 CONTROL BOARD 1
101073677-001 POWER SUPPLY BOARD 1
101073679-001 SMART GATE DRIVE BOARD 2

103003706 DISPLAY ASSY 1

103003708 TRAY, SIX FAN 1
128307027-001 FUSE 700A 700 Vac (SSW) 3

128307027-002 FUSE 630A 700 Vac (Input) 3

128307027-004 FUSE 500A 700 Vac (Output) 3
128307033-001 FUSE 160A 700 Vac (Battery) 2

129101001-006 PAD THERMAL, 4.88 X 2.36 6

© 2009 Eaton Corporation. Company Confidential. 10–5

Parts 9390 Service Manual

Table 10-7 9390 160kVA 208V “B” spares - 106 711 166 (Continued)
Part Number Description Qty.

143327009 -001 SCR 1600V 425A 3

151101079-001 FAN, 120 MM X 38 MM, 190 CF 1

151201040-001 AIR FILTER, 16 X 30 X 1 2
151201040-002 AIR FILTER, 12 X 30 X 1 2

Table 10-8 160kVA 480V “B” spares - 106 711 167

Part Number Description Qty.

101073704-001 INTERFACE BOARD 1

101073653-001 STATIC SWITCH BOARD 1

1024460 CONTROL BOARD 1
101073677-001 POWER SUPPLY BOARD 1
101073679-001 SMART GATE DRIVE BOARD 2

103003706 DISPLAY ASSY 1

103003708 TRAY, SIX FAN 1
128307025-002 FUSE 350A 700 Vac (Input) 3
128307025-007 FUSE 315A 700 Vac (Output) 3

128307027-002 FUSE 630A 700 Vac (SSW) 3

128307033-001 FUSE 160A 700 Vac (Battery) 2

129101001-004 THERMAL INTERFACE PAD 6

143321023 SCR, MODULE, DUAL, 393A, 1600V 3
151101079-001 FAN, 120 MM X 38 MM, 190 CF 1

151201040-001 AIR FILTER, 16 X 30 X 1 2

151201040-002 AIR FILTER, 12 X 30 X 1 2

10–6 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

10.3 9390 SPARE PARTS LISTINGS, 400V

Table 10-9 9390 80kVA 400V “A” spares - 1023581 (Helsinki mfd. units)
Part Number Description Qty.

103004241 400V POWER MODULE 10/14 ASSEMBLY Obsolete 2

103005788 400V POWER MODULE 10/14 ASSEMBLY New 2

103003791 SUBAS STATIC SWITCH 1

101073704-001 PCB, INTERFACE BOARD 1

101073677-003 PCB, POWER SUPPLY 1

1024460 PCB, CONTROL BOARD 1

103003706 SUBAS DISPLAY 1
1023378 PCBAS 3P80 DCLINK CAPBOARD 1

1023375 PCBAS 3P80 MAINS CAPBOARD 1

1023387 PCBAS 3P80 OUTPUT CAPBOARD 1
103003708 TRAY, SIX FANS 1

8052457 FUSE 160A 240V UR 3

1023148 FUSE 355A 240V UR 3

1022650 CONTA 3PH 125A 415V COIL 48VDC 1

120105088-001 CAPAC ELE 64000uF 63VDC 1

120311025-002 CAPAC FILM 45UF 370 Vac 1

120314020-002 CAPAC 45UF 600 Vac D-STUD 1
1022651 SWTCH 3x125A 415 Vac ON-OFF 1
1022652 SWTCH 3x200A 415 Vac ON-OFF 1

1022653 SWTCH 4x250A 415 Vac ON-OFF 1

1022874 SWTCH ACC AUX CNTCT 1NO ABB OT 1

151201040-003 AIR FILTER 16X 10 X 1 2

Table 10-10 9390 80 kVA US 400V "A" spares - 106711295 (US version)
Part Number Description Qty.

101073653-001 STATIC SWITCH BOARD 1

101073677-001 POWER SUPPLY BOARD 1

© 2009 Eaton Corporation. Company Confidential. 10–7

Parts 9390 Service Manual

Table 10-10 9390 80 kVA US 400V "A" spares - 106711295 (US version)
Part Number Description Qty.

101073704-001 PCBAS, Power Interface 1

1024460 CONTROL BOARD II 1

103003706 DISPLAY ASM INDIGO 1
103003708 TRAY, SIX FAN 1

103006767 9390 400V PWR MOD SPARES KIT 2

128307025-002 FUSE 350A 700 Vac M8 45MM SQ 3
128307025-006 FUSE 160A 700 Vac M8 45MM SQ 3

129101002-002 THERMAL INTERFACE PAD 6

143318022 SCR, MODULE, DUAL, 142A, 160 3
151101079-001 FAN, 120 MM X 38 MM, 180 CF 1

174650530-001 CARTON SHIPPING POWER MODULE 1

Table 10-11 9390 80kVA 400V s/n>318167 Kit “A1” spares - 1025186 (Helsinki)
Part Number Description Qty.

103005788 400V 9390 PM 2

103003791 SUBAS 3P80 STATIC SWITCH 1

103003706 SUBAS DISPLAY 1
103003708 SUBAS 3P80 TRAY, SIX FAN 1

101073704-001 PCBAS 3P275 INTERFACE BOARD 1

101073677-003 PCBAS 3P160 PWER SUPPLY HPO ** 1

1024460-410 CONTROL BOARD II SP 9390 1

1023378 PCBAS 3P80 DCLINK CAPBOARD ** 1
1024910 PCBAS 3P80 IN/OUT RFI-BOARD ** 1

8052457 FUSE 160A 240V UR 160LET R* 3

1023148 FUSE 355A 240V UR 355LMT R1 3
1022650 CONTA 125A 415V COL 48VDC R1 1

120105088-001 CAPAC ELE 64000uF 63VDC R1 1

1026087 CAPAC PRO 45uF 370 Vac M12 R1 1
1026088 CAPAC PRO 45uF 800VDC M12 R1 1

10–8 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-11 9390 80kVA 400V s/n>318167 Kit “A1” spares - 1025186 (Helsinki)
Part Number Description Qty.

1024935 SWTCH3x200A 415 Vac OT200E03 R1 1

1024936 SWTCH ACC SHFT290mmOXP6x290 R1 1

1024937 SWTCH ACC HNDLE 65mmOHB65J6 R1 1
1022653 SWTCH 4x250A 415 Vac ON-OFF R1 1

1022874 SWTCH ACC AUXCNTCT1NO ABBOT R1 1

151201040-003 AIR FLTER 16X10X1 STRATADNS R1 2

Table 10-12 9390 80kVA 400V “B” spares - 1023582 (Helsinki mfd. units)
Part Number Description Qty.

103004241 400V POWER MODULE 10/14 ASSEMBLY Obsolete 2

103005788 400V POWER MODULE 10/14 ASSEMBLY New 2

1019503 THYRI MOD 160A 1600V 3

101073653-001 PCB, STATIC SWITCH 1
101073677-003 PCB, POWER SUPPLY 1

1024460 PCB, CONTROL BOARD 1

151101079-001 FAN 120 MM X 38 MM, 190 CFM 2
8052457 FUSE 160A 240V UR 3

1023148 FUSE 355A 240V UR 3

151201040-003 AIR FILTER 16X 10 X 1 2

Table 10-13 80kVA 400V “C” spares - 1023583 (Helsinki mfd. units)
Part Number Description Qty.

151101079-001 FAN 120 MM X 38 MM, 190 CFM 2

8052457 FUSE 160A 240V UR 3

1023148 FUSE 355A 240V UR 3
151201040-003 AIR FILTER 16X 10 X 1 2

© 2009 Eaton Corporation. Company Confidential. 10–9

Parts 9390 Service Manual

Table 10-14 9390 160kVA 400V “A” spares - 1024456 Old (Helsinki mfd. units)
Part Number Description Qty.

103004241 400V POWER MODULE 10/14 ASSEMBLY 2

103003651-002 SUBAS STATIC SWITCH 160 kVA 1

101073704-001 PCB, INTERFACE BOARD 1
101073677-003 PCB, POWER SUPPLY 1

1024460 PCB, CONTROL BOARD 1

103003706 SUBAS DISPLAY 1
103003708 TRAY, SIX FANS 1
108307025-002 FUSE 350A 700V 3

108307025-007 FUSE 315A 700V 3

128307025-008 FUSE 630A 600 V M8 3
128307033-001 FUSE 160A 700 Vac M8 2

1023816 CONTA 3PH 275A 415V COIL 48VDC 1

120105088-001 CAPAC ELE 64000uF 63VDC 1
120311025-002 CAPAC FILM 45UF 370 Vac 1

120314020-002 CAPAC 45UF 600 Vac D-STUD 1

151201040-002 AIR FILTER 12X 30 X 1 1

151201040-001 AIR FILTER 16X 30 X 1 1

Table 10-15 9390 160kVA US 400V "A" spares - 106711296 (US version)
Part Number Description Qty.

101073653-001 STATIC SWITCH BOARD 1

101073677-001 POWER SUPPLY BOARD 1
101073704-001 PCBAS, Power Interface 1

1024460 CONTROL BOARD II 1

103003706 DISPLAY ASM INDIGO 1
103003708 TRAY, SIX FAN 1

103006767 9390 400V PWR MOD SPARES KIT 2

128307025-002 FUSE 350A 700 Vac M8 45MM SQ 3

10–10 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-15 9390 160kVA US 400V "A" spares - 106711296 (US version)
Part Number Description Qty.

128307025-007 FUSE, 315A, 700 Vac, M8 45MM 3

128307027-002 FUSE, SEMICOND, 630A, 700V 3

129101001-004 PAD THERMAL, 3.66 X 1.97 6
143321023 SCR 1600V 393A 3

151101079-001 FAN, 120 MM X 38 MM, 180 CF 1

174650530-001 CARTON SHIPPING POWER MODULE 1
151201040-006 Air Filter 1

Table 10-16 9390 160kVA 400V Kit "A" spares - 1024456 New (Helsinki)
Part Number Description Qty.

103005788 400V 9390 PM 2

103003651-002 SUBAS 3P160 STATIC SWITCH 480V 1

101073704-001 PCBAS 3P275 INTERFACE BOARD 1

101073677-003 PCBAS 3P160 PWER SUPPLY HPO ** 1
1024460-410 CONTROL BOARD II SP 9390 1

103003706 SUBAS DISPLAY 1

103003708 SUBAS 3P80 TRAY, SIX FAN 1
128307025-002 FUSE 350A 700V R* 3

128307025-007 FUSE 315A 700 Vac M8 45MM SQ R* 3

128307025-008 FUSE 630A 600 Vac,M8 45MM SQ R* 3

128307033-001 FUSE 160A 700 Vac M8 45mmSQBR* 2

1023816 CONTA 275A 415V COIL 48VDC R1 1
120105088-001 CAPAC ELE 64000uF 63VDC R1 1

1026087 CAPAC PRO 45uF 370 Vac M12 R1 1

1026088 CAPAC PRO 45uF 800VDC M12 R1 1
151201040-002 AIR FILTER 12X30X1 R1 1

151201040-001 AIR FILTER 16X30X1 R1 1

© 2009 Eaton Corporation. Company Confidential. 10–11

Parts 9390 Service Manual

Table 10-17 9390 160kVA 400V “B” spares - 1024457 (Helsinki mfd. units)
Part Number Description Qty.

103004241 400V POWER MODULE 10/14 ASSEMBLY 2

1004086 THYRI MOD 250A 1600V 3

101073653-001 PCB, STATIC SWITCH 1
101073677-003 PCB, POWER SUPPLY 1

1024460 PCB, CONTROL BOARD 1

151101079-001 FAN 120 MM X 38 MM, 190 CFM 2

108307025-002 FUSE 350A 700V 3
108307025-007 FUSE 315A 700V 3

128307025-008 FUSE 630A 600 V M8 3

128307033-001 FUSE 160A 700 Vac M8 2

151201040-002 AIR FILTER 12X 30 X 1 1

151201040-001 AIR FILTER 16X 30 X 1 1

Table 10-18 9390 160kVA 400V “C” spares - 1024458 (Helsinki mfd. units)
Part Number Description Qty.

151101079-001 FAN 120 MM X 38 MM, 190 CFM 2

108307025-002 FUSE 350A 700V 3

108307025-007 FUSE 315A 700V 3
128307025-008 FUSE 630A 600 V M8 3
128307033-001 FUSE 160A 700 Vac M8 2

151201040-002 AIR FILTER 12X 30 X 1 1

151201040-001 AIR FILTER 16X 30 X 1 1

10–12 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

10.4 9390 UPM Subassemblies

Table 10-19 9390 40kVA 400V - 103 006 736 (US VERSION)
101073791-001 PC BOARD, EMI
103004052 HRDW KIT, 9390 80kVA 480V
103004511 COMMON PARTS, 40kVA 9390

103004513 CONTROL HARNESSES 9390 40kVA

103004522 AC CAP PAN, 40kVA 480V
103006740 I/O PANEL, 40kVA 400V, US VE

103006744 400V POWER MODULE TRAY, 40kV

116750181 2.5" SWIVEL CASTER
116750182 2.5" FIXED CASTER

130913297-002 LATCH LIFT & TURN W/LOCK

138425730 LABEL, UNGROUNDED POWER MOUD
152104085 ANCHOR CABLE TIE SNAP-IN

152201080 CABLE TIE WRAPS 4 INCH

152201081 TIE WRAP 0.19 W X 7.4 LG
152201086 MOUNT CABLE TIE ADHESIVE

152201107-001 CABLE TIE, 11.0L 105 DEG

152392009-001 .25X.265 QIK CN TAB W/WSH

156500002-001 FERRITE, TOROID

157605122 ANGLE, BASE TO PALLET
157605341 ANGLE, PALLET/STABILIZING

174650604 PACKAGE KIT, 40kVA 9390

Table 10-20 9390 80kVA 208V - 103 003 656

Part Number Description

103003700 ASSY, K1,3,5 CONTACTOR

103003702 CAP PAN, LOW VOLTAGE
103003853 CONTROL HARNESSES 80kVA, 4 CAT5 cables

103004017 COMMON PARTS, 80kVA

© 2009 Eaton Corporation. Company Confidential. 10–13

Parts 9390 Service Manual

Table 10-20 9390 80kVA 208V - 103 003 656 (Continued)

Part Number Description

103004051 HARDWARE KIT, 9390 80kVA 208V

103004383 208V POWER MODULE W/GATE DRIVE BD

Table 10-21 9390 80kVA 480V - 103 003 657

Part Number Description

103003703 CAP PAN, HIGH VOLTAGE

103003709 80kVA POWER MODULE TRAY, 480V

103003760 CONTACTOR ASSEMBLY, 480V 80kVA
103003853 CONTROL HARNESSES 80kVA, 4 CAT5 cables

103004017 COMMON PARTS, 80kVA

103004052 HARDWARE KIT, 9390 80kVA 480V

Table 10-22 9390 80kVA 400V - 103 003 802 (Raleigh mfd.)
Part Number Description

103003791-001 STATIC SWITCH ASSY, 80kVA 480V

103003853 CONTROL HARNESSES 80kVA, 4 CAT5 cables

103003914 80kVA POWER MODULE TRAY, 400V

103004017 COMMON PARTS, 80kVA

103004053 HARDWARE KIT, 9390 80kVA 400V

Table 10-23 9390, 80kVA, 400V, US VERSION - 103006737

103003703 FILTER CAP, HIGH VOLTAGE

103003853 CONTROL HARNESSES 9390 80kVA

103004017 COMMON PARTS, 80kVA 9390
103004052 HRDW KIT, 9390 80kVA 480V

103006741 CONTACTOR ASSEMBLY, 400V 80K

103006745 400V POWER MODULE TRAY 80kVA
116750181 2.5" SWIVEL CASTER

10–14 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-23 9390, 80kVA, 400V, US VERSION - 103006737 (Continued)

116750182 2.5" FIXED CASTER
130913297-002 LATCH LIFT & TURN W/LOCK

138425709 DECAL, COMP ID 80/160kVA

138425730 LABEL, UNGROUNDED POWER MOUD
152104085 ANCHOR CABLE TIE SNAP-IN

152201080 CABLE TIE WRAPS 4 INCH

152201081 TIE WRAP 0.19 W X 7.4 LG
152201107-001 CABLE TIE, 11.0L 105 DEG

152392009-001 .25X.265 QIK CN TAB W/WSH

157605122 ANGLE, BASE TO PALLET
157605341 ANGLE, PALLET/STABILIZING

174650502 PACKAGE KIT, 80kVA

Table 10-24 9390 120kVA 208V - 103 004 507

Part Number Description

103003863 CONTACTOR PNL, 160kVA 208V

103003924 ASSEMBLY, K5 BYPASS

103004239 HARDWARE KIT, 160kVA 208V
103004335 ASSEMBLY, FILTER 160kVA 208V

103004383 208V POWER MODULE TRAY, 160KV

103004510 208V POWER MODULE TRAY, 40KV

103004512 COMMON PARTS, 120 kVA

103004514 CONTROL HARNESSES 120kVA, 6 CAT5 cables
103004523 ASSEMBLY, FILTER 160kVA 208V

Table 10-25 9390 120kVA 480V - 103 004 508

Part Number Description

103003864 CONTACTOR PNL, 160kVA 208V

103004240 HARDWARE KIT, 160kVA 208V

103004373 ASSEMBLY, FILTER 160kVA 208V

© 2009 Eaton Corporation. Company Confidential. 10–15

Parts 9390 Service Manual

Table 10-25 9390 120kVA 480V - 103 004 508 (Continued)

Part Number Description

103004382 208V POWER MODULE TRAY, 160KV

103004512 COMMON PARTS, 120 kVA

103004514 CONTROL HARNESSES 120kVA, 6 CAT5 cables
103004520 208V POWER MODULE TRAY, 40KV

103004524 ASSEMBLY, FILTER 160kVA 208V

Table 10-26 UPS, 120kVA, 400V, US VERSION - 103006738

Part Number Description

103004240 HRDW KIT, 160kVA 480V

103004373 ASM, FILTER 160kVA 480V

103004512 COMMON PARTS, 120kVA
103004514 CONTROL HRNESSES 120kVA

103004524 ASM, FILTER 120kVA 480V

103004595 I/O PANEL, 160kVA 480V
103006744 400V POWER MODULE TRAY, 40kV

103006745 400V POWER MODULE TRAY 80kVA

116750181 2.5" SWIVEL CASTER
120519018-001 CAPACITOR, POLYPROPYLENE, 3.

130913297-002 LATCH LIFT & TURN W/LOCK

138425709 DECAL, COMP ID 80/160kVA

138425730 LABEL, UNGROUNDED POWER MOUD

152104034-044 BUSHING,0.750 I.D.
152104085 ANCHOR CABLE TIE SNAP-IN

152201080 CABLE TIE WRAPS 4 INCH

152201081 TIE WRAP 0.19 W X 7.4 LG
152201082 TIE WRAP 0.30 W X 14.5 LG

152201086 MOUNT CABLE TIE ADHESIVE

152201107-001 CABLE TIE, 11.0L 105 DEG
152392009-001 .25X.265 QIK CN TAB W/WSH

10–16 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-26 UPS, 120kVA, 400V, US VERSION - 103006738 (Continued)

Part Number Description

152601680 HARNESS, PI1P8 TO A1P21,A2P2

157605222 RAIL, 160 kVA PALLET

157605460 PLATE, COVER
157605633 CAP PAN

174650531 PACKAGE KIT, 160kVA

Table 10-27 UPS, 160 kVA, 400V, US VERSION - 103006739

Part Number Description

103003860 FRAME COMMON PARTS, 160 kVA

103004206 CONTROL HARNESSES 160kVA

103004240 HRDW KIT, 160kVA 480V

103004373 ASM, FILTER 160kVA 480V

103004595 I/O PANEL, 160kVA 480V

103004602 K5 PANEL, 160kVA 480V

103006745 400V POWER MODULE TRAY 80kVA

116750181 2.5" SWIVEL CASTER

130913297-002 LATCH LIFT & TURN W/LOCK

138425709 DECAL, COMP ID 80/160kVA

138425730 LABEL, UNGROUNDED POWER MOUD

152104034-044 BUSHING,0.750 I.D.

152104085 ANCHOR CABLE TIE SNAP-IN

152201080 CABLE TIE WRAPS 4 INCH

152201081 TIE WRAP 0.19 W X 7.4 LG

152201082 TIE WRAP 0.30 W X 14.5 LG

152201107-001 CABLE TIE, 11.0L 105 DEG

152392009-001 .25X.265 QIK CN TAB W/WSH

152601680 HARNESS, PI1P8 TO A1P21,A2P2

157605222 RAIL, 160 kVA PALLET

© 2009 Eaton Corporation. Company Confidential. 10–17

Parts 9390 Service Manual

Table 10-27 UPS, 160 kVA, 400V, US VERSION - 103006739 (Continued)

Part Number Description

157605460 PLATE, COVER

174650593 PACKAGE KIT, 160kVA/CH

Table 10-28 9390 160kVA 208V - 103 003 857

Part Number Description

103003860 COMMON PARTS, 160 kVA

103004206 CONTROL HARNESSES 160kVA, 6 CAT5 cables

103004239 HARDWARE KIT, 160kVA 208V

103004335 ASSEMBLY, FILTER 160kVA 208V

103004383 208V POWER MODULE TRAY, 160KV

103004594 I/O PANEL, 160kVA 208V
103004601 K5 PANEL, 160kVA 208V

Table 10-29 9390 160kVA 480V - 103 003 85

Part Number Description

103003860 COMMON PARTS, 160 kVA

103003864 CONTACTOR PNL, 160kVA 480V - OBSOLETE

103004595 CONTACTOR PNL, 160kVA 480V
103004206 CONTROL HARNESSES 160kVA, 6 CAT5 cables

103004240 HARDWARE KIT, 160kVA 480V

103004373 ASSEMBLY, FILTER 160kVA 208V
103004382 208V POWER MODULE TRAY, 160KV

Table 10-30 UPS Printed Circuit Boards

Part Number Description

101073679-001 SMART GATE DRIVE BOARD - 80 & 160kVA

101073650-001 SMART GATE DRIVE BOARD - 80kVA ONLY

101073704-001 INTERFACE BOARD

10–18 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-30 UPS Printed Circuit Boards (Continued)

Part Number Description

101073652-001 POWER SUPPLY BOARD - OLD *

101073677-001 POWER SUPPLY BOARD - NEW *

101073653-001 STATIC SWITCH BOARD

101073658-001 LV CAP FILTER PCB

101073659-001 HV CAP FILTER PCB

HS CAN BRIDGE X-SLOT PCB,
101073663-001
DB-9 CONNECTOR
HS CAN BRIDGE X-SLOT PCB,
101073785-001
RJ-45 CONNECTOR, RoHS Compliant

101073666-001 DISPLAY BOARD

1024460 CONTROL BOARD
101073682-001 FEED-THROUGH BOARD

* - DO NOT MIX OLD & NEW PCBs

TOGETHER IN SAME UPM

Table 10-31 UPS Batteries

Part Number Description

103004170 1085 Battery Cabinet with 100A 3P Breaker

103004171 1085 Battery Cabinet with 125A 3P Breaker

103003923 1085 Battery Cabinet with 300A 3P Breaker

Table 10-32 UPS ACCESSORIES

Part Number Description

103004221 RELAY INTERFACE MODULE

103004222 SUPERVISORY CONTACT MODULE

103004223 REMOTE MONITOR PANEL

Table 10-33 UPS MINI-CSB KITS

Part Number Description

Part Number Description

103004409 9390 20 - 80kVA

© 2009 Eaton Corporation. Company Confidential. 10–19

Parts 9390 Service Manual

Table 10-33 UPS MINI-CSB KITS

Part Number Description

103004410 9390 100 - 160kVA

103007077 9390 40-80 kVA CSB & Firmware Upgrade Kit

103007420 9390 100-160 kVA CSB & Firmware Upgrade Kit

Table 10-34 9390 20-80kVA Mini-CSB Kit - 103 004 409

Part Number Description Qty.

103003754 ASSEMBLY, X-SLOT W/CSB 1

152601443-002 HARN, MCSB POWER 1
152601473-006 CAT5E CABLE, GRAY 2M 1

152601491-001 HARNESS, X-SLOT-3 20 PIN 1

152601491-002 HARNESS, X-SLOT-4 20 PIN 1
157605112-002 PANEL, 4X X-SLOT MOUNT 1

180190118-015 BOLT HEX FL LK M4 X 12 3

Table 10-35 9390 100-160kVA Mini-CSB Kit - 103 004 410

Part Number Description Qty.

103003754 ASSEMBLY, X-SLOT W/CSB 1

152601443-002 HARN, MCSB POWER 1

152601473-006 CAT5E CABLE, GRAY 2M 1

152601491-001 HARNESS, X-SLOT-3 20 PIN 1
152601491-002 HARNESS, X-SLOT-4 20 PIN 1

157605306-002 PANEL, X-SLOT 1

180190118-015 BOLT HEX FL LK M4 X 12 3

Table 10-36 Assembly, X-Slot W/CSB - 103 003 754

Part Number Description Qty.

101073662-001 MINI-CSB PC BOARD 1

157604708-001 HOUSING, X-SLOT EXTREME 2

10–20 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-36 Assembly, X-Slot W/CSB - 103 003 754 (Continued)

Part Number Description Qty.

157605121 CHASSIS, X-SLOT 1

157605140 PLATE, MINI-CSB MOUNT 1

157605489 BRACKET, X-SLOT RETAINER 1
180190110-306 SCREW PH STEEL M4 X 10 4

180500055-306 SCREW, CH HD, POZIDR, M4X10 4

157605617 COVER PLATE, DB-9 1
180190118-015 BOLT HEX FL LK M4 X 12 1

Table 10-37 400V 9390 PM Enhanced GDB New PCB - 103005788

101073679-001 ENHANCED SMART GATE DRIVE BO 1
101073836 9390 400V Power Module Bd As 1
116750188 BRACKET, POWER MODULE MOUNTI 1

127250358 INSULATOR, GATE DRIVE TO POW 1

127250365 INSULATOR, GATE DRIVE DC TO 6
127250466-001 9390 PM WIRE ABRASION PROTEC 2

129202025-012 BUMPER RUBBER .09 X .34 2

132208003-004 STANDOFF PWB NYLON 1/4" 8
152201107-001 CABLE TIE, 11.0L 105 DEG 2

© 2009 Eaton Corporation. Company Confidential. 10–21

Parts 9390 Service Manual

10.5 Common Parts

Table 10-38 MOST COMMON PARTS, 20-80 kVA, 400 VOLTS

Part Number Description, 20-80 kVA Most Common Parts

1004944 SCREW K M4x8 PZ DIN7985A+6907

101073650-001 SMART GATE DRIVE

101073704-001 PCB, INTERFACE BOARD

101073652-003 PCBAS 3P80 POWER SUPPLY HPO
101073653-001 PCB, STATIC SWITCH

101073662-
PCBAS MINI-CSB 9390 SP
001SP
101073663-001 X-SLOT HOTSYNC CAN BRIDGE PCB, DB-9 CONNECTOR
101073785-001 X-SLOT HOTSYNC CAN BRIDGE PCB, RJ-45 CONNECTOR

1024460 PCB, CONTROL BOARD

101073677-003 PCBAS 3P160 POWER SUPPLY HPO
101073679-001 ENHANCED SMART GATE DRIVE BRD

1015496 CONNE TERM BLOCK 95mm2 GREY

1015497 CONNE TERM BLOCK 95mm2 BLUE
1019503 THYRI MOD 160A 1600V

1021359 BUTTON K15 DISPLAY A4**

1022650 CONTA 3PH 125A 415V COIL 48VDC

1022651 SWTCH 3x125A 415 Vac ON-OFF

1022652 SWTCH 3x200A 415 Vac ON-OFF
1022653 SWTCH 4x250A 415 Vac ON-OFF

1022874 SWTCH ACC AUX CNTCT 1NO ABB OT

1023148 FUSE 355A 240V UR 355LMT
1023375 PCBAS 3P80 MAINS CAPBOARD

1023378 PCBAS 3P80 DCLINK CAPBOARD

1023379 MCCB 250A 600VDC 3P AUX UVR48V
1023387 PCBAS 3P80 OUTPUT CAPBOARD

1023477 PCBAS 3P80 RFI

1024640 CABLE 3P80 CAN PARALLEL A4

10–22 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-38 MOST COMMON PARTS, 20-80 kVA, 400 VOLTS (Continued)
Part Number Description, 20-80 kVA Most Common Parts

1024641 CABLE 3P80 PULLCHAIN PARALL A4

1024910 PCBAS 3P80 IN/OUT RFI BOARD

103003704 SUBAS 3P80 TERMINAL BLOCK 10PO
103003704SP SUBAS 3P80 TERMINAL BLOCK 10PO

103003706 SUBAS DISPLAY

103003706SP KIT 3P80 DISPLAY
103003708 SUBAS 3P80 TRAY, SIX FAN

103003708SP KIT 3P80 TRAY SIX FAN

103003791 SUBAS 3P80 STATIC SWITCH
103003791SP KIT 3P80 STATIC SWITCH 480V

103003853 SUBAS 3P80 CONTROL HARNESS

103004241 400V POWER MOD 10/14 ASSEMBLY
103004409 KIT 9390 40-80kVA MINI-CSB INST

116750188 BRACKET, POWER MODULE MOUNTNG**

120105088-001 CAPAC ELE 64000uF 63VDC
120311025-002 CAPAC FILM 45UF 370 Vac

120314020-002 CAPAC 45UF 600 Vac D-STUD

130913297-002 LATCH LIFT & TURN W/LOCK
149502081 TRAFO CURRENT 1000/1A 150A

151101079-001 FAN 120 MM X 38 MM, 190 CFM

151201040-003 AIR FILTER 16X10X1 STRATADENS

151501017-001 FAN GUARD, 4.125” MOUNT

157605169-001 DOOR, CONTROL
157605170-001 HINGE, UPPER

157605171-001 HINGE, LOWER

157605184 ANGLE, TOWER BUMPER
157605240 PANEL 3P80 DRESS SKIN

157605255 DOOR, LH, BATTERY CABINET

157605256 DOOR, RH, 423 WIDE, FIXED
157605621 PLATE 272x115 **

© 2009 Eaton Corporation. Company Confidential. 10–23

Parts 9390 Service Manual

Table 10-38 MOST COMMON PARTS, 20-80 kVA, 400 VOLTS (Continued)
Part Number Description, 20-80 kVA Most Common Parts

157605622 PLATE, BOTTOM CONDUIT 400V **

157605623 COVER, REAR 400V **

8052457 FUSE 160A 240V UR 160LET

Table 10-39 MOST COMMON PARTS, 100-160 kVA, 400 VOLTS

Part Number Description, 100-160 kVA Most Common Parts

1004086 THYRI MOD 250A 1600V

1004944 SCREW K M4x8 PZ DIN7985A+6907
101073650-001 SMART GATE DRIVE

101073704-001 PCB, INTERFACE BOARD

101073653-001 PCB, STATIC SWITCH
101073662-
PCBAS MINI-CSB 9390 SP
001SP

101073663-001 X-SLOT HOTSYNC CARD

1024460 PCB, CONTROL BOARD
101073677-003 PCBAS 3P160 POWER SUPPLY HPO

101073679-001 ENHANCED SMART GATE DRIVE BRD

101073682-001 PCB, 3P160 FEED THROUGH

101073682-501 PCB, 3P160 FEED THROUGH **

1021359 BUTTON K15 DISPLAY A4**
1023378 PCBAS 3P80 DCLINK CAPBOARD

1023379 MCCB 250A 600VDC 3P AUX UVR48V

1023477 PCBAS 3P80 RFI
1023813 CONNE 1P 35-240/16-185mm2 BASE

1023816 CONTA 3PH 275A 415V COIL 48VDC

1024640 CABLE 3P80 CAN PARALLEL A4
1024641 CABLE 3P80 PULLCHAIN PARALL A4

1026010 KIT 9390 SYNC CONTROL

103003651-002 SUBAS 3P160 STATIC SWITCH 480V

10–24 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-39 MOST COMMON PARTS, 100-160 kVA, 400 VOLTS (Continued)
Part Number Description, 100-160 kVA Most Common Parts

103003651-
KIT 3P160 STATIC SWITCH 480V
002SP

103003706 SUBAS DISPLAY

103003706SP KIT 3P80 DISPLAY
103004206 SUBAS 3P160 CONTROL HARNESS

103004241 400V POWER MOD 10/14 ASSEMBLY

103004410 KIT 9390 160kVA MINICSB INSTAL
116750188 BRACKET, POWER MODUL MOUNTNG**

120105088-001 CAPAC ELE 64000uF 63VDC

120311025-002 CAPAC FILM 45UF 370 Vac
120314020-002 CAPAC 45UF 600 Vac D-STUD

128307025-007 FUSE 315A 700 Vac M8 45MM SQ

128307025-008 FUSE 630A 600 Vac, M8 45MM SQ
128307033-001 FUSE 160A, 700 Vac, M8 45MMSQ

130913297-002 LATCH LIFT & TURN W/LOCK

145901041 SWITCH MICRO - 2A 250V
149502081 TRAFO CURRENT 1000/1A 150A

151101079-001 FAN 120 MM X 38 MM, 190 CFM

151201040-001 AIR FILTER 16X30X1

151201040-002 AIR FILTER 12X30X1

151501017-001 FAN GUARD, 4.125” MOUNT
157605169-001 DOOR, CONTROL

157605170-001 HINGE, UPPER

157605171-001 HINGE, LOWER
157605223 HINGE, LOWER RIGHT

157605255 DOOR, LH, BATTERY CABINET

157605256 DOOR, RH, 423 WIDE, FIXED
157605301 HINGE, UPPER RIGHT

© 2009 Eaton Corporation. Company Confidential. 10–25

Parts 9390 Service Manual

Table 10-40 US 400V INDIVIDUAL PARTS

123110015-002 CONTACTOR, 429 A, 1000 Vac, 3 POL 1

123110016-001 CONTACTOR, 490 A, 1000 Vac, 3 POL 1

123110016-002 CONTACTOR, 612 A, 1000 Vac, 3 POL 1

149208385-002 SENSOR, HALL EFFECT, 500 A 7

122161006-001 CIRCUIT BREAKER, 3 POLE, 600 A 1

1026807 CONTACTOR, 800A 415 Vac 3P COIL 48 1

CURR
1026806 MCCB 1250A 415 Vac 3P 50kA NOT
AVAIL

CURR
1027195 MCCB 630A 415 Vac 3P NOT
AVAIL

10–26 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

10.6 X-SLOT CONNECTIVITY DEVICE OPTIONS

See Table 5-1 for part numbers and descriptions of X-Slot connectivity device
options such as field kits for CAN Bridge, SNMP, relay and modem cards,
MODBUS, Mini-CSB, and others.

Table 10-41 CAN BRIDGE FIELD KIT - 103 004 336

Part Number Description Qty.

HS CAN BRIDGE X-SLOT PCB,

101073663-001 1
DB-9 CONNECTOR

HS CAN BRIDGE X-SLOT PCB,

101073785-001 1
RJ-45 CONNECTOR, RoHS Compliant

174650184-003 POLY BAG ZIP LOCK CLOSE 1

174650309 BOX, SHIPPING 8 X 8 X 2.75 1
180500055-306 SCREW, CH HD, POZIDR, M4X10 2

Table 10-42 9390 INTERNAL SERVICE SWITCH ASSEMBLIES

Part Number Description

103004394 9390 80kVA (208V)

103004395 9390 80kVA (480V)

103004438 9390 120-160kVA (208V)

103004439 9390 120-160kVA (480V)

Table 10-43 9390 ISS Circuit Breakers

Part Number Description

122161003-001 ISS Breaker, 9390 40kVA (480V)

122161003-001 ISS Breaker, 9390 80kVA (480V)
122129005-002 ISS Breaker, 9390 120kVA (480V)

122129005-002 ISS Breaker, 9390 160kVA (480V)

122139073 ISS Breaker, 9390 40kVA (208V)
122139073 ISS Breaker, 9390 80kVA (208V)

122139083-001 ISS Breaker, 9390 120kVA (208V)

© 2009 Eaton Corporation. Company Confidential. 10–27

Parts 9390 Service Manual

Table 10-43 9390 ISS Circuit Breakers

Part Number Description

122139083-001 ISS Breaker, 9390 160kVA (208V)

122161003-001 ISS Breaker, 9390 40kVA (400V)

122129005-002 ISS Breaker, 9390 80kVA (400V)
122129005-002 ISS Breaker, 9390 120kVA (400V)

122139073 ISS Breaker, 9390 160kVA (400V)

Table 10-44 9390 kVA UPGRADE KITS, 208 VOLT and 480 VOLT
Part Number Description

103004754-001 Model 80 / 40kVA to 50kVA

103004754-002 Model 80 / 40kVA to 60kVA

103004754-003 Model 80 / 40kVA to 80kVA
103004754-004 Model 80 / 50kVA to 60kVA

103004754-005 Model 80 / 50kVA to 80kVA

103004754-006 Model 80 / 60kVA to 80kVA
103004754-007 Model 120 / 100kVA to 120kVA

103004754-008 Model 160 / 100kVA to 120kVA

103004754-009 Model 160 / 100kVA to 160kVA
103004754-010 Model 160 / 120kVA to 160kVA

Table 10-45 9390 kVA UPGRADE KITS, 400 VOLT

Part Number Description

1025878 Upgrade Kit, 9390, Models 60 to 80 kVA

1025879 Upgrade Kit, 9390, Models 100 to 120 kVA
1025880 Upgrade Kit, 9390, Models 120 to 160 kVA

Table 10-46 LOAD SYNC CONTROL HARNESS KITS

Part Number Description Qty.

103004296 40-80 kVA Load Sync Control Harness 1

10–28 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-46 LOAD SYNC CONTROL HARNESS KITS

Part Number Description Qty.

103004290 100-160 kVA Load Sync Control Harness 1

Table 10-47 NO NEUTRAL KIT, 400 VOLT

Part Number Description Qty.

400 Volt, No Neutral Kit, for Models 20 to 160

1025568 1
kVA Units

See Sections 3.1.1 and 3.2.1, RT and Parallel Mechanical Inspection, about No-
Neutral kits.

Table 10-48 TERMINAL BLOCK CONTROL HARNESSES

Part Number Description Qty.

152601415 Old Terminal Block Configuration, 80 kVA 1

152602185 * New Terminal Block Configuration, 80 kVA 1
152601559 Old Terminal Block Configuration, 160 kVA 1

152602186 * New Terminal Block Configuration, 160 kVA 1

* 128304038-045 Fuse for 80 kVA and 160 kVA Harnesses, ATM 1 Amp 1
138425709, Rev D00 Old Label 1

138425709, Rev E00 New Label 1

© 2009 Eaton Corporation. Company Confidential. 10–29

Parts 9390 Service Manual

10.7 ESM Upgrade Kits

The kits below are required to upgrade a 9390 for ESM operation. A CSB is
required for this upgrade.

Table 10-49 9390 ESM Upgrade Kit

400/480 US Models with character 8 of the s.n. “B” or higher 103007620

P/N Description Qty

138501403-
Label Blank 2.75 X 4.18 1
005

9390 ESM Upgrade Procedure for all US 400/480 Model

164700775 40 & all other models with character 8 of the serial 1
number “B” or higher.

Table 10-50 9390 ESM Upgrade Kit

208V Models 40 & 80 and US 400/480V Models 120 & 160, character 8
of the s.n. less than “B” 103007621
P/N Description Qty

138501403-
Label Blank 2.75 X 4.18 1
005
9390 ESM Upgrade Procedure for 208V Models 40 & 80
164700776 1
and US 400/480V Models 120 & 160.

119201628 Bus Bar 3

119201630 Bus Bar 3

Table 10-51 9390 ESM Upgrade Kit

208V Models 120 & 160, character 8 of the s.n. less than “B”
103007622
P/N Description Qty

138501403-
Label Blank 2.75 X 4.18 1
005

10–30 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-51 9390 ESM Upgrade Kit

208V Models 120 & 160, character 8 of the s.n. less than “B”
103007622
9390 ESM Upgrade Procedure for 208V Models 120 &
164700777 1
160.
119201631 Bus Bar 3

119201632 Bus Bar 3

Table 10-52 9390 ESM Upgrade Kit

US 400/480V Model 80, character 8 of the s.n. less than “B” 103007623
P/N Description Qty

138501403-
Label Blank 2.75 X 4.18 1
005
9390 ESM Upgrade Procedure for US 400/480V Model
164700778 1
80.

180190078-
Bolt Hex Head M8 X 16 3
064
119201629 Bus Bar 3

10.8 9390 Capacitor Replacement Kits

The kits below provide part numbers to order replacement capacitors and the
procedure for the 9390.

Table 10-53 9390 40 400/480V AC I/O Cap Upgrade 103007583

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004522 AC CAP PAN, 40kVA 480V 1

Table 10-54 9390 40 400/480V DC Link Cap Upgrade 103007584

P/N Description Qty

© 2009 Eaton Corporation. Company Confidential. 10–31

Parts 9390 Service Manual

Table 10-54 9390 40 400/480V DC Link Cap Upgrade 103007584

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1
103004059-
SPARES KIT POWER MODULE 2
SP

Table 10-55 9390 80 400/480V AC I/O Cap Upgrade 103007585

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103003703 CAP PAN, HIGH VOLTAGE 1

Table 10-56 9390 80 400/480V DC Link Cap Upgrade 103007586

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004059-
SPARES KIT POWER MODULE 4
SP

Table 10-57 9390 120 400/480V AC I/O Cap Upgrade 103007587

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004524 ASM, FILTER 120kVA 480V 1

Table 10-58 9390 120 400/480V DC Link Cap Upgrade 103007588

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004059-
SPARES KIT POWER MODULE 6
SP

10–32 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Table 10-59 9390 160 400/480V AC I/O Cap Upgrade 103007589

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004373 CAP PAN, HIGH VOLTAGE 2

Table 10-60 9390 160 400/480V DC Link Cap Upgrade 103007590

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004059-
SPARES KIT POWER MODULE 8
SP

Table 10-61 9390 40 208V AC I/O Cap Upgrade 103007607

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004521 AC CAP PAN, 40kVA 208V 1

Table 10-62 9390 40 208V DC Link Cap Upgrade 103007608

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004058-
SPARES KIT POWER MODULE 2
SP

Table 10-63 9390 80 208V AC I/O Cap Upgrade 103007609

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103003702 CAP PAN, LOW VOLTAGE 1

© 2009 Eaton Corporation. Company Confidential. 10–33

Parts 9390 Service Manual

Table 10-64 9390 80 208V DC Link Cap Upgrade 103007610

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004058-
SPARES KIT POWER MODULE 4
SP

Table 10-65 9390 120 208V AC I/O Cap Upgrade 103007611

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004523 ASM, FILTER 120kVA 208V 1

Table 10-66 9390 120 208V DC Link Cap Upgrade 103007612

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004058-
SPARES KIT POWER MODULE 6
SP

Table 10-67 9390 160 208V AC I/O Cap Upgrade 103007613

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004335 CAP PAN, LOW VOLTAGE 2

Table 10-68 9390 160 208V DC Link Cap Upgrade 103007614

P/N Description Qty

164700764 9390 CAPACITOR UPGRADE PROCEDURE 1

103004058-
SPARES KIT POWER MODULE 8
SP

10–34 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

10.9 NEUTRAL-FORMING TRANSFORMER FIELD

KITS
The following part numbers are both the drawing numbers, found in Chapter 11
Prints, and the Field Kit part numbers shown below. CSEs can find any
additional assembly numbers on the drawings themselves. You can also find the
drawings on the Eaton Employee Intranet at: http://poweratwork/usa/. Click on
USA Menu/Applications/EISWebPrint.

Part Number Description Qty.

106711188 Field Kit, 80 kVA, Neutral-Forming Transformer 1

106711191 Field Kit, 160 kVA, Neutral-Forming Transformer 1

© 2009 Eaton Corporation. Company Confidential. 10–35

Parts 9390 Service Manual

10.10 Contactor Vendor Change from ABB to Cutler-

Hammer
Table 10-69 lists the CTO numbers and Serial numbers for the units that were
improperly coded as having the new Cutler-Hammer contactors installed. When
ordering replacement contactors for these units only, use the ABB Contactor
part number. See Section 7.21.2, 9390 Contactors, for these part numbers.
The bold letters, CBA, in the middle column indicate that Cutler-Hammer
Contactors were installed in the UPSs, except for the following CTO Numbers
dated from 5/11/06 to 12/2/05. These BOLD serial numbers should be CAA
serial numbers for ABB Contactors. CBA serial numbers for Cutler-Hammer
Contactors started in June.

Table 10-69 Contactor Serial Numbers for Vendor Change

9390 TC_ 120K 208V conversion to C-H contactors

CTO
C-H Serial Numbers Date Shipped or Sold
Numbers

TC1219300031010 EY251CBA21 6/23/06

TC1219300031010 EY251CBA20 6/24/06
TC1211000030010 EY192CBA09 5/11/06

TC1211324731010 EY184CBA12 5/11/06

TC1011360031010 EY175CBA07 5/3/06
TC1211300031010 EY093CBA04 3/7/06

TC1211300031010 EY093CBA02 3/2/06

TC1211320031010 EY085CBA05 3/2/06

TC1011301130010 EY035CBA03 1/25/06

TC1219300031010 EX511CBA04 12/13/05
TC1219300031010 EX505CBA01 12/12/05

TC1211300030010 EX504CBA01 12/12/05

TC1211300030010 EX493CBA07 12/2/05

10–36 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

10.10.1 Contactor Vendor Change Documentation

The tables below list the EatonPW Installation/Operation Manuals that cover this
change from ABB to Cutler-Hammer. The Installation and Operation manuals,
on the Acrobat Interactive CD, have changed to reflect the new contactor
information.

Table 10-70 EatonPW Installation/Operation Manuals

Part Number Installation & Operation Manual Description

164201535, Rev E 9390 40/80 kVA, with ABB Contactors

164201554, Rev E 9390 100/160 kVA, with ABB Contactors

164201603, Rev B 9390 40/80 kVA, with Cutler-Hammer Contactors

164201604, Rev B 9390 100/160 kVA, with Cutler-Hammer Contactors

Table 10-71 9390 Contactors

Assembly Contactor Part
Vendor Contactor Description
Number Number

Generation 0, ABB Contactors

103003863 Contactor Subassembly, 120&160kVA, 208V 123112004-002

103003864 Contactor Subassembly, 120&160kVA, 480V 123110010-001

103003700 Contactor Subassembly, 40&80kVA, 208V 123110011-001
103003760 Contactor Subassembly, 40&80kVA, 480V 123109021-001

103003924 K5 Bypass Subassembly, 120&160kVA, 208V 123112004-002

Generation 1, Cutler-Hammer Contactors

103004594 K1, K3 Contactor Subassembly, 160kVA, 208V 123110016-001

103004595 K1, K3 Contactor Subassembly, 160kVA, 480V 123109028-001
103004596 K1, K3 Contactor Subassembly, 120kVA, 208V 123110015-001

103004634 K1, K3, Contactor Subassembly, 120kVA, 480V 123109029-002

103004677 K1, K3 Contactor Subassembly, 80kVA, 208V 123109028-001
103004653 K1, K3 Contactor Subassembly, 80kVA, 480V 123109029-001

103004654 K1, K3 Contactor Subassembly, 40kVA, 208V 123109029-001

103004655 K1, K3 Contactor Subassembly, 40kVA, 480V 123104013-001
103004601 K5 Bypass Subassembly, 160kVA, 208V 123110016-001

103004602 K5 Bypass Subassembly, 160kVA, 480V 123109028-001

© 2009 Eaton Corporation. Company Confidential. 10–37

Parts 9390 Service Manual

Table 10-71 9390 Contactors (Continued)

Assembly Contactor Part
Vendor Contactor Description
Number Number

103004603 K5 Bypass Subassembly, 120kVA, 208V 123110015-001

103004680 K5 Bypass Subassembly, 80kVA, 208V 123109028-001

10.10.2 Reading HPO Format Circuit Board Part Numbers

Helsinki Plant Operations part numbers are shown in Figure 10-1, Serial
Number Close Up. The part number consists of 24 digits, as follows:
1. Digit 1-8 = Truncated Part Number (101073666-001 is coded as
73666001).
2. Digit 9-11 = Current Revision, with digit 9 as a blank if needed.
• Rev A00 is coded as “A0”. Rev A01 is coded as “A1”. Rev AB01 is
coded as “AB1”.
3. Digit 12-17 = Serial Number, with leading zeroes (starts over at
000001 every week, on Monday morning).
4. Digit 18-21 = Date Code, in format “yyww” (two digit year, two digit
week).
5. Digit 22-24 = Supplier Code, with digit 22 as a blank

Figure 10-1 Serial Number Close Up

10–38 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

10.10.3 9390 Power Supply Usage

101073652-002 rev. A00 to be used in 80 kVA 480V units only.
101073652-003 rev. A00 to be used in 80 kVA 480V units only.
101073677-001 rev. A00 to be used in 160 kVA 480V units.
101073677-003 to be used in all kVA 400V units.
Power supply board part number and revision must match the other power
supply boards in a given unit. Units that are 208V and 480V 160 kVA units must
use only 101073677-001 rev A00 boards.

kVA 208 V 400 V 480 V

101073652-001 rev. P05 101073652-002 rev. A00

101073677-003
80 kVA or or
101073652-002 rev A00 101073652-003 rev. A00
101073677-001 rev. P01
160 kVA or 101073677-003 101073677-001 rev. A00
101073677-001 rev. A00

10.10.4 9390 Gate Drive Transformer Core Issue

The supplier was not able to get enough material for transformer cores used in
the Gate Drive Board 101073650-001. A deviation allowed them to use a
different core material, which results in MORE power being consumed. These
boards have transformers marked with date codes ranging from 0431 to 0436
(for year 2004 week 31 to year 2004 week 36). Figure 10-2 shows transformer
date codes.
Note that these are transformer date codes, not board date codes. If boards with
these “deviated transformers” are used, they need to be restricted to 80 kVA
units only, and the F7 fuse on their Interface Boards needs to be 10A.

CAUTION
These boards with “deviated transformers” cannot be used in 160 kVA units.

© 2009 Eaton Corporation. Company Confidential. 10–39

Parts 9390 Service Manual

Date
Codes

Figure 10-2 Example of Gate Drive Board Date Codes

10.10.5 9390 Interface Board Fuse F7 Issue

Fuse F7 on all Interface Boards is being changed to 10A (instead of 5A). This is
being done at the Assembly line. See Figure 7-3, Fuse F7 Marked As 5 Amps,
Requires 10 Amp.
160 kVA units REQUIRE a 10A fuse.
80 kVA units with a “deviated transformer core” REQUIRE a 10A fuse. See
Section 7.24 above.

10–40 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

Date
Codes

Figure 10-3 Fuse F7 Marked As 5 Amps, Requires 10 Amp

10.10.6 Integrated Distribution Cabinets (IDC) (80kVA)

Refer to CTO Chart 110 577 085 in Chapter 11, Prints.

Table 10-72 9390 80kVA Distribution Cabinet Parts

Part Number Description

103003876 KIT, DRESS SKIN

103004038 ASSY, XFRMR, 208V IN, K20, AL
103004039 ASSY, COMMON PARTS, 80kVA IDC

103004040 ASSY, INPUT CB, 208V, STANDARD

103004043 ASSY, BYPASS SWITCH, 208V, 80kVA
103004046 ASSY, DOOR, LEFT, NO DISPLAY

103004072 ASSY, BYPASS SWITCH, 480V, 80kVA

103004073 ASSY, INPUT CB, 480V, STANDARD

103004076 ASSY, ADAPTER BUS, 208V, NO BYPASS

103004077 ASSY, PANELBOARD, LEFT
103004106 ASSY, PANELBOARD, RIGHT

103004107 ASSY, BYPASS SWITCH, NONE

© 2009 Eaton Corporation. Company Confidential. 10–41

Parts 9390 Service Manual

Table 10-72 9390 80kVA Distribution Cabinet Parts (Continued)

Part Number Description

103004108 ASSY, XFRMR, NONE

103004109 ASSY, DISTRIB CB, LEFT, ONE

103004110 ASSY, DISTRIB CB, LEFT, TWO
103004111 ASSY, DISTRIB CB, LEFT, THREE

103004112 ASSY, DISTRIB CB, RIGHT, ONE

103004113 ASSY, DISTRIB CB, RIGHT, TWO
103004114 ASSY, DISTRIB CB, RIGHT, THREE

103004149 ASSY, XFRMR, 480V IN, K20, AL

103004177 ASSY, OUTPUT, NONE, LEFT
103004178 ASSY, OUTPUT, LUGS, RIGHT

103004416 ASSY, COMMON PARTS, 80kVA

103004418 ASSY, XFRMR, 480V IN, K20, AL
103004419 ASSY, XFRMR, 208V IN, K20, AL

152601571 HARN, INPUT CB TO PHASE BUS

152601572 HARN, UPS NEUTRAL INPUT, 80 / 208
152601576 HARN, UPS TO INPUT CB, 80 / 480

152601589 HARN, XFRMR NEUTRAL TO PB1

152601590 HARN, XFRMR NEUTRAL TO PB2
152601591 HARN, XFMR-N FOR CB11/E11, IDC

152601592 HARN, XFMR NEUTRAL FOR CB21

152601593 HARN, NEUTRAL BUS TO PB1

152601594 HARN, NEUTRAL BUS TO PB2

152601595 HARN, NEUT BUS FOR CB11/E11
152601596 HARN, NEUTRAL BUS FOR CB21

174650513 PACKAGE KIT, IDC CABINET

174650551 PACKAGE KIT, IDC CABINET

10–42 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

10.11 Integrated Distribution Cabinets (IDC) (160kVA)

See CTO Chart 110 577 088 in Chapter 11, Prints.

Table 10-73 9390 160kVA Distribution Cabinet Parts

Part Number Description

103004179 KIT, SEISMIC MOUNTING

103004301 ASSY, DOOR, LEFT, IDC, NO DISPLAY

103004302 ASSY, XFMR, IDC, 160K, 480V, K20

103004303 ASSY, COMMON PARTS, IDC, 160K, 480V
103004304 ASSY, MIS & MBP, IDC, 160, 480V

103004307 ASSY, BOTTOM ENTRY, IDC, 160K

103004309 ASSY, BIB, IDC, 160kVA, 480V
103004310 ASSY, RIB, IDC, 160kVA, 480V

103004311 ASSY, LOADCENTER, LEFT, IDC, 160K

103004312 ASSY, LOADCENTER, RIGHT, IDC, 160K
103004313 ASSY, DISTRIB CB, LEFT, ONE

103004314 ASSY, DISTRIB CB, LEFT, TWO

103004315 ASSY, DISTRIB CB, LEFT, THREE
103004316 ASSY, DISTRIB CB, RIGHT, ONE

103004317 ASSY, DISTRIB CB, RIGHT, TWO

103004318 ASSY, DISTRIB CB, RIGHT, THREE

103004319 ASSY, TOP ENTRY, IDC, 160kVA

103004320 KIT, DRESS SKINS, IDC, 160kVA
103004321 PACK KIT, IDC, 160kVA

103004324 ASSY, BREAKER FILLER PLATE

103004325 ASSY, OUTPUT, NONE, LEFT, IDC, 160
103004327 ASSY, LUG OUTPUT, RIGHT, IDC, 160

103004411 HARN, XFMR-N FOR E11-13, IDC

103004412 ASSY, BIB, IDC, 160kVA, 480V, HI KAIC
103004413 ASSY, RIB, IDC, 160kVA, 480V, HI KAIC

152601685 HARN, E57-59 TO BIB,160kVA, 480V

152601696 HARN, XFRMR NEUTRAL TO PB1

© 2009 Eaton Corporation. Company Confidential. 10–43

Parts 9390 Service Manual

Table 10-73 9390 160kVA Distribution Cabinet Parts (Continued)

Part Number Description

152601697 HARN, XFRMR NEUTRAL TO PB2

152601704 HARN, XFMR NEUTRAL FOR CB11

152601705 HARN, XFMR NEUTRAL FOR CB21
152601707 HARN, UPS TO E57-E59,160 / 480

152601709 HARN, XFMR N FOR E11-13, IDC

152601710 JUMPERS, ONE FEED-4 CB, IDC, 160

10–44 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Parts

10.12 Parts Break-down / Look-up Procedure

This procedure is designed to ensure that Customer Service Engineers have the
flexibility to look up the most current and/or research a previously listed part
number on any Eaton® product.

10.12.1 Requirements:
a. Access to Eaton’s Division Intranet.
b. An assembly number where the parts are located.
c. For help finding a part or assembly number for the 9390 the
following link can be very helpful: http://10.222.1.10/mantech/lsg/
indigo_proced.htm. This site has pictures of the major
assemblies broken down to the individual part level with part
numbers.
d. Otherwise, contact Technical Support @ 800 479-4694.

10.12.2 Enovia Access to Part Numbers

The Enovia system used to be called Matrix. Eaton employees can request
access to the Enovia system through Outlook. Manager approval is required.
1. Open Outlook.
2. Select Tools>Forms>Choose Form.
3. Choose Organizational Forms Library.
4. Select the Electrical Group Matrix User Request Form.
5. Complete the form and submit.
E-learning is available on Eaton University. Search keyword Enovia for a list of
courses. The Enovia Search course may be most useful for searching for parts.

© 2009 Eaton Corporation. Company Confidential. 10–45

Parts 9390 Service Manual

This page was left blank intentionally.

10–46 © 2009 Eaton Corporation. Company Confidential.

 11
Prints
# of
Number Page # Title Revision
Pages
1 1 208V Power Module

2 1 480V Power Module

3 1 400V Power Module (Top Level, Service)

4 1 9390 CAN Network

10 23 218 5 1 400V UPM 80 kVA Signal Cabling A

1010000000 6 1 Power Interface Board I/O Schematic P00

7 2 Static Switch & Power Supply I/O Schematic

10 18 345 8 1 X-Slot LV Relay Interface Board A00

10 21 280 9 1 Control Board B

10 2

11 3

12 4

13 5

14 6

10 24 459 15 1 Control Board 2 B

16 2

17 3

18 4

19 5

20 6

10 24 760 21 1 9390 400V TOPLEVEL, 80 kVA N Main Circuit 3

© 2009 Eaton Corporation. Company Confidential. 11–1

Prints 9390 Service Manual

# of
Number Page # Title Revision
Pages
9390 400V TOPLEVEL, 80 kVA NHS (parallel) Main
10 24 761 22 1 3
Circuit

10 24 913 23 1 9390 400V TOP LEVEL, 160 kVA Main Circuit A

110 577 083 24 1 9390 40/80/120/160 kVA CTO Chart 12

25 2

26 3

27 4

28 5

29 6

110 577 084 30 1 9390 Battery Cabinets 6

31 2

110 577 085 32 1 9390 Integrated Dist. Cabinets (IDC) 80 kVA 6

33 2

34 3

35 4

36 5

37 6

38 7

110 577 088 39 1 9390 Integrated Dist. Cabinets (IDC) 160 kVA 3

40 2

41 3

42 4

43 5

44 6

45 7

106 711 188 46 1 9390 80 kVA Neutral Forming Transformer B00

106 711 191 47 1 9390 160 kVA Neutral Forming Transformer A00

110 717 242 48 1 685 & 1085 Battery Cabinets Y00

49 2

11–2 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Prints

# of
Number Page # Title Revision
Pages
110 071 805 50 1 Relay Interface Board 6

110 720 413 51 1 X-Slot HV Industrial Relay Board A00

110 720 506 52 1 LV Power Board A00

110 720 507 53 1 HV Power Board A00

110 720 510 54 1 Smart Gate Drive Board B00

55 2

110 720 511 56 1 Power Interface Board A00

57 2

58 3

59 4

60 5

61 6

62 7

110 720 512 63 1 ’Older’ Power Supply (part no. 101073652) P04

64 2

110 720 513 65 1 Static Switch Board A01

110 720 528 66 1 LV Filter Board A00

110 720 529 67 1 HV Filter Board A00

110 720 534 68 1 Mini-CSB Board A00

69 2

110 720 535 70 1 CAN Bridge X-Slot Card A00

71 2

110 720 538 72 1 Display Board A00

110 720 553 73 1 9390 Battery Cabinets A01

74 2

110 720 556 75 1 9390 80 kVA TOP LEVEL (See Note 1) B01

76 2

77 3

110 720 562 78 1 9390 IDC A00

© 2009 Eaton Corporation. Company Confidential. 11–3

Prints 9390 Service Manual

# of
Number Page # Title Revision
Pages
110 720 568 79 1 Enhanced Smart Gate Drive Board C00

80 2

110 720 572 81 1 Feed-Through Board A00

110 720 593 82 1 9390 IDC A00

110 720 594 83 1 Power Interface Board 1

84 2

85 3

86 4

87 5

88 6

89 7

110 720 605 90 1 9390 160 kVA TOP LEVEL A00

91 2

92 3

93 4

110 720 804 94 1 9390 Internal Battery (9390 IT) 1

138 425 756 95 1 Labels, Breaker Interlock Panel B00

152 601 415 96 1 Harness, TB1 & TB2 B01

152 601 416 97 1 Harness, K1, K3, K5 Interface A01

152 601 436 98 1 Harnesses, Bypass, Fan & Power Supply D01

152 601 437 99 1 Ribbon Cable, Rect / Inv / X-Slot B01

152 601 442 100 1 Harness, Power Supply Power B01

152 601 443 101 1 Harness, Static Switch Fan Interface B01

152 601 444 102 1 Harness, Contactor A01

152 601 445 103 1 Harness, Fan Panel A01

152 601 457 104 1 Harness, Power Supply Voltage Sensing A01

152 601 461 105 1 Harness, Contactors, 80 kVA 480 Vac 1

152 601 490 106 1 Harness, Input / Bypass Sensing C01

152 601 528 107 1 Harness, Battery to Battery B00

11–4 © 2009 Eaton Corporation. Company Confidential.

9390 Service Manual Prints

# of
Number Page # Title Revision
Pages
152 601 529 108 1 Harness, Battery to UPS B01

152 601 670 109 1 Harness, Battery Cab to Battery Cab B00

157 605 614 110 1 Panel, Breaker Interlock, IDC 160 kVA A02
9390INST001
111 1 9390 Installation One-line GE MED (80 kVA) P2
GE
9390INST002
112 1 9390 Installation One-line GE MED (160 kVA) P2
GE
9390INST052 113 1 9390 Installation One-line With ISS A

114 1 Battery Watts per Cell @ 1.75 Volts per cell

115 1 Battery Runtimes-9390 “B” Type Batteries, 0.8PF

116 2

117 3 Battery Runtimes-9390 “B” Type Batteries, 0.9PF

118 4

119 1 Battery Runtimes-9390 “C” Type Batteries, 0.9PF

120 2

121 1 Battery Weights, Pounds

122 2 Battery Weights, Kilograms

123 3 Battery Dimensions, Installed

124 1 Eaton 12V 34W Battery Spec. Sheet

125 1 9390 w/o CSB to Vycon

126 1 9390 with CSB to Vycon

127 1 Vycon 48 Vdc UVR Option

© 2009 Eaton Corporation. Company Confidential. 11–5

Prints 9390 Service Manual

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11–6 © 2009 Eaton Corporation. Company Confidential.

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© 2009 Eaton Corporation. Company Confidential. 29
 Indigo/Bigblue 9390/9395 Battery Cabinet CTO Diagram

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Max Battery Cabinet
Cabinet Size Associated UPS Model DC Voltage Battery Type Battery Config Pack Kit Future Use Future Use
Cab Protection

TS = 9390/9395 001 = 12-120

1 = 384V 1 = Battery 1 = (9390)
570MM BATT CABINET 040 = 40KVA 570 Empty tray assy 1 = number of 1* = Integral
8 Trays Breaker 0 = Future 0 = Future
103004157 103004453 Battery Line-up and
CT0 1 = T 103004086 Options Options
Cabinets Match
CTO 1 = Q 103004086-002
002 = 12-XXX
QS = 9390/9395 1085 Empty tray assy
2 = 432V 101615327-004
570MM BATT CABINET (OEM1) 050 = 50KVA
9 Trays
103004157-002
003 = 12-170/200 2 = number of 2 = Remote
570 Empty tray assy Battery 2 = (9395) 103006228
TL = 9390/9395 103004454 Cabinets
3 = 480V
1085MM BATT CABINET 060 = 60KVA
10 Trays
103003873 B12 = 12-120
570 Tray assy
103004163 3 = number of
QL = 9390/9395 Battery
1085MM BATT CABINET (OEM1) 080 = 80KVA Cabinets
B17 = 12-170 U17 = 12-170
103003873-002
570 Tray assy 570 Tray assy
103004162 103004162-030

100 = 100KVA H20 = Enersys Hx205 4 = number of

E20 = PWR 12-200 C20 = CSB 12-200
570 Tray assy Battery
570 Tray assy 570 Tray assy
103004161-042 Cabinets
103004161-022 103004161-012

120 = 120KVA E28 = PWR 12-280 C28 = CSB 12-280 B27 = 12-270 1085 U27 = 12-270 1085 H30 = Enersys Hx300
1085 Tray assy 1085 Tray assy 1085 Tray assy 1085 Tray assy 1085 Tray assy
101615250-023 101615250-013 101615250-003 101615250-033 101615250-043

160 = 160KVA E33 = PWR 12-330 C33 = CSB 12-330 B31 = 12-310 U31 = 12-310
1085 Tray assy 1085 Tray assy 1085 Tray assy 1085 Tray assy
101615250-024 101615250-014 101615250-004 101615250-034
NOTES:

E39 = PWR 12-390 C39 = CSB 12-390 B37 = 12-370 U37 = 12-370 H40 = Enersys Hx400 * LINE-UP-AND-MATCH IS CURRENTLY UNAVAILABLE FOR 9395 225 THRU 550KVA.
225 = 225KVA 1085 Tray assy 1085 Tray assy 1085 Tray assy 1085 Tray assy 1085 Tray assy
101615250-025 101615250-015 101615250-005 101615250-035 101615250-045

E50 = PWR 12-500 B47 = 12-475 U47 = 12-475 H50 = Enersys Hx500
C50 = CSB 12-500
1085 Tray assy 1085 Tray assy 1085 Tray assy 1085 Tray assy
275 = 275KVA 1085 Tray assy
101615250-026 101615250-006 101615250-036 101615250-046
101615250-016

450 = 450KVA
Description CTO Chart 9390/9395 Battery
Group/Project INDIGO / BIGBLUE
Created By: P. Kukelhan Date: 10/08/04
500 = 500KVA
Modified By: WALLACE_T Date: 07/20/09
Object ID
110577084
Checked By: Matrix Date: 07/21/09 ECO 0008260 Revision: 6
Approved By: Matrix Date: 07/21/09 Status: Released Sheet 1 of 2
550 = 550KVA
These Drawings and Specifications Are the Property Of Powerware and Shall Not be Reproduced or Copied or Used as the Basis for Manufacture of Sale of Apparatus
Without Permission

30 © 2009 Eaton Corporation. Company Confidential.

 Cabinet Protection Assembly
570 cabinet 1085 Cabinet
KVA
384V 432V 480V 384V 432V 480V
40 103004165 103004165 103004165 103004167 103004167 103004167
50 or 60 103004166 103004166 103004166 103004168 103004168 103004168
80 103004164 103004164 103004164 103004333 103004333 103004333
100 N/A N/A N/A 103004333 103004333 103004333
120 N/A N/A N/A 103004333 103004333 103004220
160 N/A N/A N/A 103004333 103004333 103004220
225 / 275 N/A N/A N/A N/A N/A 103006083
450 / 500 / 550 N/A N/A N/A N/A N/A 103006083
Label Kit 138425712-006 138425712-005 138425712-004 138425712-006 138425712-005 138425712-004

Battery Cabinet Accessories

Description CTO Option P/N if CTO2 = L P/N if CTO2 = S QTY
Dress Skins CTO 11 = 1 157605240 157605240 2
Dress Skins CTO 11 = 2 157605240 157605240 2
157605242 157605242 2
Dress Skin Hangers CTO 11 = 1 Line Up and Match
180190118-015 180190118-015 6
157605242 157605242 2
Dress Skin Hangers CTO 11 = 2 Remote
180190118-015 180190118-015 6
CTO 11 = 1, CTO 3-5 = 040-120 1
Interconnect Power Cables (UPS) 152601525 152601663
CTO 11 = 1, CTO 3-5 = 160 2
CTO 3-5 = 040 thru 120 & CTO 10 = 2 thru 4 (1X - 1 = Qty) ----
Interconnect Power Cables (BAT) 152601526 152601664
CTO 3-5 = 160 & CTO 10 = 2 thru 4 (1X - 1) *2 = Qty ----
Field Kit CTO 10 = 1 thru 4 (1X = Qty) 101615249-001 101615249-001 ----
Interconnect Control Harness (BAT) CTO 10 = 2 thru 4 (1X = Qty) 152601528 152601670 ----
Interconnect Control Harness (UPS) CTO 11 = 1, CTO 10 = 1 (1st Bat Cab only) 152601540 152601669 1
Interconnect Control Harness (UPS) CTO 11 = 1, CTO 10 = 2 thru 4 (1st Bat Cab only) 152601529 152601671 1
CTO 3-5 = 040 thru 160 (1st Bat Cab only)
Compression Lug Kit 103004169 N/A 1
CTO 3-5 = 225 thru 550 & CTO 10 = 2 thru 4 (1X = Qty)
Shipping Monitor Kit (Shock and Tip) N/A (line item) 103005923 1

X = number of cabinet(s) to be multiplied by, for CTO 10 option

If CTO2 = L and CTO3/4/5 = 100 and CTO6 = 1 or 2, then CTO10 must be greater than 1 Description CTO Chart 9390/9395 Battery
If CTO2 = L and CTO3/4/5 = 120 and CTO6 = 1 or 2, then CTO10 must be greater than 1 Group/Project INDIGO / BIGBLUE
If CTO2 = L and CTO3/4/5 = 160 and CTO6 = 1 or 2, then CTO10 must be greater than 1 Created By: P. Kukelhan Date: 10/08/04 Object
If CTO2 = S and if CTO3/4/5 = 080 and CTO6 = 1 or 2, then CTO10 must be greater than 1 Modified By: WALLACE_T Date: 07/20/09 ID 110577084
If CTO2 =L and CTO3/4/5=225/275, then CTO10 must be greater than 1. (2) cabinet minimum Checked By: Matrix Date: 07/21/09 ECO 0008260 Revision: 6
If CTO2 =L and CTO3/4/5=450/500, then CTO10 must be greater than 2. (3) cabinet minimum Approved By: Matrix Date: 07/21/09 Status: Released Sheet: 2 of 2
If CTO2 =L and CTO3/4/5=550, then CTO10 must be greater than 3. (4) cabinet minimum These Drawings and Specifications Are the Property Of Powerware and Shall Not be Reproduced or Copied or Used as the Basis for
Manufacture of Sale of Apparatus Without Permission

© 2009 Eaton Corporation. Company Confidential. 31

 CTO CHART,
Description:
INTEGRATED DISTRIBUTION CABINET- 9390 40/ 80kVA
Group/Project: 9390
Created By: CHAVEZ_M Date: 6/1/2004
Modified By: WALLACE_T Date: 7/20/2009
Object ID: 110577085
Checked By: Matrix 10 Date: 7/21/2009 ECO ECO-0008260 Revision: 6
Approved By: Date: Status: RELEASED Sheet: 1 of 8

THESE DRAWINGS AND SPECIFICATIONS ARE THE PROPERTY OF POWERWARE AND SHALL NOT BE REPRODUCED OR COPIED OR USED AS THE BASIS
FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION

32 © 2009 Eaton Corporation. Company Confidential.

 Indigo
Powerware 9390
IDC Cabinet CTO
Chart

Family
Configuration and KVA
Configuration and KVA
Breaker Ratings (All)
Input/Output
Maintenance Bypass
Transformer
Output Configuration
(left)
Output Configuration
(right)
Seismic Zone 4 rated
Open
Open
Open
Options
Language
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

P/N 110577085
T 9390 0 0 0
Q 9390 OEM1 0 0 0

0 3 30 KVA 0 None ( L & M )

0 4 40 KVA 1 Display
0 5 50 KVA 2 Dress skins
0 6 60 KVA 3 Display and dress skins
0 8 80 KVA
1 0 100 KVA 1 English
1 2 120 KVA 2 French
1 6 160 KVA 3 German
0 0 Sidecar 4 Italian
5 Spanish
1 Standard kAIC 6 Japanese
2 High kAIC 7 Mandarin
8 Russian
1 208/208 60Hz
2 480/480 60Hz
3 400/400 50Hz
4 400/400 60Hz
5 480/208 60Hz
6 600/208 60Hz
Shaded boxes denote 7 600/600 60Hz
configurations not
available at this time 0 None

Page 2 of 8
1 Maintenance Bypass
2 Maintenance Bypass with BIB
3 Maintenance Bypass with BIB and RIB

0 None
1 K1 Aluminum
2 K13 Aluminum
3 K20 Aluminum
4 K1 Copper
5 K13 Copper
6 K20 Copper

0 None
1 1x 225A breaker
2 2x 225A breaker
3 3x 225A breaker

© 2009 Eaton Corporation. Company Confidential.

4 42-pole panelboard

0 Lugs
1 1x 225A breaker
2 2x 225A breaker
3 3x 225A breaker
4 42-pole panelboard

Shaded boxes denote 0 Standard configuration

configurations not 1 Zone 4 rated
available at this time
33
34
Family
Configuration and KVA
Configuration and KVA
Breaker Ratings (All)
Input/Output
Maintenance Bypass
Transformer
Output Configuration
(left)
Output Configuration
(right)
Seismic Zone 4 rated
Open
Open
Open
Options
Language
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

P/N 110577085
Cabinet P/N (NEW) Qty
40 KVA common parts 103005716 1
0
Pack kit 174650513 1
1
40 KVA common parts 103005716 1
1 Seismic Kit 103006296 1
Pack kit 174650551 1
T 0 4
40 KVA common parts 103006011 1
0
Pack kit 174650513 1
5
40 KVA common parts 103006011 1
1 Seismic Kit 103006296 1
Pack kit 174650551 1

80 KVA common parts 103005716 1

0
Pack kit 174650513 1
5
80 KVA common parts 103005716 1
1 Seismic Kit 103006296
Pack kit 174650551 1
T 0 8
80 KVA common parts 103005959 1
0
Pack kit 174650513 1

Page 3 of 8
1
80 KVA common parts 103005959 1
1 Seismic Kit 103006296 1
Pack kit 174650551 1

80 KVA common parts 103005716-001 1

5 0
Pack kit 174650513-001 1
Q 0 8
80 KVA common parts 103005959-001 1
1 0
Pack kit 174650513-001 1

Doors and dress skins P/N (NEW) Qty

0 Standard Door 103004046 1

T 0 4,8
Standard Door 103004046 1
2
Dress skin kit 103003876 1

Q 0 4,8 0 Standard Door 103004046-001 1

© 2009 Eaton Corporation. Company Confidential.

 Family
Configuration and KVA
Configuration and KVA
Breaker Ratings (All)
Input/Output
Maintenance Bypass
Transformer
Output Configuration
(left)
Output Configuration
(right)
Seismic Zone 4 rated
Open
Open
Open
Options
Language
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Bypass & Input

P/N (NEW) Qty
Breaker Options

Bypass Breakers,
103005969 1
1 208V, Std. kAIC
Breaker Filler 103004324 2

P/N 110577085
103005969 1
Bypass Breakers w/BIB, 103005970 1
1 2 208V, Std. kAIC 152602307 1
152602312 1
Breaker Filler 103004324 1

Bypass Breakers w/BIB & 103005969 1

3 RIB, 103005970 1
T 208V, Std. kAIC 103005971 1
OR 0 4 1
Q Bypass Breakers,
103005984 1
1 480V, Std. kAIC
Breaker Filler 103006028 2

103005984 1
Bypass Breakers w/BIB, 103005985 1
5 2 480V, Std. kAIC 152602307 1
152602312 1
Breaker Filler 103006028 1

Bypass Breakers w/BIB & 103005984 1

3 RIB, 103005985 1
480V, Std. kAIC 103005986 1

Bypass & Input

P/N (NEW) Qty
Breaker Options
Bypass Breakers,
103005863 1
1 208V, Std. kAIC
Breaker Filler 103005866 2

103005863 1
Bypass Breakers w/BIB,
103005864 1
208V, Std. kAIC
1 2 152602332 1
152602333 1
Breaker Filler 103005866 1

Bypass Breakers w/BIB & 103005863 1

3 RIB, 103005864 1
T 208V, Std. kAIC 103005865 1
OR 0 8 1
Q Bypass Breakers,
103005710 1
1 480V, Std. kAIC
Breaker Filler 103004324 2

103005710 1
Bypass Breakers w/BIB, 103005711 1

Page 4 of 8
5 2 480V, Std. kAIC 152602307 1
152602312 1
Breaker Filler 103004324 1

Bypass Breakers w/BIB & 103005710 1

3 RIB, 103005711 1
480V, Std. kAIC 103005712 1

© 2009 Eaton Corporation. Company Confidential.

Transformer New P/N numbers Qty
0 Transformer, none 103004108 1

Transformer, 208V in, K1

1 103005973 1
Aluminum

1
Transformer, 208V in, K13
2 103005974 1
Aluminum

T
Transformer, 208V in, K20
OR 0 4 3 103005975 1
Aluminum
Q

Transformer, 480V in, K1

1 103006021 1
Aluminum

Transformer, 480V in, K13

5 2 103006022 1
Aluminum

Transformer, 480V in, K20

3 103006023 1
Aluminum

0 Transformer, none 103004108 1

Transformer, 208V in, K1

1 103005953 1
Aluminum

1
Transformer, 208V in, K13
2 103005954 1
Aluminum

T
Transformer, 208V in, K20
OR 0 8 3 103005955 1
Aluminum
Q

Transformer, 480V in, K1

1 103005728 1
Aluminum

Transformer, 480V in, K13

5 2 103005730 1
Aluminum

Transformer, 480V in, K20

3 103005732 1
Aluminum
35
 Configuration and KVA

Configuration and KVA

Output Configuration

Output Configuration

Seismic Zone 4 rated

Maintenance Bypass
Breaker Ratings (All)

Input/Output

Transformer

Language
Options
Family

(right)

Open

Open

Open
(left)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Distribution, left side P/N (NEW) Qty

0 Output Configuration, None 103005793 1

1 Output Configuration, 1x 225A 103005717 1

breaker, left

T 2 Output Configuration, 2x 225A 103005718 1

OR 0 4,8 breaker, left
Q
3 Output Configuration, 3x 225A 103005719 1
breaker, left

4 Output Configuration, 42-pole 103005720 1

panelboard, left

Distribution, right side Qty

0 Output Configuration, Lugs 103005794 1

1 Output Configuration, 1x 225A 103005721 1

breaker, right

T 2 Output Configuration, 2x 225A 103005722 1

OR 0 4,8 breaker, right
Q
3 Output Configuration, 3x 225A 103005723 1
breaker, right

4 Output Configuration, 42-pole 103005724 1

panelboard, right

P/N 110577085 Page 6 of 8

36 © 2009 Eaton Corporation. Company Confidential.
 Harnesses that must be CTO driven, when both Option 1 and Option 2 conditions are met
("x" means that digit can be anything)

Configuration and KVA

Configuration and KVA

Output Configuration

Output Configuration

Seismic Zone 4 rated

Maintenance Bypass
Breaker Ratings (All)
CTO Numbers

Input/Output

Transformer

Language
Options
Family
Harness

(right)

Open

Open

Open
(left)
Option 1 Option 2 P/N Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
480 / 208 & 208/208 version
152602406 1 4
152602407 1 4
No Transformer 208V Input 152602511 1 x 0 8 x 1 x 0 x x x x x x x x
152602512 1 8
152601572 1 4,8

Panelboard, Right with Transformer 152602324 1 x 0 4,8 x x x 1,2,3 x 4 x x x x x x

no Transformer 152602408 1 x 0 4,8 x x x 0 x 4 x x x x x x

Panelboard Left with Transformer 152601590 1 x 0 4,8 x x x 1,2,3 4 x x x x x x x

no Transformer 152602409 1 x 0 4,8 x x x 0 4 x x x x x x x

Distribution Breakers, Right with Transformer 152601591 1 x 0 4,8 x x x 1,2,3 x 1,2, or 3 x x x x x x

no Transformer 152601595 1 x 0 4,8 x x x 0 x 1,2, or 3 x x x x x x

Distribution Breakers, Left with Transformer 152601592 1 x 0 4,8 x x x 1,2,3 1,2, or 3 x x x x x x x

no Transformer 152601596 1 x 0 4,8 x x x 0 1,2, or 3 x x x x x x x

Lugs, Right with Transformer 152601591 1 x 0 4,8 x x x 1,2,3 x 0 x x x x x x

no Transformer 152601595 1 x 0 4,8 x x x 0 x 0 x x x x x x

P/N 110577085 Page 7 of 8

© 2009 Eaton Corporation. Company Confidential. 37
 S.No Additional Options P/N
1 Shipping Monitoring Kit (Shock & Tip) 103005923

S.No JUMPER KIT SINGLE FEED , BIB/RIB P/N

1 For 40K 208/208
2 For 40K 480/208 152602416
3 For 80K 480/208

S.No JUMPER KIT SINGLE FEED , BIB/RIB P/N

1 For 80K 208/208 152601710

P/N 110577085 Page 8 of 8

38 © 2009 Eaton Corporation. Company Confidential.
Description: CTO CHART, INTEGRATED DISTRIBUTION CABINET, 9390-160
Group/Project: 9390
Created By: LOEFFLER_C Date: 11/16/2004
Modified By: WALLACE_T Date: 7/20/2009
Object ID: 110577088
Checked By: Matrix Date: 7/21/2009 ECO: 8260 Revision: 3
Approved By: Matrix Date: 7/21/2009 Status: RELEASED Sheet: 1 of 7

THESE DRAWINGS AND SPECIFICATIONS ARE THE PROPERTY OF POWERWARE AND SHALL NOT BE REPRODUCED OR COPIED OR USED AS THE BASIS
FOR MANUFACTURE OR SALE OF APPARATUS WITHOUT PERMISSION

© 2009 Eaton Corporation. Company Confidential. 39

40
P/N 110577088
Indigo
Powerware 9390-160
IDC Cabinet CTO
Chart

Family
Configuration and KVA
Configuration and KVA
Breaker Ratings (All)
Input/Output
Bypass & Input options
Transformer
Output Configuration
(left)
Output Configuration
(right)
Open
Open
Open
Wiring Configuration
Options
Language

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

T 9390 0 0 0
Q 9390 OEM1 0 0 0

1 0 100 KVA 0 Top and Bottom entry

1 2 120 KVA 1 Bottom cable entry
1 6 160 KVA
0 None
1 Standard kAIC 1 Display
2 High kAIC 2 Dress skins
3 Display and dress skins
1 208/208 60Hz
2 480/480 60Hz 1 English
3 400/400 50Hz 2 French
4 400/400 60Hz 3 German
5 480/208 60Hz 4 Italian
6 600/208 60Hz 5 Spanish
7 600/600 60Hz 6 Japanese
7 Mandarin
0 None 8 Russian
1 Maintenance Bypass

Sheet 2 of 7
2 Maintenance Bypass with BIB
3 Maintenance Bypass with BIB and RIB

Shaded boxes denote 0 None

configurations not 1 K1 Aluminum
available at this time 2 K13 Aluminum
3 K20 Aluminum
4 K1 Copper
5 K13 Copper
6 K20 Copper

0 None
1 1 distribution breaker
2 2 distribution breaker

© 2009 Eaton Corporation. Company Confidential.

3 3 distribution breaker
4 4 distribution breaker
P 42-pole panelboard

0 Lugs
1 1 distribution breaker
2 2 distribution breaker
3 3 distribution breaker
4 4 distribution breaker
P 42-pole panelboard
 Bypass & Input options
Configuration and KVA

Configuration and KVA

Output Configuration

Output Configuration

Wiring Configuration
Breaker Ratings (All)

Input/Output

Transformer

Language
Options
Family

(right)

Open

Open

Open
(left)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Cabinet P/N Qty

160 KVA common parts 103004303 1

T 1 5
Pack kit 103004321 1

160 KVA common parts 103004303-001 1

Q 1 5
Pack kit 103004321-001 1

Doors and dress skins P/N Qty

0 Standard Door 103004301 1

T 1
Standard Door 103004301 1
2
Dress skin kit 103004320 1

Q 1 0 Standard Door 103004301-001 1

Wiring Configuration

T 0 Top & Bottom Entry 103004319 1

OR 1
Q 1 Bottom Entry Only 103004307 1

Transformer P/N Qty

120 kVA transformer, 480V in,

1 103005637 1
K1 Aluminum

120 kVA transformer, 480V in,

2 5 2 103005638 1
K13 Aluminum

120 kVA transformer, 480V in,

3 103005639 1
K20 Aluminum

Transformer, none
0 xxxxxxxxx x

T
Transformer, 208V in, K13
OR 1 1 2 xxxxxxxxx x
Aluminum
Q

Transformer, 208V in, K20

3 xxxxxxxxx x
Aluminum
6
Transformer, 480V in, K1
1 103005108 1
Aluminum

Transformer, 480V in, K13

5 2 103005109 1
Aluminum

Transformer, 480V in, K20

3 103004302 1
Aluminum

P/N 110577088 Sheet 3 of 7

© 2009 Eaton Corporation. Company Confidential. 41
 Bypass & Input options
Configuration and KVA

Configuration and KVA

Output Configuration

Output Configuration

Wiring Configuration
Breaker Ratings (All)

Input/Output

Transformer

Language
Options
Family

(right)

Open

Open

Open
(left)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Bypass & Input

P/N Qty
Breaker Options

Bypass Breakers,
103005640 1
1 480V, 120kVA
Breaker Filler 103004324 2

103005640 1
Bypass Breakers w/BIB, 103005641 1
2 1 5 2 480V, 120kVA 152601685 1
152601707 1
Breaker Filler 103004324 1

103005640 1
Bypass Breakers w/BIB & RIB,
3 103005641 1
480V, 120kVA
103005642 1

Bypass Breakers,
1 1 xxxxxxxxx x
208V, Std. kAIC

Bypass Breakers,
103004304 1
1 480V, Std. kAIC
Breaker Filler 103004324 2

1 103004304 1
T Bypass Breakers w/BIB, 103004309 1
OR 1 5 2 480V, Std. kAIC 152601685 1
Q 152601707 1
Breaker Filler 103004324 1

103004304 1
Bypass Breakers w/BIB & RIB,
3 103004309 1
480V, Std. kAIC
103004310 1
6
Bypass Breakers,
1 1 xxxxxxxxx x
208V, High kAIC

Bypass Breakers,
103004411 1
1 480V, High kAIC
Breaker Filler 103004324 2

2 103004411 1
Bypass Breakers w/BIB, 103004412 1
5 2 480V, High kAIC 152601685 1
152601707 1
Breaker Filler 103004324 1

103004411 1
Bypass Breakers w/BIB & RIB,
3 103004412 1
480V, High kAIC
103004413 1

P/N 110577088 Sheet 4 of 7

42 © 2009 Eaton Corporation. Company Confidential.
 Bypass & Input options
Configuration and KVA

Configuration and KVA

Output Configuration

Output Configuration

Wiring Configuration
Breaker Ratings (All)

Input/Output

Transformer

Language
Options
Family

(right)

Open

Open

Open
(left)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Distribution, left side P/N Qty

0 Output Configuration, None 103004325 1

Output Configuration,
1 103004313 1
1 distribution breaker, left

Output Configuration,
2 103004314 1
2 distribution breaker, left
T
OR 1
Output Configuration,
Q 3 103004315 1
3 distribution breaker, left

Output Configuration,
4 xxxxxxxxx x
4 distribution breaker, left

Output Configuration, 42-pole

P 103004311 1
panelboard, left

Distribution, right side P/N Qty

0 Lugs, right 103004327 1

Output Configuration,
1 103004316 1
1 distribution breaker, right

Output Configuration,
2 103004317 1
2 distribution breaker, right
T
OR 1
Output Configuration,
Q 3 103004318 1
3 distribution breaker, right

Output Configuration,
4 xxxxxxxxx x
4 distribution breaker, right

Output Configuration, 42-pole

P 103004312 1
panelboard, right

P/N 110577088 Sheet 5 of 7

© 2009 Eaton Corporation. Company Confidential. 43
 Harnesses that must be CTO driven, when both Option 1 and Option 2 conditions are met
("x" means that digit can be anything)

Bypass & Input options

Configuration and KVA

Configuration and KVA

Output Configuration

Output Configuration

Wiring Configuration
Breaker Ratings (All)
CTO Numbers

Input/Output

Transformer

Language
Options
Family
Harness

(right)

Open

Open

Open
(left)
Option 1 Option 2 P/N Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
xxxxxxxxx 1
No Transformer 208V Input x 1 6 x 1 x 0 x x x x x x x x
xxxxxxxxx 1

with Transformer 152601696 1 x 1 6 or 2 x x x not 0 x P x x x x x x

Panelboard, Right
no Transformer xxxxxxxxx 1 x 1 6 or 2 x x x 0 x P x x x x x x

with Transformer 152601697 1 x 1 6 or 2 x x x not 0 P x x x x x x x

Panelboard Left
no Transformer xxxxxxxxx 1 x 1 6 or 2 x x x 0 P x x x x x x x

with Transformer 152601704 1 x 1 6 or 2 x x x not 0 x 1,2, or 3 x x x x x x

Distribution Breakers, Right
no Transformer xxxxxxxxx 1 x 1 6 or 2 x x x 0 x 1,2, or 3 x x x x x x

with Transformer 152601705 1 x 1 6 or 2 x x x not 0 1,2, or 3 x x x x x x x

Distribution Breakers, Left
no Transformer xxxxxxxxx 1 x 1 6 or 2 x x x 0 1,2, or 3 x x x x x x x

with Transformer 152601709 1 x 1 6 or 2 x x x not 0 x 0 x x x x x x

Lugs, Right
no Transformer xxxxxxxxx 1 x 1 6 or 2 x x x 0 x 0 x x x x x x

P/N 110577088 Sheet 6 of 7

44 © 2009 Eaton Corporation. Company Confidential.
 Line Item Options
Description Part Number
Seismic Mounting Kit 103004179
Jumper Kit for Single Feed with BIB/RIB Input Breakers 152601710
Shipping Monitor Kit (Shock and Tip) 103005923

P/N 110577088 Sheet 7 of 7

© 2009 Eaton Corporation. Company Confidential. 45
 38
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76 © 2009 Eaton Corporation. Company Confidential.

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© 2009 Eaton Corporation. Company Confidential. 123
 Technical specifications
Cells per unit 6
Powerware series PWHR1234W2FR
Voltage per unit 12
Capacity 34W @ 15-minute rate to 1.67V per cell @ 77°F (25°C)

Eaton 12V 34W Battery Weight

Maximum
discharge current
Approximately 5.64 lb (2.56 kg)
130A (5 sec)

Internal Approximately 17 m Ω
resistance
Operating Discharge: 5°F~122°F (-15°C~50°C)
temperature Charge: 5°F~104°F (-15°C~40°C)
range Storage: 5°F~104°F (-15°C~40°C)
Features
Nominal 77°F ± 5°F (25°C ± 3°C)
• Designed for high power density applications operating
temperature range
• Small volume, lightweight and high discharge efficiency
Float charging 13.5 to 13.8 Vdc/unit
• Can be used for more than 260 cycles at 100% discharge in voltage Average at 77°F (25˚C)
cycle service
Recommended 3.4A
• UL-recognized components under UL924 and certified by maximum
ISO 9001 and ISO 14001 charging current
limit
• Exclusive two-year battery parts coverage and one-year battery
labor coverage Equalization and 14.4 to 15.0 Vdc/unit
cycle service Average at 77°F (25˚C)
Self discharge Batteries can be stored for six months at 77°F (25°C).
Please charge batteries before using. For higher
temperatures the time interval will be shorter. Voltage
test prior to battery installation is recommended.
Terminal F2- Faston Tab 250
Container ABS UL94-HB/File E50263
material Flammability resistance of UL94-V0/File E88637 is
CONSTANT POWER DISCHARGE CHARACTERISTICS: WATTS/CELL (77°F, 25°C) available upon request.
End point volts/cell 2 min 4 min 6 min 8 min 10 min 15 min 20 min 30 min 60 min 90 min
1.85V 68 57 47 41 36 29 23 17 10 7
1.80V 76 61 51 44 40 32 25 18 10 8
1.75V 84 66 54 47 42 33 25 18 11 8
1.70V 92 70 57 49 43 34 26 19 11 8
1.67V 97 73 59 50 44 34 26 19 11 8
1.60V 107 78 63 51 44 34 27 19 11 8
All mentioned values are average values per battery per cell.
Tolerance: X <6 min (+15% ~ -15%), 6 min X < 10 min (+12%~ -12%), 10 min X < 60 min (+8% ~ -8%), X 60 min (+5% ~ -5%)

DIMENSIONS [H x W x D, in (mm)]

UNITED STATES CANADA EUROPE/MIDDLE EAST/AFRICA ASIA PACIFIC

8609 Six Forks Road Ontario: 416.798.0112 Denmark: 45.3686.7910 Australia: 61.2.9693.9366
Raleigh, NC 27615 U.S.A. Toll free: 1.800.461.9166 Finland: 358.94.52.661 New Zealand: 64.0.3.343.3314
Toll Free: 1.800.356.5794 France: 33.1.6012.7400 China: 86.21.6361.5599
or 919.872.3020 LATIN AMERICA Germany: 49.0.7841.604.0 HK/Korea/Taiwan: 852.2745.6682
Argentina: 54.11.4124.4000 Italy: 39.02.66.04.05.40 India: 91.11.2649.9414 to 18
www.powerware.com/batteries Brazil: 55.11.3616.8500 Norway: 47.23.03.65.50 Singapore/SEA: 65.6825.1668
México: 52.55.9000.5252 Sweden: 46.8.598.940.00
Portugal: 55.11.3616.8500 United Kingdom: 44.1753.608.700 Eaton, Powerware and PowerChain
Management are trade names, trademarks,
and/or service marks of Eaton Corporation
or its subsidiaries and affiliates. All other
trademarks are the property of their respec-
tive owners.

© 2008 Eaton Corporation

All Rights Reserved
Printed in USA
BAT07FXA
October 2008

124 © 2009 Eaton Corporation. Company Confidential.

 9390 RT INTERCONNECT (without mini CSB) for 1 Vycon VDC,VDC XE and VDC 140

Conduit UPS VYCON SITE WIRING RATINGS

DESCRIPTION DESCRIPTION VOLTAGE CURRENT WIRE SIZE
1 E4 POS DC TB4 + * MAIN DC POWER + 600 VDC MAX DETERMINED SEE TABLE
1 E5 NEG DC TB4 - ** MAIN DC POWER - 600 VDC MAX BY UPS KVA*. 9390 DC MAX AMPS*.
1 FRAME GND FRAME GND GROUND BUS POWER GROUND GROUND FOLLOW NEC FOLLOW NEC

2 TB1-7 BATTERY BRKR UVR+ UVRelay Pin14 UVR TRIP SIGNAL + 24 VDC 100 mA (1) #14 AWG see drawing 9700020-00
2 TB1-8 BATTERY BRKR UVR - UVRelay Pin 13 UVR TRIP SIGNAL - 24 VDC 100 mA (1) #14 AWG rev b
2 TB1-5 BATTERY BREAKER AUX J18-3 CB1 AUX N.O. 24 VDC 100 mA (1) #14 AWG
2 J18-5 CB1 AUX N.C. 24 VDC 100 mA (1) #14 AWG
2 TB1-6 BATTERY BREAKER AUX J18-4 CB1 AUX COMM 24 VDC 100 mA (1) #14 AWG
2 TB2-1 BLUIDING ALARM 2 J16-3 VYCON READY 24 VDC 100 mA (1) #14 AWG
2 TB2-2 BUILDING ALARM 2 RET J16-2 RETURN 24 VDC 100 mA (1) #14 AWG

3 J17-1 REMOTE EPO N.O. Isolated N.O. Contact Do 24 VDC 100 mA (1) #14 AWG
3 J17-2 REMOTE EPO COMM NOT parallel with UPS 24 VDC 100 mA (1) #14 AWG

Must be protected by CB.

4 TB1- L1 AUXILIARY POWER LINE Have electrians run from 277 VAC MAX 5.7A @ 208 VAC (1) #14 AWG
4 TB1- L2 AUXILIARY POWER LINE critical bus power from 277 VAC MAX 2.5 A @ 480 VAC (1) #14 AWG
4 TB1- PE AUX POWER GROUND downstream of MBP. GROUND (1) #14 AWG

*Connect to CB1+ for VDC 140

**Connect to CB1-- for VDC 140

TABLE 9390 DC MAX AMPS

* DC POWER CABLING BETWEEN FLYWHEEL AND UPS

Max Cab rating/ Actual rating Maximum DC Amps Minimum conductor size # per pole
9390 40/20 37 8 1
40/30 56 4 1
40/40 75 Three 1
80/40 75 Three 1
80/50 93 Two t
80/60 112 Zero 1
80/80 148 Three 0 1
160/100 187 Four 0 1
160/120 223 Three hundred 1
160/160 298 350 mcm 1

9390 RT AND VDC,VDC XE and VDC 140 INTERCONNECT WIRING

© 2009 Eaton Corporation. Company Confidential. 125

 9390 RT INTERCONNECTS (with Mini CSB) for 1 or more Vycons VDC, VDC XE and VDC 140

Conduit UPS EACH VYCON SITE WIRING RATINGS

DESCRIPTION DESCRIPTION VOLTAGE CURRENT WIRE SIZE
1 E4 POS DC TB4+ MAIN DC POWER + 600 VDC MAX DETERMINED SEE TABLE
1 E5 TB4 - MAIN DC POWER - 600 VDC MAX BY UPS KVA*. 9390 DC MAX AMPS*.
1 FRAME GND FRAME GND GROUND BUS POWER GROUND GROUND FOLLOW NEC FOLLOW NEC

2 TB1-7 BATTERY BRKR UVR+ UVRelayPin 14 UVR TRIP SIGNAL + 24 VDC 100 mA (1) #14 AWG see drawing 9700011-00
2 TB1-8 BATTERY BRKR UVR - UVRelayPin13 UVR TRIP SIGNAL - 24 VDC 100 mA (1) #14 AWG rev c
2 TB1-5 BATTERY BREAKER AUX J18-3 CB1 AUX N.O. 24 VDC 100 mA (1) #14 AWG
2 J18-5 CB1 AUX N.C. 24 VDC 100 mA (1) #14 AWG
2 TB1-6 BATTERY BREAKER AUX J18-4 CB1 AUX COMM 24 VDC 100 mA (1) #14 AWG

2 J5-1 CSB bldg alarm # 3 J11-1 FLYWHEEL ALARM 24 VDC 100 mA (1) #14 AWG
2 J5-2 return J11-2 RETURN 24 VDC 100 mA (1) #14 AWG
2 J5-3 CSB bldg alarm # 4 J13-1 FLYWHEEL WARNING 24 VDC 100 mA (1) #14 AWG
2 J5-4 return J13-2 RETURN 24 VDC 100 mA (1) #14 AWG
2 J5-5 CSB bldg alarm # 5 J15-1 FLYWHEEL CHARGING 24 VDC 100 mA (1) #14 AWG
2 J5-6 return J15-2 RETURN 24 VDC 100 mA (1) #14 AWG
2 J5-7 CSB bldg alarm # 6 J16-1 VYCON READY 24 VDC 100 mA (1) #14 AWG
2 J5-8 return J16-2 RETURN 24 VDC 100 mA (1) #14 AWG

3 J17-1 REMOTE EPO N.O. Isolated N.O. Contact Do 24 VDC 100 mA (1) #14 AWG
3 J17-2 REMOTE EPO COMM NOT parallel with UPS 24 VDC 100 mA (1) #14 AWG

Must be protected by CB.

4 TB1- L1 AUXILIARY POWER LINE Have electrians run from 277 VAC MAX 5.7A @ 208 VAC (1) #14 AWG
4 TB1- L2 AUXILIARY POWER LINE critical bus power from 277 VAC MAX 2.5 A @ 480 VAC (1) #14 AWG
4 TB1- PE AUX POWER GROUND downstream of MBP. GROUND choose one of above (1) #14 AWG

TABLE 9390 DC MAX AMPS

* DC POWER CABLING BETWEEN FLYWHEEL AND UPS

Max Cab rating/ Actual rating Maximum DC Amps Minimum conductor size # per pole
9390 40/20 37 8 1
40/30 56 4 1
40/40 75 Three 1
80/40 75 Three 1
80/50 93 Two t
80/60 112 Zero 1
80/80 148 Three 0 1
160/100 187 Four 0 1
160/120 223 Three hundred 1
160/160 298 350 mcm 1

9390 RT Interconnects 1 or more vycon 012809

126 © 2009 Eaton Corporation. Company Confidential.

 8 7 6 5 4 3 2 1

THIS DOCUMENT CONTAINS INFORMATION WHICH IS BOTH CONFIDENTIAL AND REVISIONS

PROPRIETARY TO VYCON, INC. NEITHER THIS DOCUMENT NOR THE INFORMATION REV. ECN NO. DESCRIPTION DATE APPROVED
CONTAINED HEREIN SHALL BE COPIED, DISCLOSED TO OTHERS OR USED FOR ANY
PURPOSES BEYOND THE SPECIFIC PURPOSE FOR WHICH THIS DOCUMENT WAS 1 2 A 5283 PRODUCTION RELEASE 8/6/08 P NGUYEN
DELIVERED WITHOUT THE EXPRESS WRITTEN PERMISSION OF VYCON, INC.
2005 VYCON, INC. - ALL RIGHTS RESERVED. 1 1 B 5303 ADDED VDC, VDC XE 10/7/08 H MOTLAQ
1. ADDED NOTE 2 & 3
C 5337 2/3/09 P NGUYEN
2. ADDED 2X 9101958-05
F
F

4
2
3 1
1

5
2
E
VDC 140 E

D D

1
13 - TO UPS 48 VDC
13 (COM) 14 (+) UVR CIRCUIT
14 + (CUSTOMER CONNECTION)

48 VDC COIL VDC, VDC XE

C
C 9
1 (NC) 2
1
9 (COM) 5 (NO)
5
4 (NC) (RED)
4 (+24)
12 (COM) 8 (NO)
8

C
(RED)
12 TO J18/1 (I/O BOARD) FACTORY WIRING
(BLACK) INTERNAL TO VDC
TO J18/2 (I/O BOARD)
2 9101958-05 SCREW, PN HD, 10-32 X .50LG, W/ EXT TOOTH, ZINC PLATED 5
RELAY AND DIN RAIL SOCKET (24V COMMON)
B
B
(BLACK) 2 9350007-00 END ANCHOR 4
1 9308003-00 RELAY WITH DIODE, BLADE TERMINAL, 48VDC 3
1 9308004-00 SOCKET FOR BLADE TERMINAL, DIN RAIL MOUNT 2
3
3 FOR VDC 140 TO TB4/12A 1 9350005-03 DIN RAIL, 3.0 INCH LONG 1
FOR VDC, VDC XE TO TB2/11A QTY. PART NUMBER DESCRIPTION ITEM NO.
2 FOR VDC 140 TO TB4/1B UNLESS OTHERWISE SPECIFIED: CONTRACT
PARTS LIST

FOR VDC, VDC XE TO TB2/5A

DIMENSIONS ARE IN INCHES.
TOLERANCES ARE:
DECIMALS ANGLES
23695 VIA DEL RIO,
.XX .01 .5 APPROVALS DATE YORBA LINDA, CA 92887
A
1 PLACE DIN RAIL APPROX. WHERE SHOWN,
.XXX .005
INTERPRET PER ASME Y14.5M.
BREAK EDGES .015-.003.
DRAWN
C DANG 8/4/08
A

MOUNT RELAY IN SOCKET AND MOUNT SOCKET FILLET RADII .020-.005. CHECKED

OPTION, 48 VDC UVR INTERFACE

SURFACE ROUGHNESS:
ON DIN RAIL 125 RMS PER ANSI 846.1 -
ENGINEERING
-

DO NOT SCALE DRAWING

XX XX O ULIBAS 8/6/08
MATERIAL SIZE CAGE CODE DWG NO. REV.

NOTES: UNLESS OTHERWISE SPECIFIED NEXT ASSY USED ON

FINISH
QUALITY ASSURANCE
G GRANBERY 8/6/08 D --- 9700011-00 C
APPLICATION MANUFACTURING SCALE SHEET
P NGUYEN 8/6/08 NONE 1 OF 1
© 2009 Eaton Corporation. Company Confidential. CAD GENERATED DRAWING,
127
8 7 6 5 4 3 2 DO NOT MANUALLY UPDATE 1