9355 30kVA Service Manual - A02

Powerware 9355
20-30 kVA
UNINTERRUPTIBLE POWER SUPPLY
Service Manual
July 2006
164201621 Revision A02
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
Electrical duly authorized or trained certified personnel.
Notwithstanding the foregoing, Eaton Electrical assumes NO

responsibility for any damage or injury to any persons or property
which may be caused to any extent by reliance on the information
provided herein except to the extent such damage or injury results
solely and directly from the willful negligence of Eaton Electrical, its
agents or employees. Additionally, Eaton Electrical shall not be liable
for any indirect, special incidental or consequential damages, such as,
but not limited to, loss of anticipated profits, good will or other
economic 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 disclosed to
or could have been reasonably foreseen by Eaton Electrical.
The information contained herein is proprietary to Eaton Electrical and

may be used or copied only in accordance with written agreement with
Eaton Electrical. 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 QUANTITIES SPECIFIED BY WRITTEN AGREEMENT
WITH EATON ELECTRICAL.
Periodically, changes are made to the contents herein. Please contact

Eaton Electrical 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 RECIPIENTS/USERSS OWN
RISK.
The equipment provided by Eaton Electrical contains areas that

conduct lethal voltages. The maintenance of Eaton Electrical
equipment requires factory trained personnel that are aware of the
potential danger areas.
2006 - Eaton Corporation

9355 20 30 kVA Table of Contents
Table of Contents
Chapter 1 System Overview
1.1 System Description 1-1
1.1.1 Single Module Systems 1-1
1.2 Single ModuleReverse Transfer (RT) Modes of Operation 1-4
1.2.1 NORMAL Mode 1-4
1.2.2 BATTERY Mode 1-6
1.2.3 Power Share Operation 1-8
1.2.4 BYPASS Mode 1-8
1.3 Parameter Settings 1-12
1.3.1 Parameter List 1-12
1.4 Input Isolation Transformer (60 Hz Only) 1-16
1.4.1 PW 9355 1-16
1.5 Seismic Capability 1-16
1.6 External Battery Cabinets 1-16
1.7 Remote Emergency Power Off (REPO) 1-16
1.8 Environmental Monitoring Probe (EMP) 1-16
1.9 Parallel Tie Cabinet with System Bypass 1-17
Chapter 2 Safety
2.1 General Safety Considerations 2-1
2.1.1 Tools, Equipment, and Expendable Field Service Supplies 2-1
2.1.2 General Safety Rules 2-1
2.2 Environmental Safety 2-2
2.3 Electrical Safety 2-3
2.4 Mechanical Safety 2-4
2.5 Eye Safety 2-4
2.6 UPS Safety 2-5
2.6.1 Operating Environment 2-5
2.6.2 Normal Operation 2-5
2.6.3 Maintenance/Service 2-5
2.6.4 Batteries 2-6
2.7 Site Safety 2-7
2.8 Summary 2-8
2.9 Electrostatic Discharge (ESD) Procedure And Equipment Requirements 2-8
2.9.1 Purpose 2-8
2.9.2 Objective 2-8
2.9.3 Applicable Documents and Materials 2-8
2.9.4 Definitions 2-9
2.9.5 Procedure 2-9
2.9.6 Removal of Boards 2-10
2.9.7 Packaging of Boards 2-11
2.9.8 General Handling Guidelines for ESD Protection 2-11
Chapter 3 Installation and Startup
3.1 MODEL 9355 20 30kVA SINGLE MODULE (RT) 3-1
3.1.1 Mechanical Inspection 3-1
3.1.2 Electrical Inspection 3-5
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Table of Contents 9355 20 30 kVA
Operational Inspection 3-7

3.2 MODEL 9355 20 30kVA Parallel (PC/PR) 3-10
3.2.1 Mechanical Inspection 3-10
3.2.2 Electrical Inspection 3-16
3.2.3 Operational Inspection 3-19
3.2.4 Inspection Completion 3-21
Chapter 4 Functional Descriptions
4.1 Model 9355 20 30kVA 4-1
4.1.1 Overview 4-1
4.1.2 X-Slot Connections 4-2
4.1.3 Native RS Port 4-2
4.2 Electronics Module Functional Sections 4-3
4.2.1 Display Panel 4-3
4.2.2 Control Board 4-3
4.2.3 Power Module Boards 4-3
4.2.4 Bypass Control Board 4-3
4.2.5 I/O Board 4-3
4.2.6 EMI / Surge Board 4-3
4.2.7 Contactors 4-4
4.2.8 Internal Battery 4-4
4.2.9 External Battery 4-4
4.2.10 Battery Circuit Breaker 4-4
4.2.11 Ferrite Toroids 4-4
4.2.12 Chokes 4-5
4.2.13 Fans 4-5
4.3 LCD Display Panel 4-5
4.3.1 Overview 4-5
4.3.2 Detailed Description of Settings 4-6
4.3.3 User Settings 4-6
4.3.4 Service Settings 4-9
4.4 CONTROL BOARD (PCB) 4-11
4.4.1 Firmware Description and Operation 4-11
4.4.2 Shutdown State 4-12
4.4.3 Startup State 4-13
4.4.4 Battery Starting State 4-15
4.4.5 Utility Starting State 4-16
4.4.6 Inverter Starting State 4-18
4.4.7 Standby State 4-19
4.4.8 User Interface & XCP 4-20
4.4.9 On Inverter State 4-20
4.4.10 On Bypass State 4-21
4.4.11 The Bleeding State 4-25
4.4.12 Bypass-Locked State 4-26
4.4.13 Failure Shutdown State 4-27
4.4.14 Methods of Turning the UPS Off 4-28
4.4.15 XCP Command Codes 4-28
4.4.16 Hardware Signals 4-29
4.5 POWER MODULE BOARD (PCB) 4-31
ii 2006 - Eaton Corporation

4.5.1 Introduction & Overview 4-31

4.5.2 Description and Operation 4-32
4.5.3 Other Connector Descriptions 4-32
4.6 Power Board Functional Blocks 4-33
4.6.1 Voltage Sensing 4-33
4.6.2 Rectifier 4-33
4.6.3 Battery Converter 4-33
4.6.4 Inverter 4-34
4.6.5 IGBT Gate Drives 4-34
4.7 Advanced Battery Management 4-35
4.7.1 Introduction 4-35
4.7.2 Purpose 4-35
4.7.3 General Terms 4-36
4.7.4 Charging Cycles 4-38
4.7.5 Temperature Compensation 4-39
4.7.6 Forcing on Rest Mode 4-40
4.7.7 User Disabling of ABM Charging Cycles 4-41
4.7.8 Battery Failure Testing 4-42
4.8 Battery Lifetime 4-44
4.8.2 Operational Sequence 4-44
4.8.3 Battery Discharge 4-44
4.8.4 Run-Time and Temperature 4-45
4.9 Battery Test 4-45
4.9.2 Battery Test 1 4-45
4.9.3 Battery Test 2 4-45
4.9.4 Battery Test Calculations 4-46
4.10 I/O BOARD (PCB) 4-49
4.10.1 Overview 4-49
4.10.2 I/O Connector Descriptions 4-50
4.11 I / O Board Functional Sections 4-59
4.11.1 Auxiliary Power Supply 4-59
4.11.2 Rail Precharge 4-59
4.12 Current Measurements and Hardware Current limits 4-60
4.12.1 Output Current Measurement 4-60
4.12.2 Input and Output Filtering Scheme 4-60
4.12.3 Inverter/Rectifier Fault Methodology 4-61
4.12.4 Single Feed/Dual Feed Input Contactors 4-61
4.12.5 Battery Relay, Battery Start and Current Measurement 4-61
4.12.6 Balancer Relays and Drive 4-62
4.12.7 Battery CB Trip 4-62
4.12.8 Input/Output CB Trip 4-62
4.12.9 Other Sensing 4-62
4.12.10 X-Slots 4-62
4.12.11 AC Fans 4-63
4.12.12 Chassis GND 4-63
4.12.13 Troubleshooting 4-63
2006 - Eaton Corporation iii
Table of Contents 9355 20 30 kVA
4.13 Bypass Board System Overview 4-64

4.14 Bypass Board Functional Blocks 4-66
4.14.1 BAUX Power Supply 4-66
4.14.3 Input Contactor 4-67
4.14.4 Alarm Supply 4-67
4.14.5 EPO Alarm 4-67
4.14.6 Building Alarms 4-67
4.14.7 RS-232 4-67
4.14.8 NO/NC Relay Contacts 4-67
4.15 Bypass SCR Gate Drive and SCRs 4-67
4.15.1 Standalone Bypass Functionality 4-68
4.15.2 Bypass State Machine 4-68
4.15.3 AC Fans 4-72
4.16 ELECTRO-MAGNETIC INTERFERENCE (EMI) BOARD (PCB) 4-73
4.16.2 EMI Board Functional Sections 4-73
Chapter 5 Connectivity and Communications
5.1 9355 GENERAL CONNECTIVITY DEVICES 5-1
5.1.1 Basic Serial Communication 5-1
5.1.2 Relay Signaling 5-1
5.1.3 Building Alarm Inputs 5-1
5.1.4 Additional Connectivity & Software 5-1
5.2 9355 X-SLOT CONNECTIVITY DEVICES 5-2
5.2.1 Modem Handling 5-2
5.2.2 Modem Operation 5-4
5.2.3 Modem Call Handling States 5-8
5.2.4 Communication During a Modem Session 5-16
5.3 9355 COMMUNICATION 5-19
5.3.1 Default Communication Access Passwords 5-19
5.3.2 Signal Inputs & Programmable Functions 5-19
5.3.3 Programmable Functions 5-19
5.3.4 Signal Inputs on Front Panel Display 5-22
5.3.5 Configuration Fields 5-23
5.3.6 HyperTerminal 5-27
Chapter 6 Options
6.1 Communications and Connectivity Options 6-2
6.1.1 Single Port RS-232 Serial or AS/400 Signal Card 6-2
6.1.2 Multi-Port/Multi-Server Card 6-3
6.1.3 Low Voltage (LV) Relay Interface Card 6-5
6.1.4 High Voltage (HV) Industrial Relay / RMP Interface Card 6-7
6.1.5 ConnectUPS Network Adapters 6-8
6.1.6 MODBUS Communications Card 6-9
6.1.7 Modem Card 6-10
6.1.8 USB Module 6-13
6.1.9 CAN Bridge Card 6-14
6.1.10 Remote Monitor 6-14
6.2 Options Cabinet 6-15
iv 2006 - Eaton Corporation
6.3 Power Distribution Unit (PDU) 6-18

6.4 Remote Power Panel (RPP) 6-19
6.4.1 IQ 100 Series RPP 6-19
6.4.2 IQ 200 Series RPP 6-19
Chapter 7 Troubleshooting and Maintenance
7.1 Troubleshooting Charts 7-1
7.1.1 Action Levels 7-1
7.1.2 Alarm, Notice, Status & Flag Definitions 7-3
7.1.3 Detailed Definitions 7-22
7.1.4 Failure Analysis 7-27
7.1.5 Electronics Module and Other Failures 7-36
Chapter 8 Removal and Replacement
8.1.1 Removal Preparation 8-1
8.1.2 Removing the L3 Power Module 8-1
8.1.3 Replacing the L3 Power Module 8-4
8.1.4 Removing the L2 Power Module 8-6
8.1.5 Replacing the L2 Power Module 8-7
8.1.6 Removing the L1 Power Module and Bypass Board 8-8
8.1.7 Replacing the L1 Power Module / Static Switch Assembly 8-12
8.1.8 Removing the I/O Board Assembly 8-13
8.1.9 Replacing the I/O Board 8-19
8.2 TECHNICAL SUPPORT KNOWLEDGE BASE 8-21
Chapter 9 Calibration
9.1.1 Calibrate Bypass AC Input Voltage 9-4
9.1.2 Calibrate Utility AC Input Voltage 9-5
9.1.3 Calibrate Battery Voltage 9-7
9.1.4 Calibrate DC Link Voltage 9-8
9.1.5 Calibrate UPS AC Output Voltage 9-9
9.1.6 Calibrate Inverter AC Output Voltage 9-10
9.1.7 Calibrate Inverter DC Output Voltage 9-11
9.1.8 Calibrate Bypass Current (Output) 9-12
9.1.9 Calibrate Utility Current 9-14
9.1.10 Calibrate Battery Current 9-15
9.1.11 Calibrate Inverter Current 9-16
Chapter 10 Parts
10.1 PW 9355 30kVA SPARE PARTS LISTINGS 10-1
10.1.1 Low Voltage PW 9355 30kVA Spare Parts Kit A P/ N 106711170 10-1
10.1.2 High Voltage PW 9355 30kVA Spare Parts Kit A P/ N 10-2
10.2 PW 9355 30kVA UPS Subassemblies 10-2
10.2.1 LV Electronic Module 10-2
10.2.2 HV Electronic Module 10-3
10.3 Parts Break-down / Look-up Procedure 10-4
10.3.1 Requirements: 10-4
10.3.2 Procedure 10-4
Chapter 11 Prints
2006 - Eaton Corporation v

Figure List 9355 20 30 kVA
Figure List
Figure 1. EATON-Powerware 9355 2030kVA UPS .............................................. 1-1
Figure 2. PW9355 30kVA Basic Single Module System............................................ 1-2
Figure 3. PW 9355 NORMAL Mode (single feed)...................................................... 1-4
Figure 4. PW 9355 NORMAL Mode (dual feed) ........................................................ 1-5
Figure 5. PW 9355 BATTERY Mode (single feed)..................................................... 1-6
Figure 6. PW 9355 BATTERY Mode (dual feed) ....................................................... 1-7
Figure 7. PW 9355 BYPASS Mode (single feed)...................................................... 1-9
Figure 8. PW 9355 BYPASS Mode (dual feed) ........................................................ 1-9
Figure 9. PW9355 Service Position ......................................................................... 1-11
Figure 10. PW9355 Maintenance Bypass Position ................................................ 1-11
Figure 11. Parallel Tie Cabinet with System Bypass.............................................. 1-17
Figure 12. Front door panel removed...................................................................... 3-1
Figure 13. Right side skin panel removed................................................................ 3-2
Figure 14. Wiring Access After Dead Front Panel Removal .................................... 3-2
Figure 15. XCP Tool Battery Toggle Positions......................................................... 3-6
Figure 16. Front door panel removed..................................................................... 3-10
Figure 17. Right side skin panel removed.............................................................. 3-10
Figure 18. Wiring Access After Dead Front Panel Removal .................................. 3-11
Figure 19. CAN Bridge Board Jumper Settings ..................................................... 3-13
Figure 20. Parallel Control Wiring .......................................................................... 3-13
Figure 21. XCP Tool Battery Toggle Positions....................................................... 3-17
Figure 22. Display Panel.......................................................................................... 4-5
Figure 23. 9355 Control Board............................................................................... 4-11
Figure 24. 9355 Control Board Machine States ..................................................... 4-12
Figure 25. 9355 Power Board ................................................................................ 4-31
Figure 26. Typical Battery Charging Cycle............................................................. 4-38
Figure 27. PW 9355 I/O Board............................................................................... 4-49
Figure 28. Bypass Control Board ........................................................................... 4-64
Figure 29. State Diagram....................................................................................... 4-68
Figure 30. Modem Call Handling States .................................................................. 5-8
Figure 31. No Modem State..................................................................................... 5-9
Figure 32. Modem Idle State.................................................................................. 5-11
Figure 33. Modem Dialing State ............................................................................ 5-13
Figure 34. Modem Session State........................................................................... 5-14
Figure 35. Hanging Up State ................................................................................. 5-15
Figure 36. Path to HyperTerminal Application ....................................................... 5-27
Figure 37. HyperTerminal Opening Screen Selections .......................................... 5-27
Figure 38. Select COM1 or COM2 from the drop-down menu ............................... 5-28
Figure 39. Port Parameter Setup ........................................................................... 5-28
Figure 40. File, Properties menu options, Settings tab, Emulation drop-down....... 5-29
Figure 41. Font Settings menu............................................................................... 5-29
Figure 42. Single Port Serial Card ........................................................................... 6-2
Figure 43. Multi-Port Serial Card.............................................................................. 6-3
Figure 44. Low Voltage Relay Interface Card .......................................................... 6-5
Figure 45. High Voltage Industrial Relay Card......................................................... 6-7
Figure 46. 10 Megabyte SNMP/Web 10/100 Megabyte SNMP/Web/Hub........ 6-8
Figure 47. SNMP / Web / Hub Card Components.................................................... 6-8
vi 2006 - Eaton Corporation
9355 20 30 kVA Figure List
Figure 48. MODBUS Communications Card............................................................ 6-9

Figure 49. MODBUS Communications Card Components ...................................... 6-9
Figure 50. Modem Card ......................................................................................... 6-10
Figure 51. X-Slot Modem Functional Parts ............................................................ 6-11
Figure 52. USB Module.......................................................................................... 6-13
Figure 53. CAN Bridge Card .................................................................................. 6-14
Figure 54. CAN Bridge Card J3 Terminals............................................................. 6-14
Figure 55. Options Cabinet with MBS Wiring ......................................................... 6-15
Figure 56. Options Cabinet with Dual-Feed Wiring ................................................ 6-16
Figure 57. Options Cabinet with Output Transformer Wiring ................................. 6-17
Figure 58. Remote Power Panels Series 100 and 200 .......................................... 6-20
Figure 59. Damage Sustained by the IGBTs Due to Severed Wiring....................... 8-2
Figure 60. Top Fan Dead Front and Bracket Plates................................................. 8-2
Figure 61. L3 and Fan Removal Points on the I/O Board ........................................ 8-3
Figure 62. Bypass Board Silk Screen ...................................................................... 8-3
Figure 63. L3 PM Shelf Insertion.............................................................................. 8-4
Figure 64. L2 Removal Points on the I/O Board ...................................................... 8-6
Figure 65. Positive Battery String Wires .................................................................. 8-8
Figure 66. Bypass Static Switch Connections.......................................................... 8-9
Figure 67. I/O Board Wiring Connections to Static Switch ..................................... 8-10
Figure 68. Static Switch Housing and SCRs.......................................................... 8-11
Figure 69. DC Link Check Points ........................................................................... 8-13
Figure 70. Removing the control board from the I/O board.................................... 8-14
Figure 71. Wiring Locations ................................................................................... 8-15
Figure 72. Wiring Removal Diagram ...................................................................... 8-16
Figure 73. TB5 ....................................................................................................... 8-17
Figure 74. Bus bar and neutral bolts ...................................................................... 8-17
Figure 75. Chassis Screws .................................................................................... 8-18
Figure 76. Analog Potentiometer Diagram............................................................... 9-1
Figure 77. Analog to Digital Circuit........................................................................... 9-1
Figure 78. Digital Potentiometer Diagram ................................................................ 9-2
Figure 79. 9355 Front Calibration Points ................................................................. 9-5
Figure 80. I/O Board Bypass Phase A, B and C .................................................... 9-12
Figure 81. 208V DC Link Voltage Calibration test points ....................................... 9-13
2006 - Eaton Corporation vii

Figure List 9355 20 30 kVA
164201621 Change sheet

Revision Item Section(s) Change
Table of Contents Accommodates new pages
Figure List Accommodates new figures
8-3 Figure 62 added for
A001 Chapter 8 (Removal procedure elaboration
and Replacement)
8-9 Figure 66 added for
procedure elaboration
Prints Page 9 110720639 TOPS Rev B00
Chapter 1 (System Section 1.3 Parameter Settings added.
Overview)
Chapter 3 (Installation Section 3.1.1 Elucidated item 1.e. under
and Startup) module inspection check
A002
ALL wiring.
Chapter 9 (Calibration) All Emphasis placed on
XCP software tool use
Prints CTO charts Added to hard copy
viii 2006 - Eaton Corporation

1
System Overview
1.1 System Description
Refer to Figure 1, EATON-Powerware 9355 2030 kVA UPS and Figure 2,
Basic Single Module System.
1.1.1 Single Module Systems

The EATON-Powerware 9355 UPS is intended to be an Online Double
Conversion Uninterruptible Power Supply rated at 20kVA30kVA, 3-phase in/3-
phase out, with 4 basic models:
20kVA 30kVA 230/400
20 or 30kVA 120/208
The power-train topology is unique to the PW9355 design but uses the same
control board as the PW9155 and PW9355-15kVA.
Figure 1. EATON-Powerware 9355 2030kVA UPS

2006 - Eaton Corporation 1-1
System Overview 9355 20 30 kVA
Figure 2. PW9355 30kVA Basic Single Module System
A digital signal processor (DSP) is used to provide all software functionality

(that is, analog metering, digital signal sampling, power-train control including
Pulse Width Modulated (PWM) gate signals, serial communications, and user
interface processing). The UPS incorporates Flash ROM for upgrades to DSP
firmware using the PW Flash Utility (via serial port communication). For more
information on the Control board, see paragraph 4.4.
These systems are designed to be one of the most enhanced and improved
EATON-Powerware UPS products, using a compilation of the most
successful features found in previous products. The basic system consists of:
a rectifier
battery converter
inverter
monitoring / operation control panel
integrated communications server
and microprocessor controlled (DSP) logic.
1-2 2006 - Eaton Corporation

9355 20 30 kVA System Overview
A single module operates independently, providing conditioned and

uninterruptible AC power to support an applied critical load. During an outage,
the module continues to operate, supporting power to the critical load from the
batteries. If the module requires service, critical loads can be manually
transferred to internal maintenance bypass. No additional cabinets or
equipment are required.
UPS input is derived from a power factor corrected, current controlled, and half
bridge boost rectifier. The conditioned output comes from a current controlled
half bridge buck inverter. The battery converter is a current controlled boost
converter, and the charger is a current controlled buck converter. Power Share
mode limits the utility current and provides DC link rail voltage regulation.
Internal batteries within the UPS are replaceable and can be hot swapped by a
qualified service technician without affecting the critical load (the UPS will not
have battery back-up available during the swap out).
Frequency / phase converter operation is possible with a de-rated output load
capacity to 80%. Frequency / phase converter mode can be configured from
the front panel or through the XCP configuration command. With default
frequency converter configuration, bypass will not be available.
Integral bypass can perform an automatic transfer (0 msec, no break) of
attached critical loads from the UPS to a bypass source if required. The unit will
recover from automatic bypass without dropping the critical load if the unit does
not indicate damage.

1.2 Single ModuleReverse Transfer (RT) Modes of Operation

The EATONPowerware 9355 UPS will support a critical load in three
different modes of operation:
1. NORMAL
2. BATTERY
3. BYPASS
The UPS can automatically use all three modes without operator intervention.
To achieve this, sophisticated detection and control logic is used to ensure that
any change in operating mode is automatic and transparent. Internal monitoring
systems indicate the current mode of operation. A more detailed explanation of
the three modes of operation, using block diagrams, will follow.
1.2.1 NORMAL Mode

Refer to Figure 3 and Figure 4 NORMAL Mode.
During normal UPS operation, power for the system is delivered from a utility
input source to the rectifier input breaker CB-1. The rectifier converts the
incoming AC (alternating current) power to DC (direct current) using IGBT
(Isolated Gate Bipolar Transistor) devices to produce a regulated DC voltage
for the inverter, while the battery is charged through a buck / boost DC
converter.
MBS
B ypass
B ypass
B ypass
S ervice
S ervice
S ervice
UP S
UP S
UP S
Bypass Input Input TB
Single feed
jumper
Output TB
LOAD
Rectifier Input
CB-3
CB-1 Optional
Static Switch
K-5
K-1 K-3
Rectifier Inverter
Battery
Converter
CB-2
<
Remote External Battery < Line Up and Match
External Battery
Figure 3. PW 9355 NORMAL Mode (single feed)

MBS
B ypa ss
B ypa ss
B ypa ss
S er vice
S er vice
S er vice
UP S
UP S
UP S
Input TB
Bypass Input
Output TB
Rectifier Input
LOAD
CB-3
CB-1 Optional
Static Switch
K-5
K-1 K-3
Rectifier Inverter
Battery
Converter
CB-2
< Line Up and Match
Remote External Battery
< External Battery
Figure 4. PW 9355 NORMAL Mode (dual feed)
The DC converter derives its input from the regulated DC output of the rectifier
and provides a regulated, boosted DC voltage charge 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 system has a shunt trip for the battery and can disconnect the
battery under a fault condition or Remote Emergency Power Off (REPO)
activation, see paragraph 1.7 for details.
The neutral from the system input is connected to the neutral throughout the
system.
CAUTION
The output neutral of the system is connected with the required neutral for the
customers critical load and should never be bonded to ground at the module output.
The inverter produces three phase AC output to a customers critical load

without the use of a transformer. The inverter derives regulated DC from the
DC Link and uses IGBT devices and PWM (pulse-width modulation) to produce
a regulated and filtered AC output. The AC output of the inverter is delivered to
the system output by way of the inverter output contactor K-3.
NORMAL appears on the module front panel to indicate that the system is
providing clean and protected power to the connected critical loads.
1.2.2 BATTERY Mode

Refer to Figure 5 and Figure 6 BATTERY Mode.
The UPS enters into BATTERY mode automatically during a utility power
failure, when the input power to the rectifier is out of specification (refer to the
specifications in your generator manual), and in some cases during a non-
catastrophic rectifier failure.
During a utility power failure, the rectifier no longer has an AC utility source to
supply the DC output power required by the inverter. When the rectifier is
turned off, the supply of DC current to the inverter is drawn from the awaiting
charged batteries. When the rectifier is partially operational, Power Share
mode is implemented.
Power Share mode provides DC link rail voltage by drawing supplemental
power from the batteries (that is, Power Share mode apportions energy jointly
from the batteries and from the rectifier to supply adequate energy to the
inverter to maintain the critical load). See paragraph 1.2.3 on for more details
about Power Share.
MBS
Service
Service
Service
Bypass
Bypass
Bypass
UPS
UPS
UPS
Bypass Input Input TB
Single feed
jumper
Output TB
LOAD
Rectifier Input
CB-3
CB-1 Optional
Static Switch
K-5
K-1 K-3
Rectifier Inverter
Battery
Converter
CB-2
< Line Up and Match
< External Battery
Figure 5. PW 9355 BATTERY Mode (single feed)

MBS
Service
Service
Bypass
Bypass
Bypass
Service
UPS
UPS
UPS
Input TB
Bypass Input
Output TB
LOAD
Rectifier Input
CB-3
CB-1
Static Switch
K-5
K-1 K-3
Rectifier Inverter
Battery
Converter
<
CB-2
Line Up and Match
< External Battery
Figure 6. PW 9355 BATTERY Mode (dual feed)
When the rectifier can no longer supply energy to the inverter, energy stored in
the battery is supplied instantaneously to the DC converter and is boosted so
that the inverter can support the customers critical load without interruption. To
prevent battery output from back-feeding, the rectifier contactor (K-1) opens on
separate feed, but this is not true of a dual fed system when the UPS goes to
battery. Opening K-1 on a single fed system prevents static system voltages
from bleeding backwards through the rectifier snubber components and re-
entering the input source. For more information on the Battery Boost Converter,
refer to paragraph 4.6.3.
While in BATTERY mode, the UPS will annunciate an audible horn, light a
visual 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 steady output. The UPS will
remain in this operating mode until the input power to the rectifier is again
within specification.
If the input power fails to return, or is not within the acceptance window
required for normal operation, the battery will continue discharging until a DC
voltage level is reached and the inverter output can no longer support the
critical load.
When this occurs, the UPS will issue another set of audible and visual alarms
indicating SHUTDOWN IMMINENT. Unless the rectifier has an immediate valid
input, the output will only be supported for approximately one (1) minute before
the UPS shuts down, dropping the critical load.

If the input power becomes available during battery discharge, the rectifier
contactor (K-1) is closed; the rectifier turns on and provides power to the DC
Link for the inverter, and begins recharging the battery.
At this point, 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 might be seen for a short time due to the
current required to recharge the battery.
The UPS total operating time on battery will depend on many factors. Some
factors that affect battery support are battery type and capacity, the number of
parallel strings, environmental temperatures, battery age, and fluctuations in
load demand during battery discharge. The greater the load, the less support
time the battery can sustain; as the load decreases, the battery support time
generally increases.
1.2.3 Power Share Operation

Power Share mode pulls energy from the batteries and from the rectifier to
supply energy to the inverter. Two conditions that cause the unit to enter
power share mode are:
1. A scheduled battery test and
2. The rectifier exceeds the maximum input current
The utility voltage determines the maximum power that the rectifier may provide
and the maximum input current allowed. If the power required by the inverter
exceeds the maximum rectifier power, the rectifier is run in a constant power
mode, and the battery converter is turned on to make up the deficit. In this way,
the UPS draws maximum power from the rectifier while supplementing the
power shortfall as efficiently as possible using the batteries.
When the battery test is running, rectifier power is regulated so that the power
required for testing is drawn from the batteries. For more details on
Advanced Battery Management, refer to paragraph 4.7.
1.2.4 BYPASS Mode

Refer to Figure 7 and Figure 8, BYPASS Mode.
When the inverter is unable to support the critical load, the UPS will transfer the
load to the internal bypass to ensure the critical load remains energized.
In BYPASS mode, the output of the system is provided with three-phase AC
power directly from the system input (or utility source). While in this mode, the
output of the system is not protected from voltage, frequency fluctuations or
power outages. Some power line filtering and spike protection is provided to the
critical load, but no active power conditioning or battery support is available to
the critical load during the bypass mode of operation.

MBS
Service
Service
Service
Bypass
Bypass
Bypass
UPS
UPS
UPS
Input TB
Bypass Input
Single feed
jumper
Output TB
LOAD
Rectifier Input
CB-3
CB-1 Optional
Static Switch
K-5
K-1 K-3
Rectifier Inverter
Battery
Converter
CB-2
< Line Up and Match
Remote External Battery < External Battery
Figure 7. PW 9355 BYPASS Mode (single feed)
MBS
Service
Service
Service
Bypass
Bypass
Bypass
UPS
UPS
UPS
Input TB
Bypass Input
Single feed
jumper
Output TB
LOAD
Rectifier Input
CB-3
CB-1 Optional
Static Switch
K-5
K-1 K-3
Rectifier Inverter
Battery
Converter
CB-2
< Line Up and Match
< External Battery
Figure 8. PW 9355 BYPASS Mode (dual feed)

The internal bypass is comprised of a solid-state Silicon Controlled Rectifier

(SCR) static switch. The (SCR) static switch is rated as a continuous duty
device that is used anytime the inverter is unable to support the applied critical
load. The bypass static switch is an electronically controlled device, so if a
system fault occurs necessitating an emergency transfer to bypass, the static
switch can be turned on immediately to pick up the critical load from the
inverter, while the inverter output contactor (K-3) automatically opens to isolate
the inverter.
During an outage, transfers to BYPASS are prohibited with single feed input.
For the safety of those who may be working on the power lines upstream from
the UPS, back-feed protection is provided by opening the bypass contactor
(K-5), which prevents system output voltage from bleeding across the bypass
static switch (SCR) components to the input source.
The output of the system will be transferred automatically to the internal bypass
if any of the following abnormal conditions occur on the output of the system:
the output of the system exceeds acceptable voltage or frequency
tolerances.
the system is overloaded.
there is an inverter failure.
The transfer is initiated by turning on the bypass static switch (SCR) and by
opening the inverter output contactor (K-3). This kind of transfer is normally
referred to as a make-before-break transfer, or emergency transfer to bypass.
The transfer should take place in less than 4 msec (one-quarter cycle) to
ensure critical loads on the system output are not interrupted. The bypass static
switch (SCR) remains on until either the inverter is able to support the system
output, or until the unit is placed in maintenance configuration to facilitate
repairs.
If the UPS automatically initiates transfer to bypass without operator
intervention, the UPS will attempt to automatically restart the inverter, and to
transfer the UPS back to on-line status to support the system output.
Three attempts will be made automatically within ten minutes to bring the
inverter back on-line 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. The UPS can also be manually transferred
to BYPASS using the front panel controls.
A Maintenance Bypass Switch (MBS) is installed on all units. When the switch
is in the UPS position it operates as discussed in the previous paragraphs.
When the switch is in the Service position the critical load is powered by
utility, and the UPS has power available for troubleshooting and maintenance
(see Figure 9). When the switch is in the Bypass position power to internal
bypass is secured and the critical load is supplied by utility (see Figure 10).
CB-1 controls the input power to the rectifier in a single or dual feed UPS.
For more information on Bypass Mode, refer to paragraph 4.4.10.

MBS
Se rvi ce
Se rvi ce
Se rvi ce
Byp ass
Byp ass
Byp ass
U PS
UPS
UPS
Input TB
Bypass Input
Single feed
jumper
Output TB
LOAD
Rectifier Input
CB
CB-3 Optional
CB-1
Static Switch
K-5
K-1 K-3
Rectifier Inverter
Battery
Converter
CB-2
< Line Up and Match
< External Battery
Figure 9. PW9355 Service Position
MBS
Se rvice
Se rvice
Se rvice
Bypass
Byp ass
Byp ass
UPS
UPS
UPS
Input TB
Bypass Input
Single feed
jumper
Output TB
LOAD
Rectifier Input
CB-3
CB-1 Optional
Static Switch
K-5
K-1 K-3
Rectifier Inverter
Battery
Converter
CB-2
< Line Up and Match
< External Battery
Figure 10. PW9355 Maintenance Bypass Position

1.3 Parameter Settings

This section describes the parameters list option in the 9X55 service menu.
This menu is intended so that a service technician can change UPS settings
without serial communication.
This list is correct for 9X55 ESW version 1.06.xx for the 9355.
1.3.1 Parameter List

Note:
Send over CAN means that in a parallel system, updating 1 unit will
update all units in the parallel system that are connected to the CAN
network.
Numbers missing in numerical sequence either apply to 9155 units
exclusively or the setting has been disabled.
Table 1. Parameters List Setting for the 9X55 LV Service Menu
Param Description Default Options Option description Send over
Num CAN
0 Start Screen 0 0 Power ware logo No
1 Mimic Screen
1 Language 0 0 English No
1 French
2 Spanish
3 Horn enable 1 0 Horn is disabled No

1 Horn is enabled
4 Overload transfer 1 0 Transfer to bypass immediately YES
to bypass
1 Transfer to bypass after a delay
5 Sync required for 1 0 Synchronization is not required YES
bypass transfer
1 Synchronization is required
6 Sync disable 0 0 Synchronization to bypass is YES
enabled
1 Synchronization to bypass is
disabled
7 Bypass disable 0 0 Transfer to bypass is allowed YES
1 Transfer to bypass is not
allowed
8 Site fault disable 0 0 Site fault is enabled No
1 Site fault is disabled
9 REPO disable 0 0 REPO is enabled YES
1 REPO is disabled

10 Disable control 0 0 Control commands from X-Slot1 No

commands from are allowed
X-Slot1
1 Control commands from X-Slot1
are not allowed
11 Disable control 0 0 Control commands from X- No
commands from Slot1/ service port are allowed
X-Slot1/Service
port 1 Control commands from X-
Slot2/ service port are not
allowed
12 Automatically 1 0 Battery test will only run when No
schedule battery requested from LCD or XCP
test
1 Battery test will run every ABM
cycle without user intervention
13 ABM disable 0 0 ABM cycling is disabled No
(constant float)
1 ABM cycling is enabled
14 Charger temp. 0 0 Temperature compensation is No
compensation enabled
disable
1 Temperature compensation is
disabled
15 Modem installed 0 0 No modem is installed No
1 Modem is installed in X-Slot1
2 Modem is installed in X-Slot2
16 On battery delay 5 0-99 Time in seconds before UPS YES
on Battery alarm is activated
17 XCP Auto-on 0 0-32767 XCP auto-on delay in seconds YES
delay
-1 Restart through LCD or remote
only
18 XCP Auto-off -1 0-32767 XCP auto-off delay in seconds YES
delay
-1 Disabled
19 Input signal 120 0-65535 Used if input signal is YES
shutdown delay programmed for delayed
shutdown
20 X-Slot signal 5 0-65 After the set time delay, the No
input activation RS323 pin is recognized to be
delay an active signal (3-12 Vdc).
Refers to function of signal
inputs
21 Number of Model 0-22 Number of parallel strings of No
internal battery specific internal batteries
strings
23 Internal battery 34 1-32767 Capacity, in W/cell of internal No
capacity batteries at 15min rate

24 Battery low alarm 1880 1750- Voltage, in mV/cell, that sets the YES
level 1950 Battery Low alarm
25 Constant float 2300 2150- Battery float voltage, in mV/cell No
voltage 2335 when ABM cycling is disabled
26 Max charge 340 50-3400 Maximum battery charge No
current current, in mA * 100, per battery
string
27 Nominal Output 1200 1200 Nominal output voltage is YES
voltage 120Vac to neutral
1270 Nominal output voltage is
127Vac to neutral
28 Bypass voltage 10 1-20 Upper voltage window for YES
high limit bypass, in percent nominal
voltage
29 Bypass voltage -15 (-1)- (- Lower voltage window for YES
low limit 20) bypass, in percent nominal
voltage
30 Sync window 2000 1000- Frequency window around YES
3000 nominal that inverter will sync to
bypass in mHz
31 Utility sync 2000 1000- Frequency window around YES
window 3000 nominal that inverter will sync to
utility in mHz
32 Nominal output 60000 50000 Nominal output frequency is YES
frequency 50Hz
60000 Nominal output frequency is
60Hz
35 Reset Modem NA 1 Causes the UPS to send a reset No
command to the modem
36 Reset History NA 1 Clears the UPS event history No
37 Reset to factory NA 1 Resets all parameters on this No

defaults list to factory default
38 Lock X-Slot2 to 0 0 X-Slot2/service port are No
service port multiplexed
1 X-Slot2 is disabled, service port
only is usable
40 Scheduled NA 1 Requests battery No
battery commissioning test to run
commissioning
test
41 Enable full power 1 0 UPS is not allowed to back feed No
battery test utility during battery test
1 UPS is allowed to back feed
utility during battery test

42 Auto-sense input 1 0 Do not auto-sense input YES

frequency frequency, get inverter
frequency configuration from
eeprom
1 On next power-up, auto-sense
input frequency and configure
inverter to match, then clear this
bit. (One time only)
43 Parallel UPM 0 0 Single unit configuration No
number
1-4 Parallel system configuration.
Each UPM in parallel system
must have a different UPM
number
46 Parallel mode 0 0 Parallel redundant system YES
1 Parallel capacity system
47 Start parallel NA 1 Initiates parallel system auto- YES
auto-calibration calibration
48 Start No-load/full NA 1 Initiates no load/full load test No
load
49 Error state reset NA 1 Clears parallel comm errors. YES
Also resets 0xC9 encryption
lock out
50 Remove offset NA 1 Initiates offset auto-calibration No
51 Force xcp sub- 0 0 Parallel unit accepts system

unit and sub-module commands
1 Forces parallel unit to sub-
module mode always
53 Number of 0 0-65535 Number of external battery No
external battery strings of different capacity than
strings internal batteries
56 Reset battery NA 1 Clears Battery needs service
alarms and battery test failed alarms

1.4 Input Isolation Transformer (60 Hz Only)

1.4.1 PW 9355
The input isolation transformer is contained in the Options Cabinet and can
come in various configurations. See chapter 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.
1.6 External Battery Cabinets

The UPS will operate with up to three (3) External Battery Cabinets (EBCs),
containing four battery strings in each cabinet. The EBCs can increase battery
capacity to a maximum of 18 battery strings, Including the internal batteries: a
maximum of twelve (12) strings of 24 ampere-hour batteries in the EBCs and
six (6) internal battery strings of 9 ampere-hour batteries.
1.7 Remote Emergency Power Off (REPO)

The remote emergency power off (REPO) switch is a provision for powering
down the customers critical load when rapid shutdown is required.
The REPO function is activated by an external contact. Both normally open and
normally closed REPO contacts are provided. The REPO control can be used
in conjunction with a room or building REPO, so that the utility can be removed
no matter what position the UPS Maintenance Bypass Switch (MBS) is in.
WARNING
AN ACTIVE REPO SIGNAL WILL DE-ENERGIZE THE CRITICAL LOAD.
When REPO is activated with utility present or on battery, the load is de-
energized immediately. The UPS will shut down all converters, de-energize all
system contactors, trip the CB-1 and CB-2 breakers, and fully power down the
UPS within 10 to 15 seconds.
Note:
If the REPO switch is not connected to the feeder breaker, the
Customer critical load will maintain power in the Maintenance Bypass
position.
1.8 Environmental Monitoring Probe (EMP)

The Environmental Monitoring Probe is used only with a Web/SNMP Card.
Refer to the Supporting Documents for information on installation and for
additional information.

1.9 Parallel Tie Cabinet with System Bypass

The Parallel Tie Cabinet is capable of paralleling up to 4 UPMs. It has a
maintenance bypass switch and auxiliary contacts to force the UPS to bypass
mode when the UPS maintenance output breakers (MOBs) are closed and the
UPS in normal operating mode.
CB1
UPM#1
Input
Breaker CB1
UTILITY
INPUT
UPM#2 #1 #2
Input
Breaker
CB1
#3 #4
Input
Breaker
UPM#3
CB1 TO LOAD
Input
Breaker
UPM#4
Figure 11. Parallel Tie Cabinet with System Bypass

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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 Electrical 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

Adhere to the following safety rules for working with electrical and mechanical
equipment in the maintenance and repair procedures:
The UPS must be used as intended. Follow the instructions given in the
user guide and installation manual.
Installation and use of the UPS must comply with all national and local
safety regulations and procedures.
All primary power switches installed downstream from the UPS must be
labeled as follows: ISOLATE UPS (Uninterrupted Power Supply) before
working on this circuit.

Safety 9355 20 30 kVA
2.2 Environmental Safety

Observe the following rules:
WARNING
DO NOT WORK ALONE AS DANGEROUS VOLTAGES ARE PRESENT INSIDE
THE UNIT. THE UPS MUST BE INSTALLED AND SERVICED ONLY BY SERVICE
PERSONNEL FROM THE MANUFACTURER OR FROM AN AGENT AUTHORIZED
BY THE MANUFACTURER.
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 un-authorized 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. If your hair is worn long, fasten it to make it safe.
8. Lift the equipment or parts by using your leg muscles to prevent
back strain. Do not lift any heavy equipment or parts that cannot
be lifted comfortably.
9. Always keep tool kits away from walk areas to prevent a tripping
hazard. If possible, keep all tools and tool kits 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 safety devices that are worn or defective with new
ones. Remember that safety devices protect personnel from a
hazard. Ensure all safety devices are reinstalled when the
maintenance/service has been completed.
9355 20 30 kVA Safety
2.3 Electrical Safety

Observe the following rules when working on electrical machinery:
1. Follow the manual shut down and maintenance bypass
procedures to prevent loss of power to the customers load.
Switch input and logic power off if recommended in the service
manual and:
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:
WARNING
DO NOT SERVICE INPUT, OUTPUT, OR BYPASS CIRCUIT BREAKERS,
TRANSFORMERS, CTS, OR PTS WITH POWER ON.
3. If working on equipment that has exposed live electric circuits,

OBSERVE the following precautions:
To protect against high leakage current; connect protective
earth (PE or ground) before connecting power supply cables.
Ensure another person who is properly trained in the power-off
controls is in a close proximity at all times to switch off power,
if necessary.
Remove jewelry, chains, metal frame eyeglasses, or other
personal metal objects.
Use only insulated probe tips or extenders.
Use one hand while working on or near energized equipment.
Keep one hand in your pocket or behind your 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 operators, 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
the service manual).

5. The output neutral of the system is connected with the required

neutral for the customers load and should never be bonded to
ground at the module output.
6. Ensure ALL battery breakers, and EBMs, are open before
checking voltages.
WARNING
NEVER ASSUME THAT POWER HAS BEEN REMOVED FROM A CIRCUIT.
CHECK AND ENSURE THAT POWER HAS BEEN REMOVED BY USING A
VOLTMETER.
7. Do not touch live electric circuits with the surface of a dental

mirror. The mirror handle is conductive and can cause equipment
damage and/or personal injury.
8. If an electrical accident occurs:
Instruct another person to get medical aid
2.4 Mechanical Safety
CAUTION
Do not touch moving mechanical parts at any time (Including fans). To prevent
overheating, do not obstruct the air flow or block the ventilation openings to the unit.
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 cause eye injury (that is, a UPS
module under power, input or bypass)

Do not wear soft contact lenses when working on or around electrical

equipment.
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 in close proximity to gas or electric heat sources.
3. The system is not intended for outdoor use.
4. The operating environment should be within the parameters listed
in Chapter 1.
2.6.2 Normal Operation

1. Keep equipment doors closed to ensure proper cooling airflow,
and to protect you 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
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 clothing and remove all jewelry.
3. Use correct documentation and appropriate tools as outlined in
this manual.

4. Use static secured work area and procedures when performing

component replacement or modifications.
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 with more detailed safety precautions described at
the appropriate paragraph later in this manual.
2.6.4 Batteries
1. The lead-acid batteries are maintenance-free sealed batteries.
No electrolyte/water can be added. Lead-acid batteries must be
disposed of correctly in compliance with the local regulations.
CAUTION
The battery breaker on the rear of the electronic module or Extended Battery Module
(EBM) shall be in the OFF position prior to connecting or disconnecting batteries.
The RED wires from the electronics module must be connected to the POSITIVE (+)
terminal of the battery trays and the BLACK wires from the electronics module must be
connected to the NEGATIVE (-) terminal of the battery trays. There is a risk of explosion
if a battery or batteries are replaced by an incorrect type.
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:
If acid comes in contact with skin:
Wash immediately with soap and water
Contact a physician if any burn results
If acid is splashed in the eyes:
Wash for 20 minutes under running water
4. Contact a physician.

2.7 Site Safety

Personnel associated with the UPS should be aware of the presence of
potentially lethal voltages. 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 in close proximity to gas or electric heat sources.
3. The system is not intended for outdoor use.
4. The operating environment should be within the parameters listed
in Chapter 1.
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.
5. Ensure the site is safe.

6. Inspect power cables and plugs; check for loose, damaged, or
worn parts.
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
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. At the minimum inspect
the following:
Power receptacles wired incorrectly.
Safety devices or features missing or defective.
Maintenance or change history that is wrong or incomplete.
A UPS design problem.
A UPS that has shipping damage.
An unsafe change or attachment installed in the UPS.
An engineering change or a sales change installed Incorrectly.
A defective part.
A potentially unsafe old UPS or one that has been operated in
an extreme environment.
2.8 Summary
Prevention is the key and main aid 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!
2.9 Electrostatic Discharge (ESD) Procedure And Equipment

Requirements
2.9.1 Purpose
To provide guidelines on handling electrostatic sensitive materials.
2.9.2 Objective
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 a static field, and typically has a surface resistance
of 109 to 1014 ohm/cm.
Conductive material: Material that provides a Faraday cage effect and
protects against static generation and a static field with a surface resistance of
<105 per cm.
Dissipative material: Material that provides some protection against a static
field and typically has a surface resistance 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 that 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.
Static sensitive material: Any static sensitive component/device
(semiconductors, film resistors and capacitors, and so on) 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: Must include as a minimum, but not be
limited to, a wrist strap with 1 meg ohm resistor, a 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
(THAT IS, 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 and grounded mats, or a grounded surface with
equivalent or better ground than the surface of the mat, shall be
used when handling static sensitive material.

3. When removing or installing boards in a unit or subassembly, a

wrist strap shall be used and it shall be connected to the frame of
the unit or subassembly.
4. Rejected boards (returned to factory/rework center) equally
sensitive to electrostatic discharge and shall be handled with the
same protection as good/accepted boards (that is, 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 that
provide a complete Faraday cage. The protection for both is
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.
Use the 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 and grounded mats, or a table with a surface ground
equivalent or better than that of a mat, shall be used when
handling static sensitive material.
3. When removing or installing boards in a unit or subassembly, a
wrist strap shall be used and it shall be connected to the frame
ground 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 (that is, 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. The
protection for both is 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
Packaging of boards, unless otherwise specified, will be packaged in

egg-crate type cartons, separating each board with partitions.
2.9.8 General Handling 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. The packing 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. Resistance requirements are as follows:
Interior (anti-static) 109 to 1014 W per square.
NOTICE
The resistance will be the same for any size square. 144 x 144 x 144
will have the same resistance as a 244 x 244 x 244 square.
Inter-layer resistance (insulating and direct discharge
protection) greater than 1014 W per square.
Exterior resistance (conductive) less than or equal to 105 W
per square.
Total thickness of static bags (including all layers) must be 3
MILS minimum.
Static bags must be sealed in some manner.

HANDLING FLOWCHART
Handling of Boards Handling of Handling for Field
Components Engineers and Sales
Personnel
| | |
| | |
Wrist straps and grounded Wrist straps and grounded Dissipative mats are to be
mats, or tables with an mats, or tables with an used by field engineers and
equivalent surface will be equivalent surface will be used sales personnel.
used when handling all static when handling all static
sensitive material. sensitive material.
| | |
| | |
Boards without static sensitive All static sensitive components Field engineering personnel
material, as a minimum, must must arrive in antistatic tubes or shall be equipped with
be in pink poly wrap for shielding packages. portable static controlled field
protection. service kits.
| | |
| | |
Boards with static sensitive Static sensitive components All other ESD procedures for
material must be in static shall be handled at a static boards and components will
shield bags. safe-guard station only be observed by field
personnel.
| |
| |
All boards with on-board Transport static sensitive

batteries must be placed in components in a static shielding
pink poly wrap prior to bag or container.
insertion in static shielding
bag.
|
|
Rejected boards are to be

handled with the same care as
accepted boards.

3
Installation and Startup
3.1 MODEL 9355 20 30kVA SINGLE MODULE (RT)
3.1.1 Mechanical Inspection
1. Visually inspect the module for any shipping damage:
a. Remove the front right side door and battery dead front
panels.
Figure 12. Front door panel removed
b. If possible, remove the right side skin panel, see Figure 17.

Installation and Startup 9355 20 30 kVA
Figure 13. Right side skin panel removed
c. Remove bolts from the dead front panel for wiring access.
Figure 14. Wiring Access After Dead Front Panel Removal

9355 20 30 kVA Installation and Startup
d. Perform an external and internal inspection (no dents, paint

blemishes, frame is straight).
e. Inspect to ensure that all internal subassemblies are secure
and ALL wiring connections are secure:
- Check input/output connections on the I/O Board, (see
Figure 71 and Figure 72).
- Check K1 and K3 contactor wiring connections (see
below).
Ensure wiring is secure
f. Remove the protective film from the unit front panel (use a
ground strap while removing the protective film) if installed.
g. Inspect the auxiliary cabinets for shipping damage.
(transformer, battery, or other cabinets)
2. Visually inspect the module for proper installation:
a. Check for properly rated feeder-breaker and wire size
(reference the installation and operation manual for
recommended breaker and wire sizes).
b. The UPS label matches the application (voltage, kVA,
frequency, power).
c. Ensure that the input and bypass connections are properly
wired and torqued (refer to users manual).
d. The system neutral must be supplied by the utility input
power source.
CAUTION
Do NOT bond neutral to ground internally in the UPS module.
3. Verify all options are installed and wired properly:
a. X-Slot Connectivity Devices:
- Connect the UPS SNMP / Web adapter

- Inspect the multi-port serial card

- Inspect the relay card (isolated form C contacts, AS400
type status)
- Inspect the single port serial card (RS-232 and AS400
signal levels)
- Inspect the USB module / card
- Inspect the X-Slot modem card (either V.34 or V.90) (X-
Slot-1 only)
b. External Maintenance Bypass Switch (If provided)
c. Remote Emergency Power Off (REPO)
d. External Power Distribution (PDM module or customer
provided)
e. External Transformers (optional cabinet or customer
provided)
f. Remote Monitoring Panel (RMP)
WARNING
STEP 4. CANNOT BE PERFORMED IF THE UPS INPUT IS ENERGIZED.
4. Verify there are no installation ground faults using a properly

functioning DVM (this includes the UPS module and any optional
cabinets):
Note:
The MBS should be in the UPS position.
- Neutral may have to be lifted removing the input source
neutral to ground bond
a. Verify there are no faults on the main inputs, phase to phase
and phase to ground
b. Verify there are no faults on themain outputs, phase to
phase and phase to ground
- All readings should be 2Meg or greater.
- Output Phase A to GND should be 80
c. Reconnect neutral if removed previously.
CAUTION
The battery circuit breaker on the UPS and/or EBC must be in the OFF position prior to
connecting or disconnecting batteries.
connected to the NEGATIVE (-) terminal of the battery trays

5. Verify that the Internal and External Battery Cabinet (EBC) battery
strings have been properly assembled and attached to the UPS:
a. Verify CB-2 is open.
b. Verify Inter-tray connections (Red to Black, Black to Red) for
batteries in series (use the diagram on the battery cabinet
and/or the UPS).
c. Verify inner-cabinet connections for strings in parallel.
d. Using a DVM, verify that the polarity of all parallel strings
match BEFORE making final connections.
6. Verify each string in the UPS, and EBC if installed. (Open cell
voltage for any string should be >210 VDC.)
a. Connect all black connectors, leaving the red connectors on
each string disconnected.
b. Verify each individual string prior to making final
connections.
c. The battery must NOT be ground referenced (either pole tied
to ground).
d. If a string doesnt indicate > 210 VDC, verify the inner
connections and recheck.
7. Verify battery strings, each pole to ground < 1 VDC.
3.1.2 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

DOWN STREAM BREAKERS ARE OPEN AND LOADS ARE DISCONNECTED OR
UNPLUGGED BEFORE PROCEEDING.
NOTICE
Use Startup Worksheets and Checksheet found at the end of this chapter.
1. Verify CB-1 is open and the MBS is in the UPS position.

2. Apply utility power to the UPS. (If dual feed also apply bypass
input power)
Note:
The bypass control board will have power applied to it but it will not
energize logic power in the remainder of the UPS.
3. Using a DVM, verify the system has correct input voltages

a. Using a DVM, verify AC voltages: phase-to-phase, phase-to-
neutral, phase-to-ground
b. Using a DVM, verify voltage neutral to ground is less than 5
VAC RMS (Root-mean square).
4. Using an oscilloscope or phase rotation meter, verify phase
rotation at the rectifier and bypass inputs.
5. Energize the system input, close CB-1. The following events
occur:
a. Logic power starts
b. The display energizes
c. The ALARM lamp on the front panel is lit
d. The active event for the batteries is disconnected
e. Horn sounds once every 3 seconds (pushing any button
silences the horn)
6. Using the XCP Service Software Tool, verify the unit setup:
a. Using the CTO (Configuration to Order) tab, verify that the
unit CTO number and power ratings correspond to the unit
labeling and installation
- You may have to enter the CTO the first time you connect.
b. Using the Battery Setup tab, configure the UPS for the
connected battery
The battery vendors data sheet or the battery label may be required.
If there are only internal batteries, enter the total number of strings and watts
per cell on the Battery 1 Battery Selection toggle switch if it is not already set,
see Figure 21.
If the external batteries are the same type as the internal batteries then include
both on the Battery 1 Battery Selection toggle switch if it is not already set on
the XCP Service Tool, see Figure 21.
If the external battery is different from the internal battery, enter the number of
strings and watts per cell on the Battery 2 Battery Selection toggle switch on
Figure 15. XCP Tool Battery Toggle Positions
To clear the setup required bit:

- After verifying the battery setup push the Battery Setup

Complete button. This will clear the setup required bit.
- A pop up will appear, click on the Battery Configuration
Complete to continue.
As soon as the setup bit is cleared the unit will start pre-
charge,
K5 will close,
K1 will close after precharging is complete (approx. 1
minute),
The front inverter fans will start.
c. Using the OPTIONS tab, verify the availability of customer
options.
- Verify that the required setups for the Configure To Order
(CTO) type are enabled
d. Using the MODEM tab, configure the unit for outcall
operations (if applicable)
Refer to the outcall setup procedures for specific instructions
7. Confirm the status of the following indicators:
a. The LCD display indicates the following active event
messages:
- Batteries Disconnected
b. The ALARM LED is lit.
8. Verify the following front panel operations:
a. The time and date are set correctly (the clock is a 24 hour
clock)
b. All screens correctly show the current operating status
c. All buttons are in working order
d. Status in the UPS STATUS window displays:
- UPS is OFF
- BATTERY NOT CONNECTED
Note:
Auto-Frequency detection is enabled from the factory when input power is first applied.
Once the system has initialized, the auto-frequency detection is disabled. It can be re-
enabled using the XCP Service Tool.
Operational Inspection
1. Start the UPS:
a. Close battery breaker CB-2.
b. Close output breaker CB-3 if installed.
c. Select UPS ON/OFF, cycle to select TURN UPS ON, and
hold the enter key until the beeping stops.

d. The output contactor closes; the NORMAL lamp on the front

panel is lit, the output fans energize and the rear fans
energize.
e. Verify the output voltage
f. Investigate and resolve any alarms or notices before
continuing.
2. Verify BATTERY operation:
a. Open utility input breaker for 30 seconds.
b. Using a DVM, verify stable output voltage & frequency, the
battery screen shows discharge.
c. Using the front panel meter screen, verify that NORMAL,
BATTERY, and NOTICE lamps are lit on the front panel, and
the horn sounds every 3 seconds.
d. Close the utility input breaker, verify battery recharge, and
that the system indicates NORMAL.
e. Review the module event history queue for expected events.
f. Investigate and resolve any unexpected events.
3. Verify the operation of all applied equipment options (where
applicable) for External Maintenance Bypass, and so on. The
module must be in bypass.
a. External and / or Internal Maintenance Bypass:
- The UPS must be in bypass or standby mode.
- Check voltage across external MBP, it should be <1VAC.
- Check the voltage across the input terminal block and the
output terminal block for internal MBP, it should be <1VAC
- UPS output should be recorded using a scope during
transfers.
b. X-Slot connectivity \ communication options:
- Refer to specific product instructions for setup and
verification.
c. Remote monitoring panels or status relays:
verification.
d. Eaton - Powerware Remote Monitoring (if applicable):
- Refer to specific instructions for setup and testing.
WARNING
IF THE CUSTOMERS EPO IS A BUILDING EPO AND THE UPS EPO IS
CONNECTED TO THE BUILDING EPO, A BUILDING LOAD DUMP COULD OCCUR
DURING UPS REPO TESTING.

e. Remote Emergency Power Off (REPO):

- Exercised while the module is operating in NORMAL
operation.
- The UPS battery breaker will open.
- The input contactor will open.
- CB-1 will open.
- The Inverter / rectifier will turn off.
- After testing REPO restart the UPS.
f. Check building alarm inputs (if used)
- After REPO the display and LEDs will sound and flash
until the UPS bleeds down.

3.2 MODEL 9355 20 30kVA Parallel (PC/PR)
NOTICE
This process for converting a 9355 RT to a Parallel Unit is described in

document #164700576.
3.2.1 Mechanical Inspection

1. Visually inspect the module for any shipping damage:
a. Remove the front right side door and battery dead front
panels.
Figure 16. Front door panel removed
b. Remove the right side skin panel, see Figure 17.
Figure 17. Right side skin panel removed
c. Remove bolts from the dead front panel for wiring access.

Figure 18. Wiring Access After Dead Front Panel Removal
d. Perform an external and internal inspection (no dents, paint

blemishes, frame is straight).
e. Inspect to ensure that all internal subassemblies are secure
and ALL wiring connections are secure.
f. Remove the protective film from the unit front panel (use a
ground strap while removing the protective film) if installed.
g. Inspect the auxiliary cabinets for shipping damage.
(transformer, battery, or other cabinets)
2. Visually inspect the module for proper installation:
a. Check for properly rated feeder-breaker and wire size
(reference the installation and operation manual for
recommended breaker and wire sizes).
b. The UPS label matches the application (voltage, kVA,
frequency, power).
c. Ensure that the input and bypass connections are properly
wired and torqued (refer to users manual).
d. The system neutral must be supplied by the utility input
power source.
e. Check the phase rotation on all connection points. This is
extremely critical, failure to have all phase connections
correct WILL result in damage to all UPMs.

CAUTION
Do NOT bond neutral to ground internally in the UPS module.
WARNING
IF CHECKING THE ACROSS MOBS FOR PROPER PHASE ROTATION WHEN THE
CUSTOMERS LOAD IS ON EXTERNAL BYPASS THERE WILL BE VOLTAGE
PRESENT ON THE MOBS. CLOSING THE MOBS WILL RESULT IN THE UPM
BEING BACKFED. MAINTAIN ELECTRICAL SAFETY PRECAUTIONS HIGH
VOLTAGE IS PRESENT.
WARNING
IF THE TERMINAL CONNECTIONS, PHASE A, B, AND C, ARE SWAPPED,
RESULTING IN A MISMATCH IN PHASES WHEN PARALLELING, IT COULD
RESULT IN DAMAGE TO ALL UPMS. SPECIAL ATTENTION SHOULD BE GIVEN
TO ENSURE THE CONNECTIONS ARE CORRECT.
3. Inspect Parallel Wiring Configuration

a. Remove the CAN Bridge card and verify jumpers are set
correctly on the CAN Bridge Board in accordance with
Figure 19 and re-install in each UPM. Set jumpers on first
and last UPM CAN Bridge Board J7 to Pins 1 and 2. On
middle UPM(s), set jumper on J7 to Pins 2 and 3. If only two
UPMs are being paralleled, then both cards should be set to
Pins 1 and 2.

Figure 19. CAN Bridge Board Jumper Settings
b. Verify all parallel control wiring is connected in accordance

with Figure 20. The CAN connections should be a maximum
of 18 gauge twisted pair with optional shield. Its
recommended a shielded wire bundle be used. CAN Bridge
boards can be installed in X-Slot one or two.
Note:
A modem card can only be used in X-Slot 1. If both a modem and CAN
Bridge board are used the CAN Bridge board must go into X-Slot 2.
Figure 20. Parallel Control Wiring

4. Verify all options are installed and wired properly:

a. X-Slot Connectivity Devices:
- Connect the UPS SNMP / Web adapter
- Inspect the multi-port serial card
- Inspect the relay card
- Inspect the single port serial card
- Inspect the USB module / card
- Inspect the X-Slot modem card (X-Slot-1 only)
b. External Maintenance Bypass Switch (If provided)
c. Remote Emergency Power Off (REPO)
d. External Power Distribution (PDM module or customer
provided)
e. External Transformers (optional cabinet or customer
provided)
f. Remote Monitoring Panel (RMP)
g. Internal MBS should always remaining the UPS position
- Only operate during maintenance when the MOB is open
and all parallel control wiring is disconnected.
WARNING
STEP 4. CANNOT BE PERFORMED IF THE UPS INPUT IS ENERGIZED.
5. Verify there are no installation ground faults using a properly

functioning DVM (this includes the UPM and any optional
cabinets):
- Neutral may have to be lifted removing the input source
neutral to ground bond
CAUTION
If the unit has external maintenance bypass you may also have to lift the output neutral.
a. Main inputs, phase to phase and phase to ground

b. Main outputs, phase to phase and phase to ground
- All readings should be 2Meg or greater.
- Output Phase A to GND should be 80 due to the rear
fan.
c. Reconnect neutral if removed previously.

CAUTION
The battery circuit breaker on the UPM and/or EBC must be in the OFF position prior to
connecting or disconnecting batteries.
connected to the NEGATIVE (-) terminal of the battery trays
6. Verify that the Internal and External Battery Cabinet (EBC) battery
strings have been properly assembled and attached to the UPS:
a. Verify CB-2 is open.
b. Verify Inter-tray connections (Red to Black, Black to Red) for
batteries in series (use the diagram on the battery cabinet
and/or the UPMs).
c. Verify inter-cabinet connections for strings in parallel.
d. Using a DVM verify the polarity of all parallel strings match
BEFORE making final connections.
7. Connect the Positive (red) wire to each string from the UPM or
EBC
a. Open cell voltage for any string should be >210 VDC.
b. Verify each individual string prior to making final
connections.
c. The battery must NOT be ground referenced (either pole tied
to ground).
8. Verify battery strings, each pole to ground < 1 VDC.

3.2.2 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

DOWN STREAM BREAKERS ARE OPEN AND LOADS ARE DISCONNECTED OR
UNPLUGGED BEFORE PROCEEDING.
NOTICE
Use Startup Worksheets and Checksheet found at the end of this chapter.
1. Verify CB-1 is open and the MBS is in the UPS position.

2. Apply utility power to one UPM at a time. (If dual feed also apply
bypass input power). DO NOT CLOSE CB-1.
Note:
The bypass control board will have power applied to it but it will not
energize logic power in the remainder of the UPS.
3. Using a DVM, verify the system has correct input voltages
a. Using a DVM, verify AC voltages: phase-to-phase, phase-to-
neutral, phase-to-ground
b. Using a DVM, verify voltage neutral to ground is less than 5
VAC rms.
4. Using an oscilloscope or phase rotation meter, verify phase
rotation at the rectifier and bypass inputs.
Secure power to the UPM and repeat Steps 1-4 for each
additional UPM.
5. Apply utility power to all UPMs:
6. Perform steps 7 through 11 on one UPM at-a-time ensuring that
the previous UPM is off before starting the next UPM.
7. Close CB-1; the following will occur:
a. Alarm will sound (press any key to silence)
b. Alarm light is lit
c. UPS status = OFF on the UPS status screen
d. BATTERIES DISCONNECTED appears on the UPS
battery status screen
e. Within 30 seconds K-5 will close with an audible click.

8. Using the XCP Service Software Tool, verify the unit setup:
a. Using the CTO (Configuration to Order) tab, verify that the
unit CTO number and power ratings correspond to the unit
labeling and installation
- You may have to enter the CTO the first time you connect.
b. Using the Battery Setup tab, configure the UPS for the
connected battery
If there are only internal batteries, enter the total number of strings and watts
per cell on the Battery 1 Battery Selection toggle switch if it is not already set,
see Figure 21.
If the external batteries are the same type as the internal batteries then include
both on the Battery 1 Battery Selection toggle switch if it is not already set on
If the external battery is different from the internal battery, enter the number of
strings and watts per cell on the Battery 2 Battery Selection toggle switch on
Figure 21. XCP Tool Battery Toggle Positions
To clear the setup required bit:

- After verifying the battery setup push the Battery Setup
Complete button. This will clear the setup required bit.
- A pop up will appear, click on the Battery Configuration
Complete to continue.
As soon as the setup bit is cleared the unit will start pre-
charge,
K1 will close after precharging is complete (approx. 1
minute),
The front inverter fans will start.
c. Using the OPTIONS tab, verify the availability of customer
options.
- Verify that the required setups for the Configure To Order
(CTO) type are enabled
d. Using the MODEM tab, configure the unit for outcall
operations (if applicable)
- Refer to the outcall setup procedures for specific
instructions

9. Confirm the status of the following indicators:

a. The LCD display indicates the following active event
messages:
- Batteries Disconnected
b. The ALARM LED is lit.
c. The alarm was previously silenced when acknowledged in
previous step 7a.
10. Verify the following front panel operations:
a. The time and date are set correctly (the clock is a 24 hour
clock)
b. All screens correctly show the current operating status
c. All buttons are in working order
d. Status in the UPS STATUS window displays:
- UPS is OFF
- BATTERY NOT CONNECTED
11. Set up Parallel System (you cannot have the same UPM ID on
multiple UPMs)
a. Using the XCP Service Tool Option (IF THIS OPTION IS
USED YOU DO NOT NEED TO PERFORM THE FRONT
DISPLAY OPTION)
Connect to each UPM and on the PCB Tab select
- UPM ID = Unit #1, Unit #2, Unit #3 or Unit #4
- Slide bar to Parallel Redundant or Parallel Capacity (Must
be the same for all UPMs)
b. Using the Front Display Option (IF THIS OPTION IS USED
YOU DO NOT NEED TO PERFORM THE XCP SERVICE
TOOL OPTION)
- On the XCP Service Tool Options Tab enable the service
menu option.
- For each UPM select ID number in parallel system: UPM
#1, UPM #2, UPM #3 or UPM #4. Select: SETTINGS ->
SERVICE SETTINGS -> PARALLEL OPERATION
SETTINGS -> PARALLEL UNIT NUMBER.
- Select parallel operation Redundant or Capacity: Select:
SETTINGS -> USER SETTINGS -> PARALLEL
OPERATION SETTINGS -> PARALLEL OPERATION
MODE.
Note:
For a reverse transfer UPM the ID will be zero (0); if the UPM ID is
changed to zero (0) the UPM will act as an RT UPS.
12. Repeat Steps 7 through 11 on each UPM.

3.2.3 Operational Inspection

1. Close CB-1 input breakers on all UPMs:
2. After all UPMs are in standby (fans running):
a. Close battery breaker CB-2.
- The LED should turn off.
b. Close output breaker CB-3 if installed.
c. Close the MOBs to all UPMs.
3. On any UPM turn the SYSTEM ON.
Note:
After the first startup, the load sharing of the system needs to be
calibrated. For best results No Load is preferred for auto-calibration;
however, the system can still be calibrated on load.
4. Select: Settings->Service Settings->PARALLEL OPERATION
->SETTINGS->START AUTO CALIBRATION
5. After completing the parallel calibration allow 10 minutes for the
UPMs to stabilize and verify that they share the load equally. If
load share is lop-sided, perform the parallel calibration again.
(With smaller loads the system may not load share equally).
6. Verify BATTERY operation:
a. Open CB-1 input breaker for 30 seconds on each UPM (only
perform on one UPM at-a-time) and verify the following:
- Using a DVM, verify stable output voltage and frequency,
the battery screen shows discharge.
- Using the front panel meter screen, verify that NORMAL,
BATTERY, and NOTICE lamps are lit on the front panel,
and the horn sounds every 3 seconds.
b. Close the CB-1 input breaker, verify battery recharge, and
that the UPM indicates NORMAL.
c. Review the module event history queue for expected events.
d. Investigate and resolve any unexpected events.
7. Repeat Step 6 as a system test by opening CB-1 on all UPMs at
the same time.
8. Verify the operation of all applied equipment options (where
applicable).
a. External Maintenance Bypass only:
- The UPS must be in bypass or standby mode.
- Check voltage across external MBP, it should be <1VAC.
- UPS output should be recorded using a scope during
transfers.
b. Test MBP/Tie Cabinet AUX contents:

- With UPMs in NORMAL, close the external MBS

- UPMs should go to BYPASS
- Open MBS
- UPMs should go back to NORMAL
c. X-Slot connectivity \ communication options:
verification.
d. Remote monitoring panels or status relays:
verification.
e. Eaton - Powerware Remote Monitoring (if applicable):
- Refer to specific instructions for setup and testing.
WARNING
IF THE CUSTOMERS EPO IS A BUILDING EPO AND THE UPS EPO IS
CONNECTED TO THE BUILDING EPO, A BUILDING LOAD DUMP COULD OCCUR
DURING UPM REPO TESTING.
f. Remote Emergency Power Off (REPO):

Note:
Unless all REPOs are paralleled only one UPM will shut down.
If UPMs are paralleled, all UPMs will shut down.
- Exercised while the module is operating in NORMAL
operation.
- The UPM battery breaker will open.
- The input contactor (K-1) and out (K-3) will open.
- CB-1 will open (and CB-3 if installed).
- The inverter / rectifier will turn off.
- After testing REPO restart the UPM.
Note:
UPMs will alarm and turn completely off after the capacitors are
drained.
g. Check building alarm inputs (if used)
- After REPO the display and LEDs will sound and flash
until the UPS bleeds down.

3.2.4 Inspection Completion

1. Temporarily apply the customers load, if available, or load bank
to the system and using a DVM verify all measured values against
the values that are displayed by both the unit front panel and the
XCP Service Software Tool meters tab.
a. Use the provided work sheet as needed.
b. Perform calibration of those parameters that are outside of
tolerances. (Refer to Chapter 8 for calibrations)
c. Shut down the unit, reinstall all panels and restore unit to
normal condition.
d. Restart the unit and place it online.
e. With the XCP Service Tool enable battery commissioning.
Note: Do not cycle logic power after the battery commissioning button
is selected (it will reset it).
2. Unit Data and Customer Reports
3. Download Setup Values
a. Download Unit History
b. Download Alarm / Event Nodes (if applicable)
4. Installation Acceptance Completion:
a. Conduct unit operation training for the customer.
b. If logic power cycles before battery testing, battery
commissioning must be re-enabled.
c. Provide a signed copy of the installation and startup check
sheet and a hardcopy of the unit setup values to the
customer.

Installation and Startup CHECKsheet

(the linked CD MSWord form can be filled-out and saved)
Powerware 9355 (20 - 30 kVA)
1. Apply customers load before final readings / measurements
2. Using a DVM verify all measurements and readings are within 1%
3. Make copies of this worksheet and fill one out for each UPM.
Single Module (RT)

Parallel Redundant / Capacity
UPM# SN IP Address
Location Recorded Values Expected
AC VOLTAGE MEASUREMENTS
Measured XCP Tool LCD OK( )
Input A-B V V 208 400
B-C V V 208 400
A-C V V 208 400
V
(L1 = Phase A) A-N V V V 120 230
(L2 = Phase B) B-N V V V 120 230
(L3 = Phase C) C-N V V V 120 230
(N = Neutral) A-G V V 120 230
(G = Ground) B-G V V 120 230
C-G V V 120 230
V
V
Neutral to Ground N-G V <5
V
V
UPS Output A-B V V 208 400
B-C V V 208 400
C-A V V 208 400
A-N V V V 120 230
(L2 = Phase B) B-N V V V 120 230
(L3 = Phase C) C-N V V V 120 230
(N = Neutral) A-G V V 120 230
(G = Ground) B-G V V 120 230
C-G V V 120 230
V

AC CURRENT MEASUREMENTS
Location Recorded Values
Measured XCP Tool LCD OK ( )
UPS Input (L1) A A A A
UPS Input (L2) B A A A
UPS Input (L3) C A A A
UPS Input (L1) A A A A

UPS Input (L2) B A A A
UPS Input (L3) C A A A
DC MEASUREMENTS
Location Recorded Values Expected
Values
DC Link Voltage VDC V V V
Battery Voltage VDC V V V
Battery Current ADC A A A

%
Batt. Time Remaining Mins.
Battery Charge Level % % %
POWER
Location Recorded Values
Input Power kVA
KW
Hz
PF
Output Power kVA
KW
Hz
PF

Powerware 9355 (20 - 30 kVA)

Single Module (RT)
Parallel Redundant / Capacity
DATE:
CUSTOMER
SITE PHONE
UPS S/N:
CTO REQUEST/ORD
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:

4
Functional Descriptions
This chapter provides a functional description for the Powerware 9355 20kVA to 30
kVA power train and the printed circuit boards.
4.1 Model 9355 20 30kVA

4.1.1 Overview
Reference Documents: 110720639 Electronics Module Schematic in the Prints
chapter at the end of this document.
The power-train topology is common among all 9355 UPS models and is
developed using common control and display boards.
The three phase low volt Electronics Module (EM) contains the I/O, EMI,
control, bypass and power module boards. The I/O board provides
interconnections to the control board. The power module boards contain the
system power-train components. The control board contains the
microprocessor and controls the entire UPS. The EMI Board handles surge
protection and EMI.

Functional Descriptions 9355 20 30 kVA
4.1.2 X-Slot Connections

X-Slot One X-Slot Two
Reference Description Reference Description
Designator Designator
X55-1 GND X55-1 GND
X55-2 GND X55-2 GND
X55-3 GND X55-3 GND
X55-4 GND X55-4 GND
X55-5 PAR RED1 X55-5 PAR RED1
X55-6 TX X55-6 TX
X55-7 PAR RED2 X55-7 PAR RED2
X55-8 RX X55-8 RX
X55-9 K3 DRV X55-9 K3 DRV
X55-10 K1 DRV X55-10 K1 DRV
X55-11 GND X55-11 GND
X55-12 DTR X55-12 DTR
X55-13 GND X55-13 GND
X55-14 K4 DRV X55-14 K4 DRV
X55-15 CAN HI X55-15 CAN HI
X55-16 K2 DRV X55-16 K2 DRV
X55-17 NC X55-17 NC
X55-18 +12VDC X55-18 +12VDC
X55-19 CAN LO X55-19 CAN LO
X55-20 +12VDC X55-20 +12VDC
4.1.3 Native RS Port

Reference Designator Description
X53-1 DCD
X53-2 RXD
X53-3 TXD
X53-4 DTR
X53-5 GND
X53-6 DSR
X53-7 RTS
X53-8 CTS
X53-9

9355 20 30 kVA Functional Descriptions
4.2 Electronics Module Functional Sections

4.2.1 Display Panel
Refer to paragraph 4.3 Display Panel.
The Display Panel is the user interface. It has an LCD for displaying system
information and buttons for navigating through the menus. The Display Board
communicates with the control board over the CAN network via a PIC18F448
Micro Controller and provides the user interface.
4.2.2 Control Board

Refer to paragraph 4.4 Control Board.
The Control Board contains the DSP micro-controllers and is responsible for
overall operation of the UPS except for certain bypass functions. The Control
Board contains a Texas Instruments (TI) TMS320F2812A Digital Signal
Processor (DSP). The 150 MIPS TI DSP provides software functionality, that is:
analog sensing, digital signal sampling, power-train control including Pulse
Width Modulated gate signals, serial communications, serial EEPROM, and a
CAN 2.0B network.
4.2.3 Power Module Boards

Refer to paragraph 4.5 PW9355 Power Board.
The Power Board Assembly (1024049) contains IGBT modules for the
converters, IGBT gate drives, and for additional sensing.
4.2.4 Bypass Control Board

Refer to paragraph 4.13 PW9355 Bypass Control Board.
The Bypass Board Assembly (1024057) provides self-contained bypass
functionality and provides external interfaces to the customer.
4.2.5 I/O Board

Refer to paragraph 4.2.5 1.X PW9355 I/O Board.
The IO Board Assembly (1024053) handles IO. It controls the rectifier and
inverter contactors as well as tripping the circuit breakers. The I/O Board also
provides interconnect to the Control Board.
4.2.6 EMI / Surge Board

Refer to paragraph 4.2.6 EMI Board.
The Electro-Magnetic Interference (EMI) Board provides input filtering and
surge protection for the UPS.

4.2.7 Contactors
The Rectifier Input Contactor K1 provides:
Input protection to the rectifier.
Inverter Output Contactor K3 provides:

inverter isolation when open.
Bypass Back-feed Contactor K5 provides:

Back-feed protection when open.
The control for each contactor is:

K1 (24VDC signal from a connection to the I/O board at X27-1 and X27-3)
K3 (24VDC signal from a connection to the I/O board at X21-1 and X21-3)
K5 (24VDC signal from a connection to the Bypass board at X51-1 and
X51-3)
4.2.8 Internal Battery

The system can be configured with up to six (6) strings of batteries. Each
string is eighteen (18) 12V batteries connected in series. The strings are then
connected in parallel on a connection board located behind the battery breaker.
4.2.9 External Battery

The external battery has the positive connection to the circuit breaker line side
along with the internal batteries. The negative connection is to the load side of
the breaker. This ensures that all wiring is protected by circuit breakers and
that accessible terminals are disconnected when the breakers are tripped.
4.2.10 Battery Circuit Breaker

The battery circuit breaker is a magnetic type with a DCV rating of 300V
including a trip coil (24V) and an auxiliary contact, both on the same circuit. The
coil voltage must be removed after tripping the breaker or it is possible to
damage the trip coil. The I/O board provides the signal for tripping the circuit
breaker from the X50 connector. Embedded software determines when the
breaker shall be tripped; otherwise, when the current through the breaker
exceeds the breaker rating the breaker will trip.
4.2.11 Ferrite Toroids

PW9355 Ferrite Toroids
There are several Ferrite Toroids throughout the 9355 UPS system. Used as
transformers in main power supplies, toroidal coils reduce resistance, due to
the larger diameter and smaller number of windings. The magnetic flux in the
toroids is confined to the core, preventing its energy from being absorbed by
nearby objects.
4.2.12 Chokes
The following is a list of PW9355 Chokes:
Battery Chokes: L2, L5, L8
Inverter Chokes: L3, L6, L9
Rectifier Chokes: L1, L4, L7
4.2.13 Fans
The PW9355 UPS has six (6) vane axial fans rated at 120VAC/110CFM. The
fans are housed in the fan assembly.
Table 2. Fan Assembly Iteration with Associated Serial Numbers
9355 20-30 kVA Fan Assembly Evolution Associated Serial Numbers
old fan assemblies and old switchgear EY213KXX07 and lower last digit
"new fan assembly" and "new switchgear" EY213KXX08 and higher last digit
4.3 LCD Display Panel
Figure 22. Display Panel
4.3.1 Overview
This section describes the functionality of the PW9355 display firmware and the
basic principles of operation.
The PW9355 display module has four push buttons, four light-emitting diodes
(LEDs), a buzzer and a graphical Liquid Crystal Display (LCD). These are
controlled by a micro-controller (PIC) which communicates with the main
processor (DSP) using the Controller Area Network (CAN) bus. Refer to

paragraph paragraph 6.1.9 CAN Bridge Card and Figure 53 for more
information about the Controller Area Network.
Character images are stored to the PIC flash memory. The PIC provides the
time-bases for LED flashing and buzzer control. The PIC also takes care of
low-level LCD handling.
4.3.2 Detailed Description of Settings

Refer to the details of the user settings that are listed in the 9355 UPS Users
Guide. CSEs have access to these settings as well as the CSE Service
Settings.
4.3.3 User Settings

For details of the User Settings, refer to the user setting information that is
listed in the 9355 UPS Users Guide.
Table 3. Disable control commands via communication user settings

Front Panel LCD User Setting Setting Definition
To disable all control commands from a The control commands are all XCP commands that
communication channel. The setting is done change/modify any parameters, variables, UPS
independently per channel. operation, and so on in the UPS; or hardware
commands that are multiplexed to communication
receive lines, thus simulating a long break.
Display Contrast Adjustment The user can adjust the best LCD display contrast for
the environment.
Change Language The language selection is between English and other
languages.
Start Screen in the Display The default screen: Eaton Powerware logo or the
mimic screen.
This screen is displayed at reset, when ESC is pushed
until the system menu returns to the top, or when the
display has been untouched for a specific time period.
User Settings Password Sets if the password is required for user settings.
Lock Communication to D-Sub Disables the automatic multiplexing of communication
channel 2 between the X-Slot 2 and the D-sub, and
directs the communication to D-sub permanently.

(or XCP command)
Set Date & Time The date and time is used for time-stamping the history
log items.
Serial Port Configuration The available speeds are 1200bps, 2400bps, 9600bps,
and 19200bps, which are set independently per
communication channel.
Go to Bypass The transfer is done only if bypass is available.


(or XCP command)
Battery Test Command When the test is launched with the XCP command, the
test duration is given in the command. The test selected
from the LCD has fixed time. The following is a
sample of a Battery Commissioning Test using
command <ESC>B.:
BATTERY COMMISSIONING TEST
BATTERY TEST # 1
TIME: 12:31:30 DATE: 11/14/2004
TEST 1 NOT COMPLETED
VOLTAGE 0.00
POWER (W/CELL) 0.00
TEST 2 NOT COMPLETED
VOLTAGE 0.00
POWER (W/CELL) 0.00
OPEN CIRCUIT VOLTAGE 0.00
CALCULATED RESISTANCE 0.0000
BATTERY HEALTH 0.0000
Audible Alarms The settings are:
Disable audible alarms and normal sound.
Set Nominal Output Voltage With XCP, the value can be set with 0.1V steps. The
front panel setting has larger steps. Changing this value
will automatically change the voltage window defined by
Bypass Voltage High Limit and Bypass Voltage Low
Limit.
Bypass Voltage High Limit The value is a positive percentage added to Nominal
Output Voltage, and it follows changes automatically in
the Nominal Output Voltage setting. It can be set with
1% steps, for example: +10%.
Bypass Voltage Low Limit The value is a negative percentage subtracted from
Nominal Output Voltage, and it automatically follows
changes in the Nominal Output Voltage setting. It can
be set with 1% steps. Example: -15%.
Synchronization Window The value can be set with 0.1Hz steps. This sets the
frequency window used for synchronization around the
Nominal Output Frequency, and it automatically follows
changes in the Nominal Output Frequency setting.
Number of Battery Strings Zero (0) means that no batteries are connected.
Total battery size is number_of_strings W/cells
cells/strings.
(W/cell, 15 min rate to 1.67 VPC at 25 C)
Battery Size Setting The size is given as Watts per battery cell, in 1W steps.
Total battery size is number_of_strings W/cells
cells/strings.
(W/cell, 15 min rate to 1.67 VPC at 25 C)
Battery Low Alarm Level The maximum current used for charging the batteries is
set with this setting, in 0.1A steps.
Automatic On Delay Values 0 ... 32767 define the extra delay in seconds,
which is counted down every time the UPS is about to


(or XCP command)
turn on its output.
With value -1, the automatic restarts are disabled; the
UPS will not turn on automatically (uncommanded) after
low battery shutdown.
Nominal Output Frequency With an XCP command, the nominal output frequency
can be set with 0.001Hz steps (the front panel has
larger steps). Changing this value will move the
Synchronization window in accord with it.
ABM Charging Cycling Disable Disables the cyclic ABM charging and uses the
continuous mode.
Output Frequency Slew Rate The maximum speed of changing the output frequency
that the UPS uses while synchronizing or maintaining
synchronization; set with 0.1Hz/sec steps.
Operation Priority While Rectifier Input This selects if the UPS will prefer bypass operation to
Break battery operation when rectifier input fails, and bypass
is available.
Rectifier Current Limit The maximum current drawn from utility by the rectifier
is set here, in 0.1A steps.
Alarm Relay Configuration For each alarm, the user selects the relay to activate.
Signal Inputs Function For each alarm input, the user selects the function.
Input Signal Delayed Shutdown Delay This is the delay for hardware Remote off with
automatic restart command.
Factory setting is 120 sec, but the user may modify it.
X-Slot Shutdown Signal Input Activation This is the delay duration the X-Slot hardware shutdown
Delay signal (connector pin 8) must be below before the
associated function is activated.
Factory setting is 5 sec.
Unsynchronized Transfer to Bypass This selects if synchronization is required for making
transfers to bypass.
Synchronization to Bypass This selects if the synchronization to bypass is done.
Usage of Bypass This selects if the bypass is used (enabled) when
needed / required, or if it is never used (disabled).
Site Wiring Fault (NOTICE) The user can enable or disable this alarm.
When set as Disabled, no alarm nor notice is given on
the front panel. Nothing is logged into the history log.
When set as Enabled, the factory setting is used,
alarm activation and inactivation are logged.
Note: With Nodebits (service setting) it is possible to
make a more detailed setting. The user setting (front
panel) shows as Disabled when set as event and not
logged. Otherwise, the user setting shows as Enabled.

4.3.4 Service Settings

The following Service Settings are available to the CSEs for troubleshooting. In
addition, CSEs have access to the User Settings that are listed in paragraph
4.3.3. For details of the User Settings, refer to the user setting information that
is listed in the 9355 UPS Users Guide. The default access to Service Settings
on the LCD Display in PW9355 for the U.S. and Canada will be disabled. In
other overseas markets the Service access will be enabled.
Table 5. Service Settings
(or XCP command)
Service Control This is an implementation defined parameter, which
allows service to do special hardware controlling
Rectifier Synchronization Window This setting defines the rectifier input frequency window
that is used for synchronization when the bypass voltage
has failed.
Auto Frequency Detection
Back-feed Enable
Battery Charging Temperature This setting defines the number of battery cells in a
Compensation battery string.
On Battery Alarm Delay This setting defines the number of seconds the UPS is
on battery operation before UPS on battery alarm is
given.
Battery Test Schedule
EPO Disable This setting disables/enables the Emergency Power Off
signal and functions.
Modem Communication Define the communication channel where the modem is
connected.
A value of zero (0) means that no modem is connected.
Modem Call Number Setting This string is sent to the modem when a call is initiated. It
holds the call command and the phone number to dial.
Modem Initialization String This string is used when the modem is to be initialized.
Modem Communication Password This string defines the password that is required when
someone tries to change the UPS configuration or control
the UPS through a modem line.
Modem Hang Up String This string is used to hang up (disconnect) the
modem/phone line.
Set Modem Call Command
Set Modem Call Events
Adjust Events
Reset Custom Event Settings
Adjust Parameters
Reset Configuration to Factory Setting With this setting it is possible to reset most of the UPS
configuration to the factory settings.

Table 5. Service Settings

(or XCP command)
Clear History Log With this setting it is possible to reset the UPS event
history log.
Constant Float Voltage This setting defines the battery charging voltage (volts
per cell) when ABM charging cycles are disabled.
Nodebits Service setting. Each event can be configured several
different ways.
An alarm, notice, or non-alarming event
Logged into the event log or not
Cause a modem call
Cause an audible alarm

4.4 CONTROL BOARD (PCB)

Reference Documents: 1021280 Control Board Schematic
Figure 23. 9355 Control Board
4.4.1 Firmware Description and Operation

Refer to Figure 24 Control Board Machine States
The 9355 has the following operation states:
Shutdown - Shutdown commanded from the display or the rails cant be
powered. The load is powered-up after the UPS is commanded from the
display, or the load is on bypass and the UPS is waiting until conditions
accomodate transfer to normal mode. The X-Slots are not powered.
Startup - The unit performs startup-steps to power up rails. The X-Slots are not
powered.
Standby - The inverter is ready to feed the load. The X-Slots are powered. The
XCP tool can be used to power-up the load.
On Inverter - The load is fed by the inverter. Energy is taken from the utility
and/or from the batteries. The X-Slots are powered.
On Bypass - The load is fed through the bypass line. Energy for the load is
taken from the bypass/utility, but battery energy may be used for UPS testing
and for other internal purposes. The X-Slots are powered, the ABF relay is
closed, and the rails cannot be bled down.
Bleeding UPS performs full shutdown. The DC bus is drained. Bleeding
cannot be called if the unit is on bypass. The X-Slots are disabled.
Bypass-Locked - The load is on bypass. The UPS is internally shut down and
will automatically restart when utility power returns. This is done during flash
recovery.
Failure Shutdown There is an active alarm that prevents UPS startup. It is

possible to clear this alarm by starting the UPS from the display. The X-Slots
are powered during this state.
Shutdown
Bypass-
locked Failure
shutdown
Startup
Bleeding
On bypass
Standby
On inverter
Figure 24. 9355 Control Board Machine States
4.4.2 Shutdown State

The load is down. The X-Slots are not powered. The only way to restart the
UPS is to use the front panel UPS On function.
If auxiliary power goes active while startup is not possible, the unit stays in the
shutdown state.
If auxiliary power goes active while the load is on bypass and startup is not
possible, the unit waits until startup is possible and transfers the load to the
inverter.
4.4.2.1 User Interface & XCP

XCP status = UPS OFF
XCP status = ON BYPASS

4.4.2.2 Initialization
4.4.2.3 Hardware
Bypass off
Inverter thyristors off
X-Slots are off
4.4.2.4 Other
None
4.4.2.5 Operation
1. Wait for front panel UPS on command.
2. Wait for good startup conditions and change the state to start-up
state if the load was on bypass when start-up state was called.
4.4.3 Startup State

The UPS is performing its start-up sequence and automatically progressing
toward standby operation or load on inverter operation.
The load can be on bypass if commanded. The X-Slots are not powered up.
The UPS powers up the DC bus. Rectifier, inverter and battery operations start.

4.4.3.2 Operation
4.4.3.3 Initializing State

This state is always called before shutdown state. Some startup procedures are
executed here. The next state is utility startup, battery startup or shutdown
depending on the conditions.
1. Disable EPO, disregard all measurements as X-Slot and other
measurements are taken from the Control Board signals, with the
exception of 24V measurement.
2. Check that the unit is 9355, that the Control Board is supported
and the PLD version is known. If not, set the software
incompatibility detected alarm and jump to failure shutdown state.
3. Wait until the 24V measurement is higher than 17V; if not
registering higher than 17V after 6 seconds, set the auxiliary
power startup failure alarm, and jump to failure shutdown state.
4. Wait for correct bypass status information.

5. Initialize bypass signals.

6. Activate I/O_GOOD (Control board logic good).
7. Set bypass to Idle state if fire state is not detected.
8. Turn on PWRCLK0 (Gate power clock).
9. Turn on PWRCLK1 (Aux. power clock).
10. Turn on 12V_1 (Main circuit +12V).
11. Wait 500ms.
12. Reset the auxiliary voltage monitoring alarms in PLD.
13. Wait 400ms.
14. Enable the meters.
15. Wait 100ms.
16. Initialize slow utility measurements to fast measurement values.
17. Reset CLK_FAIL and EPO alarms.
18. Wait 1 second.
19. Enable auxiliary voltage alarm monitoring.
20. Wait 1 second to settle filtered measurements.
21. Check 12V, continue monitoring. If ok, all measurements and
monitoring signals are functioning now.
22. Clear auxiliary power startup failure, the back-feed failure, the
abnormal output voltage alarm, the bypass SCR failure, the DC
charger failure, the balancer relay failure, the rectifier failure, the
inverter startup failure, the fuse failure, and the DCOV and DCUV
alarms.
23. Initialize rectifier control values.
24. Start monitoring temperature alarms, building alarms, voltages,
and so on.
25. Auto zero Hall Sensor offsets. Inverter and rectifier sensors are
zeroed.
26. If utility startup is possible, perform utility startup.
27. If battery startup is possible, perform battery startup, otherwise
shutdown.
4.4.3.4 Shutdown State

1. Wait for the front panel UPS ON command.
OR
1. Wait for the proper startup conditions when the load is on bypass.

2. Prepare to lose auxiliary power and jump back to the initializing

state if the utility fails.
4.4.4 Battery Starting State

1. Clear the old EPO alarm.
2. Activate the EPO.
3. Close the balancer relay.
4. Wait 60ms.
5. Activate GATE_ENABLE and the PLD gate outputs.
6. Use the input phase 1 lower IGBT to transfer energy from
negative rail to positive rail in order to keep auxiliary power up
and running.
7. Wait for the front panel ON command or utility voltage before
continuing. If nothing happens in 3 minutes, open the battery
breaker. Jump to utility startup if utility voltage is good.
8. Wait 500ms.
9. If not in parallel mode, bypass is not active and the output voltage
is > 50V, then set the abnormal output voltage alarm, open the
battery breaker and jump to the bleeding state.
10. If bypass is not active and the bypass voltage is > 50V, then set
the bypass breaker failure alarm, open the battery breaker and
jump to the bleeding state.
11. Wait 100ms and initialize slow bypass voltage measurements to
fast measurements.
12. If the unit is not in parallel mode and bypass is not active and the
output voltage is > 50V, then set the abnormal output voltage and
bypass SCR failure alarms, open the battery breaker and jump to
the bleeding state.
13. If bypass is available and not active, then request bypass idle
mode.
14. Wait 20ms.
15. Activate the DC_CHARGE to charge the positive rail.
16. Check positive rail voltage after 10 seconds: if it is below 20V,
then set DC charge failure alarm, open the battery breaker and
17. Wait until positive rail voltage is above battery voltage by 45V. If
unresponsive after 2 minutes, then set the DC charge failure
alarm, open the battery breaker and jump to the bleeding state.
18. Stop charging the positive rail.
19. Wait 10ms.

20. Use the input phase 1 upper IGBT to transfer energy from positive
to negative rail.
21. Request battery relay balancing.
22. If negative DC voltage goes over 233V, then set the balancer
relay failure alarm, open the battery breaker and jump to the
bleeding state.
23. Check the negative voltage after 20s, if below 50V, then set the
balancer relay failure alarm, open the battery breaker and jump to
the bleeding state.
24. Wait until the battery relay is balanced. Maintain minimum positive
rail voltage (120V). If not ready after 2 minutes, then set the
balancer relay failure alarm, open the battery breaker and jump to
the bleeding state.
25. Stop the charging negative rail.
26. Wait 1 second.
27. Deactivate the DC_CHARGE.
28. Ramp boost the voltage starting from lower rail voltage 240V / 1
second.
29. Wait until final rail reference is reached (188V).
30. Startup the balancer.
31. Ramp boost voltage again starting from lower rail voltage 40V / 1
second, now with the balancer active.
32. Wait 1 second.
33. Turn on 12V_2 (X-Slots), accept X-Slot communication.
4.4.5 Utility Starting State

1. Clear the old EPO alarm.
2. Activate EPO.
3. Start monitoring utility voltages, jump to shutdown if not good.
4. Check the site wiring fault and shutdown if the chassis voltage
measurement is > 50V.
5. Wait 500ms.
6. If not in parallel mode, bypass is not active and output voltage >
50V, then set the abnormal output voltage alarm and jump to the
bleeding state.
7. If bypass is enabled and not active and bypass voltage > 50V,
then set the bypass breaker failure alarm and jump to the
bleeding state.

8. Wait 100ms and initialize slow bypass voltage measurements to

fast measurements.
9. Enable gate power and PLDs.
10. If rail is already up, exit the Utility starting state sequence and go
to the turn inverter on state. Otherwise, continue the sequence
and turn rectifier L1 on, in a mode which bleeds the balancer
capacitor down.
11. Request bypass idle mode.
12. Wait 100ms.
13. If capacitor voltage is < 25V, close the balancer relay.
14. Wait 40ms.
15. Activate the DC_CHARGE to charge the positive rail.
16. Check positive rail voltage after 10s; if below 20V, then set DC
charge failure alarm and jump to the bleeding state.
17. Wait until (+) rail voltage is above L1 positive peak by 45V. If it is
not ready after 2 minutes, then set DC charge failure alarm and
18. Use input phase 1 upper IGBT to transfer energy from (+) to (-)
rail.
19. Check negative voltage after 20 seconds. If below 50V, then set
the balancer relay failure alarm and jump to the bleeding state.
20. Wait until negative DC is higher than L1 maximum peak + 55V or
233V. If not ready after 2 minutes, then set balancer relay failure
alarm and jump to the bleeding state.
21. Stop charging the negative rail.
22. Wait until the positive rail voltage is above L1 positive peak by -
45V. If not ready after 1 minute, then set the balancer relay failure
alarm and jump to the bleeding state.
23. Wait 5 seconds.
24. Deactivate the DC_CHARGE.
25. Use the input phase 1 lower IGBT to transfer energy from the (-)
rail to the (+) rail.
26. Wait until positive and negative rails are equal (+/-5V). If not
ready after 20 seconds, then set the balancer relay failure alarm
and jump to the bleeding state.
27. Wait 5 seconds.
28. Open the balancer relay, K1-K4, and wait 20ms.
29. Close the K1 contactor. The contactor is too slow to operate at
zero crossing. Wait 100ms.

30. Set the initial rectifier reference to higher rail voltage + 15V or
188V.
31. L1 Rectifier on.
32. Ramp up rectifier reference voltage (10V / 1s).
33. Wait until the final rail reference is reached (188V). If not ready
after 10 seconds, then set rectifier failed alarm and jump to the
bleeding state.
34. L1 Rectifier off.
35. L1, L2 and L3 Rectifier ON.
36. Wait 100ms while the rectifier is running normally. If not ready
after 10 seconds, then set the rectifier failed alarm and jump to
the bleeding state.
37. Set the flag which communicates that the rail is high enough to
commutate the battery SCR if it was turned on.
38. Turn on the 12V_2 (X-Slots), accept x-slot communication.
4.4.6 Inverter Starting State

1. If the unit is on bypass, configure the inverter (this is for flash
recovery), enable the battery, close the battery contactor, transfer
the unit to bypass and exit the inverter starting state.
2. Configure the inverter.
3. Inverter ON.
4. Wait 40ms.
5. Check the inverter fuses. If inverter voltage is under 50V, then set
the fuse failure and inverter startup failure alarms and jump to the
bleeding state.
6. Check that the inverter is within its operational window. If not,
then set the inverter startup failure and jump to the bleeding state.
7. If not in parallel mode, bypass is not active and UPS output
voltage is > 50V, then set the abnormal output voltage and
inverter startup failure alarms and jump to the bleeding state.
8. Enable battery operations and close the battery contactor.
9. Wait 5 seconds.
10. Jump to the standby state.

4.4.7 Standby State

The UPS is brought to this state on the first startup after auxiliary power comes
up, load is not on bypass and startup is possible.
During standby state the load is down and the X-Slots are powered; the
inverter, rectifier and battery operations are active; and the output SCRs are
open. The batteries are charged if utility is good. Auxiliary power is drawn from
utility or from the battery if utility isnt available.
During standby the UPS output has been turned off. The UPS is ready to turn
the output on when commanded to do so, or when the utility is OK, depending
on the standby precursory condition resolution.
Standby stays active as long as all of the following conditions are met and the
load is not commanded on.
Table 6. Active Standby Conditions
Conditions Required to Maintain DC Bus Voltages Timeout Before Action
Inverter hardware over current limit 0ms
Rectifier hardware over current limit 0ms
Overload >100% and shutdown timeout reached 0ms
Auxiliary power failure 0ms
DC bus over voltage (>250 V) 0ms
DC bus very low voltage (<100 V) 0ms
Inverter output fuse failure 0ms
Any phase of utility > 144V 0ms
Utility not available and boost/charger hardware over current limit
0ms
Utility not available and boost/charger over temperature shutdown

0ms
Utility not available and low battery shutdown * 0ms *

Inverter output out of window 300ms
Temperature sensor failure 300ms
Rectifier over temperature shutdown 300ms
Inverter over temperature shutdown 300ms
Balancer over temperature 300ms
Boost/charger hardware over current limit 300ms
* Low battery shutdown timeout is 60 minutes on standby state.
When utility power fails and auxiliary power is taken from the battery, a 60-
minute countdown starts. When the countdown expires or the battery voltage
reaches 1.67 volts/cell, the unit goes to the bleeding state and auxiliary power
is shut down. If utility returns, the counter counts backwards until the 60-minute
limit is reached. If standby was caused by a low battery shutdown, there is a

60-minute countdown mentioned above, but load will be powered when utility
returns.
4.4.8 User Interface & XCP

4.4.8.1 Hardware
Bypass off
X-Slots are on
4.4.8.2 Other
Restarts automatically if the automatic on function is enabled and when the
turn-off reason is:
Automatic off delay
OR
Binary input delayed shutdown function
OR
XCP delayed load power off and restart command.
4.4.8.3 Operation
The restart flag indicates if the UPS output is automatically turned back on
when the utility is OK.
The minimum time to remain in standby after turn-off is 10 seconds. This
feature prevents inadequate breaks on the UPS output voltage.
While the UPS is in this state UPS communications is working (this means the
D-sub, X-Slots, binary inputs, signal relay, and so on). Battery power is used,
when necessary. The UPS must be ready to restart when commanded to do
so.
While remaining in this state, the battery voltage is constantly monitored. If
battery voltage decreases to the shut down level, battery draining ceases and
the UPS is turned off; if a one-hour-long utility break occurs, the same shut
down sequence occurs. The utility break counter is decreased when utility is
good.
If the UPS is turned off, the restart flag state is stored. When the utility returns,
the state of the flag is checked, and the UPS output is automatically restarted.
4.4.9 On Inverter State

The load is fed by the inverter. Energy is taken from the utility and/or from the
batteries. The X-Slots are powered.


The XCP status is given in the following prioritized order:
XCP status = ON BATTERY, when discharging batteries
XCP status = OUTPUT OVERLOAD, when the UPS is overloaded
XCP status = SYSTEM NORMAL, when there are no alarms
XCP status = UPS SUPPORTING LOAD, when alarms are active
4.4.9.2 Hardware
Bypass off
Inverter thyristors on
X-Slots are on
4.4.9.3 Other
None
4.4.9.4 Operation
During the program loop, the firmware checks for any conditions that would
invoke a transfer on bypass, output shutdown, or conditions preventing a
transfer on bypass. When a transfer on bypass is possible, the state of the UPS
changes to a transfer on bypass state.
The firmware checks the conditions that caused inverter output shutdown and
transfer to bypass, and the output is remedied accordingly. The XCP load off
commands will then change the state of the UPS to standby. Other conditions
may require rail discharge in addition to securing the output.
Depending on the condition, shutdown may also be delayed. A Delayed
Pending Shutdown is aborted if conditions become inactive before the delay
has expired.
4.4.10 On Bypass State

The table below shows the conditions that normally will cause the transfer to
bypass.
If the transfer cannot be made, the table shows whether a condition causes an
output shutdown.
Table 7. Conditions Prompting an Output Shutdown

Conditions Requesting Transfer to ON Bypass Transfer If Transfer is
Disabled if... Disabled,
Shutdown After...
User command to use bypass operation ABC -
Overload level 1 102% ABC 10 minutes
Overload level 2 111% ABC 60 seconds

Table 7. Conditions Prompting an Output Shutdown

Conditions Requesting Transfer to ON Bypass Transfer If Transfer is
Shutdown After...
Overload level 3 126% ABC 5 seconds
Overload level 4 151% AB 300ms
Inverter output out of window AB 300ms
Temperature sensor failure AB 300ms
Rectifier over temperature shutdown AB 300ms
Inverter over temperature shutdown AB 300ms
Balancer over temperature AB 300ms
Battery low limit counter expired and load on battery AB 0ms
Battery usage prevented and load on battery AB 0ms
Hardware over current limit AB 0ms
Auxiliary power failure AB 0ms
DC bus very low voltage (<100 V) AB 0ms
DC bus over voltage (>250 V) AB 0ms
Service command to use forced bypass operation A -
A. Disable bypass mode or bypass not installed.

B. Bypass voltage/frequency is unacceptable, bypass has been disabled by
signal input, minimum time (3 seconds) on the inverter hasnt expired,
neutral fault, bypass failure, bypass processor not ready or unsynchronized
transfers are disabled and the inverter is not synchronized to bypass.
C. Bypass temporarily inhibited or the minimum time on battery before bypass
counter hasnt expired (4 seconds).
This table lists other conditions to shutdown the output.
Table 8. Other Condtions Prompting Output Shutdown

Conditions to Shutdown the Output Transfer If Transfer is
Shutdown After...
Battery connected, Battery low limit counter expired - 0ms
Emergency power off (EPO) - 0ms
Turn UPS off command from front panel - 0ms
Automatic off delay function - 0ms
XCP UPS off command - 0ms
XCP delayed off command - 0ms
Output transformer over temperature - Configurable

The following table shows the conditions that prevent the transfer to inverter
from bypass. The transfer is done 5 seconds after the last active condition
becomes inactive. The following table also shows the conditions that dont
prevent transfers when bypass fails.
Table 9. Condition Preventing Bypass to Inverter Transfer

Conditions Preventing Transfer From Doesnt Prevent
Bypass to Inverter Transfer if Bypass is Bad
User command to use bypass operation S
Service command to use forced bypass operation
Overload >100% * Prevents Soft transfers
Hardware over current limit
Inverter output fuse failure
Rectifier failure
Rectifier over temperature alarm * Prevents Soft transfers
Rectifier over temperature shutdown
Inverter over temperature alarm * Prevents Soft transfers
Inverter over temperature shutdown
DC bus over voltage (>250 V)
DC bus very low voltage (<100 V)
Auxiliary power failure
Balancer over temperature
Temperature sensor failure
Battery under voltage * Prevents Soft transfers
Inverter inhibit * Prevents Soft transfers
Inverter not synchronized to bypass * Prevents Soft transfers
Inverter output out of window
CAN bus transfer command (used in paralleling)
Redundant transfer command (used in paralleling)
* The condition prevents soft transfers only. Hard transfers (bypass failures) are allowed
It is possible that the load is on bypass, on shutdown, startup, the bleeding and
bypass-locked states. Transfer to inverter is never possible in these states.

The following table shows conditions that prevent using bypass. Any of these
will cause immediate transfer to the inverter, if possible.
Table 10. Conditions Forcing Hard Transfer From Bypass to Inverter

Bypass voltage < U out 15% (fast one cycle meter)
Bypass voltage > U out + 10%
Bypass frequency < 47Hz
Bypass frequency > 53Hz
Bypass processor in unknown state
Neutral failure
The following table shows the conditions, which cause output shutdown.
Table 11. Conditions that Shutdown the Output From Bypass

Neutral failure and inverter not available
Emergency power off (EPO)
Turn UPS off command from front panel
XCP UPS off command
XCP delayed off command

The XCP status is given in the following prioritized order:
XCP status = OUTPUT OVERLOAD, when the UPS is overloaded
4.4.10.3 Hardware
Bypass on
X-Slots are on
4.4.10.4 Other
None
4.4.10.5 Operation
During the program loop, the firmware checks the conditions to transfer on
inverter or to require output shutdown.
The firmware checks for a condition that warrants turning the inverter off or the
rectifier off. If such a condition exists, the rails stay peak charged and the
converters are turned off.

If the rectifier or inverter is off, and all failures are clear, then the rectifier and
inverter should be restarted. Let the inverter run at least 5 seconds prior to
transferring online.
The firmware checks conditions that prevent transfer on inverter.
The firmware checks if the bypass condition forces the transfer on inverter.
The firmware checks the conditions that cause output shutdown (these
conditions include a neutral fault while the inverter is unavailable and the UPS
off command). The output is turned off accordingly.
4.4.11 The Bleeding State

In the bleeding state the DC bus is drained. The rectifier, inverter and battery
operations are shut down. All measurements are disabled for 50 seconds at the
end of bleeding.
Bleeding is not allowed if the unit was on bypass, because the ABF relay is
feeding both the rectifier and bypass. If bleeding is justified and the unit is on
bypass, the bypass state takes priority and bleeding does not occur.
If utility is good after bleeding and there are no active alarms, the UPS will
continue to the shutdown state; or, if the load is on bypass, to the startup state.
If the utility is bad after bleeding, the auxiliary power shuts down.
Bleeding can be interrupted by a front panel UPS ON command.

4.4.11.3 Hardware
X-Slots are off
4.4.11.4 Other
None
4.4.11.5 Operation
The X-Slots are off. The DC bus is drained. Measurements are disabled at the
end of this state. The following steps are done at UPS DC bus discharge:
1. Open the inverter output contactor.
2. Turn off the inverter.
3. Wait 30ms.
4. Stop monitoring rail voltages, disable battery operations, open the
battery relay, shut down the rectifier, turn off X-Slot power.
5. Wait 2ms.

6. Open the ABF relay.

7. Wait 40ms.
8. Disable EPO.
9. Wait 100ms for ABF to open.
10. Bleed the balancer capacitor down with rectifier L1.
11. Wait 100ms.
12. If voltage cannot be bled less than 25V, set the balancer relay
failed flag and interrupt the bleed routine.
13. If bleed down was okay, close the balancer relay.
14. Wait 60ms.
15. Use the input phase 1 lower IGBT to transfer energy from
negative rail to positive rail.
16. Make sure that the positive rail stays between 188V and 178V.
17. Wait 40 seconds, or until the negative rail is lower than -20V
before continuing.
18. Check for UPS on command; if TRUE, turn back on; if FALSE,
disable GATE_ENABLE and PLD rectifier gate outputs.
19. Wait 10 seconds or until the positive rail is lower than 150V before
continuing.
20. Wait 40ms.
21. Open the balancer relay.
22. Wait 40ms.
23. Disable all meters and meter based alarms.
24. Shut down the main 12V.
25. Request an EEPROM restart bit write.
26. Wait for EEPROM write completion.
27. Wait 40 seconds.
28. Jump to the initialization state or failure shutdown state.
4.4.12 Bypass-Locked State

The load is on bypass. The UPS auxiliary power is off. The unit restarts and
transfers the load on inverter as soon as utility returns and startup is possible.

4.4.13 Failure Shutdown State

If bleeding was caused by an alarm listed below, the unit goes to the failure
shutdown state. This state ensures that the X-Slots are powered and the
modem can be used to communicate the failure.
Auxiliary power startup failure
Back-feed failure
Abnormal output voltage at startup
Bypass SCR failure
DC charger failure
Balancer relay failure
Rectifier failure
Inverter startup failure
Fuse failure

4.4.13.3 Hardware
Bypass off
X-Slots are on
All analog measurements are disabled
4.4.13.4 Other
None
4.4.13.5 Operation
The purpose of this state is to maintain communication, possibly alarming a
shut down cause. The only way to turn the output back on is to use the front
panel UPS ON function.
While the UPS is in this state the X-Slot communication is working. However,
all measurements are disabled because auxiliary power is reserved for the X-
Slots.
The DC bus isnt maintained in this state. It means that auxiliary power shuts
down and all communication is lost during a utility break.

4.4.14 Methods of Turning the UPS Off

This section describes user signals or settings that can be used to shut down
the UPS output.
4.4.14.1 Front Panel UPS Off

The normal means to shut down the UPS.
The UPS will restart only from the front panel.
4.4.14.2 Emergency Power Off (EPO)

The signal acceptance is configurable. When accepted, it shuts down the UPS.
The UPS will restart only from the front panel.
4.4.14.3 Automatic Off Function

This is a user settable parameter for automatically turning the output off in case
of utility failure (actually, any time when operating on battery).
1. AutoOffDelay = -1 = 65535, no automatic off function. This is the
factory setting (default value).
2. AutoOffDelay = 065534, the number of seconds before the
output is automatically turned off if the UPS has been discharging
batteries. If the UPS transfers to some other state, the automatic
off countdown is aborted.
Note
The automatic off countdown is not active when a service command or
a battery test (or similar reason) has caused the transfer on battery.
After shutdown, the output off follows the functionality of the XCP Delayed
Power off and Restart command. The UPS restarts automatically when the
utility returns, but only after a minimum 10 second down time.
4.4.15 XCP Command Codes

XCP command codes are issued remotely, or from a local laptop computer, by
the XCP software tool.
4.4.15.1 Delayed Power Off & Restart

A command code: turn UPS output off after a delay, restart automatically when
utility is OK.
The command is disabled when communication control commands are
disabled from the front panel.
4.4.15.2 UPS Off Command

A command code: turn UPS output off immediately.
Restarts when commanded with XCP, or from the front panel.
4.4.15.3 Scheduled Off

A command code: turn UPS output off after a delay.
Restarts when commanded with XCP, or from the front panel.
4.4.16 Hardware Signals
4.4.16.1 X-Slot Signal

The X-Slot shutdown signal uses a serial communication receive data line.
Both X-Slots (serial channels) implement this shutdown function similarly, but
independently. The X-Slot shutdown signals are disabled when communication
control commands are disabled from the front panel.
This shutdown works also from the service port D-sub, as it is multiplexed with
X-Slot 2. This function is independent from normal serial communication.
Normal communication is functional, while receive lines are monitored for the
shutdown signal.
When a logic 0 is received continuously for 5 seconds (as the same value for
both channels), the shutdown flag is activated. When a logic 1 is received, the
flag becomes inactive without the delay after slight filtering.
The shutdown flag may be mapped to one of three shutdown functions:
The UPS output is shut down after delay, automatic restart.
The UPS output is controlled off and on with the signal. Note that there is
always the delay (default 5 seconds) before the flag activates.
The UPS output is turned off.
Note:
The shut down signal from X-Slot 2 does not work while the service
port D-sub is used for communication. This is because the D-sub
communication disables X-Slot 2 communication and receive input.
4.4.16.2 Building Input

Either building input can be mapped to function as a shutdown flag. The
shutdown flag may be mapped to one of three shutdown functions:
The UPS output is shut down after delay, automatic restart.
The UPS output is controlled off and on with the signal.
The UPS output is turned off.

4.4.16.3 Remote Off with Automatic Restart

This function has a user selectable control source.
When the signal is active:
The UPS output is shut down after 120 seconds (EEPROM setting).
After shut down, the output is off at least 10 seconds.
When utility voltage is OK, the UPS restarts automatically if allowed by the
user settable Automatic ON Delay.
Note:
The utility condition doesnt affect shutdown signal acceptance, the
signal is always accepted.
4.4.16.4 Remote On - Off

When the signal is active, the UPS output is off. When the signal is inactive, the
output is on.
4.4.16.5 Remote Off

The UPS is shut down and requires the user to turn it back on via the front
panel. This is the same as if the front panel UPS OFF function were used.

4.5 POWER MODULE BOARD (PCB)

Reference Documents: PW 9355 1024051 Power Board Schematic, see the
Prints chapter at the end of this document.
Figure 25. 9355 Power Board
4.5.1 Introduction & Overview

The description contained in this section pertains only to the hardware found on
the Power Module Board. The Power Module Board provides interconnections
to the I/O Board. It contains the system power train.
Each Power Board is the location of the 3 main power converters: one phase of
the Boost Rectifier1/3 of the Battery Boost/Buck Charger, one phase of the
Buck Invertertheir respective gate drives, and one IGBT thermal sensor.
This board along with chokes and heat sink comprise a power module capable
of handling 1/3 of the output power. DC voltage sensing is provided on this
board. It is the home of the positive and negative rail bulk storage caps. There
is also a heat sink thermostat sensor. Each interfaces with the I/O board
through a 20-pin ribbon cable.

4.5.2 Description and Operation
4.5.2.1 X11 Connector Description

X11 connector is a 20-pin ribbon connector that connects the I/O board to the
Power Board.
Table 12. X11 Pinout
Pin Signal Description
1 Logic ground Ground
2 PWRCLK0 Gate clock
4 Temperature1 IGBT module temp sensor (middle)
5 Spare NC
6 INVDC_L2 Inverter choke hot end sense
7 INVDC_L1 Battery choke hot end sense
8 IO1 Thermostat (heatsink)
9 POWMOD_GOOD Power Module good signal (detects blown gate drive fuse)
11 GATE 14 Battery gate drive signal
12 GATE 13 Battery gate mode select (boost or charger)
13 GATE 8,10,12 Lower Inverter gate drive signal
14 GATE 7,9,11 Upper Inverter gate drive signal
15 GATE 6,4,2 Lower Rectifier gate drive signal
16 GATE 1,3,5 Upper Rectifier gate drive signal
18 +12V +12V to power gate drives
20 +12V +12V to power gate drives
4.5.3 Other Connector Descriptions

X1 Negative rail busbar
X2 Positive rail busbar
X3 Neutral busbar
X5, X6 Rectifier Choke connections
X7, X8 Inverter Choke connections
X9, X10 Battery Choke connections
X12 Heatsink Thermostat connector
X13 Heatsink Neutral tie connector

4.6 Power Board Functional Blocks

The following paragraphs describe the functional blocks of the Power Board.
4.6.1 Voltage Sensing

The Power Board provides DC voltage sense resistors for voltage sense
measurements done on the Control Board. Voltage sense resistors are two
1Meg ohm resistors in series. The measurements are differential
measurements with respect to neutral. Redundant battery and inverter DC are
sensed.
4.6.2 Rectifier
The three-phase 20khz rectifier circuit consists of an IGBT half bridge converter
located in position (V3) of the IGBT module, on the heatsink closest to the
busbars of each power module (that is, Power Modules L1, L2, L3). During
startup one rectifier half bridge (PM L1) is first used in balancer mode (~50%
duty cycle), together with rectifier chokes (L7A/B) and balancer relay (K1-3 on
the I/O board), to pre-charge the negative rail capacitors from the pre-charge
energy stored in the positive rail capacitors.
This rail pre-charge takes place in order for the input contactor to close without
causing a high inrush current from the utility to the rail caps. After this pre-
charge period ends the balancer relays are opened and the input contactor is
closed. The 3 phase rectifier half bridges (PM L1, L2, L3) midpoints are then
connected to utility through parallel input chokes (L1A/B, L4A/B, L7A/B) and
begin operating in boost PFC mode, boosting the rail caps to +/-195VDC wrt
neutral for the inverter to use. While maintaining the boosted rail voltage it also
draws a sine wave of current from utility. After the input contactor is opened
during battery operation, if utility fails the rectifier relays return to the above
balancer mode, in order to balance the voltage on the rail caps wrt neutral
coming from the Battery Boost converter (see the next section).
4.6.3 Battery Converter
4.6.3.1 Battery Boost

The 20khz Battery Boost circuit consists of parts of three IGBT half bridge
converters located in middle (V1) IGBT module position on the main heatsink of
each power module. In this mode it only involves the lower IGBT and the upper
diodes operating in boost mode. The negative side of the battery is connected
to the negative rail. The positive side of the battery is connected through two
parallel chokes (L2A/B, L5A/B and L8A/B) to the midpoint of each half bridge.
The lower IGBT of each half bridge is turned on storing energy in the respective
battery chokes. When the lower IGBTs are turned off the stored energy in the
chokes is dumped through the upper half bridge diodes into the positive rail.
This 216VDC nominal battery voltage is then boosted to 380VDC rail-to-rail.
The L1 rectifier balances the rail voltages to +/-195VDC. Each power module
gate drive is staggered 120 degrees to draw an effective 60khz ripple from the
battery and its filter cap.

4.6.3.2 Battery Charger

The 20khz battery charger circuit consists of remaining parts of three IGBT half
bridge converters located in the middle (V1) IGBT module on the main heatsink
of each power module. In this case the upper IGBTs and the lower diode
operate in buck mode. The upper IGBT of each half bridge is turned on storing
energy in the battery chokes while charging the battery.
Then, when the upper IGBTs are turned off, the stored energy in the chokes
are dumped through the lower half bridge diodes into the battery as well. This
then bucks the ~390VDC rail-to-rail voltage online down to the battery voltage
required for floating the battery, charging it in the process. The power module
gate drives are also staggered 120 degrees to supply an effective 60khz ripple
to the battery and its filter cap. This charger is capable of quickly charging
many parallel battery strings and is only limited by maximum input current.
4.6.4 Inverter
The 3 phase 20khz inverter circuit consists of an IGBT half bridge converter
located in the (V2) IGBT module on the main heatsink furthest from the busbars
in each power module (Power Modules L1, L2, L3). Its sine wave PWM bucks
the +/-195VDC rail down in order to create a 120VAC nominal sine wave output
voltage wrt neutral. The half bridge midpoints are connected through parallel
inverter chokes (L3A/B, L6A/B, L9A/B), through fuses (F1-F3), and the inverter
contactor located on the I/O board assembly, out to the load.
4.6.5 IGBT Gate Drives

The above converter gate drive circuits are located on this board. The gate
waveforms are +17V/-8V, 20khz PWM signals. These signals are derived from
the control board (see connector table X11) and feed optically isolated drivers
to each individual gate:
(V4, V22 for each rectifier),
(V44, V66 for each inverter),
(V41 for each battery boost),
and (V14 for each charger).
With signals from the DSP, Logic IC-U3 selects whether it is in charger or boost
mode.
4.6.5.1 IGBT Gate Drives Power Supplies

There are three independently fused-isolated-forward converter supplies for the
above gate drives located on this board. They get their clock signal from
PWRCLK0. The supplies get their power from +12V and put out +18V/-9V to
the above gate driver ICs.

The battery boost/charger gate supply consists of :

FETs V31,
XFMR T1,
and fuse F1.
The inverter gate supply consists of:

FETs V121,
XFMR T11,
and fuse F2.
The rectifier gate supply consists of:

FETs V18,
XFMR T12,
and fuse F3.
U1 provides a POWMOD_GOOD signal if all the fuses are ok.
4.6.5.2 IGBT Module Thermal Sensor

The thermal sensor of the central IGBT module on each heatsink is the only
one that is being monitored by the DSP. If the temperature gets too high, the
IGBTs are turned off and the unit is put on bypass.
4.7 Advanced Battery Management

4.7.1 Introduction
The purpose of this section is to describe common (platform) ABM operation
with common terminology. For details about Power Share, refer to
paragraph 1.2.3.
4.7.2 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 (UPS).

Studies on the end of life mechanisms of batteries in stand-by service reveal

that the cause of battery failure is positive grid corrosion due to constant float
charging. A key feature of ABM is that the batteries be held at rest rather than
on float for most of their service life. This is accomplished by giving them a
periodic freshening charge and allowing them to rest.
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 the excess charging does not occur.
4.7.3 General Terms

battery rest a battery state where it is neither charging nor discharging. This
is done by disconnecting the battery from its charger.
charge mode - begins a charging cycle; the battery voltage is being recharged
after discharging, after an extended inactive period, and when open cell voltage
decreases below batOpChrgV in rest mode. The mode ends when the battery
voltage reaches batChargeV, or if the mode has lasted batChargeTMax time.
charging cycle - consists of charge, float and rest modes. Battery voltage is
charged in charge mode, then the voltage is kept steady in float mode, and
finally batteries are inactive.
continuous-float charging - batteries are held at constant voltage,
batConstFloatV, instead of using a charging cycle scheme: user selectable.
float charging - during ABM cycling: charging at a higher voltage level than in
continuous-float charging; used to bring all cells in a battery string to their full
charge state. This is done for a limited duration.
float mode - after charge mode the battery voltage is kept constant at
batEqualizeV during (batFloatTExt + batFloatT) time
OCV - open cell voltage
rest mode - batteries are inactive after float mode, without discharging nor
charging.
VPC - volts per cell
4.7.3.1 Values and Limits

batChargeT - charge time: how long the charge mode lasted.
batChargeTMax maximum charge timedefault is 100 hours; the time-out
for charge mode after which the float mode is started, even if the battery
voltage has not yet reached batChargeV level.
batChargeV - charge voltagedefault 2.335VPC / 25C; the level where
charge mode changes to float mode.
batChrgI - charging current in charge mode.
batChrgRefV - charger voltage reference in charge modedefault 2.385VPC /
25C.

batConstFloatV - continuous-float voltagedefault 2.30VPC / 25C: used to

constantly charge batteries when ABM charging cycles are disabled by the
user.
batDischT - cumulative discharge timecalculated internally by the UPS.
batEqualizeV - ABM cycling float mode voltagedefault 2.30VPC / 25C.
batFloatT - ABM cycling float timedefault 48 hours.
batFloatTExt - ABM cycling float time extension: batFloatTExt = 1.5 y
batChargeT.
batMaxRestT - maximum rest mode timedefault is 28 days: duration of rest
mode, if neither discharging nor batOpChrgV have initiated a new charging
cycle.
batMinDischT - minimum discharge timedefault 20 seconds: limit for
cumulative discharge times after charge mode to initiate a new charging cycle.
batOpChrgV - opportunity charge voltagedefault 2.10VPC; if battery voltage
decreases below this limit in rest mode, a new charging cycle is initiated
immediately.
batRestFailT - battery OCV failure timedefault 10 days in rest mode.
batSuppTestT - battery support test time momentdefault 24 hours from the
beginning of float mode.
batSuppTestV - low voltage limit for battery support testdefault 1.75VPC.
4.7.3.2 Discharging
XCP Battery data block reports ABM status: discharging.
Discharging of batteries interrupts any charging mode. Cumulative discharging
time is being calculated in batDischT.
If after a discharge period, the value of batDischT exceeds batMinDischT, then
a new charging cycle is initiated; otherwise the previous charging mode is
continued.

4.7.4 Charging Cycles
Charge Mode ABM Float Mode Rest Mode

Battery Test 1
batChrgRefV 2.39V 8% of expected runtime (varies
batChargeV 2.34V based on batteries installed)
batEqualizeV 2.30V
batConstFloatV 2.
2.30V
Battery Test 2
30 seconds initial commissioning test;
50 seconds thereafter.
batOpChrgV 2.10V
<10days
batRestFailT
batStartChrgV 2.00V
batTestMinV 1.90V
batDCUVLogicPwrV 1.80V
batDCUV 1.75V
24Hrs
batAbsDCUV 1.56V batSupTestT
100Hrs max 48Hrs + 28 days

batChargeT batFloatT + batFloatTExt batMaxRestT
batChrgRefV 2.39V Shoot for target when starting charge mode. BTR = Battery Time Remaining
batChargeV 2.34V Stop at voltage to begin ABM float charge.
batEqualizeV 2.30V ABM Float charge level.
batConstFloatV 2.30V ABM is DISABLED - Constant Float charge level.
batOpChrgV 2.10V Starts charger if volt level is reached in <10days of rest mode.
batOCV 2.07V For BTR, only used prior to a commissioning test.
batStartChrgV 2.00V For BTR, to determine the state of charge on battery.
batTestMinV 1.83V 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 1.67V Absolute DCUV if reached prior to end of 2 min. timer.
Figure 26. Typical Battery Charging Cycle
4.7.4.1 Charge Mode

XCP Battery data block reports ABM status: charging.
When a battery is being charged, it is charged at the batChrgI constant current
rate until it reaches a set voltage (batChargeV). The charging cycle is then
changed to float mode.
While charging the battery voltage, the charger voltage reference is set to
batChrgRefV, which prevents excessive battery voltage in the event of faulty
battery voltage measurement.
The charge mode duration is measured and stored in UPS internal variable
batChargeT. This data is used to determine the value of batFloatTExt.

4.7.4.2 Float Mode

XCP Battery data block reports ABM status: floating.
At initialization of float mode the value for batFloatTExt is calculated:
batFloatTExt = 1.5 batChargeT
The battery voltage is kept at constant voltage batEqualizeV for time

(batFloatTExt + batFloatT).
Automatic Battery Support test (batSuppTestV) is done 24 hours after float
mode begins.
4.7.4.3 Rest Mode

XCP Battery data block reports ABM status: resting.
The battery is effectively disconnected from the UPS. The rest mode lasts until:
time defined by batMaxRestT has expired.
the value of batDischT exceeds batMinDischT.
the battery voltage has dropped below level batOpChrgV.
4.7.5 Temperature Compensation
4.7.5.1 Introduction
Battery temperature variation is compensated for by modifying battery-charging
voltage.
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:
BattChargeVthe level where charge mode changes to float mode.
BattEqualizeVABM cycling float mode voltage.
BattConstFloatVused ABM charging cycles are disabled by user setting.
BattChrgRefV is adjusted. This is the voltage reference value for the charger
while in charge mode. If an ABM charging scheme is working properly this
reference limit is never reached, but has changed to float mode at
BattChargeV.
The values are adjusted in temperature ranges from 0C to 50C. Outside of
these limits, the values stay the same.

4.7.5.2 Algorithm
The compensation temperature range is from 0C to 50C, the voltage per cell
is decreased 3 mV for each C. The EEPROM values mean the voltage levels
at 25C. The charger values uses the following algorithm:
value (T ) = eeprom _ value 3mV (T 25C )
T = battery temperature
Under 0C, value (0C) is used. Above 50C, value (50C) is used.
NOTICE
IEEE optimum temperature for battery life is 25C (77F).

Example
Using default values for the settings, the voltage values at some temperatures are:
Charging Voltage Volts Per Cell
Parameter C 10C 25C 40C 50C
BattEqualizeV 2.380 2.350 2.305 2.260 2.230
BattChargeV 2.410 2.380 2.335 2.290 2.260
BattChrgRefV 2.460 2.430 2.385 2.340 2.310
BattConstFloatV 2.345 2.315 2.270 2.225 2.195
BattChargeV = BattEqualizeV + 0.03 VPC

BattChrgRefV = BattEqualizeV + 0.08 VPC
4.7.5.3 Disabled or Impossible Compensation

The temperature compensation can be disabled using a user setting. In this
case, the EEPROM values (compensation values at 25C) are used directly.
Also, when the battery temperature measurement is not available, 25C is assumed.
4.7.6 Forcing on Rest Mode

There is an internal flag, ForceRestMode, which disables battery charging. For
example, one of the building inputs in the unit can be directed to this flag.
When active, batteries are discharged when needed, but otherwise the flag
forces the ABM rest mode. The original mode is resumed when the
ForceRestMode flag becomes inactive.
While forced on rest mode, battery failure testing/monitoring is not done.
While the ForceRestMode flag is active, discharging time (batDischT) is
monitored normally. If it exceeds batMinDischT, then a new charging cycle is
initiated when the ForceRestMode flag becomes inactive.

This flag also works when the ABM charging cycles are disabled by the user.
When active, the charging is disabled (rest mode is forced). When the flag
becomes inactive, continuous-float charging is resumed.
4.7.7 User Disabling of ABM Charging Cycles

The user has the option of disabling the charging cycles and to select a
continuous charging scheme. Cycling enabled is the factory default setting.
When batteries are not discharging, the charger functions to keep batteries at a
constant voltage, defined by batConstFloatV.
Although batteries are charged constantly, the UPS keeps the normal ABM
timer running. The operation is very similar to normal ABM cycling:
1. Charge mode begins when
- the cumulative discharging time (batDischT) exceeds
batMinDischT
OR
- when time batFloatTExt + batFloatT + batMaxRestT has
gone since the last charge mode.
2. Charge mode changes to float mode at batChargeV.
3. The external battery charger is controlled just as with normal ABM
cycling: during charge mode and during float time extension,
batFloatTExt.
4. Battery support tests are done normally, at a point defined by
batSuppTestT, just as though cycling was enabled.
5. While in float mode, the battery voltage is kept at constant
voltage, defined by batEqualizeV.
6. Rest mode is never entered, but float mode is continued over the
batMaxRestT time at the batConstFloatV, except when ABM
forced rest mode is initiated.
The differences to ABM cycling are:
Float voltage is lower, batConstFloatV.
There is no rest mode; float mode continues until cumulative discharging
time (batDischT) exceeds batMinDischT, or batMaxRestT time has gone.
Battery testing/monitoring is reduced: open cell voltage monitoring test is
not done.
The charge failure test measures charge mode time. This test is done
normally, the only difference being a lower float mode voltage level.
As the ABM cycling timing is internally running, the battery support test is
done normally, just as when cycling was enabled.
The ABM status is reported normally, charge or float. (including rest mode
when in forced rest mode).

The external battery charger is controlled just as with normal ABM cycling:
during charge mode and during float time extension, batFloatTExt.
4.7.8 Battery Failure Testing

Several battery tests are performed to try and determine the overall usability of
the attached batteries, and to try and detect when the attached batteries will no
longer provide adequate discharge time. Specific tests are performed to detect
failed batteries and to detect battery end-of-life.
The tests that are covered in this section are:
Battery test / Commissioning test (user initiated)
Detection of failed (shorted) cell(s) caused by failure to reach float voltage
Detection of failed (shorted) cell(s) caused by a rapid drop of open cell
voltage in rest mode
Detection of loss of capacity caused by failing to maintain cell voltage
under load.
4.7.8.1 Battery test / Commissioning test

The battery test and battery commissioning test are almost identical, but the
commissioning test is performed:
the first time the unit batteries are initially charged for 24 hours,
whenever the batteries are replaced,
and whenever batteries are added or removed.
The results of this test are stored in EEPROM and are the baseline for
subsequent battery tests. The test consists of taking data when the UPS is at 2
levels, typically at 25% load and at 100% load. This topology is accomplished
by running the rectifier and battery converter at the same time (Power Share
mode). For more details on Power Share, refer to paragraph 1.2.3.
The Power Share control sets the rectifier sine reference magnitude to regulate
battery power at the desired level. The rectifier is running in a constant current
mode while the battery converter operates normally to regulate the rails.
Experiments have shown that running the second part of the test at or near full
load yields the best results. If full load is not available at the output of the UPS,
full load on the battery can still be achieved by allowing the rectifier to back-
feed power to the utility.
Back-feeding the rectifier is the preferred method of running the test, but the
user can disable back-feeding from the front panel.
If the user disables back-feeding, the second part of the test will be run with the
available load, which must be at least 50% of the UPS rating. When the test
starts, battery power is set to 25% of load. Unfortunately, when the load is first
put on the battery, the voltage will drop, and then recover (termed crack of the
whip). In order to get past this phenomenon, the test runs for 8% of the
expected runtime at load level 1 before taking the measurement. After test 1,

the power is set to test level 2 and run for 30 seconds on the initial
commissioning test, and for 50 seconds thereafter. The battery voltage and
power level are recorded.
When the test executes, it will be transparent to the user. Unless the battery
test detects a bad battery, there will be no beeping alarms and the front panel
will not change state because the test is being performed. The XCP status will
not change to On Battery. The battery test section of the LCD control menu
will give an indication of test progress.
4.7.8.2 Battery Impedance / Open Cell Voltage Measurement

The battery impedance and open cell voltage will be determined by performing
the following steps:
Run test level 1 at 25% of the full UPS watt rating on the battery. The test
duration is 8% of the expected runtime at this power level. The battery voltage
and power are recorded at the end of test level 1. Current is also recorded for
XCP battery data block only and does not impact runtime calculations.
Run test level 2 at the full available load for 50 seconds. After 50 seconds,
battery voltage and power are recorded. Current is also recorded for XCP
battery data block only and does not impact runtime calculations.
Calculate Open Cell Voltage:
Open Cell Voltage = ((Test 1 Voltage Test 2 Power ) (Test 2 Voltage Test 1 Power )) (Test 2 Power Test 1 Power )
If this is a commissioning test, this voltage is stored as is; otherwise it is filtered

with previous test results.
Calculate Battery Resistance:
Battery impedance = (Open Cell Voltage Test 1 Voltage ) Test 1 Power
If this is a commissioning test, then calculated battery impedance is stored as
both commissioning impedance and test impedance, otherwise:
3
Battery test impedance = (3 Battery test impedance + calculated battery impedance ) 4 filter
4
If this is a commissioning test the battery health is set to 1, otherwise:
Battery health = Commissioning impedance Battery test impedance
4.7.8.3 Cell Voltage Failure Under Load

When the unit drops on battery, the battery cell voltage is monitored during the
first 25% of the discharge as determined by the battery runtime prediction. If
the battery cell voltage drops below a certain level during the first 25% of
discharge, Battery Test Failed is set. Failure of this test represents a loss of
battery capacity and is not considered a potentially hazardous condition. This
alarm is not stored in EEPROM and charging is not disabled as a result of test
failure. This alarm is cleared when power is cycled, the batteries are replaced,
or the battery test successfully completes. This test is active during the battery
test/commissioning test.

The failure limit for this test is 1.833V/cell if expected runtime is greater than 15
minutes, or 1.81V/cell if expected runtime is less than or equal to 15 minutes.
4.8 Battery Lifetime

4.8.1 Introduction
The 9355 battery lifetime algorithm is executed every second. It accounts for
run-time, chronological (wall clock) time, battery temperature, and battery
discharges when calculating the expected battery lifetime available.
4.8.1.1 User Interface

Battery lifetime, in hours, is maintained in nonvolatile memory and is displayed
as a percentage of nominal.
4.8.1.2 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. The
default value is 43830 hours or five years.
2. Nominal Battery Lifetime can be set by the user to any value
less than 4,294,967,296 (2^32) hours. The 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 runs from
battery. The default value is one hour.
4.8.2 Operational Sequence

When the PW9355 first powers up, 2 hours are subtracted from the battery life
as UPS down time is not monitored. If it is known that the unit has been
powered down for longer than 2 hours, 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. After the
initial call of the battery lifetime routine, only battery discharge and run-time
effects are calculated, until a temperature sensor for the batteries is available.
4.8.3 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 short (less
than 1 second), the discharge may occur between a call to the battery lifetime
routine, in which case the routine may not detect the discharge and the Battery
Lifetime will not be updated.

4.8.4 Run-Time and Temperature

A run-time and temperature algorithm currently does not compensate for the
temperature degradation of the battery, due to a lack of battery temperature
sensors. 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 counter algorithm
does not account for the depth of battery discharge.
4.9 Battery Test

4.9.1 Introduction
This section describes the operation of ABM and battery test in PW9355.
4.9.1.1 Battery Test Run Time

The run time calculation uses voltage load and battery information to give a
prediction of battery run time.
4.9.1.2 Battery Test Operation

Battery testing occurs periodically and each 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 it is
typically set to half of the float time.
4.9.2 Battery Test 1

The Battery Test begins with test 1. During this test, the battery is discharged
at the specified load for a specified duration. 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 back-
feed the line with the excess power. The test will abort if the utility is lost, if
battery voltage falls below a preset level, or if a charger malfunction occurs.
4.9.3 Battery Test 2

The Battery Test ends with test 2. During this test, the battery is discharged at
a specified load for a specified duration. 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 back-
feed the line with the excess power. The test will abort if the utility is lost, if
battery voltage falls below a preset level, or if a charger malfunction occurs.
4.9.3.1 Battery Test Levels and Times

Test 1 is typically set for 25% of load for an 8% discharge of the battery (6
minutes). Test 2 is set for 100% of load for 30 seconds.

4.9.4 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 above data, the Battery Open Circuit voltage, Battery resistance and
Battery health are calculated. The data is then used to alter the battery time
remaining algorithm.
Table 13. Battery Setup Data
Name Effects Description
Battery setup Charger Setup Bitword 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
Battery Equalize Charger The level that is used to charge the batteries for the
ABM Battery Float Time, typically 48 hours
Battery Charge Charger The target voltage level at the beginning of an ABM
ABM charge cycle. This voltage is higher than Battery
Equalize.
Battery is Charged Level Charger ABM Lower than Battery Charge, the level that ends
regulation to Battery Charge.
Battery Float Level Charger Level to regulate to, if ABM is disabled.
Float
Battery Not Charged ABM If the battery voltage falls below this level within the
ALARM rest fail time, a Check Battery alarm is
annunciated, otherwise an ABM cycle is started.
Battery DCUV ABM This is the level that triggers the low Battery
BTR shutdown alarm. The system will shutdown in the
programmed Battery DCUV Time
ALARM
OPER.
BATTERY DCUV Shutdown Time BTR Time in seconds before shutdown if the Battery
OPER voltage falls below Battery DCUV.
Absolute Battery DCUV OPER If the Battery Voltage falls below this level, the
system is shutdown within a few seconds.
Battery DCUV for Logic Power Off OPER The power supply is disabled if the battery is sully
the power and the battery voltage falls below this


level.
Battery temperature compensation Nothing Place holder for future applications
Battery Charge Current Limit Charger Level at which the battery charge current is limited.
Battery Charge Current Limit On Nothing Place holder for future applications
Generator
Support Test Time Batt Test Hours, When ABM enters float, the Battery test runs
after float charging the Battery for this time.
Battery Charge Time Max ABM Hours, ABM must reach equalize voltage before this
time or a Check Battery alarm is annunciated
Battery Float Time ABM Hours, ABM float charges the battery for this time
during each ABM Charge cycle.
Battery rest fail Time ABM Hours, If the battery voltage falls below a preset
level before this time, a Check Battery alarm is
annunciated.
Max Rest Time ABM Hours, the time before an ABM charge cycle is
initiated.
Maximum Battery Discharge Time ABM Seconds, if the unit drops on battery for greater
before Charge than this time an ABM charge cycle is initiated.
Battery Run Time at Battery Watts BTR Tenth minutes, Run Time at Battery Watts, typically
full load run time
Battery Watts BTR Watts/cell, Battery watts at Battery run Time
Battery open Cell Voltage Batt test Volts/cell, used only until commission test occurs
BTR
Battery Start charge BTR Volts/cell, Used by BTR to determine the state of
charge on the battery while resting or charging.
Battery resistance BTR Q15, milliohms, used by BTR until the

commissioning test runs
Battery Test 1 voltage BTR Volts/cell, Used by BTR until the commissioning test
runs.
Lin Pred BTR Not used
Lin PUV BTR Not Used
On Battery delay ALARM Delay time before queuing ON Battery
Battery Current Meter zero Meter Number of tenth amps below which the battery
current meter is zeroed
Battery Discharge Coef. Battery Number of hours to subtract off of battery life when
Lifetime we drop on battery
Expected Battery Lifetime Battery Number of hours before replacement of battery is
Lifetime recommended.
Battery Lifetime left Battery Life Number of hours the battery currently has left
Time before replacement is needed
Battery Test 1 Power Batt Test Tenth KW, Total KW for Battery Test 1
BTR


Battery test 1 Time Batt test Seconds, Time Battery test 1 runs at Battery Test 1
Power
Battery Test 2 Power Batt Test Tenth KW, Total KW for Battery Test 2
Battery test 2 Time Batt Test Seconds, Time Battery test 2 runs at Battery Test 2
Power
Battery Test Min Voltage Batt Test If the battery voltage falls below this level during
battery test, the test is aborted and a Check
Battery alarm is annunciated.
4.9.4.1 User Interface to Battery Test Information
4.9.4.2 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
information provided by 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 V^2/P
Calculated Battery Health (percentage health)
4.9.4.3 Battery Test Information via XCP

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

4.10 I/O BOARD (PCB)

Reference Documents: PW9355 1024055 I/O Board Schematic, see the
Prints chapter at the end of this document. For detailed descriptions of board
components, refer the Chapter 8, Removal and Replacement.
Figure 27. PW 9355 I/O Board
4.10.1 Overview
The IO Board has many functions within the Electronics module. It provides
input and output filtering (including EMI) for the system. AC and Battery
Voltage sensing is provided in many locations. Current sensing for the inverter,
rectifier, and battery converter and load are contained here - along with level
shifting for the control board. Fusing is provided for the inverter path only. In
this topology the inverter is connected to the output by a contactor - which is
contained on the IO Assembly. The IO Board feeds input mains to the Power
Board and provides battery start capability. Single or dual feed mains input
with a separate Rectifier contactor is contained here. Also, the balancer and
battery relays are contained on this board. Battery start circuitry and AC Fan
power to 3 of the fans is provided here.

It also contains an Auxiliary Power supply that is derived from mains (or
battery) during startup and then runs from the positive rail. This A-aux supply
powers the relays, control board, and the X-Slot, and it powers the IGBT gate
drives and alarms circuitry. The control board interface is located on this
board, a battery circuit breaker trip circuit/sensor, a manual bypass switch
position sensor, and an input output circuit breaker trip. Finally it contains the
rail cap pre-charge circuitry.
4.10.2 I/O Connector Descriptions
4.10.2.1 Control Board Interconnect Description
Table 14. Control Board Interconnect Description

X8-1 Logic ground Ground
X8-2 XSLOT2_K4
X8-3 XSLOT2_K3
X8-4 XSLOT2_K2
X8-5 XSLOT2_K1
X8-6 XSLOT1_K4
X8-7 XSLOT1_K3
X8-8 XSLOT1_K2
X8-9 XSLOT1_K1
X8-11 XSLOT2_TX
X8-12 XSLOT1_RX
X8-13 XSLOT2_RX
X8-14 XSLOT1_TX
X8-16 CAN_HI
X8-17 CAN_LO
X8-18 ID connected to logic ground
X8-19 Not Used
X8-21 XSLOT1_DTR
X8-22 XSLOT2_DTR
X8-23 PAR_RED1
X8-24 PAR_RED2
X8-25 POWMOD_GOOD Gate drive fuses OK


X8-27 IO1 Thermostat
X8-28 Not Used DC Fan (unused)
X8-29 +12_2ON
X8-34 EPO_ ENABLE
X8-35 V114 gate Reserved for display
X8-36 Not Used
X8-37 Not Used
X8-38 Not Used Enables IGBT gate drive (unused)
X8-39 IO_GOOD
X8-41 SER_RX
X8-42 SER_TX
X8-43 ALARM_RELAY
X8-44 BLD_ALARM2
X8-45 BLD_ALARM1
X8-46 EPO_ ENABLE
X8-48 Not Used
X8-49 Not Used
X8-50 Not Used
X8-51 Not Used
X8-52 Not Used
X8-53 Not Used
X8-54 DALLAS_IN
X8-55 DALLAS_OUT
X8-58 +5V
X8-61 +5V


X8-62 +12_ON
X8-63 DC_CHARGE
X8-64 Not Used
X8-65 Not Used
X8-67 +12V /control
X8-69 +24V AAUX
X8-70 +12V/control
X8-72 +24V AAUX
X8-75 GATE13 Battery L1 gate
X8-76 GATE14 Battery Boost/Charger Mode Select
X8-77 GATE5 Upper Rectifier L3 gate
X8-78 GATE6 Lower Rectifier L3 gate
X8-87 GATE11 Upper Inverter L3 gate
X8-88 GATE12 Lower Inverter L3 gate
X8-94 POWERCLOCK0 unused
X8-95 POWERCLOCK1 Gate supply, EPO supply, BLD ALMS supply , and rail
precharge clock


X9-2 CHASSIS_VOLT Chassis Voltage measurement referenced to Neutral
X9-3 OUTP_DCVOLT_L1 Inverter L1 DC sense
X9-4 DCN1 Inverter L1 DC sense
X9-11 RAIL_VOLTS_PLUS Rail sense
X9-12 RAIL_VOLTS_MINUS Rail sense
X9-13 BATT_VOLT1 Measures L1 input cap voltage
X9-14 BATT_VOLT2 Battery + Voltage (before Battery relay) measurement
referenced to Neutral
X9-16 BATT_VOLT1_BACKUP Negative battery sense
X9-17 BATT_VOLT2_BACKUP Positive battery sense after the chokes on L1 power
module
X9-18 Unused
X9-19 +5V_REF Unused
X9-21 N1 Neutral reference for rail (and battery) voltage sense
X9-22 N1_BACKUP Neutral reference for rail (and battery) voltage sense
X9-24 UTI_CURR_L1 Line 1 Rectifier Choke current measurement
X9-28 OUT_CURR_L1 Line 1 Output Current measurement
X9-32 INV_CURR_L1 Line 1 Inverter Choke current measurement


X9-36 BATT_CURR1 Battery Choke current measurement
X9-37 CASE_TEMPERATURE Ambient Temp measurement
X9-39 TEMPERATURE1 Battery Boost IGBT module temperature sensor L1 power
module
module
module
X9-43 UTIL_VOLT_L1N Line 1 Utility Voltage Measurement L-N before contactor
X9-47 INV_VOLT_L1N Line 1 Inverter Voltage Measurement L-N
X9-51 BUPASS_VOLT_L1N Line 1 Bypass Voltage Measurement L-N after Bypass
Relay and Fuse
Relay and Fuse
Relay and Fuse
X9-55 OUTP_VOLT_L1N Line 1 Output Voltage Measurement L-N
X9-60 SPI_SI Signals to backup EPROM
X9-61 SPI_CS Signals to backup EPROM
X9-62 SPI_SD Signals to backup EPROM
X9-63 SPI_CLOCK Signals to backup EPROM
X9-65 ID0 Connected to logic ground


X9-66 ID1 NC
X9-69 INV_SCR/CONTACTOR Enable signal for Inverter Contactor active low
X9-71 Not Used
X9-72 INVONLINE Output signal used to control D1 state machine for Bypass
X9-73 MBS MBS switch position
X9-74 REL_BAL Balancer relay drive active low
X9-75 BATT_CB_TRIP BATT CB trip signal
X9-76 REL_L2-3 Redundant Input Rectifier Contactor Drive active low
X9-78 Not Used
X9-79 REL_L1 Input Rectifier Contactor Drive active low
X9-80 BYP_RDY Output from D1 used by control to determine state of D1
X9-81 BACK-FEED Bypass Contactor Drive
X9-82 EPOCBTRIP EPO CB Trip (if needed)
X9-83 B_UP_OK Not used
X9-85 BYP_AVAIL Output signal from control board used to control D1 state
machine
X9-86 BATT_CB_STATE BATT CB switch state sense
X9-87 SPARE_IN1 Not used
X9-88 SPARE_IN2 Not used
X9-90 Not Used
X9-91 RES_ON Signal for turning on contactor cap reservoir
X9-93 Not Used
X9-94 REL_BAT Battery Relay Drive active low
X9-95 Not Used

Table 15. Interconnect Descriptions

X50 To Battery CB Trip
X48, X49 Batt + from CB
X34, X51 Batt - from CB
X26 From Rect Contactor to L1 Rect input
X13 L3 input, also to rectifier contactor
X54 N input
X78 To Output CB Trip
X2 To Input CB Trip
X37 Inv L1 Out to Inv Contactor
X38 N output (unused)
X40 From Inv Contactor to L1 output
X3, X20 Neutral connection to Power Board Neutral Bursar
X34, X51 Battery Neg connection to Power Board Ned Rail Busbar
X30 Pos Rail connection to Power Board Pos Rail Busbar
X67 AC Fan connection (inverter L1-N)
X21 Inverter Contactor Control
X27 Rectifier Contactor Control
X17 Display jack
X44 AAUX 24V
X5 L1 Rectifier choke connection
X70 L1 Rectifier choke current sense connection

Table 15. Interconnect Descriptions

X74 L1 Battery Choke current sense connection
X4 L1 Battery Choke connection
X19 L1 Inverter choke connection
X73 L1 Inverter choke current sense connection
X58, X59 Marine ground connection
X79 Battery start pushbutton connector
X43, X45, X46, X47, X52 Hipot/test connectors
X55, X56 X-Slot connectors
Table 16. 4.10.3 X6, X7, X11 Connector Pinout

2 PWRCLK1 Gate Clock
4 TEMPERATURE1,2,3 IGBT module Temp sensor from power board
5 SPARE Unused
6 OUTP_DCVOLT_L1N,L2N,L3N Inverter DC feedback
7 BATT_VOLTS2_BACKUP Batt Choke hot end
8 THERMAL SWITCH Heatsink Thermostat Closes on Temperature
9 POWMOD_GOOD Gate drive fuses OK
11 GATE14 Battery Boost/Charger Mode Select
12 GATE13 Battery gate
13 GATE8, 10, 12 Lower Inverter L1, L2, L3 gate
14 GATE7, 9, 11 Upper Inverter L1, L2, L3 gate
15 GATE2, 4, 6 Lower Rectifier L1, L2, L3 gate
16 GATE1, 3, 5 Upper Rectifier L1, L2, L3 gate

Table 16. 4.10.3 X6, X7, X11 Connector Pinout

18 +12V +12V for gate drive supply
20 +12V +12V for gate drive supply
Table 17. X12 Connector Pinout

2 BUPASS_VOLT_L1N Line 1 Bypass Voltage Measurement L-N after
Bypass Relay and Fuse
6 AAUX +24V supply on IO board
7 ALARM_RELAY
8 MBS
9 BAUX +24V supply on BYP board
10 Unused
11 SER_RX
12 SER_TX
14 EPO_ ENABLE
15 BLD_ALARM1
16 BLD_ALARM2
18 INVONLINE Output signal used to control D1 state machine for
Bypass
19 BYP_RDY Output from D1 used by control to determine state
of D1
20 BACK-FEED Bypass Contactor Drive
22 B_UP_OK Not used
23 BYP_AVAIL Output signal from control board used to control
D1 state machine
24 IO_GOOD


25 LED_OVERRIDE Display
4.11 I / O Board Functional Sections

4.11.1 Auxiliary Power Supply
This circuit (N8, V62, T1) is an 80W-isolated flyback switching power supply. It
receives input power from rectified 120VAC during an AC start or 216VDC
nominal battery during a DC start. Once the Rails are charged it runs from
nominal 195VDC positive rail. This input is then converted to 24VDC (AAUX).
This 24V output supplies input power for the RS-232 supply and alarms on the
bypass board. It is also powers the Battery and Balancer relays. It is used for
operating the rectifier, inverter contactors, and momentarily to power the
battery circuit breaker shunt trip from the cap reservoir.
The Aux Power Supply is stepped down by two buck converters to 12VDC.
The first buck converter circuit (N10) outputs (+12V) capable of ~3A, powers
the rail precharge circuit, contactor relays, input/output CB trip relays, and IGBT
gate drives on the Power Board.
The second circuit (N12) output (+12V_2), capable of ~1A, only powers the two
X-Slots. There is a linear voltage regulator (N1) that reduces it to (+12V) for
use by the Control Board.
4.11.2 Rail Precharge

The Rail Precharge circuit (V70, V68, V69, T3, N9, L2) function is to precharge
the positive rail capacitors located on the power boards during startup. It
receives its input from rectified 120VAC during an AC start or from 216VDC
nominal battery during a DC start. This constant current converter takes
several seconds to charge all these caps to near input voltage. (T_ON) is the
signal that is used to power this converter (N9). This circuit continues to
precharge the positive rail until precharge of both rail caps are done (see next
section).

The IO Board provides Voltage Sense Resistors for most of the AC and DC
voltage sense measurements (including chassis) done by the Control Board.
There are also some additional sense resistors located on the power board and
the bypass board. Voltage sense resistors are made up of two 1Meg ohm
resistors in series for safety reasons. The measurements are differential
measurements with respect to Neutral. Op Amps are referenced to signal
+5V_REF created on the control board.
Outputs of the Op Amps are divided down to a 1.5V reference to the DSP with
an anti-aliasing filter.

4.12 Current Measurements and Hardware Current limits

Inverter, Rectifier, and Battery Current Measurements are made on the IO
board. The measurements are made by the LEM-LAS100 closed loop hall
sensor. All measurements made are choke current measurements. There are
two chokes in parallel in each phase of the Inverter and Rectifier, but only 1
choke is measured. The battery converter has 6 chokes in staggered parallel;
however, only 3 chokes are measured, one from each power module. See
paragraph 4.5.3 for respective choke connections.
Table 18. Phase and Battery Chokes
Sensor Converter Choke Split
B1 Rectifier Line 1 L7A 2
B7 Inverter Line 1 L9A 2
B8 Battery L2A L5A L8A 2
LEM sensors are powered by +5V which is derived from the control board.
They output a nominal 2.5V with no current. The +5V is buffered and divided to
3.3V and used as the reference voltage for N3-A, N3-B, N3-C, N5-D, N5-C, N5-
B and N5-A. Each Op amp will now put out a nominal +3.3V with no current
running through its respective LEM sensor. Measurements are scaled so that
control board hardware current limit is set at approximately 240Apk @ 20kHz.
This allows for overload conditions and system non-linear loads with high crest
factors. Calibration takes care of any slop caused by current splitting scheme
used to measure current. Software current limits are also in place.
4.12.1 Output Current Measurement

Line 1, 2, 3 phase currents are monitored by B5, B9, B10 CTs respectively.
These measurements (currents) are not split. R54 and R55 adjusts gain for
Line 1 measurement, R146 and R147 adjusts Line 2 measurement gain, and
R148 and R149 adjusts Line 3 measurement gain. This measurement is sized
to handle 110% overload on the inverter with 1% low tolerance and a 3:1 crest
factor. Measurement will also handle the 150% overload at low line at a 2.2:1
crest factor per the PDR (reference 1).
4.12.2 Input and Output Filtering Scheme

High Frequency Y-Caps are provided on Input, Output, Neutral, and Battery
Connections to Chassis:
High Frequency X-Caps are provided on Input, Output Connections to Neutral
and across the Battery:
Ferrite cores are also placed strategically to form a common mode choke
pi filter on the input for emi.
Input and output filter capacitors for the rectifier and inverter carrier
rejection are provided on the I/O board:
- C115-117, C129-134, C210-212
These caps along with the system inductor provide a 2nd order filter with the
following corner frequency:
fr = 1/ (2LC) = 1960Hz where L = 50H and C = 132F
4.12.3 Inverter/Rectifier Fault Methodology

An input breaker feeds the rectifier path, which may trip if there is a bus fault
with the rectifier or inverter. If the fault is due to a inverter IGBT module failure,
fuses (F1, 2, 3) may clear also. The inverter and rectifier have hardware and
software current limit protection.
The inverter output path is fused with 160A LET semiconductor fuses (F1, 2, 3).
The inverter path is connected through a contactor to the bypass SCR output.
These paths are ORd, which leads to fast transfer times in the unit. This
connection is then run through the load CTs.
In an output short circuit condition, the inverter will current limit, transfer to
bypass, and then open the inverter contactor if the load short circuit does not
clear. Software keeps the inverter from going back online after bypass until the
load short circuit has cleared. The bypass feed is protected by fuses (not on
this board), and an upstream (customer) circuit breaker.
4.12.4 Single Feed/Dual Feed Input Contactors

The Low Voltage UPS module uses either a single feed or dual feed by adding
or removing a jumper. There are separate contactors for the Bypass and
Rectifier paths. The redundant drive for the rectifier contactor (circuit consisting
of K12, K14, X27) is located on this board. The drive for the inverter contactor
(circuit consisting of K11, X21) is located on this board. Both drives are
powered from the 24V reservoir capacitors. It takes approximately 4A for about
100ms (100W) to pull in the contactors.
4.12.5 Battery Relay, Battery Start and Current Measurement

The Low voltage UPS module contains a system battery breaker; Battery + and
Battery connections come to the IO board.
Battery capacitors C15, 81, 14 are provided and work with the two parallel
battery chokes to form a carrier ripple filter.
The Battery Relay (K5-10six 40 Amp relays in parallel), is driven by way of
V7D and V7C and clamped with V1. The battery relay connects the battery-to-
battery chokes once the rails are charged, so there is no inrush. Battery
current is then measured by LEM sensor B8. Choke currents from each power
module are each split by two (see paragraph 4.5.3) so that half of battery
current is sensed by the LEM.

During a battery start SCR V6 provides battery start capability in absence of

utility. This SCR is triggered by a battery start pushbutton connected to X79
once the battery breaker is closed. This circuit then provides power to the
AAUX supply. Once the battery start circuit latches, control board power
comes up and the control board comes alive.
A precharge circuit then pumps up the positive rail to hold up the AAUX power
supply. The balancer relay (K19-21) closes and the L1 rectifier converter,
acting as a balancer, transfers charge to the negative rail. Software waits for a
UPS on command from the front display. If the unit is not started, software
properly shuts down the unit.
4.12.6 Balancer Relays and Drive

A Line 1 Rectifier converter is used to balance the rails to neutral when on
battery and during startup. Balancer Relay (K1-4) is used to connect Line 1
after the contactor is opened to Neutral.
The coils are powered with +24V from AAUX and are driven by V8-C, V8-G
and are clamped by V11.
Firmware is in place to keep the Balancer relay and the rectifier contactor from
being closed at the same time avoiding a short on the utility and welded relays.
4.12.7 Battery CB Trip

This circuit shunt trips the battery CB. It gets its power from +24V reservoir
capacitors through FET V105 out connector X50. It takes approx 4A for
~100ms (100W) to trip the breaker.
4.12.8 Input/Output CB Trip

The circuit (K4,14, X2, 78) shunt trips the input/output CB. It gets its power for
the input trip coil from the L1 input and for the output trip coil from the L1
output.
4.12.9 Other Sensing

There are three buffers dedicated for sensing. The state of the Battery CB is
reported back to the control board through buffer V91-G from connector X50.
The state of the SPARE_IN1 is reported back to the control board through
buffer V91-D from connector X61. The state of the SPARE_IN2 is reported
back to the control board through buffer V91-C from connector X60. Ambient
temperature is sensed by U1.
4.12.10 X-Slots
Connectors X55 and X56 go out to the two X-Slots. The X-Slots each get
+12V_2 through a 5 ohm 1A PTC thermistor R285, R286 plus signals to and
from the control board.

4.12.11 AC Fans
There are three AC fans powered from this board. Fan 1 (X65) is connected
phase L3- N across the inverter. Fan 2 (X66) is connected phase L2-N across
the inverter. Fan 3 (X67) is connected phase L1-N across the inverter. All are
located after the inverter fuse. They can also be powered by the output when
the inverter is off by closing the inverter contactor.
4.12.12 Chassis GND

Chassis screws E14, E15, normally ground logic common. The emi Y-caps are
connected via screws E13, E16.
4.12.13 Troubleshooting
4.12.13.1 Fuses
The IO Board contains the inverter (F1-3) fuses that disconnect any failed
converters on the power modules.
4.12.13.2 Circuits
If the display is not working check the F4 fuse going to the AAUX supply. Look
for the presence of +24V on X44.
4.12.13.3 Relays
Check for welded balancer relays (K1-3) if the rectifier CB is tripped open or a
rectifier converter has failed. Check for welded battery relays (K5-10) after a
battery converter failure.

4.13 Bypass Board System Overview

Reference Documents: PW9355 1024059: Bypass Board Schematic and
1024062: silkscreen, see the Prints chapter at the end of this document.
Figure 28. Bypass Control Board
Each Power Board is the location for the 3 main power converters:
one phase of the Boost Rectifier, 1/3 of the Battery Boost/Buck Charger,
one phase of the Buck Inverter, and their respective gate drives,
and one IGBT thermal sensor.
This board, along with chokes and heatsink, comprise a power module capable
of handling 1/3 of the output power. DC voltage sensing is provided on this
board. It is the home of the positive and negative rail bulk storage caps. There
is also a heatsink thermostat sensor. Each interfaces with the I/O board
containing a 20 pin ribbon cable
Table 19. Interconnect Description
X24 Bypass L3 input to SCRs after contactor
X10 N input

Table 19. Interconnect Description

X25 From MBS switch status
X51 To Bypass Back-feed contactor
X53 RS-232 9 pin DSUB
X5 L1 output after SCRs
X1 PIC flash phone jack
X17 AC Fan connection Bypass L1-N load side
X27 Pull Chain connection
X2-4, X14-16 Bypass SCR gate connectors

6 AAUX +24V supply on IO board
7 ALARM_RELAY
8 MBS
9 BAUX +24V supply on BYP board
10 Unused
11 SER_RX
12 SER_TX
14 EPO_ ENABLE
15 BLD_ALARM1
16 BLD_ALARM2
18 INVONLINE Output signal used to control D1 state machine


for Bypass
19 BYP_RDY Output from D1 used by control to determine state
of D1
20 BACK-FEED Bypass Contactor Drive
22 B_UP_OK Not used
23 BYP_AVAIL Output signal from control board used to control
D1 state machine
24 IO_GOOD
25 LED_OVERRIDE Display
4.14 Bypass Board Functional Blocks

4.14.1 BAUX Power Supply
This circuit (N1, Q1, T2) is an 80W isolated flyback switching power supply. It
receives input power from rectified 120VAC during an AC start. This input is
then converted to 24VDC (BAUX). It is used for operating the bypass contactor
from the cap reservoir circuit of N8, C34, and C35.
The BAUX Power Supply is stepped down by a buck converter to 12VDC
(+12V_2). The buck converter circuit (N11) output (+12V) capable of ~3A,
powers the bypass SCR gate drives. It is then stepped down by linear
regulator (N2) to +5V (+5V_2), capable of ~1A to power the bypass PIC (D1).
The +5V is stepped down by linear regulator (N10) to serve as a +2.5V
reference.
This circuit is protected by fuse F4.

The Bypass Board provides Voltage Sense Resistors for bypass voltage sense
measurements done on the Control Board. The measurements are made after
the bypass contactor and fuses.
Voltage sense resistors are two 1Meg ohm resistors in series. Reference
sense resistors to Neutral are provided on the Power Board. The
measurements are differential measurements with respect to Neutral. Op
Amps are referenced to signal +5V_REF created on the control board. Outputs
of the Op Amps are divided down to a 1.5V reference to the DSP with an anti-
aliasing filter. Voltage measurement signals are described in paragraph 4.5.2.1.

4.14.3 Input Contactor

The system uses an input all pole break input bypass contactor. The drive for
the contactor (a circuit consisting of K1, X51) is located on this board. It is
powered from the 24V reservoir capacitors. It takes approx 4A for ~100ms
(100W) to pull in the contactor.
4.14.4 Alarm Supply

There is a separate un-fused forward converter for supplying EPO and Building
Alarms. Alarm Supply gets its power from +24V (AAUX on I/O) and is reduced
to +12V by (N5) and uses a gate signal from N3. The circuit consists of FET
V87 and XFMRs T4, 5, 6. This results in three isolated ~12VDC outputs for use
by the alarms.
4.14.5 EPO Alarm

There is a normally open EPO input on X12 and a normally closed input on
X52. Opto isolator V110 sends this alarm to the control board.
4.14.6 Building Alarms

There are two building alarms on X44 and X45 that can be programmed to be
used in a number ways by the customer (via the display board) just by adding a
jumper. OPTO isolators V108 and V84 send these alarms to the control board.
4.14.7 RS-232
There is another separate un-fused forward converter for supplying isolated
RS-232 power. The circuit consists of N13, N14, V113, and T7. It runs from the
24V (AAUX on I/O) input and outputs +/-6V for use by the transmit and receive
circuits of isolators V102 and V103. This appears on DB9 RS-232 connector
X53 as RxD, TxD, and GND.
4.14.8 NO/NC Relay Contacts

There is a set of isolated NO/NC relay contacts K7 ouput on connector X57.
4.15 Bypass SCR Gate Drive and SCRs

Bypass SCRs are mounted on the back of the lower power module heatsink.
The gate drives operate at approximately 22kHz with a 25% duty cycle. The
drive is controlled by N4, which is a UC3845A Current Mode controller that gets
its power from +24V (BAUX). Transformers T18, T19, T21, T22, T23, and T24
provide gating pulses. These transformers provide SELV isolation from the line
to the gate drive, which operates from system logic ground.
_2 is regulated with a linear regulator N2. This voltage is used for the logic
power for bypass PIC D1.

4.15.1 Standalone Bypass Functionality

Bypass function is controlled by PIC processor D1. The processor is a
microcontroller and operates at 5MIPS.
Pins 6, 9, and 10 control the processors state transition. Pin 8 tells the main
processor what state it is in with a clocked output. Pin 5 feeds a window
comparator with a clock. This comparator disables the bypass gate drive with a
brownout condition, clock failure, or watchdog failure. Pin 7 locks the LED on
the unit display when the unit goes to bypass. Pin 11 drives Darlington drivers
V6-C, V8-B, and V43-H. These drivers turn on the Static Switch gate drive,
latch on the contactor drive relay. LED V4 shows what state the processor is in
and is driven via a Darlington driver with pin 12. Connector X1 is used to
program the processor.
4.15.2 Bypass State Machine

Operation of the Bypass Control Board is described below using machine
states. Bypass machine states can be viewed as modes of operation. Each
table below describes a machine state. The last group of tables describes all
possible machine state transitions
Fire
Ready
Ready
Armed
Idle
Init
Figure 29. State Diagram

The following tables describe the Bypass Control states show in Figure 29:
Table 21. Fire State
[FIRE STATIC SWITCH] = ON
[CLOSE BYPASS] = ON
[CLOCK OUT] = 50% duty cycle 10KHz
[BYPASS READY] = 50% duty cycle square wave (1020 Hz)
[BYPASS RELAY] = ON
[GREEN LED] = ON
Table 22. Ready State

[FIRE STATIC SWITCH] = OFF
[CLOSE BYPASS] = OFF
[CLOCK OUT] = OFF
[BYPASS RELAY] = OFF
[GREEN LED] = 1 Hz 10% duty cycle BLINKING
Table 23. Ready Armed State

[CLOCK OUT] = OFF
[GREEN LED] = TOGGLE EVERY .5 SEC
Table 24. Idle State

[CLOCK OUT] = OFF
[BYPASS READY] = 20 millisecond square wave (50Hz)
[GREEN LED] = OFF

During the Intialization state the Microcontroller is initialized and tested. All
Microcontroller outputs will be disabled.
Table 25. Initialization State
[CLOCK OUT] = OFF
[BYPASS READY] = OFF
[GREEN LED] = OFF
Machine State Transitions

Table 26. From Initialization to Idle State
For 100 milliseconds:
{INVERTER ON LINE} = TRUE AND
{BYPASS AVAILABLE} = FALSE AND
{POWER FAIL} = FALSE AND
{IO GOOD} = TRUE
Table 27. From Idle State to Ready State

{INVERTER ON LINE} = FALSE AND
{BYPASS AVAILABLE} = TRUE AND
{IO GOOD} = TRUE
Table 28. From Ready State to Ready Armed State

{IO GOOD} = TRUE
Table 29. From Ready State to Fire State

For 750 microseconds:
{IO GOOD} = TRUE

This state transfer should only be executed when the system is configured as
parallel for redundancy.
Table 30. From Ready Armed State to Fire State
{POWER FAIL} = FALSE
OR
{IO GOOD} = FALSE AND
{POWER FAIL} = FALSE
Table 31. From Fire State to Ready Armed State

{IO GOOD = TRUE
I/O GOOD insures we dont come off of bypass and drop load if the Control
Board Logic Voltage fails. Make sure that bypass available true in hardware
is not naturally pulled-up state. That way if in logic there is Failure on
Interface Board we stay on bypass.
Table 32. From Armed State to Ready State
For 5 milliseconds:
{IO GOOD} = TRUE
Table 33. From Ready State to Idle State

For 50 millisecond:
{IO GOOD} = TRUE

4.15.2.1 Control Interface

The Control Interface is comprised of three dedicated control signals:
Inverter on line (input)
Bypass Available (input)
O GOOD (input) and Bypass Ready (output).
The Inverter uses the first two control signals to tell the Bypass Control Board
what the "State" the whole system is in. The Bypass Control uses these
signals (Inverter on Line and Bypass Ready) to transition from state to state.
The Bypass Control uses IO GOOD (input) to insure that the system does not
drop load if there is a logic failure on the control board. The Bypass Control
uses the third control signal to tell the Inverter Control what state the Bypass
Control is in.
4.15.2.2 Clock signals

All clock signals generated by the bypass board should vary in frequency by no
more than 5%. Since CLK_OUT and FIRE_STSW are generated directly by an
ISR they should not vary. BYP_READY is generated by the state machine and
could vary, but no more than +/- 5%.
This state is entered when a Microcontroller reset occurs. Reset could occur
because of any of the following reasons:
Table 34. From All Machine States to Initialization States
LOGIC POWER RESET
FROM THE LOGIC POWER FAIL STATE
WATCHDOG TIMEOUT
S/W MALFUNCTION.
{RESET IN} = TRUE
{INVERTER ON LINE} = DON'T CARE
{BYPASS AVAILABLE} = DON'T CARE
{POWER FAIL} = DON'T CARE
{FIRE BYPASS} = DONT CARE
4.15.3 AC Fans
There are three AC fan connectors X17, X18, and X19. X17 is connected
phase L1- N across the output. X18 is connected phase L2- N across the
output. X19 is connected phase L3- N across the output.

4.16 ELECTRO-MAGNETIC INTERFERENCE (EMI) BOARD

(PCB)
Reference Documents: EMI Board Schematic (110720620) in the Prints
chapter at the end of this document.
4.16.1 Introduction
The EMI Board handles surge protection and EMI filtering.
4.16.1.1 EMI Connector Descriptions
4.16.2 EMI Board Functional Sections
4.16.2.1 Surge (PW 9355)
4.16.2.2 EMI Filter (PW 9355)
4.16.2.3 Paralleling Inductors (PW 9355)

TBD
4.16.2.4 Miscellaneous
The connection to the logic power supply on the I/O Board comes from the
connections J1 and J2 on the EMI board. This connection bypasses the ABF
contactor.


.

5
Connectivity and
Communication
5.1 9355 GENERAL CONNECTIVITY DEVICES
5.1.1 Basic Serial Communication
Two serial ports are available with the standard unit. One of the serial ports is
dedicated to an X-Slot. The other port is exclusively an X-Slot or it can be
shared with a local DB9 RS-232 port. The second X-Slot can be used at the
customers discretion.
5.1.2 Relay Signaling

One general-purpose relay, with SELV compliant contacts, is available for
output signaling. The default set-up for this relay is Alarm.
5.1.3 Building Alarm Inputs

The unit will have two configurable, galvanic isolated (SELV) building alarm inputs.
5.1.4 Additional Connectivity & Software

The UPS will support the XCP protocol. The units will support the following:
LanSafe-power management software for system data integrity
PowerVision-UPS performance analysis, monitoring software
Foreseer
Modem-based Remote Notify
Power Strategy Command
XCP-based service tools
UPS Firmware flashing at all levels will be accommodated through any serial
channel. Flashing of controls and communications code segments will be
handled separately.

Connectivity and Communication 9355 20 30 kVA
5.2 9355 X-SLOT CONNECTIVITY DEVICES

The Powerware 9355 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 Powerware 9355 product supports two (2) X-Slots which house
these devices. Slots 1 and 2 can be used for any of the available cards. An
optional X-Slot driver board (Mini-CSB) may add three (3) additional external X-
Slots. All X-Slot cards are Hot-Swappable, meaning that the UPS does not
have to be powered 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 www.powerware.com for
sales brochures and product manuals.
Table 35. X-Slot Connectivity Device Options
PART NUMBER DESCRIPTION
05146533-5501 X-Slot, Single Port RS-232 / Serial / AS400 (Field Kit)
05146447-5501 X-Slot, Multi-Port / Multi-Server Serial / AS400 Signals (Field Kit)
05146508-551 X-Slot, USB Module
05146288-5501 X-Slot, ConnectUPS-M SNMP (Field Kit)
IPK-0330 X-Slot, ConnectUPS-X SNMP / Web Adapter 10 (Field Kit)
103002974-5501 X-Slot, ConnectUPS-S SNMP / Web / Hub 10/100 (Field Kit)
1018460 X-Slot, Low Voltage (LV) Relay Interface (Field Kit)
103003055 X-Slot, High Voltage (HV) Industrial Relay / RMP Interface (Field Kit)
103002510-5501 X-Slot, MODBUS (Field Kit)
1019017 X-Slot, Modem (Generic) (Field Kit)
1019018 X-Slot, Modem (New Zealand, Australia) (Field Kit)
103002687-001 Remote Monitoring Display Field Kit (Powerware)
103004336 X-Slot CAN Bridge Card
*Field Kits include Board, Cable, Screws, Manual, and Software
For more details on X-Slot cards, refer to the 9355 UPS Users Guide,
Communication Options.
5.2.1 Modem Handling

A modem can be connected so that the UPS can receive calls and the UPS
can make out-going calls when a programmed event occurs (Remote Notify
and P-record Phone Home). When connected, the modem is pinged
periodically.

9355 20 30 kVA Connectivity and Communication
5.2.1.1 Modem Pinging

The Modem is pinged not only to ensure that is connected, but also for modem
hang-up, initialization and also prior to making any out-call to assure that the
modem is functional. A transfer to the pinging state occurs for the following
reasons.
The modem is pinged whenever the serial port has not received data for
15 minutes
Communication Server Board (CSB) Logic Power On
Remote Notify or P-record Phone Home Request
5.2.1.2 Modem Connected (Incoming Call)

When the Modem Connected Response is received from a serial port
connected to a Modem, the status Modem Connected is queued in the event
history queue.
5.2.1.3 Remote Notify State or XCP Modem Call Request

Any event in the system can cause a XCP Phone Home or Remote Notify call
when the event transitions to its active state. The modem is always pinged prior
to the call to ensure that the modem is functional and initialized. To do this, a
transfer to the Ping Modem State occurs when a call is requested.
All of the following items must be true for an out-call to be initiated:
A request is made for a Remote Notify or XCP call. (See requesting calls,
below.)
One minute has expired since an out-call to any Phone # has been made.
This serial port is set up to make the corresponding Remote Notify call.
Input as not be received for 15 Minutes.
Note:
Only one modem can be connected.
After the Outcall, the modem is hung up if inactivity occurs for 1 minute.
5.2.1.4 Requesting Calls

As shown below, any event can trigger an out-call. When the event goes active,
the request activates if enabled for the corresponding serial port.

P-
The Call requests are made periodically until the Call request is cleared. Up to
three calls are made hourly. The modem must be disconnected for fifteen
minutes before a call is initiated.
5.2.2 Modem Operation
5.2.2.1 Modem Communication Terminology

AT command set fairly standardized command set used by modems. Most
commands to the modem start with AT and end to a carriage-return.
Carriage-return the ASCII code 0x0D, that is commonly used as string/line
termination.
D-sub the 9-pin communication connector in PW9355.
FORS software running in a service center host computer. Whenever there is
some active alarm requiring service attention, the UPS calls to FORS.
Also, FORS may periodically call to the UPS to request the state and history
log from the unit.
Modem a communication device that allows using serial communication over
public telephone lines.
XCP the communication protocol used with PW9355.
X-Slot an extension card slot. PW9355 has two X-Slots, 1 and 2.

5.2.2.2 Introduction
This document describes the modem support in PW9355. The modem handling
is designed to work with FORS service system and any modem that uses the
industry standard AT command set. When the UPS requires service attention,
it automatically calls to the service center. Then, using the normal XCP, the
service center host computer requests data from the UPS. The service center
may initiate the call to the UPS.
This makes modem handling in the UPS simple. The UPS is only responsible
for:
Detecting the condition that requires service attention: this is done by
correctly selecting and setting the alarms, which cause the UPS to make
the call.
Making the call: this is done by periodically sending a correctly set
command string to the modem. This is repeated until the connection is
created, or predefined number of tries has been made.
Responding: while the connection is active, the UPS responds normally to
any XCP monitoring commands. All control commands are disabled, until
the required password is given.
Disconnecting the line: this is done by periodically sending a correctly set
hang-up string to the modem, until the modem responds expectedly.
The 9355 modem support uses binary XCP. The ASCII Computer Mode
(ACM), which is mentioned in the XCP Protocol Specification, is not used.
5.2.2.3 Communication Speed

The communication speed for the modem communication channel (between
the UPS and the modem) must be set correctly. Modems may be able to detect
this speed automatically, but the recommendation is to use a fixed speed in the
modem.
The factory setting for both communication channels is 19200bps.
5.2.2.4 Lock Communication to D-Sub

Normally the serial communication of channel 2 is done via the X-Slot 2. When
the D-sub is used for communication, then channel 2 is automatically switched
there from the slot. When the D-sub isnt used anymore, the channel 2 is
switched back to the X-Slot 2.
The setting disables the automatic switching between the two, and locks the
communication to the D-sub. This removes the possibility of losing the first
command/message when a communication session is started with the UPS.
This setting is recommended if channel 2 communication is used only by the D-
sub. For example, this is the case when the modem is installed to the D-sub
while the serial communication in the X-Slot 2 is unused. This setting has no
effect on communication channel 1.
The factory setting is FALSE, not locked to D-sub.
5.2.2.5 Control Commands Inhibition

This setting is for security: it disables all control and configuration commands
coming from the communication channel. There is an independent setting for
each channel. This is settable using the front panel LCD menu only.
When this setting is not allowed for the modem communication channel, all
UPS control and configuration commands via the modem are disabled. To
allow any control of the UPS via the modem, this setting must be set to
allowed for the communication channel, and the correct modem
communication password must be given during the modem session.
Note:
The factory setting for both channels is not allowed.
5.2.2.6 Modem Communication

This setting tells the UPS if a modem is connected to the UPS. Zero value
means that no modem is installed. Other values define the communication
channel where the modem is installed. All modem handling and communication
restrictions (AT commands and password requirements, for example) are
directed to this channel. The other communication channel operates normally.
When the modem is installed and this parameter is correctly set, the UPS will
automatically make a call when an event requires it. The call is made to the
number defined by the modem call number string.
The factory setting is zero, modem not installed.
5.2.2.7 Modem Call Number

This is a string that holds the call command and the cal number. The maximum
string length is 39 characters. To initialize a modem call, the UPS simply sends
this string to the modem; it must include all (commands/numbers) the modem
needs to make the call.
For example, the phone number of the service center computer is 123-4567:
Modem call number = ATDT1234567.
The string may also include other modem control commands.
The factory setting is an empty string, only the automatically added
carriage-return is sent to the modem.
5.2.2.8 Modem Initialization String

This string is used to initialize the modem. Normally, the correct configuration is
stored into the modem non-volatile memory, and this string only directs the
modem to reset itself and use the stored configuration. The maximum string
length is 47 characters.
While the modem handling is in the modem idle state, the UPS firmware
automatically sends the initialization string to the modem every 15 minutes. The
modem initialization can be commanded using a XCP parameter or with the

front panel. Using this command causes the modem to be initialized

immediately. If there is an open modem call, it will be hung up.
The factory setting is ATZ0.
5.2.2.9 Modem Communication Password

When a new modem call begins, only UPS monitoring is allowed; this means
commands that retrieve normal user data from the UPS, meters, status,
alarms, history log, and so on. To make any UPS control or configuration via
the modem, a password must be given. The given password is valid only during
the present modem session, and it must be given again when a new modem
call is made.
The password is given using the XCP Configuration Field command. The
password is a write-only string for the user. Service may change the password.
The maximum string length is 9 characters. In addition to giving the correct
password, the control commands must be allowed for the communication
channel.
The factory setting is an empty string - the user must use the XCP
Configuration Fields command to fill the empty string.
5.2.2.10 Modem Hang-up String

This string is used for escaping the modem to command mode and hanging-
up the line. The maximum string length is 31 characters. All other characters
except comma , (ASCII 0x2C) are sent to the modem. The comma character
causes a 2 second pause before continuing.
The factory setting is ,+++,ATH0.
5.2.2.11 Modem Message String

When this string is set, (its length > 0) then the operation changes when the
UPS makes the call. About 5 seconds after the connection is made
(CONNECT), the UPS sends this string to the line, then sends the internal
alarm message string and number (in ASCII format) that requested the call,
then the UPS disconnects the line and returns to Modem Idle state.
The maximum string length is 31 characters, or preferably 63 bytes if there is
room in the EEPROM.
The factory setting is an empty string.

5.2.3 Modem Call Handling States
No Modem
Modem Idle
Modem
Initializing
Modem
Hanging Up
Modem
Dialing
Modem
Session
Figure 30. Modem Call Handling States
Modem handling has six states:

1. No Modem: the parameter modem communication has the value
zero. The serial communication works normally without extra
modem handling.
2. Modem Idle: no active communication is occurring through the
modem. The firmware is waiting on an incoming call, or an alarm
causing the UPS to make a call.
3. Modem Initializing: the modem is being initialized.
4. Modem Dialing: the modem is dialing, trying to make the
connection with the remote host computer.
5. Modem Session: communication with the remote host computer is
active.
6. Modem Hanging Up: the modem is disconnecting the line.

5.2.3.1 No Modem
Refer to Figure 31 No Modem State
As long as the parameter modem communication is zero, the modem
handling firmware stays in this state.
The serial communication operates normally to both communication channels
without additional modem handling. When the parameter value is changed to 1
or 2, the modem handling is directed to that channel, and the firmware changes
to modem idle state.
NO modem
NO Modem
The parameter < > 0
YES
Modem idle
Figure 31. No Modem State

5.2.3.2 Modem Idle

Refer to Figure 32 Modem Idle State
In this state, the modem is disconnected from the phone line.
On entering to this state, the modem handling is initialized and all active call
requests from currently active alarms are cleared. Only a new alarm will cause
the modem call. The internal flag modem communication password given is
cleared. If the service needs to use control commands in the next modem
session, the password must be given again.
A new alarm that requests a modem call will cause the firmware to start the
dialing sequence. First, a simple test is made that the modem really is off-hook.
This is achieved by sending the AT command, which the modem should
respond to with OK. If this is not responded to correctly after two attempts, the
hang up state will be executed before dialing. The state then changes to
modem dialing.
If a command, or a string starting with CONNECT, is received from the modem,
then a call to the UPS has been received. The state changes to modem
session.
While looping in this state, the UPS periodically initializes the modem by
sending the modem initialization string to the modem.

Modem idle
Clear call requests of currently active

alarms. (A modem call is initialized
only by a new alarm.) Clear internal
flag Modem Communication
Password Given.)
YES
Time to initialize
Send the initialization string
the modem? to the modem.
NO
Connect or a YES
command Modem session
from the modem?
NO
YES
An alarm
a call? Modem dialing
NO
YES
Modem installed? The parameter < > 0
NO
NO
Figure 32. Modem Idle State

5.2.3.3 Modem Initializing

In this state, the initialization string is sent to the modem. The response OK is
expected as an indication of successful initialization.
Depending on the situation, after initialization the modem either returns to idle
state or continues dialing.
5.2.3.4 Modem Dialing

Refer to Figure 33 Modem Dialing State
To initialize the call, UPS sends the modem call number string to the modem.
When the connection is opened, the UPS receives a string that starts with
CONNECT, or any command from the line.
If the connection is not made in the dialing time of 50 seconds, dialing is
interrupted by sending a carriage-return (0x0D) to the modem. The dialing time
(factory setting 50 seconds) is an EEPROM value, and changeable by service.
The UPS makes call attempts (up to 9 times) until the connection made. The
sequence consists of three groups of three attempts. A new attempt in a group
is done about one minute after the previous one. The groups have 10 minutes
in between them. When starting a new re-attempt group, an additional
initialization of the modem is performed.
The dialing is stopped if the connection cannot be opened during nine call
attempts. The call requests are cleared and the firmware jumps to modem idle
state to wait the next new alarm to request a call.

Modem dialing
Initialize dialing sequence
Send the call number

string to the modem
Connect or a YES
command received Modem session
from the modem?
NO
NO
50 seconds gone?
YES
Interrupt the dialing by sending

a carriage return to the modem
NO
Wait a while. Dialing sequence
done?
YES
Modem idle
Figure 33. Modem Dialing State
5.2.3.5 Modem Session

Refer to Figure 34 Modem Session State
The monitoring commands (status, meters, history log, and so on) work
normally during a modem session. The control commands require that they be
allowed for the communication channel, and that the modem communication
password is correctly given during the session. The password is valid only
during the current session; it must be given again for the new session.

When the UPS receives a hang-up command, 5 minutes (EEPROM setting)

has elapsed since the last command was received, string OK+carriage return,
or a string starting as NO CARRIER is received, then the firmware state
changes to hanging up.
Modem session
Execute any monitoring commands. If

the control commands are allowed via
the channel and the internal flag Modem
Comm. Password Given is set, execute
control commands.
YES
Correct "Modem Set the internal flag "Modem
communication communication password given".
password" given?
NO
YES
Hang up command?
NO
YES
"OK"+carriage-return
or "NO CARRIER"
received?
NO
NO
5 minutes gone since
the last command
received?
YES
Modem hanging up
Figure 34. Modem Session State

5.2.3.6 Hanging Up
Refer to Figure 35 Hanging Up State
The modem hang up string is sent to the modem every 10 seconds until the
modem responds with OK+ a carriage return, meaning the modem is hanging
up. The firmware jumps to the modem idle state.
Note that the comma , in the modem hang-up string has a special meaning:
it is not sent to the modem, but a 2-second pause is observed before
continuing with the next character in the string.
Modem hanging up
Send the hang up

string to the modem.
Initialize 10 sec timer.
"OK"+carriage-return Modem idle

received?
NO
NO
10 seconds gone?
YES
Figure 35. Hanging Up State

5.2.3.7 Modem Failure

After sending a command (except the off-hook test in Idle Mode) when the OK
response is expected but is not received, sending the same command is
repeated up to 10 times. After each try, the anticipated response duration is 10
seconds.
If the modem still fails to respond correctly after the retries, the modem failed
notice will become active. Modem failure does not affect the behavior of
modem handling, but it causes an additional initialization if a new modem call is
requested. Modem failure will be deactivated (modem OK in history log) when
the modem is working properly again, that is, either the periodic initialization is
carried out successfully or an incoming call is answered.
5.2.4 Communication During a Modem Session
5.2.4.1 XCP Monitoring Commands

All XCP monitoring commands work normally. These commands are the ones
that read information from the UPS, but do not write or change anything.
5.2.4.2 XCP Control Commands

To be able to use the control commands during a modem session, the control
commands must be enabled for the modem communication line, and the
modem communication password must already be given during that session.
The control commands must be preceded by an appropriate authorization
code.
5.2.4.3 Requesting the History Log

An ASCII dump of the history log in PW9355 can be requested with a special
command <ESC>L (= 0x1B, 0x4C). There is no XCP command for this. The
history log dump can easily be requested using simple terminal software. The
following is a sample of a 9355 History Log using <ESC>L command.
[2J01/24/2005 16:30:07.590 Event #173: UPS Off Command
01/24/2005 16:30:07.660 Event #139: Inverter Off
01/24/2005 16:30:12.860 Event #140: Charger Off
01/24/2005 16:30:16.260 Alarm #199: Batteries Disconnected
01/24/2005 16:30:21.605 Notice #059: Utility Not Present
01/24/2005 16:30:21.960 Notice #008: Input Under or Over Frequency
01/24/2005 16:30:21.960 Notice #057: Utility Fail
01/24/2005 16:30:24.960 Notice #105: Bypass Not Available
01/01/0001 00:00:00.000 Event #138: Control Power On
01/24/2005 16:30:22.260 Alarm #199: Batteries Disconnected
01/24/2005 16:30:23.460 Alarm #199: Batteries Connected
01/24/2005 16:30:59.355 Event #172: UPS On Command
01/24/2005 16:31:12.960 Notice #105: Bypass Not Available
01/24/2005 16:31:13.160 Notice #105: Bypass Not Available ok
01/24/2005 16:31:21.560 Event #139: Inverter On
01/24/2005 16:31:36.660 Event #140: Charger On

5.2.4.4 Hang-Up Command

At the end of a session, the host can, and should, command the UPS to hang
up. This ensures that the UPS knows that the session has ended and is
immediately ready for the next call.
The hang up command is the Exit XCP to Unspecified Mode (0xFF). The host
sends first the standard authorization code, and then:
SFD LEN CMD CSUM

AB 01 FF XX
Note:
PW9355 exit XCP to unspecified mode (0xFF) command in one of
the control commands that is always resident, as the service center
host computer uses it as the hang-up command.
5.2.4.5 Giving the Modem Communication Password

The modem communication password is given with the XCP configuration field
command (0x96) using field number 0xFFFE, enter access password.
The modem user initially has a lower access level than a normal user with
direct connection: he can use only monitoring commands. By giving the correct
modem password, the user is raised to the normal user level. This affects not
only 0x96 commands, but all control commands.
The PW9355 checks the given password immediately. If the password is
accepted, then XCP response is executed (0x31). If the password is incorrect,
then the response is parameter out of range (0x35).
Example 1: To give the factory default password (empty string), the host sends
first the standard authorization code, and then:
SFD LEN CMD Field # format length CSUM

AB 05 96 FE FF 01 00 XX
Example 2: To give the password WHATISTHIS, the host first sends the
standard authorization code, and then:
SFD LEN CMD Field # format length string CSUM

AB 0F 96 FE FF 01 0A W H A T I S T H I S XX

5.2.4.6 Setting the Modem Communication Password

To set the modem communication password, the XCP configuration field
command (0x96) field number 0x0017, modem communication password
must be used. Prior to issuing this command, the user must have used the
configuration field command field 0xFFFE enter access password to get the
correct access level for setting this string.
Example 1: To set the password of WHATISTHIS, the host first sends the
standard authorization code, and then:
SFD LEN CMD Field # format length string CSUM

AB 0F 96 17 00 01 0A W H A T I S T H I S XX

5.3 9355 COMMUNICATION

5.3.1 Default Communication Access Passwords
Access Password
User -
Service SERV
5.3.2 Signal Inputs & Programmable Functions

This section describes the signal inputs used in the Powerware 9355 UPS. The
signal inputs are control inputs that can be used to trigger a programmable
function. This section also discusses both how to use the signal inputs and
what programmable functions are available.
5.3.2.1 Signal Inputs 1 & 2

The UPS incorporates two programmable inputs: X44 and X45. The connectors
X44 and X45 can be found on the front of the UPS. Shorting the pins with a
maximum resistance of 10 ohms activates the input signal.
The function programmed to the input is triggered after the input has been in
the active state for at least 1ms (0.2ms) continuously. The same timing
applies for inactivation.
The inputs can also be programmed to use reverse logic. In that case, the input
would be shorted by default, then opened to activate the programmable
function. The logic direction is selectable from the front panel display.
5.3.2.2 X-Slot Inputs 1 & 2

Pulling the X-SLOT serial port RX-signal to a voltage between +3V and +15V
for more than 5 seconds activates the input signal. The time for activating the
signal is user configurable and can be selected between 0 and 65 seconds
from the front panel display. The same parameter can be found in the service
menu.
The input signal related to X-SLOT 2 can also be activated from the service (D-
sub) connector since the signals are multiplexed.
The programmed function goes inactive after the activating condition has been
absent for 1 second.
5.3.3 Programmable Functions

The signal inputs can be used to trigger a programmable function.
By default, each signal input is linked to a building alarm, which is active while
the corresponding input signal is active. The only exceptions are if the signal
input is configured to the empty setting or to trigger another building alarm.

The corresponding building alarms are listed below.
INPUT 1 Building Alarm 1
INPUT 2 Building Alarm 2
X-SLOT 1 Building Alarm 3
X-SLOT 2 / Building Alarm 4

SERVICE
5.3.3.1 Disable Bypass

This command disables the usage of bypass. While the signal is active, the unit
will not change to bypass, neither in normal operation nor as a response to the
bypass command. While active, it prefers dropping the load to changing to
bypass. This function is only overridden using the Force Bypass setting.
5.3.3.2 Shutdown
Causes the unit to shut down immediately when activated.
This function does not initiate the automatic restart itself, but if the automatic
restart is already pending, it will not cancel it either.
This function is edge activated. Shutting the unit down using this function will
not prevent starting it up again using the front panel display or XCP.
Note:
The LV unit bleeds the DC rails down and does a full shut down,
whereas the HV unit goes to Standby Mode.
5.3.3.3 Remote On / Off

Activating the function causes the unit to shut down. Inactivation causes the
unit to start up again.
If two or more input signals configured to this function are active, the start-up
will be triggered when the last of the inputs inactivate.
Shutting the unit down using this function will not prevent starting it up again
using the front panel display or XCP.
5.3.3.4 Delayed Shutdown

Activating this function causes the unit to shut down after a user-defined delay.
The default shutdown delay is 120 seconds. It can be changed on the front
panel display.
After shutting down, the automatic restart is initialized which will start the unit
up after a delay. The pending automatic restart has higher priority than starting
the unit up by XCP or by other signal input function.

Both the pending shutdown and automatic restart can be cancelled by pressing
the front panel display on/off button (TURN UPS OFF). While the automatic
restart is pending, the front panel display can be used to turn the unit ON
immediately.
5.3.3.5 Force Bypass

Forces the unit to bypass operation immediately when the signal activates. The
transfer is unconditional and causes load loss if bypass operation is not
possible (bypass not available, etc.).
Note:
Force Bypass does not have any effect if the usage of bypass is
disabled with the user parameter.
5.3.3.6 Request Bypass

The unit tries to transfer to bypass operation for two seconds each time when
the function activates. This function is edge-triggered and only responds to the
activation.
The unit will not transfer to bypass if bypass is disabled with an active disable
bypass signal input function
The unit will not transfer to bypass if bypass is disabled with the user
parameter.
5.3.3.7 Request Normal

This function clears an active bypass request. When the unit is in requested
bypass operation, this function will cause the unit to return to normal operation.
This function is edge-triggered and only responds to the activation.
5.3.3.8 Normal / Bypass

The unit tries to transfer to bypass operation for two seconds each time this
function is activated.
If bypass operation was achieved, the inactivation of this function causes the
bypass request to be cleared and the unit to return to normal operation. If two
or more input signals configured to this function are active, the normal
command is given when the last one is inactivated.
5.3.3.9 External Battery Breaker

This is the external battery breaker status. While this status is active, it causes
the Battery Breaker Open alarm to be active. The alarm remains active while
one or more signal inputs configured to this function are in the active state.
During the active state the batteries will not be charged (ABM: battery not
connected).
When the function is inactivated, the ABM will start a new charging cycle. This
function also causes the active Battery Test Failed notices to be cleared.

5.3.3.10 Charger Off

Turns off the charger and forces the ABM cycling to the resting status. The
battery charging disabled notice is active while the function is active.
It stays active while one or more signal inputs configured to this function are in
active state. The ABM returns to normal operation when the function is
deactivated.
5.3.3.11 Building Alarms

Causes the selected building alarm to be active while the input signal is active.
The building alarm stays active while one or more signal inputs causing the
same alarm are in the active state.
5.3.3.12 External Transformer Overtemperature

Starts the Transformer Overtemperature alarm. If the signal is constantly
active during the user settable delay, the UPS output is shut down.
5.3.3.13 On Generator
While active, the UPS detects that the input is fed from a generator.
5.3.3.14 Empty
This is an empty function that does not do anything. It does not cause the
default building alarm to activate.
5.3.4 Signal Inputs on Front Panel Display

The input signal configuration menu on front panel display can be found under
Settings? / User Settings? / Signal Inputs.
5.3.4.1 Selecting the Input Signal

In the first phase, the desired input signal is selected using the up/down arrow
buttons. While selecting, the current settings can be seen on the display.
Pressing enter () selects the desired signal input for reconfiguring.
5.3.4.2 Selecting the Function

In this phase, the desired function can be selected using the up/down arrow
buttons. Pressing the bent arrow (the leftmost button) cancels the selection and
returns to selecting the signal.
On input signals 1 and 2, pressing enter () moves on to selecting the logic
setting.
If the selected signal is either of the X-SLOT input signals, pressing the enter
button confirms the selection and it will be taken into use.

Note:
If the selected input signal is active when confirming the selection, the
function will activate immediately. There is a danger of load loss if the
selected function is, for example, shutdown and the unit is online.
5.3.4.3 Selecting the Logic Setting

In this phase, the desired logic setting can be selected using the up/down arrow
buttons. Logic 1 means that the function is active when the input is shorted
(normally open). Logic 0 means that the function is active when the input is
opened (normally closed). Pressing the bent arrow (the leftmost button) cancels
the selection and returns to selecting the signal.
Pressing the enter () button confirms the selection and activates the new
function.
Note:
If the selected input signal is active when confirming the selection, the
function will activate immediately. There is a danger of load loss if the
selected function is, for example, shutdown and the unit is online.
5.3.5 Configuration Fields

This command is used to set or modify the UPS configuration (parameters,
variables). This is an XCP command that allows various types of configuration
settings.
Table 36. Configuration Settings
NAME DESCRIPTION UNITS TYPE
Audible Alarms 0 = disable horn, 1 = normal, 2 = mute U8_T
current alarms 8-bit, range 0 255.
Nominal Output Voltage Changing this value will also adjust the 0.1V U16_T
window set by Bypass Voltage 16-bit, range -32768
Maximum and Bypass Voltage +32767.
Minimum
Bypass Voltage Maximum Max accepted bypass deviation from 1% S8_T
Nominal Output Voltage. Follows 8-bit, range -128
changes in Nominal Output Voltage +127.
setting
Bypass Voltage Minimum Min. accepted bypass deviation from 1% S8_T

Nominal Output Voltage. 8-bit, range -128
Follows changes in Nominal Output


Voltage setting +127.
Nominal Output Changing this value will also adjust the 0.001 Hz U16_T
Frequency Synchronization Window 16-bit, range -
accordingly 32768+32767
Synchronization Window Accepted bypass frequency 0.1 Hz U8_T
deviation from Nominal Output 8-bit, range 0 255.
Frequency. Follows changes in
Nominal Output Frequency setting
Output Frequency Max The maximum speed for UPS to 0.1 Hz/s U16_T
Slew Rate change the output frequency 16-bit, range -32768
+32767.
Number Of Battery Strings 1 U16_T
16-bit, range -32768
+32767.
Battery Watts Per Cell 15 min. rate to 1.67 VPC at 25 C 1 W/cell U16_T
+32767.
Battery Cells Per String 1 U16_T
+32767.
Constant Float Voltage Sets the battery charging voltage 0.001 U16_T
when ABM cycling is disabled V/cell 16-bit, range -32768
+32767.
Low Battery Warning Voltage level at which the low 0.001 U16_T
Level battery alarm is given V/cell 16-bit, range -32768
+32767.
On Battery Alarm Delay The number of seconds on battery 1s U16_T
after which UPS on Battery alarm is 16-bit, range -32768
given +32767.
Maximum Charge Current The maximum current for battery 0.1 A U16_T
charging 16-bit, range -32768
+32767.
Automatic On Delay Values 0...32767 = extra turn-on delay 1s U16_T
in seconds; value -1 = no 16-bit, range -32768
automatic restarts +32767.
Automatic Off Delay Values 0...32767 = seconds on 1s U16_T
battery after which output is 16-bit, range -32768
automatically turned off; value +32767.
-1 = no timed turn-off
Hardware Remote Off The delay before the shutdown, when 1s U16_T
Delay hardware Remote off with 16-bit, range -32768
restart command is activated. +32767.
X-Slot shutdown signal The filtering delay, before the input 1s U16_T
activation delay signal is considered active. 16-bit, range -32768

+32767.
Rectifier Current Limit Maximum current the rectifier draws 0.1 A U16_T
from utility 16-bit, range -32768
+32767.
Modem Communication Which communication channel the 1 U8_T
Password modem is installed to; value 0 = no 8-bit, range 0 255.
modem
Modem Call Number The call command and number for the SSTRING_T
modem to make the call String. Maximum 128
bytes.
Modem Initialization String This string is used to initialize the SSTRING_T
modem String. Maximum 128
bytes.
Modem Communication Giving this password is required to SSTRING_T
Password control the UPS via modem String. Maximum 128
bytes.
Unit Telephone Number SSTRING_T
String. Maximum 128
bytes.
CTO Number SSTRING_T
String. Maximum 128
bytes.
Serial Number SSTRING_T
String. Maximum 128
bytes.
Part Number SSTRING_T
String. Maximum 128
bytes.
UPS Family Name For XCP ID block, front panel SSTRING_T
display, etc String. Maximum 128
bytes.
Reset Changes automatically back to zero BMASK16_T
after execution
Bit 0: Reset most configuration fields
to factory setting
Bit 1: Reset the history log
Bit 2: Reset & initialize the modem
Battery Bit 0: Automatic battery support test: BMASK16_T
Handling 0=enable/1=disable
Bit 1: ABM charging cycling:
0=enable/1=disable
Bit 2: Charging temperature
compensation: 0=enable/1=disable


Operation Settings Bit 0: Preferred operation mode BMASK16_T
during rectifier input fail: 8-bit bit field + 8-bit
0=on battery/1=on bypass mask defining the
Bit 1: In case of overload, transfer on implemented bits.
bypass 0=immediately/1=after a delay
Bit 2: To transfer on bypass, the
synchronization is 0=not
required/1=required (never
transfers unsynchronized)
Bit 3: Synchronization is
0=enabled/1=disabled
Bit 4: Usage of bypass is
Bit 5: Site wiring fault alarm is
Service Control This is UPS specific control, read U16_T
service manual for details 16-bit, range -32768
+32767.
5.3.5.1 CAN Traffic

The bridge will monitor the internal CAN bus for messages that have 0xD in the
Source field of the routing identifier. The bridge will then modify the source
solely to identify which bridge card the message is being transferred from, and
transmit the message on the external CAN bus. The bridge will also monitor
the external CAN bus for messages with a destination field that matches its
identifier, all units identifier (0xE), or the everyone identifier (0xF). The bridge
will then strip the destination and replace it with 0xD and transmit the message
on the internal CAN bus.
5.3.5.2 CAN IDs
5.3.5.3 Baud Rates

The internal CAN bus is 1 Mbit and the external CAN bus is 250 Kbit.
5.3.5.4 Serial Port

The RS-232 serial port on the bridge card has two modes of operation. If the
Serial Function (Command 0x04) is set to 0, the RS-232 will be a pass-through
to the X-Slot interface. If the Serial Function is set to 1, the RS-232 will be a
serial over CAN interface.
The RS-232 serial port on the bridge card will be controlled by a serial to CAN
routine to pass the information to the serial processing on the Control Board (or
Mini-CSB).

5.3.6 HyperTerminal
5.3.6.1 HyperTerminal Emulation Configuration for the

Powerware 9355 UPS
1. Click on the Start Button, go to Programs, go to Accessories, go
to
Communications, Click on HyperTerminal, Figure 36.
Figure 36. Path to HyperTerminal Application
2. Click on HyperTerminal.exe
Enter a name for the emulation and select an icon,
when complete Select OK, Figure 37.
Figure 37. HyperTerminal Opening Screen Selections

3. The Connect To window appears,

Connect using: COM1 or COM2 Select OK after selecting the
active serial port from the drop-down menu, Figure 38.
Figure 38. Select COM1 or COM2 from the drop-down menu
4. When the COM1 or COM2 Properties window appears, make the

following selections on the screen, Figure 39:
- Bits per second: 19200
- Data Bits: 8
- Parity: None
- Stop Bits: 1
- Flow Control: None
- when complete select OK
Figure 39. Port Parameter Setup

5. Go to the File menu on the Menu bar, click on Properties, Figure 40.
Figure 40. File, Properties menu options, Settings tab, Emulation drop-down
6. The Properties window comes up, click on the Tab labeled Settings,
Figure 40.
7. In the window click on the Emulation drop-down menu and select ANSI
- Go to the View menu on the Menu bar, click on Font,
ensure that the Font selected is Terminal
Figure 41. Font Settings menu
When you have completed the previous instructions dont forget to save your
new emulation. Go to File and select Save.
The following functions are available in the Terminal Emulation:
ESC B Battery Test Queue
ESC L Set to Print out the History Log, see para 5.2.4.3.
These buttons should be pressed sequentially, not simultaneously. Failure to
follow this procedure may cause communications to lock-up. Example: Press
and release the ESC key, wait 2 seconds and press the L (log history) key.
This page was intentionally left blank.

6
Options
Chapter 6 Options
6.1 Communications and Connectivity Options 6-2
6.1.1 Single Port RS-232 Serial or AS/400 Signal Card 6-2
6.1.2 Multi-Port/Multi-Server Card 6-3
6.1.3 Low Voltage (LV) Relay Interface Card 6-5
6.1.4 High Voltage (HV) Industrial Relay / RMP Interface Card 6-7
6.1.5 ConnectUPS Network Adapters 6-8
6.1.6 MODBUS Communications Card 6-9
6.1.7 Modem Card 6-10
6.1.8 USB Module 6-13
6.1.9 CAN Bridge Card 6-14
6.1.10 Remote Monitor 6-14
6.2 Options Cabinet 6-15
6.3 Power Distribution Unit (PDU) 6-18
6.4 Remote Power Panel (RPP) 6-19
6.4.1 IQ 100 Series RPP 6-19
6.4.2 IQ 200 Series RPP 6-19

Options 9355 20 30 kVA
6.1 Communications and Connectivity Options

6.1.1 Single Port RS-232 Serial or AS/400 Signal Card
Figure 42. Single Port Serial Card
This card makes an additional RS-232 communications port available, and

AS/400 interface signals via open collector outputs, containing the following
signals:
PS Available/On Bypass
Utility Failure
Low Battery
Connection to the card is accomplished with a single DB9 female connector:

Pin 1 = (OUT) Low Battery signal (Open Collector (O.C.)
Pin 2 = (OUT) TXD Transmit to external device
Pin 3 = (IN) RXD Receive from external device
Pin 4 = (IN) DTR PnP from external device
Pin 5 = (GND) Signal common
Pin 6 = (OUT) DSR Module Ready to external device
Pin 7 = (IN/OUT) RTS PnP from external device (default) or On Bypass signal (O.C.)
(jumper-selectable)
Pin 8 = (OUT) AC Fail signal (O.C.)
Pin 9 = (OUT) Power Source +V (8 to 24 volts DC power)

9355 20 30 kVA Options
6.1.2 Multi-Port/Multi-Server Card
Figure 43. Multi-Port Serial Card
This card provides multiple RS-232 ports for communications between several
UPS modules or multiple computer servers and is available for use on any of
the provided X-Slots. Six (6) DB-9 female connectors (COM1 COM6) are
provided.
COM1 (configuration port) supports both RS-232 and AS/400 signals. AS/400
signals are all open collector type outputs:
UPS Available/On Bypass
Utility Failure
Low Battery
Pin 1 = (OUT) Low Battery signal (Open Collector (O.C.))

Pin 6 = (OUT) DSR Module Ready to external device
Pin 7 = (IN/OUT) RTS PnP from external device (default) or On Bypass signal (O.C.)
(jumper-selectable)
Pin 8 = (OUT) AC Fail signal (O.C.)
Pin 9 = (OUT) Power Source +V (8 to 24 volts DC power)

COM2 COM6 are RS-232, but only configurable for the following modes:
Terminal
Computer (XCP)
Modem
Pin 1 = (IN) DCD input

Pin 6 = (OUT) DSR .Module Ready to external device
Pin 7 = (IN) RTS From external device
Pin 8 = (OUT) CTS To external device
Pin 9 = (OUT) Power Source +V (8 to 24 VDC power) Out

6.1.3 Low Voltage (LV) Relay Interface Card
Figure 44. Low Voltage Relay Interface Card
This card provides true FORM C relay contacts (NC and NO) through two
methods which are: 1) a single 15 point terminal block, and 2) a single two row
DB-15 male connector.
Table 37. Low Voltage Relay Interface Contacts
RELAY # SYSTEM STATE D15 / TB1 CONTACT *
K1: Utility Fail 1 C
Utility OK 2 NC
Utility Failure 3 NO
K2: Battery 4 C
Normal Battery 5 NC
Low Battery 6 NO
K3: UPS Alarm 7 C
UPS Alarm 8 NC
UPS OK 9 NO
K4: Bypass 10 C
On Bypass 12 NC
On Inverter 11 NO
LV Supply ** 13 +12 VDC
14 C
UPS Shutdown ** 15 (IN)
* - Normally Closed (NC) and Normally Open (NO) are indicated when the card /
relay is de-energized.
** - To activate a UPS shutdown via an external contact closure, the UPS
shutdown input (Pin 15) must be held high (+12VDC) for a minimum of 5 seconds.
Relay contacts are rated for a maximum 1A at 30VAC or 200 ma at 60 VDC.
All relay outputs are galvanically isolated from other circuits in the UPS (IEC 950,
EN 50091-1).

NOTES:
The shut down function is only supported by single-phase products.
The relay contacts must not be galvanically connected to any mains
connected circuits.
Do not use Pin 13 (+12 VDC) as a power supply source to support
external devices.
Reinforced insulation to the mains is required for equipment and
cables connected to these devices.

6.1.4 High Voltage (HV) Industrial Relay / RMP Interface Card
Figure 45. High Voltage Industrial Relay Card
This card provides both an RMP signal interface and four sets of Form C relay
contacts serving as both an RMP driver and a Relay Interface Module (RIM).
The 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)
The Industrial Relay Card (IRC) can provide the following signals as shown in
the following table:
Table 38. High Voltage Relay Interface Contacts
RELAY # SYSTEM STATE J2 CONTACT *
K1: Utility Fail Utility OK 1 NC
2 C
Utility Failure 3 NO
K2: Bypass On Bypass 4 NC
5 C
On Inverter 6 NO
K3: Battery Normal Battery 7 NC
8 C
Low Battery 9 NO
K4: UPS Alarm UPS Alarm 10 NC
11 C
UPS OK 12 NO
* Normally Closed (NC) and Normally Open (NO) are indicated when the
card / relay is de-energized..
Relay contacts are rated for a maximum 5A at 250 VAC or 1A at 60 VDC.
All relay outputs are galvanically isolated from other circuits in the UPS
(IEC 950, EN 50091-1).

6.1.5 ConnectUPS Network Adapters

These devices provide UPS data to one or more computers over an Ethernet
network. Board connections include:
RJ-45 network connector
DB-9, RS-232 configuration port
There are several different vintages of these adapters:
Classic (external enclosures, non-X-Slot)
Models M, MX, X
10 MB SNMP/Web Card Adapter
10/100 MB SNMP/Web/Hub Card Adapter
Figure 46. 10 Megabyte SNMP/Web 10/100 Megabyte SNMP/Web/Hub
Figure 47. SNMP / Web / Hub Card Components

6.1.6 MODBUS Communications Card
Figure 48. MODBUS Communications Card
The MODBUS card provides both RS-232 and RS-485 serial data to a
customers Building Management System (BMS). Board connections include:
Both a 2 wire and 4 wire topology
RS-232 and RS-485 Communications
RS-485 Hard Wire Terminal Block
RS-485 DB-9 MOD Bus Port
RS-232 DB-9 MOD Bus Port
RS-232 DB-9 Configuration Port
Figure 49. MODBUS Communications Card Components

Table 39. MODBUS Communications Card Connector Pins

SIGNAL RS-232 (DB-9F) RS-485 (DB-9F) RS-485 (TB)
TxD (+) 2 2 1
RxD (+) 3 1 2
TxD (-) - 7 3
RxD (-) - 6 4
Signal Ground 5 5 5
6.1.7 Modem Card
Figure 50. Modem Card
The X-SLOT Modem is made for UPS remote monitoring purpose. The modem
card allows the unit to be connected to remote computers via a standard phone
line connection. It is installed to UPS X-SLOT extension place and it offers one
RJ-11 phone-jack connector for telephone network connection and four LEDs
to indicate its status on its faceplate. There are also an on-board RS-232 port
and DC-socket for the purpose of configuration which are not available when
the Modem is installed in the UPS.
The X-SLOT Modem is based on Conexant SocketModem or Multitech
ModemModule chip. SocketModem is a fully functional modem that needs only
+5 VDC and some external components for the interfaces to operate. The
following will explain the functional parts of the modem board.

Figure 51. X-Slot Modem Functional Parts
6.1.7.1 Functional Parts

1. SocketModem chip (C9, M1, R2, R5)
Fully functional modem chip. There are two alternative
manufacturers: Conexant and Multitech.
2. Jumpers (J1 - J3)
These jumpers set modem behavior in terms of hardware signals.
The assembly picture explains how to assemble these jumpers.
By default, hardware signals are not used.
3. Telephone network interface (F1, V9, X7)
The telephone network interface consists of RJ-11 connectors
and overvoltage-(V9) and overcurrent (F1) surge arresters.
4. Indicator LEDs (R13 - R16, V1 - V4)
Indicator LEDs shows modem status. There are four LEDs:
Receiving (RX), Sending (TX), Data Carrier Detect (off-hook)
(DCD) and Data Terminal Ready (that is, modem is ready (DTR)),
which will nearly always be lit.

5. RS-232 interface (C4 - C8, D1, R17, X3)

RS-232 interface consists of a 9-pin RS-232 port and MAX3232
voltage level conversion IC (D1). This port is for configuration
purposes. Modem should be configured before it is assembled in
the UPS.
6. +5V DC-DC converter (C1 - C3, C10, L1, N1, R1, V5, V8)
This circuit will make the operating voltage for the modem board.
It will convert 8 - 25 VDC input from the X-SLOT +V to +5 VDC.
This DC-DC converter is based on National Simple Switcher IC
(N1).
7. Current limiter (C11, R3, R4, R7 - R11, V6, V7)
The current limiter is situated between the X-SLOT +V (8-25
VDC) output and +5V DC-DC converter input. It protects UPS
power supplies from overloading. Current is limited to under
550mA with transistor circuitry. Short-circuit protection is
implemented with fusible resistors R3 and R4.
8. DC-socket (X4)
This DC-socket is for configuration purposes. 9 - 25 VDC is
supplied via this connector when the modem board is configured.
9. Faceplate screw terminals (X5, X6)
The faceplate of the modem board is attached through these
terminals. There is not any electrical connection between modem
circuitry and faceplate terminals.
10. X-SLOT connector (X1)
The modem draws its power and communicates with the UPS
through the X-SLOT connector when the modem is assembled
into the UPS.

6.1.8 USB Module

The X-Slot Universal Serial Bus (USB) Module Card is an X-Slot connectivity
device that allows your UPS system to communicate with a USB - compliant
computer using LanSafe power management software.
Figure 52. USB Module
The following requirements must be met to install the USB Module:

A computer with a USB port
LanSafe III power management software (v4.15 or higher)
Microsoft Windows 98 or higher

6.1.9 CAN Bridge Card
Figure 53. CAN Bridge Card
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.
Refer to Figure 53 of the CAN Bridge Card.
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 9355 parallel system. The bridge card also controls
one relay, one building alarm, and an RS-232 serial port.
6.1.10 Remote Monitor

The Remote Monitor panel has a two-wire connection. The breakdown of the
connections is shown below in Figure 54 CAN Bridge Card J3 Terminals.
J3
Building Alarm 2 replacement, or can be Connections for Parallel

used for Pull-Chain wiring if Building System Control
Alarm 2 on TB1 is already in use.
Connections for Connections for

Bypass Status RMP, RIM, or SCM
Figure 54. CAN Bridge Card J3 Terminals

6.2 Options Cabinet
NOTICE
For more in-depth information about the Options Cabinet, including

setup and installation, download the 9355 UPS 20/30kVA Users Guide
from www.Powerware.com.
The Options Cabinet is available in four models:
1. Options Cabinet with a maintenance bypass switch that provides
wrap-around bypass for UPS maintenance or service without
shutting down the load, see Figure 55.
Options Cabinet
with MBS Only
L1
L2
L3 Input
N
N
L1
L2
L3
Output
N
N
Maintenance
Options Cabinet with Bypass Auxiliary
MBS and Input Contacts
Isolation Transformer
L1
L2 Input
L3
L1
L2
L3
Output
N
N
Figure 55. Options Cabinet with MBS Wiring
2. Options Cabinet with both MBS and input isolation transformer

that allows operation from a 208V, 480V, or 600V 60-Hz source
(input transformer in single-feed systems or bypass transformer in
dual-feed systems).

3. Options Cabinet for dual-feed systems, see Figure 56, provides

the second input from a 208V, 480V, or 600V 60-Hz source.
Second Options Cabinet Second Options Cabinet
with Rectifier Transformer with MBS Only
L1 L1
L2 Input L2
L3 L3 Input
N
N
L1
L2
L3
Output
N
N
Maintenance
Bypass Auxiliary
Contacts
Figure 56. Options Cabinet with Dual-Feed Wiring

4. Options Cabinet with an output isolation transformer for 480V

loads, see Figure 57.
Second Options Cabinet First Options Cabinet
with Output Transformer with MBS Only
L1
L2
L3 Input
N
N
L1 L1
L2 L2
L3 L3
Output Output
N N
N N
Maintenance
Bypass Auxiliary
Contacts
Figure 57. Options Cabinet with Output Transformer Wiring

6.3 Power Distribution Unit (PDU)

The 9355 20-30kVA UPS module(s) may be connected to an optional Power
Distribution Unit, see publication 164201641, Powerware PDU 30-300kVA. A
three phase power input is wired to the input of the Power Distribution Unit
(PDU) and distributed to numerous output panels (one to ten). Each of these
output panels contains a main circuit breaker that feeds up to 42 smaller
branch circuit breakers and / or sub-feed breakers.
The branch circuit breakers can be single or multi-phase and are wired to the
customers load. The PDU may also contain a transformer for isolation and/or
voltage conversion.

6.4 Remote Power Panel (RPP)

6.4.1 IQ 100 Series RPP
Eatons Cutler-Hammer IQ 100 is designed for basic feeder applications where
minimal data is required by the end user, see Figure 58.
This simple-to-use meter provides accurate measurement and displays up to
12 electrical parameters including average voltage and current for the system,
plus line-to-line and line-to-neutral measurements. As an option, frequency can
also be monitored. The IQ 100 has programmable voltage and current
transformer ratios and true RMS indication for accurate measurement of
distorted waveforms, which can be viewed through four screens via a high
visibility LED display. The IQ 100 is an invaluable tool for all power monitoring
applications. There are two models in the IQ 100 series of meters:
The IQ 110 models provide voltage and current measurement only.
The IQ 115 models provide frequency monitoring in addition to voltage
and current measurement.
All other characteristics are identical in all meters in the IQ 100 series.
6.4.2 IQ 200 Series RPP

Eatons Cutler-Hammer IQ 200 compact size and flexible mounting capabilities
make it perfectly suited for machine control panels such as panel board and
switchboard mains and feeders, low voltage metal-enclosed switchgear
feeders, motor control centers, and especially for individual load monitoring,
see Figure 58.
The base module can be display mounted, panel-mounted, DIN-rail mounted or
side mounted. The display fits into a standard 1/4 DIN cutout, and for retrofit
applications a 100mm ANSI collar is available.
One IQ 200 provides an alternative to an assortment of individually wired and
mounted ammeters, voltmeters, ammeter and voltmeter switches, watt-meters,
var-meters, power factor meters, frequency meters, watt hour and demand
meters. ANSI C12 Class 10 revenue metering accuracy make the IQ 200 an
ideal choice for sub-metering and sub-billing applications. The IQ 200 can be
easily programmed and monitored from the faceplate keypad which features a
4 line x 20 character LED back-lit LCD display. Opting for the compatible Eaton
Cutler-Hammer Power Net system allows the user to program and monitor the
meter remotely from a PC.
Retrofit Opportunities:
Retrofit of existing electrical distribution systems with the IQ 200 for load
and energy monitoring
Five mounting options makes installation easier

IQ 100 series IQ 200 series

Figure 58. Remote Power Panels Series 100 and 200

7
Troubleshooting and
Maintenance
7.1 Troubleshooting Charts
7.1.1 Action Levels
The following table explains the various action levels and actions taken for the
Powerware 9355. This table is to be used when determining a course of
action to respond to a system event generated by the UPS Events or Web
Card. See paragraph 7.1.2 and paragraph 7.1.4 for Failure Analysis.
Table 40. 9355 Action Levels

Mon. SW
Name of Action Description of Action to be Taken Examples Alert
Level Level
Advisory User should be aware that a condition Building Alarm, Inform
exists which does not threaten the Shutdown
protected equipment, but that might need to Scheduled,
be checked. Some Events
Alarm Level 1 The User should note the condition and Check Modem, Major
(User Alarm - User may need to take immediate action. In Battery Voltage
action required) some UPS products, the message is Low, and so on.
displayed on the Active Alarm/Notice
Screen and the Alarm Lamp will light when
the associated bit is active.
Alarm Level 2 Not defined.
Alarm Level 3 This alarm condition indicates that Load Over 100%, Critical
(Shutdown is shutdown of the UPS could occur. The Over-
Imminent) Shutdown could result in a load loss. In Temperature, and
some UPS products, the message is so on.
displayed on the Active Alarm/Notice
Screen and the Alarm Lamp will light when
Alarm Level 4 A condition in the UPS has been detected Check Battery, Minor
(Schedule Service) that requires servicing but could be Redundant Fan
scheduled and does not require immediate Failure, and so
service. In some UPS products, the on.
message is displayed on the Active
Alarm/Notice Screen and the Alarm Lamp

Troubleshooting and Maintenance 9355 20 30 kVA

Mon. SW
Level Level
will light when the associated bit is active.
Alarm Level 5 A technically oriented alarm condition. The Inverter Current Minor
(Service Information) user should call for service to evaluate the Limit, Inverter
condition. These conditions may clear but Overload,
may indicate a pending problem. In some Rectifier
UPS products, the message is displayed on Overvoltage, DC
the Active Alarm/Notice Screen and the Link Overvoltage
Alarm Lamp will light when the associated
bit is active.
Alarm Level 6 Service of the UPS is required. In some Inverter Failure, Major
(Service Required) UPS products, the message is displayed on Fan Failure, and
the Active Alarm/Notice Screen and the so on.
Alarm Lamp will light when the associated
bit is active.
Command UPS Control Commands UPS ON, UPS Inform
OFF, and so on.
Immediate Service A condition exists which can threaten the On Bypass, Fan Major
protected equipment; it must be addressed Failure
today.
Load Power Off The UPS is not providing power to the UPS Off by Critical
protected equipment at this time. Command, DCUV
Non-Critical A condition exists in which the UPS may Major
Shutdown not be able to continue protecting all loads;
non-critical equipment should be shutdown
at this time.
Normal None (Normal)
Notice Level 1 Notice conditions that are for Information Input AC Under Inform
(Information Only) only. These Notices require no action. In Voltage,
some UPS products, the message is Equalizing
displayed on the Active Alarm/Notice Battery, and so
Screen and the Notice Lamp will light when on.
Notice Level 2 Notice conditions that tell the User to do User is being told Minor
(User Interaction) something. In some UPS products, the to close the Input
message is displayed on the Active Breaker.
Alarm/Notice Screen and the Notice Lamp
will light when the associated bit is active.
Notice Level 3 Notice conditions that inform the User that Bypass is Not Minor
(Protection Level) the level of load protection has increased or Available, System
decreased. In some UPS products, the Not Redundant,
message is displayed on the Active System
Alarm/Notice Screen and the Notice Lamp Redundant, and
will light when the associated bit is active. so on.
Notice Level 4 The user should investigate the UPS. In Building Alarms, Minor
(Investigate UPS) some UPS products, the message is Emergency
displayed on the Active Alarm/Notice Transfer to
Screen and the Notice Lamp will light when Bypass

9355 20 30 kVA Troubleshooting and Maintenance

Mon. SW
Level Level
Notice Level 5 Not Defined.
Notice Level 6 Not Defined
Notification Simple Event Notification; no action Some Events Inform
required
OFF An Indicator, LED, or Switch is OFF; no Front Panel LED Inform
action required.
ON An Indicator, LED, or Switch is ON; no Front Panel LED Inform
action required.
Safety A condition exists which may imperil Door Ajar with Major
Hazard personnel near the UPS. Voltage Present
Schedule PM A condition exists which must be addressed Battery Health Minor
by scheduling service for the UPS. Low
Service Status conditions that are service oriented Inverter On, Input Inform
Status Filter closed
(Information Only)
Shutdown Required The UPS can only provide power to the Low Battery Critical
protected equipment for less than the Shutdown
configured Low Battery Warning Time; all Pending,
protected equipment should commence Shutdown
shutdown procedures immediately. Imminent
User Status Status conditions that are User oriented. On Battery, Unit Inform
(Information Only) Normal, Input
Breaker Closed
Warning User should be aware that a condition On Battery - Minor
exists which does not currently threaten the Battery not
protected equipment but that it indicates an charged, Output
underlying problem and may lead to a Overload
situation that will.
7.1.2 Alarm, Notice, Status & Flag Definitions

The following are lists of all the various notices and alarms that can be
annunciated or acted on by the Powerware 9355 UPS. Use these charts with
the charts in paragraph 7.1.2, Action Levels and paragraph 7.1.4, Failure
Analysis to determine the course of action. The functional descriptions are also
an excellent source for determining the expected machine states during start
up and shut down. This can help narrow down which board is generating the
problem error.

Definitions (Alarm # = Node Bit #)(Listed in alphabetical order of LCD

Description) for PW9355
Alarm # LCD Web card Comments Notes
Description description
222 Abnormal The output condition Voltage detected on the After replacing
output voltage (other than Output output when there shouldn't SCRs, using the
at startup Overload) is out of be any (bypass SCRs XCP Tool,
tolerance assumed bad) Options Tab,
enable auto freq
detect.
Shut the unit
down completely
(no logic power)
and restart. Unit
will autoconfig
and auto freq
will disable.
203 Ambient over UPS Temperature Ambient temperature
temperature Alarm condition sensor reads higher than
exists limit (45C)
202 Ambient under UPS Temperature This alarm is listed in the
temperature Alarm condition alarm block, but is never set
exists in DSP firmware
219 Autocalibration UPS General System An attempt to automatically
Failed Test failed (re-) calibrate the UPS has
failed.
206 Automatic UPS turn off Unit has received scheduled

shutdown countdown underway off command from XCP
pending
199 Batteries Replace Battery Battery circuit breaker open,
disconnected Warning condition or voltage less than
exists disconnected limit
107 Battery UPS Circuit Breaker Signal input, disables
contactor open Alarm condition charger
exists
47 Battery current UPS hardware fault Hardware current limit trip,
limit detected Unit saw boost or charger
current reached the
hardware limit for 20
consecutive line cycles
68 Battery DC UPS hardware fault Battery voltage higher than
over-voltage detected 50mV/cell above charger
float voltage, shunt trips
battery
breaker
56 Battery low Low Battery Alarm Battery voltage is below
present configured level
(1.88V/cell). Only active if
unit is on battery


149 Battery needs Replace Battery Detected reversed battery
service Warning condition polarity
exists
191 Battery test Replace Battery 1 or more of the ABM
failed Warning condition battery tests failed, see
exists ABM documentation
256 Battery Test in A UPS Notice A Battery Test has begun.
Progress condition exists
19 Building alarm 1 One of the defined Signal input, user
building alarms has configurable
occurred
occurred
occurred
occurred
occurred
occurred
3 Bypass ac over UPS bypass Bypass voltage is > user
voltage unavailable configured over voltage
level.
4 Bypass ac UPS bypass Bypass voltage is < user
under voltage unavailable configured over voltage
level.
33 Bypass breaker A Relay, Contactor, Bypass voltage is detected
fail or Breaker has failed at startup (should be
mapped to alarm #195,
"Back-feed
contactor failure")
188 Bypass failure A Relay, Contactor, DSP cannot read status of
or Breaker has failed bypass pic, or bypass pic is
not changing states when
commanded to
105 Bypass not UPS bypass Bypass voltage and/or
available unavailable frequency is out of
configured limits, bypass
transfer is not allowed


119 Bypass phase UPS bypass Indicates bypass phase Using the XCP
rotation unavailable displacement is different Tool, Options
from inverter phase Tab, enable
displacement, bypass auto freq detect.
transfer is not allowed Shut the unit
down completely
(no logic power)
and restart. Unit
will autoconfig
and auto freq
will disable.
109 Bypass The bypass breaker is
Switchgear open.
Open
38 Bypass A UPS Notice This is a warning that the
Uncalibrated condition exists autocalibration has failed,
while calibrating Bypass
sensor.
5 Bypass UPS bypass Bypass frequency is outside
under/over unavailable of user configured window
frequency
21 Charger over An internal Battery converter / Charger
temperature temperature is out of IGBT module temperature
tolerance exceeds its limit
249 Charger over An internal Boost IGBT temperature

temperature temperature is out of exceeded shutdown level
shutdown tolerance (90C)
140 Charger Status Not Applicable The charger is on.
121 Check Parallel UPS hardware fault The board used for
Board detected paralleling control appears
to have failed.
36 Check Static A Relay, Contactor, Static switch fault: The
Switch or Breaker has failed static switch appears to
have failed.
224 Configuration UPS hardware fault EEROM error. Eeprom
error detected section does not match
mirror, eeprom section
needed to be rebooted, or
eeprom version is higher
than code supports (back
rev)
241 Contact Service UPS hardware fault Battery failed to reach float
(battery test detected voltage in time allowed
failed)
244 Contact service UPS hardware fault Internal CPU error
(illegal detected
instruction)


138 Control Power N.A. Control power has been
Status applied. This status is set
when the controls first
power up. It is used to
record the date and time of
return of power after a
power fail.
146 CPU ISR error UPS hardware fault This alarm is listed in the
detected alarm block, but is never set
in DSP firmware
28 dc link over UPS hardware fault Either positive rail was
voltage detected greater than 250V, or
negative rail was less than -
250V
29 dc link under UPS hardware fault Either positive rail was less
voltage detected than 100V, or negative rail
was greater than -100V
178 DC Start N.A. The UPS has been started

Occurred on battery when AC input
power is not present. This
alarm is used to record the
date and time of this event.
42 DC Voltage A UPS Notice This is a warning that unit is

Uncalibrated condition exists not calibrated.
193 Fan failure The failure of one or Fan tach pulses are too
more fans in the UPS slow
has been detected
95 From Bypass A command has been
Command received to transfer the load
from bypass to the inverter.
This command may come
from a local control panel or
from a remote source.
191 Fuse failure The UPS batteries If no separate bypass input,

need to be replaced is set if bypass voltage is
(IETF). not equal to utility voltage.
Also set if no inverter
voltage when the inverter is
turned on.
73 Heatsink Over An internal Heat sink fault: the heat sink
Temperature temperature is out of temperature at an
tolerance unspecified module
exceeds the upper
temperature limit for normal
operation


74 Heatsink UPS hardware fault Rectifier/inverter IGBT
temperature detected sensor or ambient temp
sensor fail sensor read either
unreasonably high or low,
indicating open/shorted
sensor
212 Incoming N.A. A modem connected to the
Modem Call UPS has received an
Started incoming call and has
begun to negotiate a
connection.
6 Input ac over Utility power has Input voltage is greater then
voltage failed eeprom limit (144VAC), unit
can't run utility, is on battery
8 Input Utility power has Input frequency is outside of

under/over failed limits (45-65Hz for normal
frequency unit, 55-65Hz for
transformer
unit) Unit is on battery
1 Inverter ac UPS Inverter fault Set if phase-to-phase or
under voltage detected phase-to-neutral voltage is
< 90% of set point.
221 Inverter output UPS Inverter fault Fast inverter UV, inverter
failed detected voltage outside window limit
27 Inverter output UPS Output Hardware current limit trip,

over current overloaded Unit saw inverter current
reached the hardware limit
for 20
24 Inverter over An internal Inverter IGBT temperature
temperature temperature is out of sensor is reading higher
tolerance than eeprom limit (80C).
Has 2 levels 80C is
warning level, 90C is
transfer to bypass if
available, dump load if not.
111 Inverter Over An internal The inverter temperature

Temperature temperature is out of has exceeded it s rating
Trip tolerance operating temperature.
48 Inverter startup UPS Inverter fault Startup alarm, inverter
failure detected alarm present when inverter
is started, inverter voltage
below limit, output voltage
present when inverter
started (SCR failure)
139 Inverter Status N.A. The inverter is on.


41 Inverter A UPS Notice This is a warning that the
Uncalibrated condition exists autocalibration has failed,
while calibrating inverter.
159 L1 Overload UPS Output PHA VA or watts greater
overloaded than 111% UPS rating
(Extreme Level) overloaded than 149% UPS rating
(High Level) overloaded than 126% UPS rating
160 L2 Overload UPS Output PHB VA or watts greater
161 L3 Overload UPS Output PHC VA or watts greater
170 Load Dumped UPS output has been No power is being provided
(Load Power turned off to the load (load dump).
Off) This alarm is used to record
the date and time of a
power-off event.
173 Load Off N.A. A load control command to
Command turn OFF the/an output has
Received been issued to the UPS
(may be with a delay). This
172 Load Power On N.A. A load control command to

Command turn ON the/an output has
Received been issued to the UPS
(may be with a delay). This
174 Low battery UPS Battery Battery voltage is less than

shutdown completely 1.75V/cell, 1 minute
discharged shutdown timer is started
143 Maintenance The UPS has been The load is being supplied
Bypass Mode placed on power by a wrap-around
Maintenance / maintenance bypass switch.
Manual Bypass by an


operator
216 Modem call N.A. A modem connected to the

completion UPS has failed to
failed successfully complete a
transaction sequence as
expected.
214 Modem N.A. A modem connected to the
Connection UPS has established a
Established connection with a remote
modem or paging service.
211 Modem failed N.A. Cant communicate with

modem
53 Non-volatile UPS General System EEPROM has failed
RAM failure Test failed
213 Outgoing N.A. A modem connected to the
Modem Call UPS has gone off hook and
Started has begun to either dial a
number or negotiate a
connection.
10 Output ac under The output condition This alarm is listed in the
voltage (other than Output alarm block, but is never set
Overload) is out of in DSP firmware
tolerance
25 Output overload UPS Output Greater than 102% load on
overloaded any output phase
58 Output Short The output condition Output short circuit detected
Circuit (other than Output
Overload) is out of
tolerance
72 Power supply UPS hardware fault Digital input from control
12 volt fault detected board power supply
monitoring chip
71 Power supply 5 UPS hardware fault Digital input from control
volt fault detected board power supply
monitoring chip
70 Power supply UPS hardware fault One of the internal power
failure detected supplies is failed
30 Rectifier failed An uncorrected Startup failure, either
problem has been rectifier didn't report
detected within the "normal" status or was
UPS charger unable to maintain dc
subsystem link voltage after rail
precharge.


26 Rectifier input UPS hardware fault Hardware current limit trip,
over current detected Unit saw rectifier current
for 20
223 Rectifier over An internal Rectifier IGBT temperature
temperature temperature is out of sensor is reading higher
tolerance than eeprom limit (80C).
Has 2 levels 80C is
225 Redundancy In a parallel UPS The specified power rating

Loss Due To system, one of the of an "n+1" parallel system
Overload power modules has has been exceeded. The
failed or the specified load is supported, but the
power rating has system lacks redundant
been exceeded protection while this
overload persists.
12 Remote UPS output has been Signal input, output is de-

emergency turned off energized and battery
power off breaker is tripped. Output
can't be
energized while active
220 Selective Trip One module in a A UPS module has been
Of Module parallel or multiple automatically removed from
component system a parallel system, usually
has failed due to improper load
sharing or other fault.
55 Shutdown UPS Shutdown UPS will shut the load
imminent Imminent Alarm down, either from low
condition exists battery or delay UPS off
command pending
194 Site fault UPS hardware fault Measure chassis voltage
detected too high measured against
neutral
176 Software UPS General System Wrong PLD version, wrong
incompatibility Test failed DSP rev, wrong unit
detected
229 System Alarm A System / Critical Alert (Summary
Active Subsystem Alarm is Alarm): If non-zero, there is
active at least one severe alarm
active at the system level at
this time.


132 System Not In a parallel UPS For an "n+1" parallel
Redundant system, one of the system, the load is
power modules has supported, but the system is
failed or the specified no longer has redundant
power rating has protection.
been exceeded
257 System Test in A UPS Notice One of the Systems Tests
Progress condition exists has begun.
258 Test Aborted A UPS Notice A Battery or Systems Test
condition exists has been aborted while
running due to conditions or
operator command, or was
inhibited from starting.
94 To bypass UPS internally Signal input used to send

command bypassed unit to bypass
201 Transformer An internal Signal input
over temperature is out of
temperature tolerance
237 UPS Normal N.A. The UPS is in its normal
operating mode of
operation.
168 UPS on battery UPS switched to UPS is on battery
battery power
169 UPS on bypass UPS internally UPS is on bypass
bypassed
248 UPS on The system is being Signal input
generator powered by its
Alternate Power
Source
57 Utility fail Utility power has Utility voltage or frequency
failed outside limits. Does not
necessarily mean unit is on
battery.
59 Utility not Utility power has Utility voltage is outside
present failed limits, unit is on battery
192 The failure of one or
more fuses has been
detected
Alarm # LCD Description Web card Comments Notes

description
1 Inverter AC under UPS Inverter fault Set if Phase to phase or
voltage detected phase to neutral voltage is
< 90% of setpoint.


description
3 Bypass ac over UPS bypass Bypass voltage is > user
level.
4 Bypass ac under UPS bypass Bypass voltage is < user
level.
5 Bypass under/over UPS bypass Bypass frequency is
frequency unavailable outside of user configured
window
6 Input ac over voltage Utility power has Input voltage is greater
failed then eeprom limit
(144Vac), unit can't run
utility, is on battery
8 Input under/over Utility power has Input frequency is outside
frequency failed of limits (45-65Hz for
normal unit, 55-65Hz for
transformer
unit) Unit is on battery
10 Output ac under The output This alarm is listed in the
voltage condition (other alarm block, but is never
than Output set in DSP firmware
Overload) is out of
tolerance
12 Remote emergency UPS output has Signal input, output is de-
power off been turned off energized and battery
breaker is tripped. Output
can't be energized while
active
building alarms configurable
has occurred
has occurred
has occurred
has occurred
has occurred
has occurred


description
21 Charger over An internal Battery converter /
temperature temperature is out Charger IGBT module
of tolerance temperature exceeds it's
limit
24 Inverter over An internal Inverter IGBT temperature
temperature temperature is out sensor is reading higher
of tolerance than eeprom limit (80C).
Has 2 levels 80C is
25 Output overload UPS Output Greater than 102% load
overloaded on any output phase
26 Rectifier input over UPS hardware Hardware current limit trip,
current fault detected Unit saw rectifier current
for 20 consecutive line
cycles
27 Inverter output over UPS Output Hardware current limit trip,
current overloaded Unit saw inverter current
for 20 consecutive line
cycles
28 dc link over voltage UPS hardware Either positive rail was
fault detected greater than 250V, or
negative rail was less than
-250V
29 dc link under voltage UPS hardware Either positive rail was
fault detected less than 100V, or
negative rail was greater
than -100V
30 Rectifier failed An uncorrected Startup failure, either
problem has been rectifier didn't report
detected within "normal" status or was
the UPS charger unable to maintain dc
subsystem link voltage after rail
precharge.
33 Bypass breaker fail A Relay, Bypass voltage is detected
Contactor, or at startup (should be
Breaker has failed mapped to alarm #195,
"Back-feed
contactor failure")
36 Check Static Switch A Relay, Static switch fault: The
Contactor, or static switch appears to
Breaker has failed have failed.
38 Bypass Uncalibrated A UPS Notice This is a warning that the
condition exists auto calibration has failed,
while calibrating Bypass
sensor.


description
41 Inverter Uncalibrated A UPS Notice This is a warning that the
condition exists auto calibration has failed,
while calibrating inverter.
42 DC Voltage A UPS Notice This is a warning that unit
Uncalibrated condition exists is not calibrated.
47 Battery current limit UPS hardware Hardware current limit trip,
fault detected Unit saw boost or charger
current reached the
hardware limit for 20
48 Inverter startup UPS Inverter fault Startup alarm, inverter
failure detected alarm present when
inverter is started, inverter
voltage below limit, output
voltage present when
inverter started (SCR
failure)
53 Non-volatile RAM UPS General EEPROM has failed
failure System Test failed
55 Shutdown imminent UPS Shutdown UPS will shut the load
Imminent Alarm down, either from low
condition exists battery or delay UPS off
command pending
56 Battery low Low Battery Alarm Battery voltage is below
present configured level
(1.88V/cell). Only active if
unit is on battery
57 Utility fail Utility power has Utility voltage or frequency
failed outside limits. Does not
necessarily mean unit is
on battery.
58 Output Short Circuit The output Output short circuit
condition (other detected
than Output
Overload) is out of
tolerance
59 Utility not present Utility power has Utility voltage is outside
failed limits, unit is on battery
68 Battery dc UPS hardware Battery voltage higher
overvoltage fault detected than 50mV/cell above
charger float voltage,
shunt trips battery
breaker
70 Power supply failure UPS hardware One of the internal power
fault detected supplies is failed
71 Power supply 5 volt UPS hardware Digital input from control
fault fault detected board power supply
monitoring chip


description
72 Power supply 12 volt UPS hardware Digital input from control
fault fault detected board power supply
monitoring chip
73 Heatsink Over An internal Heat sink fault: the heat
Temperature temperature is out sink temperature at an
of tolerance unspecified module
exceeds the upper
temperature limit for
normal operation
74 Heatsink UPS hardware Rectifier/inverter IGBT
temperature sensor fault detected sensor or ambient temp
fail sensor read either
unreasonably high or low,
indicating open/shorted
sensor
94 To bypass command UPS internally Signal input used to send
bypassed unit to bypass
95 From Bypass A command has been
Command received to transfer the
load from bypass to the
inverter. This command
may come from a local
control panel or from a
remote source.
105 Bypass not available UPS bypass Bypass voltage and/or
unavailable frequency is out of
configured limits, bypass
107 Battery contactor UPS Circuit Signal input, disables
open Breaker Alarm charger
condition exists
109 Bypass Switchgear The bypass breaker is
Open open.
111 Inverter Over An internal The inverter temperature
Temperature Trip temperature is out has exceeded it s rating
of tolerance operating temperature.
119 Bypass phase UPS bypass Indicates bypass phase
rotation unavailable displacement is different
from inverter phase
displacement, bypass
121 Check Parallel UPS hardware The board used for
Board fault detected paralleling control appears
to have failed.


description
132 System Not In a parallel UPS For an "n+1" parallel
Redundant system, one of the system, the load is
power modules supported, but the system
has failed or the is no longer has redundant
specified power protection.
rating has been
exceeded
138 Control Power N.A. Control power has been
Status applied. This status is set
when the controls first
power up. It is used to
record the date and time
of return of power after a
power fail.
139 Inverter Status N.A. The inverter is on.
140 Charger Status N.A. The charger is on.
143 Maintenance Bypass The UPS has The load is being supplied
Mode been placed on power by a wrap-around
Maintenance / maintenance bypass
Manual Bypass by switch.
an operator
146 CPU ISR error UPS hardware This alarm is listed in the
fault detected alarm block, but is never
set in DSP firmware
149 Battery needs Replace Battery Detected reversed battery
service Warning condition polarity
exists
162 L1 Overload (High UPS Output PHA VA or watts greater
Level) overloaded than 126% UPS rating
163 L2 Overload (High UPS Output PHB VA or watts greater
164 L3 Overload (High UPS Output PHC VA or watts greater


description
168 UPS on battery UPS switched to UPS is on battery
battery power
169 UPS on bypass UPS internally UPS is on bypass
bypassed
170 Load Dumped (Load UPS output has No power is being
Power Off) been turned off provided to the load (load
dump). This alarm is used
to record the date and
time of a power off event.
172 Load Power On N.A. A load control command to
Command Received turn ON the/an output has
been issued to the UPS
(may be with a delay).
This alarm is used to
record the date and time
of this event.
173 Load Off Command N.A. A load control command to
Received turn OFF the/an output
has been issued to the
UPS (may be with a
delay). This alarm is used
to record the date and
time of this event.
174 Low battery UPS Battery Battery voltage is less
shutdown completely than 1.75V/cell, 1 minute
discharged shutdown timer is started
176 Software UPS General Wrong PLD version,
incompatibility System Test failed wrong DSP rev, wrong unit
detected
178 DC Start Occurred N.A. The UPS has been started
on battery when AC input
power is not present. This
date and time of this
event.
188 Bypass failure A Relay, DSP cannot read status of
Contactor, or bypass pic, or bypass pic
Breaker has failed is not changing states
when commanded to
191 Battery test failed Replace Battery 1 or more of the ABM
Warning condition battery tests failed, see
exists ABM documentation
191 Fuse failure The UPS batteries If no separate bypass
need to be input, is set if bypass
replaced (IETF). voltage != utility voltage.
Also set if no inverter
voltage when inverter is
turned on.


description
192 The failure of one
or more fuses has
been detected
193 Fan failure The failure of one Fan tach pulses are too
or more fans in slow
the UPS has been
detected
194 Site fault UPS hardware Measure chassis voltage
fault detected too high measured against
neutral
199 Batteries Replace Battery Battery circuit breaker
disconnected Warning condition open, or voltage less than
exists disconnected limit
201 Transformer An internal Signal input
overtemperature temperature is out
of tolerance
202 Ambient under UPS Temperature This alarm is listed in the
temperature Alarm condition alarm block, but is never
exists set in DSP firmware
203 Ambient over UPS Temperature Ambient temperature
temperature Alarm condition sensor reads higher than
exists limit (45C)
206 Automatic shutdown UPS turn off Unit has received
pending countdown scheduled off command
underway from XCP
211 Modem failed N.A. Cant communicate with
modem
212 Incoming Modem N.A. A modem connected to
Call Started the UPS has received an
incoming call and has
begun to negotiate a
connection.
213 Outgoing Modem N.A. A modem connected to
Call Started the UPS has gone off
hook and has begun to
either dial a number or
negotiate a connection.
214 Modem Connection N.A. A modem connected to
Established the UPS has established a
connection with a remote
modem or paging service.
216 Modem call N.A. A modem connected to
completion failed the UPS has failed to
successfully complete a
transaction sequence as
expected.
219 Autocalibration UPS General An attempt to
Failed System Test failed automatically (re-)


description
calibrate the UPS has
failed.
220 Selective Trip Of One module in a A UPS module has been
Module parallel or multiple automatically removed
component from a parallel system,
system has failed usually due to improper
load sharing or other fault.
221 Inverter output failed UPS Inverter fault Fast inverter UV, inverter
detected voltage outside window
limit
222 Abnormal output The output Voltage detected on the
voltage at startup condition (other output when there
than shouldn't be any (bypass
OutputOverload) SCRs assumed bad)
is out of tolerance
223 Rectifier over An internal Rectifier IGBT
temperature temperature is out temperature sensor is
of tolerance reading higher than
eeprom limit (80C). Has 2
levels 80C is warning
level, 90C is transfer to
bypass if available, dump
load if not.
224 Configuration error UPS hardware EEROM error. Eeprom
fault detected section does not match
mirror, eeprom section
needed to be rebooted, or
eeprom version is higher
than code supports (back
rev)
225 Redundancy Loss In a parallel UPS The specified power rating
Due To Overload system, one of the of an "n+1" parallel system
power modules has been exceeded. The
has failed or the load is supported, but the
specified power system lacks redundant
rating has been protection while this
exceeded overload persists.
229 System Alarm Active A System / Critical Alert (Summary
Subsystem Alarm Alarm): If non-zero, there
is active is at least one severe
alarm active at the system
level at this time.
237 UPS Normal N.A. The UPS is in its normal
operating mode of
operation.
241 Contact Service UPS hardware Battery failed to reach float
(battery test failed) fault detected voltage in time allowed
244 Contact service UPS hardware Internal CPU error
(illegal instruction) fault detected


description
248 UPS on generator The system is Signal input
being powered by
its Alternate
Power Source
249 Charger over An internal Boost IGBT temperature
temperature temperature is out exceeded shutdown level
shutdown of tolerance (90C)
256 Battery Test in A UPS Notice A Battery Test has begun.
Progress condition exists
257 System Test in A UPS Notice One of the Systems Tests
Progress condition exists has begun.
258 Test Aborted A UPS Notice A Battery or Systems Test
condition exists has been aborted while
running due to conditions
or operator command, or
was inhibited from starting.

7.1.3 Detailed Definitions
7.1.3.1 Automatic Off Delay

This is user settable parameter for automatically turning the output off in case
of utility failure (any time when operating on battery).
1. AutoOffDelay = -1 = 65535, no automatic off function. This is
factory setting (default value).
2. AutoOffDelay = 065534, the number of seconds preceding
output turn-off if the UPS has been discharging batteries. If the
UPS transfers to some other state, the automatic-off countdown is
aborted.
Note that the automatic-off countdown is not active when a service
command or battery test is issued (or for some other operator initiated
reason) causing the transfer on battery.
7.1.3.2 Automatic On Delay

This is user settable parameter for adding extra delay before turning UPS
output on. This parameter can also be used for disabling the automatic restarts.
1. AutoOnDelay = 0, no extra delay. This is factory setting (default
value).
2. AutoOnDelay = 165534the number of seconds that is
counted down when the output is about to be turned on (at start-
up, at automatic restart, and so on)
3. AutoOnDelay = -1 = 65535the number of seconds automatic
restarts (any non-commanded) are disabled after low battery
shutdown.
7.1.3.3 Batteries Disconnected

The battery relay can be closed only when the battery circuit breaker is closed.
On start-up, and after closing the battery breaker, the UPS performs the
following steps:
1. During startup and if battery circuit breaker is closed, then
a. Check that battery voltage isnt negative.
b. Trip battery breaker and give Battery Needs Service alarm
if test fails
2. Equalize battery relay voltages using boost and charger IGBTs
a. Close the battery relay
b. Wait 2 seconds
c. Check that battery voltage and battery backup voltage
measurements are about equal (10V)

d. Trip battery breaker and give Battery Contactor Fail alarm if

test fails
e. Make sure that Battery Over Temperature shutdown and
battery hardware current limit alarms arent active.
3. If battery circuit breaker is open, then:
a. Open battery relay
b. Give Battery Contactor Open alarm
c. Disable battery operation until the battery circuit breaker has
been closed
7.1.3.4 Battery DC Overvoltage

Battery voltage has been too high for a constant period. The factory setting of
the time limit is 60 seconds. The voltage level follows the temperature
compensated battery charging scheme (if the temperature compensation is
disabled, then the voltage level stays the same):
Battery over voltage level = batChargeV + 0.05VPC
where batChargeV is the battery voltage, where charge mode changes to float
mode (see ABM document), and 0.05VPC is taken from EEPROM.
Causes Battery DC Overvoltage alarm and the battery circuit breaker to be
opened; this will disable battery operation.
7.1.3.5 Battery Low

This is the alarm level of battery voltage (about 1.88VPC). Battery low alarm is
enabled when the charger has been running for 100ms, after opening the
battery relay, or when boost is active.
The alarm stays active until boost is deactivated and Low Battery Shutdown is
inactive.
7.1.3.6 Battery Needs Service

Battery Needs Service is activated when the UPS senses negative voltage on
battery measurement. Negative battery voltage is checked during UPS startup.
The alarm is triggered when battery voltage is below 100 volts.
7.1.3.7 Binary Input - Delayed Shutdown Function

A binary input can be set to use this function. When the input signal is active,
the UPS output is turned off after a configurable delay (factory setting is 120
seconds). The output is turned on when the utility is OK.
7.1.3.8 Binary Input - On / Off Function

the UPS output is turned off. When the signal becomes inactive, the UPS
output is turned back on.

7.1.3.9 Binary Input - Shutdown Function

the UPS output is turned off, as when the front panel menu function is used to
shut down the unit.
7.1.3.10 Bypass Disable Timer

Bypass is disabled for 3 seconds when transferring from bypass because of
bypass power failure.
7.1.3.11 Bypass Disabled Flag

This is a service settable mode, useful with emergency lighting for example. In
this mode, the bypass operation is always disabled.
7.1.3.12 Bypass Down Flag

A small bypass processor controls the bypass hardware. This processor
signals when bypass is up and bypass control is possible. When the signal is
inactive, bypass is down: it is not controllable and bypass voltage
measurement is not possible.
When the bypass is down, the back-feed contactor is controlled-open.
When the bypass becomes up, the back-feed contactor is controlled-
closed, and after few seconds, bypass voltage measurement is usable
and use of bypass is possible.
7.1.3.13 Bypass Operation Preferred to Discharging Batteries

This is user setting. When the UPS On Battery alarm is active, the load will
transfer to bypass, if bypass is acceptable. Load stays on battery for 4 seconds
before transferring on bypass.
7.1.3.14 DC Bus Low Voltage

Low DC voltage, on either or both sides, causes the battery converter to begin
discharging the batteries.
Voltage limit is 29V below rail setpoint.
7.1.3.15 EPO - Emergency Power Off

Shuts down the inverter and the batteries are disconnected (CB opened). The
load becomes unpowered. Usually, if the load is on bypass, the bypass is also
shut down; but when DSP is unable to communicate with the bypass processor
(PIC), the bypass stays on. EPO input is disabled during shutdown, startup,
failure shutdown, bleeding and bypass-locked states. The user can also set a
disable EPO parameter.

7.1.3.16 Input Transformer Overtemperature

Input Transformer Overtemperature will drop the load after a configurable delay
and the UPS remains in standby mode. The default delay is 120 seconds.
7.1.3.17 Inverter Temporary Inhibit

There is a mechanism to prevent the UPS from constantly transferring from
inverter to bypass and vice versa. It is possible that the UPS doesnt detect a
reason to transfer to bypass, but the inverter cannot support the load. If the
UPS transfers load from inverter to bypass 3 - 5 times within ten minutes,
transfers to the inverter are temporarily inhibited.
A variable ForcedFromInverterCounter is initialized to the value of three (3)
once in ten minutes. Every time the UPS transfers load from inverter to bypass
the variable is decremented. If the variable becomes zero, then flag
InvTmpInhibit is set.
The transfers are automatically enabled once in an hour, the flag InvTmpInhibit
is cleared, and the variable ForcedFromInverterCounter is reset to value three
(3).
The user can enable transfers by pressing any front panel button, which does
the same initialization.
7.1.3.18 Low Battery Shutdown

If on-battery status is active and the battery voltage has dropped below the
minimum limit (typically 1.75VPC), the timer counts down (typically for 60
seconds), after which discharging of batteries must be stopped. The counter is
initialized when the Low Battery Shutdown alarm is inactive.
If battery voltage drops to absolute minimum limit (typically 1.67VPC), the timer
duration is reduced to 1 sec.
Low battery shutdown alarm stays active until the rectifier is running or the
system is not on bypass.
7.1.3.19 Neutral Fault Detection

Neutral fault is triggered when chassis voltage is over 15V and voltage on
either DC bus is over 250V. Neutral fault can be disabled by a user parameter.
A neutral fault causes transfer on the battery. The neutral fault is reset every
minute so that the UPS can attempt to use the utility again.
When the neutral fault is detected, the Neutral fault alarm is activated and the
utility voltage and bypass voltage alarms are disabled. The Utility Fail and
Bypass not Available alarms are activated.
The neutral fault alarm is cleared only after neutral fault flag has been cleared
for one minute. If the neutral fault is detected again after transfer online, the
same alarm persists and a new alarm is not generated.

7.1.3.20 On Battery Status

This status is given when batteries are discharging. Status is not given if a
battery test is in progress and the low battery alarm is not active.
This is not an alarm, but only shows that the UPS is discharging batteries. See
UPS On Battery Alarm for battery alarm status.
7.1.3.21 Output Shutdown

When bypass is not available, then:
UPS load level 4 151% will shut down the output after 300ms
UPS load level 3 126% will shut down the output after 5 sec.
UPS load level 2 111% will shut down the output after 60 sec.
UPS load level 1 102% will shut down the output after 10 min.
7.1.3.22 Overload
Loading condition is detected from output wattage and output current
,compared to nominal (100%) level, to determine the load level for each. For
units with multi-phase outputs, the loading condition for each individual phase
is detected.
The quantity, which has highest load level, determines the UPS load level.
When the UPS load level is above 100%, the UPS is overloaded.
7.1.3.23 Site Wiring Fault

Site wiring fault is checked during startup. If chassis voltage measurement is
over 50V, the Site Wiring Fault alarm becomes active and startup is aborted.
7.1.3.24 Transfer to Bypass

When bypass is available and the UPS load level is above 102%, the UPS
transfers to bypass. The following delays are used when delayed transfer to
bypass on overload is set in EEPROM:
UPS load level 4 151% will transfer to bypass after 0 seconds
As long as the bypass is OK and the UPS load level is above 100%, the UPS
will stay on bypass.

7.1.3.25 UPS on Battery Alarm

Normally, when the UPS has been continuously discharging batteries for 5
seconds, this alarm is given. This alarm is not given during battery testing, nor
when service command is forcing batteries to be discharged, if battery low
alarm is not active. This alarm is the signal for the software to start the
shutdown countdown.
7.1.3.26 Utility Overvoltage

To prevent very high voltage on the rectifier and/or DC bus, >144V (EEPROM
value) at the rectifier input on any phase causes a transfer to battery operation.
7.1.3.27 XCP Delayed Load Power Off & Restart Command

When this command is given, the UPS output is shut down after the delay
duration defined with the command. After the shutdown, the UPS waits until the
utility is OK and restarts. The output shutdown has a minimum 10 second
duration.
7.1.3.28 XCP Scheduled Load Power Off Command

When this command is given, the UPS output is shut down after the delay
duration defined with the command. The UPS output is kept off until an ON
command is received.
7.1.3.29 XCP Scheduled Load Power On Command

When this command is given, and the UPS output was turned off with an XCP
command, the UPS will turn on the output after the delay duration defined with
the command. If the utility is down, then turning on the output is delayed until
the utility is OK.
7.1.3.30 XCP UPS Off Command

When this command is given, the UPS output is turned off immediately. The
UPS output is kept off, until an ON command is received.
7.1.3.31 XCP UPS On Command

The UPS output has been turned off with an XCP command when this
command is given. The UPS will turn on the output as soon as the utility is OK.
7.1.4 Failure Analysis

The following are lists of all the various notices and alarms that can be
annunciated or acted upon by the Powerware 9355 UPS. Use these charts
with the charts in paragraph 7.1.1 Action Levels and paragraph 7.1.2, Alarm,
Notice, Status, and Flag Definitions to determine course of action.

7.1.4.1 Definitions of Table Headings

FAILURE FAILURE POTENTIAL OCC. CONTROLS RECOMMENDED
MODE EFFECT CAUSE CORRECTIVE
ACTION
FAILURE MODE - These are the ways in which the activities / processes
associated with Equipment could fail, or go wrong
FAILURE EFFECT - How would the customer feel this failure? What impact
would it have? There may be more than 1 effect for each failure.
POTENTIAL CAUSE - Why might this failure happen? What could lead to its
occurrence?
USE THE 5 WHYs - Follow these steps to get to the root cause:
d. First, identify what you believe to be the cause
e. Then ask yourself why would this problem occur and what
would cause it
f. Then, starting with the answer to this question, repeat steps
a. and b. five times until you arrive at the real cause for this
failure
OCCURRENCE - Rate the failure (1-10). How likely is the failure to occur?
1 is unlikely
10 is very likely (inevitable)
CONTROLS - What exists that might detect the failure or the impact of the
failure?
RECOMMENDED CORRECTIVE ACTION - possible ways to correct this

failure.
Table 41. Power Board Failures
ACTION
Battery Charger Batteries do not Component 3 FW Verify if any other
Circuit - No get charged, Unit failure measurement alarms are active. If
Charge alarms detection the system appears
within 24 hours. to be operating
normally, with the
exception of the
battery charger,
verify the batteries
and the battery fuse
are not bad. If the
batteries and fuse
are good, change the
IGBTs on the Power
Board. Inspect the
Power Board, if any


failure.
ACTION
damage is present
replace the Power
Board also.
Battery Charger Batteries will get Component 3 Battery Verify if any other
Circuit - Over hot, swell failure breaker will alarms are active. If
Charge Battery shunt trip, the system appears
Measure to be operating
battery normal with the
voltage, LED exception of the
red blinking, battery charger verify
alarm the batteries and the
battery fuse are not
bad. If batteries and
fuse are good,
change the IGBTs on
the Power Board.
Inspect Power Board,
if any damage is
present replace the
Power Board also.
Battery On battery - load Electrical over 3 Sufficient Check correct torque
Converter dropped stress, IGBT electrical values. Replace
devices margin. Power Board and
possible IGBTs
spring failure,
gate drives.
On battery - load Thermal 2 Sufficient Verify ambient
dropped Overstress thermal temperature in the
margins room. If the room
verified, temperature is too
calculated and hot, the fans cannot
measured create enough cool
airflow over the heat
sink.
If online - switch Customer 3 Verify Customers
to Bypass Overloads and load, room
abnormal temperature, or any
conditions, other abnormal
thermal conditions.
overstress
Rectifier Online - go to Electrical over 4 Current Verify input current
bypass stress, IGBT limiting and and if within
devices sensing, specifications replace
possible MOVs on IGBTs. Inspect the
spring failure, input Power Board for
gate drives damage if IGBTs are
destroyed then


failure.
ACTION
replace the Power
Board also if needed.
Online - go to Thermal 4 Concerned Verify customers
bypass overstress with overload load is not in a
conditions. overload condition.
Check ambient room
temperature.
On battery - load Electrical over 3 Sufficient Check correct torque
dropped stress, IGBT electrical values. Replace
devices margin. Power Board and
possible IGBTs
spring
failure, gate
drives
On battery - load Thermal 3 Sufficient Verify ambient
dropped overstress thermal temperature in the
margins room. If the room
verified, temperature is too
calculated and hot the fans cannot
measured. create enough cool
sink.
Inverter Circuit Online go to Electrical over 3 Current Verify input current
bypass stress, IGBT limiting and and if within
devices sensing. specifications replace
possible IGBTs. Inspect
spring Power Board for
failure , gate damage if IGBTs are
drives destroyed, then
replace the Power
Board also if needed.
Online go to Thermal 3 Thermal Verify ambient
bypass overstress margin temperature in the
verified room. If the room
calculated and temperature is to hot
measured the fans cannot
create enough cool
sink.
on battery - load Electrical over 3 Sufficient Replace Power
dropped stress, IGBT electrical Board and IGBTs
devices margin.
possible
spring failure,
gate drives
on battery - load Thermal 3 Thermal Verify ambient


failure.
ACTION
dropped overstress margin temperature in the
verified room. If the room
calculated and temperature is to hot
measured. the fans cannot
create enough cool
sink.
Communications No X-Slot failure 2 Separate If the X-Slot card is
- X-Slot Short Communications supply from not working swap
circuit critical positions and verify
circuits. its not he position. If
the problem is still
present try a new
card. If the problem
is still present
replace the Power
Board.
User Interface No display and or LCD, cable, 1 Proven Replace Display
(LCD) front panel user component Design and Assembly
controls failure circuit used in
HV by HPO
Internal Voltage Online - Goes to Component 2 Component Using the calibration
Sensing Bypass failure not procedure to identify
overstressed. voltage checks, verify
all voltages are
present and no fuses
are open. After
verifying all correct
verify the LED on the
Control board is
flashing if not replace
the Control Board.
Test sensing
voltages from I/O
Board to X6 and
verify sensing
voltages are going to
the Control Board.
On battery - Component 2 Component Verify Battery
drops load failure not Breaker has not
overstressed, failed or open. Verify
mature design Batteries are good.
Battery On battery - Over voltage 2 FW and Replace Power
disconnect Dropped load on PS, Failed auxiliary set of Board or I/O Board.
control trips component contacts, FW Check Power Supply
breaker monitors PS voltage on each
voltage board.


failure.
ACTION
Online - Transfer Over voltage 2 FW and Replace Power
to Bypass, once on PS, Failed auxiliary set of Board or I/O Board.
DSP reset, component contacts, FW Check Power Supply
transfer to online, monitors PS voltage on each
alarm voltage board.
Battery Back-feeding on Failed 2 All-pole break,
disconnect an EPO event Component, and FW
control cannot loss of A_AUX
trip breaker supply
IGBT Gate Drive Online go to Component 2 Proven design Replace Power
Circuits bypass failure Circuit used in Board and IGBTs
HV by HPO
On battery drop Component 2 Proven design Replace Power
load failure Circuit used in Board and IGBTs
HV by HPO
Bridging Control board Component 1 Calculations Engineering Test
Resistors failure during failure and Failure N/A to field
Hypot measurement personnel.
On battery drops Component 1 Sufficient Replace IGBTs and
load failure Electrical maybe Power Board.
Margin
EPO Circuit Safety, battery Component 2 Proven design Replace I/O Board.
Failure still connected failure Circuit used in
HV by HPO
Alarms Loss of Component 2 Proven design Replace Control
customer failure Circuit used in Board.
customization HV by HPO
Ambient Temp No overtemp Component 2 Alternate
Sensor warning failure temp sensing
(heatsink)
Heatsink temp Online - Goes to Component 4 FW detection FW and DVT
sensor Bypass failure - part
indicates
overtemp
Online - Goes to Component 2 FW detection FW and DVT
Bypass failure - part
does not
indicate
overtemp
On Battery drops Component 2 FW detection
load failure - part
does not
indicate
overtemp


failure.
ACTION
LPS Goes to Component 1 None
Bypass, yellow failure
LED, Alarm
Table 42. Control Board Failures

ACTION
Control board Online - Goes Shipping 9 Mechanical / Reseat card
disengaged to Bypass DVT
Table 43. I/O Board Failures

ACTION
Voltage On output goes Component 2 Proven design Replace I/O Board
Sensing to bypass failure Circuit used in
HV by HPO
On battery, Component 2 Proven design Replace I/O Board
drops load failure Circuit used in
HV by HPO
Current If on battery - Component 3 Proven design Replace I/O Board
Sensing - trip battery failure Circuit used in
Battery breaker and HV by HPO
drop load
If online Component 3 Proven design Replace I/O Board
alarms, no failure Circuit used in
effect HV by HPO
Current If online - switch Component 3 Proven design Replace I/O Board
Sensing - to Bypass failure Circuit used in
Input HV by HPO
If on-battery - Component 3 Proven design Replace I/O Board
no effect failure Circuit used in
HV by HPO
Current If online - switch Component 3 Proven design Replace I/O Board
Sensing - to Bypass failure Circuit used in
Output HV by HPO
If on-battery - Component 3 Proven design Replace I/O Board
Drops Load failure Circuit used in
HV by HPO


ACTION
Current If online - Component 3 Proven design Replace I/O Board
Sensing - Alarms, no failure Circuit used in
Bypass effect HV by HPO
If on-Battery - Component 3 Proven design Replace I/O Board
Alarms, no failure Circuit used in
effect HV by HPO
If on-bypass - Component 3 Proven design Replace I/O Board
Alarms, no failure Circuit used in
effect HV by HPO
Bypass SCR Bypass in Over current, 1 MOV front Replace I/O Board
parallel with breakdown end and
UPS voltage is Snubber
exceeded,
DVDT
Inverter Fuse On-battery - Component 2 HW Current FW Current limit,
drops load failure limit verify settings.
Replace fuse.
On-battery - Unusual load 4 HW Current FW Current limit,
drops load conditions limit check fuse, Replace
I/O Board
On utility - and Unusual load 4 HW Current FW Current limit,
bypass not conditions limit Replace I/O Board
available lose
load
On utility - and Unusual load 4 HW Current FW Current limit,
bypass is not conditions limit Replace I/O Board
available
Inverter SCR On Battery and Defective 1 Fused FW Controls , Check
Bypass is not Component fuses, Replace I/O
available - Board
Drop load
Online - go to Defective 1 Fused Check fuses
bypass Component
Inverter SCR On Battery and Defective 1 Proven design Replace I/O Board
Gate Drive Bypass is not Component Circuit used in
Circuits available - HV by HPO
Drop load
Online - go to Defective 1 Proven design Replace I/O Board
bypass Component Circuit used in
HV by HPO
Bypass SCR Bypass in Component 2 Proven design Replace I/O Board
Gate Drive parallel with failure Circuit used in
Circuits UPS HV by HPO
On Bypass - Component 2 Proven design Replace I/O Board
Drops Load failure Circuit used in
HV by HPO


ACTION
LPS Goes to Component 1 Mature proven Replace I/O Board
Bypass, yellow failure design
LED, Alarm
Battery Start Will not battery Component 6 DVT Replace I/O Board
Circuit start failure
Battery life Component 6 DVT Complete calculations
reduction in rest failure for battery life
mode reduction. Add to
users manual to open
battery breaker if unit
is powered down for
an extended period
Bypass Fuse Drop load Load 3 Return to Replace Fuses
open due to characteristics inverter
high in-rush
Rectifier fuse If on battery - Electrical 3 Current limit, Replace Fuses
open no effect overstress and FW
If online go to Electrical 3 Current limit, Replace Fuses
bypass overstress and FW
Table 44. Relay Failures

ACTION
Battery Relays Relay sticks - Breaking or 3 3 relays Check relays on I/O
Sticks Closed battery drain making current, sharing, equal board and if need
after unit not sharing, trace lengths replace I/O Board.
shutoff rating
exceeded
Battery Relays Alarm sounds Component 2 FW Controls, Replace I/O Board.
Never closes failure current
sensing, and
voltage
sensing
Balancer Relay UPS will not Defective 1 None Replace I/O Board.
stuck on start Component
Battery
Contactor Drop on Over-voltage, 1 Detected Replace I/O Board.
Driver relay Battery, Battery Relay that through
Open, cannot alarm, drives coil fails power-up,
close schedules cannot start
shutdown
Contactor Safety Relay failure 3 FW detection Replace I/O Board.
Driver relay
Closed when
should be open

Table 45. Fan Failures

ACTION
Fan Failure Alarm sounds Fan component 4 Tach and F/W Replace Fan
failure
Tach Fails Alarm sounds Fan or Tach 2 none Replace I/O Board.
Circuit
7.1.5 Electronics Module and Other Failures

ACTION
Inductors Converter Windings 7 None Replace Inductor
failure shorted to core Assembly.
Lack of current Bad connection 7 EM test limits, Individual component
sharing either at PCB or current scalers testing on current
internal sensors. See
Calibration
procedure.
DC Coil Goes on Over-voltage, 1 No controls in Replace I/O Board.
Contactor Fails battery, alarm, Relay that place,
to close or write to log, drives coil fails scheduled
opens scheduled shut shutdown
unexpectedly down
DC Coil Possible Contactor 1 FW controls Replace Contactor.
Contactor Fails back-feed after welded
to open EPO
(back-feed)
EMI / Surge Loss of surge Electrical 2 Mature Replace EMI Board
Assembly withstand overstress Design within
capability Powerware
One Battery Latent failure Battery open 5 Should be
String not mode on detected by
connected battery, short Service at
runtime start-up
during battery
test

8
Removal / Replacement
8.1.1 Removal Preparation
1. Remove the UPS front door panel.
2. Remove the top fan dead front, see Figure 60.
3. Bleed the DC Bus or check for <20VDC.
4. Remove the fan wires directly from fans 4, 5 and 6
5. Unplug the fan wires to remove the fan assembly.
(If this is an older unit, remove the right front cover if it is not
integrated with the fan assembly).
Remove the inverter fan plugs from the I/O board and push
the wires through, and away from, the I/O board (X65, X66,
and X67, see Figure 61).
Remove the fan plugs on the bypass fan assembly, see Figure
62.
6. Unplug the battery start (cold start) wires, see Figure 61 for
location.
Note :
If there is an External Battery Cabinet (EBC), ensure that the EBC
breaker is open.
7. With a DVM, ascertain an absence of voltage on the front Input
and output terminals, X1 and X2, power connections.
Note :
CB-1 and CB-2 need to be open.
If this is a dual feed unit, check for an absence of voltage at CB-1.
8.1.2 Removing the L3 Power Module
WARNING
THE MBS NEEDS TO BE IN BYPASS WITH CB-1 AND CB-2 OPEN.
WAIT UNTIL THE DC LINK VOLTAGE HAS BLED DOWN BEFORE PROCEEDING.

Removal and Replacement 9355 20 30 kVA
CAUTION
Be careful to avoid scraping or cutting any wiring during the removal and replacement
of the L3 Power Module, see Figure 59.
Figure 59. Damage Sustained by the IGBTs Due to Severed Wiring
Figure 60. Top Fan Dead Front and Bracket Plates
1. Remove the DC link screws from the I/O board, see Figure 61.

9355 20 30 kVA Removal and Replacement
X11 Ribbon Cable
X61 X60
DC Link Screws L3
X55
BATT CD
TRIP
X50
DC+
X12
X11
INV L3
X7
X6
AAUX
X71, X15
INV
X21
INV L2
X27
INV L1
FANS
Fan Plugs
K3
RECT L3
X68, X14
IN/OUT CB
X78 X2
TRIP
BAT COLD
START
X79
X76
BATTERY CHOKES
L3
X76
K1
BKUP
BATT
X46
X28 X29 X4
L3 L2 L1
X45
X28
BAT
DC-
X82
X25 X23 X13 X54

X42 X41 X40
Figure 61. L3 and Fan Removal Points on the I/O Board
Figure 62. Bypass Board Silk Screen

2. Remove the right front bracket plate, see Figure 60.

3. Cut the tie wraps from the ribbon cable and other wiring.
4. Remove the bus bar screws.
5. Remove wires at X71, X15, X68, X14, X28 and X76 from the I/O
board, see Figure 61.
6. Remove ribbon cable X11 from the I/O board, see Figure 61.
7. Slide the L3 Power Module out of the UPS by grasping the lower
module lip.
CAUTION
Do not grasp the middle aluminum bar to remove the Power Module. Be aware of the
proximity of wiring so that wires near the top and sides are not severed by the UPS
frame during removal.
8.1.3 Replacing the L3 Power Module

The following procedure reverses the preceding removal procedure.
CAUTION
of the L3 Power Module
1. Perform Removal Preparation, see paragraph 8.1.1.

2. Slide the L3 Power Module into the top front shelf of the UPS
being careful to avoid cutting any loose wiring on the UPS shelf
lip, see Figure 63.
Figure 63. L3 PM Shelf Insertion
3. Replace the bus bar screws.

4. Attach ribbon cable X11 to the I/O Board, see Figure 61.
5. Re-attach wires at X71, X15, X68, X14, X28 and X76 to the I/O
board, see Figure 61, and secure the wiring with tie-wraps.
6. Insert and tighten the I/O board DC link screws, see Figure 61.
7. Plug the battery cold start wiring into the I/O board.
8. Placing the fan assembly in place on the UPS:
thread the fan wiring through the UPS assembly to the I/O
board, reattaching the inverter fan plugs (X65, X66, and X67,
see Figure 59).
Re-attach the fan plugs to the bypass fan assembly, see
Figure 60. (If this is an older unit, replace the right cover if it is
not integrated with the fan assembly)
9. Re-attach the top fan dead front, Figure 60.

8.1.4 Removing the L2 Power Module
CAUTION
WARNING
1. Perform removal preparation, see section 8.1.1.
2. The MBS needs to be in bypass with CB-1 and CB-2 open.
Note :
3. Remove the DC Link screws from the I/O board, see Figure 61.
X7 Ribbon Cable
X61 X60
X55
BATT CD
TRIP
X50
DC+
X12
X11
INV L3
X6
X7
AAUX
INV
X21
INV L2
X27
X72, X18
INV L1
FANS
DC Link Screws L2 K3
RECT L3
X69, X10
IN/OUT CB
X78 X2
TRIP
BAT COLD
START
X79
X76
L3
BATTERY CHOKES
X75
K1
BKUP
BATT
X46
X28 X29 X4
L3 L2 L1
X45
X29
BAT
DC-
X82
X25 X23 X13 X54

X42 X41 X40
Figure 64. L2 Removal Points on the I/O Board
4. Cut the tie wraps from the ribbon cable and other wiring.
5. Remove wires at X18, X72, X10, X69, X75 and X29, see Figure
64.

6. Remove ribbon cable X7 from the I/O board, see Figure 64.
7. Slide the L2 Power Module out of the UPS by grasping the shelf
lower module lip.
CAUTION
Do not grasp the middle aluminum bar to remove the Power Module. Be aware of the
proximity of wiring so that wires near the top and sides are not severed by the UPS
frame during removal.
8.1.5 Replacing the L2 Power Module
CAUTION

1. Slide the L2 Power Module into the UPS.
2. Re-attach the ribbon cable to X7, see Figure 64.
3. Re-attach wires at X18, X72, X10, X69, X75 and X29, see Figure
64.
5. Consolidate and secure the wiring with tie-wrap.
6. Insert and tighten the DC link screws on the I/O board, see Figure
61.
7. Plug the battery cold start wiring into the I/O board.
8. Placing the fan assembly in place on the UPS:
thread the fan wiring through the UPS assembly to the I/O
board, reattaching the inverter fan plugs (X65, X66, and X67,
see Figure 59).
Re-attach the fan plugs to the bypass fan assembly, see
Figure 60. (If this is an older unit, replace the right cover if it is
not integrated with the fan assembly)
9. Re-attach the top fan dead front, Figure 60.

8.1.6 Removing the L1 Power Module and Bypass Board
CAUTION
Use needle nose pliers to disconnect the plugs from the Bypass Board, do not pull the
plugs by the plug wires.
WARNING
BEFORE PERFORMING THIS PROCEDURE ENSURE THAT THE UPS IS IN
EXTERNAL MAINTENANCE BYPASS, THAT ALL MAIN BREAKERS ARE OPEN,
AND THAT THE POWER TO THE UPS IS OFF.
IF USING SIDE ACCESS, THIS PROCEDURE MAY BE PERFORMED USING
INTERNAL MAINTENANCE BYPASS.
8.1.6.1 Removing the Power Module L1 / Static Switch

Assembly from the UPS.
1. Perform Removal Preparation, see section 8.1.1.
2. Unplug the battery start (cold start) wires.
3. Remove the battery dead front and disconnect the positive red
wires (6) from the each battery string: T1, T3, T5, T7, T9 and T11,
see Figure 65.
Figure 65. Positive Battery String Wires

Note :
If there is an External Battery Cabinet (EBC), ensure that the EBC
breaker is open.
4. With a DVM, ascertain an absence of voltage on the front X1 and
X2 power connections.
5. Unplug the static switch ribbon cable and remove the front, side
panel.
6. Disconnect the X25 plug and push it through the assembly.
7. Unplug the X10 neutral wire from the bypass board in the Static
Switch module, see Figure 66.
X10 X23,X26,X22
X51
Figure 66. Bypass Static Switch Connections
8. Disconnect the gate drive plug, X51, and the plugs at X23, X26
and X22 (from front to back) on the Bypass Board in the Static
Switch Assembly, see Figure 66.
9. Remove the bus bar screws.

Note :
Tilt the screws slightly downward once they extend beyond the I/O
Board to prevent the washers from falling into the UPS cabinet.
10. Remove the ribbon cables from I/O board X6 and pull to the front
of the UPS.
11. Using a 3/16 wrench, disconnect Power Cables 1, 2, and 3 from
TB5, see Figure 73.
12. Remove the side panel.
Using an 5/16 wrench remove the K5 wiring.
13. Let the removed wires hang from the front of the UPS.
14. Using an 5/16 wrench disconnect the wires X73, X19, X70, X5,
X74, and X4 from the I/O board, see Figure 67.
X61 X60
X55
BATT CD
TRIP
X50
DC+
X12
X11
INV L3
X7
X6
AAUX
INV
X21
INV L2
X27
INV L1
X73,X19
FANS
K3
RECT L3
X70,X5
IN/OUT CB
X78 X2
TRIP
BAT COLD
START
X79
X76
L3
BATTERY CHOKES
K1
BKUP
BATT
X74
X46
X28 X29 X4
L3 L2 L1
X45
BAT
X4
DC-
X82
X25 X23 X13 X54

X42 X41 X40
Figure 67. I/O Board Wiring Connections to Static Switch
15. Slide the L1 Power Module forward, removing it from the UPS.

CAUTION
Do not grasp the middle aluminum bar.
Verify the correct placement of all plugs on their plug pins during removal and
installation of the Bypass Board
8.1.6.2 Removing the Bypass Board from the Static Switch

Housing
1. Turn the Static Switch module on its side.
CAUTION
Do not damage the Static Switch assembly connector during handling, see Figure 68.
2. Remove the two (2) Bypass Board assembly screws to remove

the board assembly from the power module housing.
3. Remove the power wires connecting the Static Switch to the
SCRs.
Note:
If you are replacing the SCRs, remove the SCRs from the heat sink. If
you have the initial release of the UPS (serial number digit 7 = X),
your SCR wiring harness sequence is 3, 1, 2. The subsequent UPS
release (serial number digit 7 = A), has an SCR wiring harness
sequence of 1, 2, 3, see Figure 68 .
4. Remove the front terminal block connections.
5. Remove the seven (7) screws securing the Bypass Board to
replace the Static Board.
Handle side of assembly with care,
board protrusion and connector
susceptible to damage during handling
3 1
1 or 2
2 3
Figure 68. Static Switch Housing and SCRs

8.1.6.3 Replacing the Bypass Board

1. Attach and secure the Bypass Board to the L1 assembly with the
seven (7) screws.
2. Replace the front terminal block connections.
3. Attach the power wires connecting the SCRs to the Static Switch.
4. Attach the board assembly to the power module housing using
the two (2) Bypass Board assembly screws.
8.1.7 Replacing the L1 Power Module / Static Switch Assembly

1. Slide the L1 module into the the UPS.
2. Plug the X10 neutral wire from the Static Switch module to the
bypass board, and reconnect the gate drive plug, X51, and the
plugs at X23, X26 and X22, see Figure 66.
3. Connect the wires X73, X19, X70, X5, X74, and X4, see Figure
67.
4. Routing the wiring through the front of the UPS, connect the
ribbon cables to I/O board X6.
6. Attach the K5 wiring.
7. Connect the X25 plug bringing it through the UPS assembly.
8. Connect the Power Cables 1, 2, and 3 going to TB5, see Figure
73.
9. Plug in the static switch ribbon cable.
10. Connect the positive red wires (6) to each battery string (T1, T3,
T5, T7, T9 and T11), see Figure 65.
11. Plug-in the battery cold start wires.
12. Place the top fan dead front in position on the UPS and re-attach
the fan plugs to the I/O board.
13. Secure the top fan dead front and UPS front door panel if
appropriate.

8.1.8 Removing the I/O Board Assembly

1. Perform removal preparation, see section 8.1.1.
2. Remove the UPS front side metal panel between the I/O board
and the Power Module (the panel is slotted at the bottom).
3. Remove the UPS side metal panel.
4. Using a DVM, check the DC link for voltage (you can use the
DC+ connector at the top of the I/O board and the DC connector
at the bottom of the I/O board as testing points).
Figure 69. DC Link Check Points
WARNING
WAIT UNTIL THE DC LINK VOLTAGE HAS BLED DOWN BEFORE PROCEEDING.
5. Remove the tie wraps from the inductor and power module wires.

Removal/Replacement 9355 20 30 kVA
6. Grasp the Control Board that is sitting on top of the I/O Board and
gently move it from side to side to lift it off of the I/O Board, see
Figure 70.
Figure 70. Removing the control board from the I/O board
CAUTION
When removing wiring from the I/O board ensure that all washers are accounted for and
correctly placed.
7. Place the Control Board in a static-free area.

8. Using an 8mm
(5/16) socket,
remove the
inverter wiring
from the I/O board
connectors, see
Figure 71:
Inverter L3
wires X71, X15
Inverter L2
wires X72, X18
Inverter L1
wires X73, X19
9. Remove the
rectifier wiring
from the I/O board
connectors, see
Figure 71:
Rectifier L3
wires X68, X14
Rectifier L2
wires X69, X10
Rectifier L1
wires X70, X5
10. Remove battery
choke wires, see
Figure 71:
Remove L3
battery choke
wires at X76,
X28.
Remove L2
battery choke
wires at X75,
Figure 71. Wiring Locations
X29.
Remove L1
battery choke
wires at X74,
X4

Removal/Replacement 9355 20 30 kVAt
11. Remove fan power plugs from X65, X66, X67, see Figure 72.
12. Remove the cold-start ribbon cable at X79.
13. Remove the ribbon cables at X11, X7, X6 and X12.
14. Unplug the XSlot cables and keyed ribbon cables X-55 and X-56,
see Figure 72.
15. Unplug the display (CAT-5) cable connector, see Figure 72.
16. Remove the TB1 output ( X25, X23, X13 and X54) and K1 wires
(X13 and X54), and the K3 output wires (X42, X41, X40).
Note:
If removing the I/O board from the assembly I/O board assembly,
remove the K3 and K1 disconnect wires, see Figure 72, and remove
the second set of wires attached to the TB1 output connectors and K3
output connectors..
X55, X56, X11, X7, X6, X12 ribbon cables
T
CA
5
X61 X60
X55
BATT CD
TRIP
X50
DC+
X21, X27
X12
X11
INV L3
X6
X7
AAUX
INV
X21
INV L2
X27
INPUTS TO
K3 DISCONNECT
INV L1
FANS
K3
RECT L3
INPUTS TO
K1 DISCONNECT
IN/OUT CB
X78 X2
TRIP
BAT COLD
START
X79
X76
L3
BATTERY CHOKES
K1
BKUP
BATT
X46
X28 X29 X4
L3 L2 L1
X45
BAT
DC-
X25 X23 X13 X54

X42 X41 X40
Figure 72. Wiring Removal Diagram

9355 20 30 kVA Removal/Replacement
17. Remove the 3 sets of wires (should be thread through the CTs)
from the I/O Board side of TB5 using a 4.5mm Allen wrench, see
Figure 73.
Figure 73. TB5
18. Remove negative battery bus bar bolts at X51, X34, and at X82,
see Figure 74.
19. Remove DC bus bar bolt X30, X81, X80 and Inverter neutral bolts
X20 and X3 (behind the blue current sensor B3), see Figure 74.
X61 X60
X55
BATT CD
TRIP
X50
DC+
X12
X11
INV L3
X7
X6
AAUX
INV
X21
INV L2
X27
INV L1
FANS
K3
RECT L3
IN/OUT CB
X78 X2
TRIP
BAT COLD
START
X79
X76
L3
BATTERY CHOKES
K1
BKUP
BATT
X46
X28 X29 X4
L3 L2 L1
X45
BAT
DC-
X82
X25 X23 X13 X54

X42 X41 X40
Figure 74. Bus bar and neutral bolts

CHASSIS SCREWS
X61 X60
X55
BATT CD
TRIP
X50
DC+
X12
X11
INV L3
X6
X7
AAUX
INV
X21
INV L2
X27
INV L1
FANS
K3
RECT L3
IN/OUT CB
X78 X2
TRIP
BAT COLD
START
X79
X76
L3
BATTERY CHOKES
K1
BKUP
BATT
X46
X28 X29 X4
L3 L2 L1
X45
BAT
DC-
X25 X23 X13 X54

X42 X41 X40
Figure 75. Chassis Screws
Note:
If you are removing the I/O Board from the assembly mounting, skip
items 20 and 21 and perform step 22.
20. Remove the Philips head retaining bracket screws and chassis
screws on the I/O assembly mounting plate to remove the I/O
assembly from the UPS.
CAUTION
The I/O board assembly is slot-mounted, so lift the board from its slotted position when
removing.
21. Tilt the I/O assembly forward to disconnect the assembly from the
side slots. Then lift the board assembly off the bottom slots and
set it down in a static-free open area.
22. Remove the ten (10) plastic stand-offs around the board
perimeter and from the center of the I/O board, and the chassis
screws, see Figure 75, to remove the I/O board.

8.1.9 Replacing the I/O Board

Note:
If you removed the I/O Board from the assembly skip steps 2 and 3.
1. Attach the I/O board to the I/O board assembly using the ten (10)
plastic stand-offs around the board perimeter and the center of
the I/O board and reattach the chassis screws (see Figure 75).
2. Attach the I/O assembly to the UPS by aligning it with the side
and bottom slots.
3. Secure the I/O assembly to the UPS by inserting the bracket
screws and chassis screws with a Philips head screwdriver.
4. Attach the DC bus bar bolts X30, X81, X80 and Inverter neutral
bolts X20 and X3 (behind the blue current sensor B3), see Figure
74.
5. Attach the negative battery bus bar bolts at X51, X34, and at X82,
see Figure 74.
6. Thread the 3 sets of wires going to the I/O Board through the
CTs.
7. Attach the 3 sets of wires to the I/O Board side of TB5 using a
4.5mm Allen wrench, see Figure 73.
8. Attach the TB1 output ( X25, X23, X13 and X54) and K1 wires
(X13 and X54), and the K3 output wires (X42, X41, X40).
Note:
If the I/O board was removed from the I/O board assembly, attach the
K3 and K1 disconnect wires and the second set of wires attached to
the TB1 output connectors and K3 output connectors.
9. Attach the 3 sets of wires from the I/O Board side of TB5 using a
4.5mm Allen wrench, see Figure 73.
10. Plug-in the display (CAT-5) cable connector, see Figure 72.
11. Plug-in the XSlot cables and all ribbon cables observing the
orientation of the red pin 1 wire, see Figure 72.
12. Attach the ribbon cables at X11, X7, X6 and X12, see Figure 72.
13. Attach the cold-start ribbon cable at X79.
14. Attach the fan power plugs from X65, X66, X67, see Figure 72.
15. Attach the battery choke wires, see Figure 71:
L3 battery choke wires at X76, X28.
L2 battery choke wires at X75, X29.
L1 battery choke wires at X74, X4

16. Attach the rectifier wiring from the I/O board connectors, see
Figure 71:
Rectifier L3 wires X68, X14
17. Using an 8mm (5/16) socket, attach the inverter wiring to the I/O
board connectors, see Figure 71:
Inverter L3 wires X71, X15
18. Attach the control board to the I/O board, see Figure 70.
19. Secure the inductor wiring and power module wiring with tie
wraps.
20. Re-attach the UPS side metal panel, if appropriate.
21. Attach the front metal panel between the Power Module and the
I/O board, if appropriate.

8.2 TECHNICAL SUPPORT KNOWLEDGE BASE

CSEs should regularly search the Knowledge Base, updated by Technical
Support personnel, for 9355 UPS information, such as:
Troubleshooting and maintenance
Connectivity and communication issues
Software and monitoring
Back up times
Technical and non-technical questions
Eaton CSEs can find the Knowledge Base by going to Powerware Intranet at:
http://poweratwork/usa/
Go to USA Groups, then click on Global Services Intranet
On Powerware Global Services page, go to Technical Support Centers,
and
click on: Technical Support Knowledge Base
Click on View Top Solutions, and Find More Solutions. Click the Search
in ALL Topics pulldown.
9355 information will be available under Three Phase, 9355. Here CSEs will
see detailed information on issues, causes, and resolutions for each product.
Authorized Distributors can find other Knowledge Base information on the
Powerware Internet at:
http://www.powerware.com/USA/default.asp
Click on Powerware 9355
Click on Powerware UPS Product Page
Click on Services for 9355 UPS
Click on Technical Support Knowledge Base Here Distributors will see
Customers Frequently Asked Questions and responses for each product.
Additionally, Eaton CSEs and Authorized Distributors can find Bulletin Board information
on the Powerware Intranet for documentation, technical support and training. Go to the
Powerware Global Services Bulletin Board and login with your User Name and
Password.
CSEs: Go to the Intranet, click on USA Groups/CSE/Quicklinks/Technical Support
Distributors: Enter this URL into your Browser address:
http://gstechsup.powerware.com/.


9
Calibration
Calibration is the adjustment of a given parameter based on known or proven
data to make that parameter truer or more consistent.
Refer to Figure 76, Analog Potentiometer Diagram.
In an analog control system, a potentiometer (or variable resistor) has often
been used to alter a DC voltage on a given test point. The adjusted voltage
could be an alarm threshold or trigger point for many different types of analog
circuits. When the voltage at the input of the circuit reaches or exceeds the
value set by the variable resistor, the circuit becomes active or inactive
depending on the design of the circuit.
12vdc Vi
TP
TP Vo
Vi Vi < TP, Vo = Inactive
Vi > TP, Vo = Active
Figure 76. Analog Potentiometer Diagram
Refer to Figure 77, Analog to Digital Circuit.

Like the analog circuit, a digital circuit can be altered in a similar manner. In
place of the analog potentiometer, a digital circuit will use an analog to digital
(A/D) converter to process the analog signal into a numeric representation for
use by a digital processor. A voltage of 6VDC may be represented in the A/D
converter by the hexadecimal number 2315. Although 2315 has no significant
meaning to us, this number represents 6VDC to the processor. This number is
often called a RAW value, meaning that the digital number is assigned by the
A/D converter to represent the 6VDC analog signal. The manner in which an
A/D Converter represents the analog data it detects is dependant on the type of
converter and its parameters.
Analog Digital
(6vdc) (0010 0011 0001 0101) 6vdc
Vi
A/D CPU Laptop
Figure 77. Analog to Digital Circuit

Calibration 9355 20 30 kVA
Refer to Figure 78, Digital Potentiometer Diagram.

Calibration in a computer environment can be looked at as a digital
potentiometer, variable resistor, or trim pot having a minimum and maximum
limit. Like analog adjustment devices, digital pots also have minimum and
maximum limits. Since values found in EEP are 16 bits in length, the range of
an individual EEP address is 0000 to FFFF in HEX or 0 to 65535 in decimal.
This becomes the minimum and maximum limits for the digital pot.
32,768
(+) (-)
(+) (-)
10,000 0
(Calibration)
Digital Potentiometer
Range: 0 - 65535
Figure 78. Digital Potentiometer Diagram
In a digital circuit (like those found in the Powerware 9355), the raw value can
be altered or scaled so that the value seen by the user has more meaning. A
formula (created by a firmware engineer) is used by the CPU firmware to make
this transition. This value now becomes known as a Metered Value. An
element of that formula is called a Meter Calibration Factor and serves to
provide a means to adjust the value used by the CPU firmware. The calibration
factor is stored in an EEPROM (EEP) location as a percentage of the computed
value from the A/D converter. These metered values and their associated
calibration factors are stored in the EEPs of the DSP processor and are
accessible by the XCP Service Tool.
All calibration factors are stored as a percentage:
10,000 represents 100.00% of scale
Values are usually linear which means:
If the Calibration Factor is increased, the reading increases
If the Calibration Factor is decreased, the reading decreases
The formula typically used to adjust any 10000 based calibration factor is as
follows:
Actual
Cal . Factor = New Cal . Factor
Unit

9355 20 30 kVA Calibration
Actual = a reading taken from a calibrated DVM:

On a single feed unit from X1-1, X1-2, and X1-3.
On a dual feed unit at CB-1 (2, 4, 6).
Unit = the metered value (on display) from the unit or METERS tab on XCP
Service Tool. (Preferred method is XCP Service Tool.)
Cal. Factor = value found in the associated EEP location
New Cal. Factor = the resulting cal. factor entered into EEP
Example #1, (Meter Calibration)
DSP EEPROM 3040 UTILITY VOLTAGE PHASE A CALIBRATION FACTOR
Value found in this location is 10000
Meter value as seen by the XCP Service Tool (and DSP) shows 208VAC.
Meter value as seen by a calibrated DVM shows 215VAC.
There is a calibration error of 7VAC.
To calibrate this metering input, the formula presented above is used:
Example:
215
10000 = 10336
208
This means that this meter calibration factor must be increased by 3.36% to a
new EEP value of 10336 (103.36%). 10000 in DSP EEP 3013 is replaced with
a value of 10336. The metered value now read by the UPS should be 215VAC,
a true representation of the actual voltage measurement.
Note:
Exact EEP values for meter calibration factors may have to be altered
slightly from the calculated result in order to be able to achieve the
exact meter values desired.
The same techniques just illustrated above are used for calibrating meter
values and display values as they relate to current and power values.
CAUTION
It is good practice to map the system EEPROMS prior to performing Calibration to
circumvent potential problems.

9.1.1 Calibrate Bypass AC Input Voltage

Tools Required:
XCP Service Software Tool
Computer with software tool authorization
Calibrated, True RMS Digital Volt Meter (DVM)
If at any time during this procedure an alarm condition prevents the continued
execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status
& Flag Definitions to determine and correct the cause of the event
annunciation.
1. UPS / Customer load should be on maintenance bypass wrap-
around or off (down stream breakers open).
2. Begin with the UPS in Standby mode.
3. Connect the XCP Service Tool and go to the Meters Tab.
4. Calibrate the Bypass AC Input Voltage (see Figure 79 for 208V
test points:
Measure Bypass AC Input: (208V) X1-1 (Phase A) to X-4 (N).
Double-click on the Bypass AC Phase A input meter on the
XCP Service Tool and enter the measured value from the
DVM.
Measure Bypass AC Input: (208V) X1-2 (Phase B) to X-4 (N).
Double-click on the Bypass AC Phase B input meter on the
DVM.
Measure Bypass AC Input:
(208V) X1-3 (Phase C) to X-4 (N).
Double-click on the Bypass AC Phase C input meter on the
DVM.
5. Verify meters on the Front Display, XCP Service Tool and DVM
and match them to within 2%. If they are not within 2%, then
repeat Step 4.
6. Calibration complete.

9.1.2 Calibrate Utility AC Input Voltage

Tools Required:
annunciation.
2. Begin with the UPS in Standby mode.
L1, L2, L3
CB1 contacts
Input
L1, L2, L3
X1-1, X1-2, X1-3
X4 - Neutral X4 - Neutral
Output
L1, L2, L3
X2-1, X2-2, X2-3
Figure 79. 9355 Front Calibration Points


4. Calibrate the Utility AC Input Voltage, see Figure 79 for 208V test
points.
Measure Utility AC Input
(208V) X1-1 (Phase A) to X-4 (Neutral).
Note:
For a dual feed UPS use the L1 contact point at the CB-1 input.
Double-click on the Utility AC Phase A input meter on the XCP
Service Tool and enter the measured value from the DVM.
Measure Utility AC Input:
(208V) X1-2 (Phase B) to X-4 (Neutral).
Note:
For a dual feed UPS use the L2 contact point at the CB-1 input.
Double-click on the Utility AC Phase B input meter on the XCP
Measure Utility AC Input:
(208V) X1-3 (Phase C) to X-4 (Neutral).
Note:
For a dual feed UPS use the L3 relay point at the CB-1 input.
Double-click on the Utility AC Phase C input meter on the XCP
repeat Step 4.
6. Calibration complete

9.1.3 Calibrate Battery Voltage

Tools Required:
annunciation.
The battery breaker must be closed to calibrate battery voltage. The UPS must
be off with logic power only. Once the battery breaker is closed, the system can
be returned to bypass mode.
2. Begin with battery breaker closed and the UPS off with logic
power only.
3. Connect your laptop to the UPS and run the XCP Service Tool:
Select the Meters tab
Verify DC is less than 25 Volts
Verify that Battery voltage is greater than 216 Volts
4. Calibrate the Battery Voltage:
Measure Battery Voltage from the positive connection X49 to
the negative connections X34.
DVM Re ading
Using the calibration equation 10000 = EEPROM entry
Meters Re ading
Double click on the Battey meter on the XCP Service Tool and
enter the measured value from the DVM. The service tool will
ask you to enter it a second time, enter the same reading you
entered the first time.
repeat Step 4.

9.1.4 Calibrate DC Link Voltage

Tools Required:
Table 46. DC Link Voltage Calibrations

Output Voltage DC Link:
208 (+) or (-) 194.5
400 (+) or (-)
annunciation.
Note:
Write down EEPROMs before beginning this procedure.
around or off (down stream breakers open.
2. Begin with UPS on NORMAL and Battery Charger off.
4. Calibrate the DC Link Rail Voltages: (see Figure 81 for 208V test
points).
Measure the Positive DC Link Voltage:
(208V) from connector X47 (DC+) to X52 (Neutral); or you
may test from the bus bar.
Double-click on the +DC meter on the XCP Service Tool and
enter the target voltage from Table 46 and the measured value
from the DVM.
Note:
The DC Link Voltage is not shown on the UPS LCD.
5. Wait until the battery charger is on and confirm voltage with a
DVM.
6. Verify XCP Service Tool meters and DVM match within 2%. If
they are not within 2%, then repeat Step 4.

9.1.5 Calibrate UPS AC Output Voltage

Tools Required:
annunciation.
2. Begin with UPS on BYPASS.
3. Connect to the XCP Service Tool and go to the Meters Tab.
4. Calibrate the UPS AC Output Voltage: (see Figure 79 for 208V
test points).
Measure UPS AC Output:
X2-1 (Phase A) to X-4 (Neutral)
Double-click on the Output AC Phase A output meter on the
DVM.
X2-2 (Phase B) to X-4 (Neutral)
Double-click on the Output AC Phase B output meter on the
DVM.
X2-3 (Phase C) to X-4 (Neutral)
Double-click on the Output AC Phase C output meter on the
DVM.
5. Verify XCP Service Tool meters and DVM match within 2%. If
they are not within 2%, then repeat Step 4.

9.1.6 Calibrate Inverter AC Output Voltage

Tools Required:
annunciation.
NOTICE
When performing a whole system calibration, the inverter voltage must

be done last.
When calibrating the Inverter AC Output, the calibration adjustment is
not to match the measured voltage, but to adjust the measured voltage
as seen in Table 47, Inverter Voltage Calibrations. The output meters
on the display were adjusted with the bypass calibration while the unit
was in bypass.
Table 47. Inverter Voltage Calibrations
Output Voltage Calibrate To:
208 120.1
400 230.9

2. Begin with UPS on NORMAL.
NOTICE
Once the Inverter has reached its target voltage, the XCP Service Tool
meters stabilize and do not change during normal operation. The
objective with Inverter AC Output calibration is to adjust the inverter
output until the DVM meter is at the target voltage listed in Table 47.
The output meters should indicate the change but the inverter meters
will not.

4. Calibrate the Inverter AC Output Voltage: (see Figure 79 for 208V

test points):
Double click on the Inverter AC Phase A output meter on the
XCP Service Tool and enter the target voltage from Table 47.
Enter the measured value from the DVM for each phase. After
entering phase A the tool will ask for phase B and then for
phase C.
Measure Inverter AC Output:
(208V) X2-1 (Phase A) to X-4 (Neutral).
(208V) X2-2 (Phase B) to X-4 (Neutral).
(208V) X2-3 (Phase C) to X-4 (Neutral).
5. Verify that the XCP Service Tool output target voltage and the
DVM match within 2%. If they are not within 2% then repeat
step 4.
9.1.7 Calibrate Inverter DC Output Voltage

Due to the special metering required to accurately measure the DC on the
inverter output, this calibration cannot be performed at this time and is not
required; however, this calibration is performed at the factory after
manufacturing.
If the Control Board must be changed, every effort must be made to set
EEPROM 3070 & 3072 on the new Control Board to the same setting as the
old Control Board. Otherwise, EEPROM 3070 & 3072 should be set to the
default of 10000.

9.1.8 Calibrate Bypass Current (Output)

Tools Required:
AMP Clamp
annunciation.
This calibration procedure requires a minimum of 80% load to be accurate. If
this procedure is not conducted with the minimum load requirement (80%),
metering results may be skewed as much as 5% or more at 100% load. Default
of 10000 is better than mis-calibration.
1. UPS / Customer load should be on or a load bank attached to the
output of the UPS.
2. Begin with UPS on BYPASS.
4. Calibrate Bypass Current:
Measure Bypass Phase A current:
(208V) at X40 on the I/O Board. (see Figure 80)
Figure 80. I/O Board Bypass Phase A, B and C
Double click on the Bypass Phase A current meter on the XCP

Measure Bypass Phase B current:
at X41 on the I/O Board. (see Figure 80).
Double click on the Bypass Phase B current meter on the XCP
Measure Bypass Phase C current:
at X42 on the I/O Board. (see Figure 80)

Double click on the Bypass Phase C current meter on the XCP

5. Verify that the XCP Service Tool meters and DVM match within
2%. If they are not within 2% repeat step 4.
X61 X60
DC+
X55
BATT CD
X47
TRIP
X50
DC+
X12
X11
INV L3
X6
X7
AAUX
INV
X21
INV L2
X27
INV L1
FANS
K3
DC
neut
RECT L3
IN/OUT CB
X78 X2
TRIP
BAT COLD
START
X79
X76
L3
BATTERY CHOKES
Batt Bkup K1
BKUP
BATT
X46
X28 X29 X4
X46
L3 L2 L1
X45
BAT
DC-
DC-
X82
X43 X25 X23 X13 X54

X42 X41 X40
Batt Plus
X49
Figure 81. 208V DC Link Voltage Calibration test points

9.1.9 Calibrate Utility Current

Tools Required:
AMP Clamp
execution of the following steps, consult paragraph paragraph 7.1.2, Alarm,
Notice, Status & Flag Definitions to determine and correct the cause of the
event annunciation.
output of the UPS.
4. Calibrate Utility Input Current , (see Figure 81 for 208V test
points):
Measure Utility Phase A current:
(208V) X1-1 (Phase A) to X-4 (Neutral)
Double click on the Utility Phase A current meter on the XCP
Measure Utility Phase B current:
(208V) X1-2 (Phase B) to X-4 (Neutral)
Double click on the Utility Phase B current meter on the XCP
Measure Utility Phase C current:
(208V) X1-3 (Phase C) to X-4 (Neutral)
Double click on the Utility Phase C current meter on the XCP
5. Verify that the XCP Service Tool meters and DVM match within
2%. If they are not within 2% repeat step 4.

9.1.10 Calibrate Battery Current

Tools Required:
Clamp-on DCCT
annunciation.
This procedure requires that the battery be discharging for a short period of
time so the discharge current can be measured and calibrated.
This calibration procedure also requires a minimum of 80% load to be accurate.
If this procedure is not conducted with the minimum load requirement (80%),
At the beginning of the procedure, the system must be in NORMAL mode with
the battery breaker closed.
2. Put the system in battery mode by opening the Utility Input
breaker, simulating a utility outage.
3. Calibrate Battery Current (with 80% load while discharging) :
a. Measure Battery Current on the battery wire connected to:
(208V) X49, see Figure 81
b. Double click on the Battery current meter on the XCP
4. Restore utility input to the system. (System should automatically
return to NORMAL mode.)
5. Verify that the XCP Service Tool meters and the DVM match
within 2%. If they are not within 2% repeat step 4.

9.1.11 Calibrate Inverter Current

Tools Required:
AMP Clamp
annunciation.
output of the UPS.
4. Calibrate Inverter Output Current:
Measure Inverter Phase A current
(for 208V see Figure 79 for Phase A test points X2-1 and X-4).
Double click on the Inverter Phase A current meter on the
DVM.
Measure Inverter Phase B current
(for 208V see Figure 79 for Phase B test points X2-2 and X-4).
Double click on the Inverter Phase B current meter on the
DVM.
Measure Inverter Phase C current
(for 208V see Figure 79 for Phase C test points X2-2 and X-4).
Double click on the Inverter Phase C current meter on the
DVM.
5. Verify that the XCP Service Tool meters and the DVM match
within 2%. If they are not within 2% repeat step 4.

10
Parts
Chapter 10 Parts
10.1 PW 9355 30kVA SPARE PARTS LISTINGS 10-1
10.1.1 Low Voltage PW 9355 30kVA Spare Parts Kit A P/ N 106711170 10-1
10.1.2 High Voltage PW 9355 30kVA Spare Parts Kit A P/ N 10-2
10.2 PW 9355 30kVA UPS Subassemblies 10-2
10.2.1 LV Electronic Module 10-2
10.2.2 HV Electronic Module 10-3
10.3 Parts Break-down / Look-up Procedure 10-4
10.3.1 Requirements: 10-4
10.3.2 Procedure 10-4
10.1 PW 9355 30kVA SPARE PARTS LISTINGS
NOTICE
Part numbers are subject to change. CSEs should always check the
latest assembly and part numbers on PRMS ACCESS to verify part
numbers before ordering.
10.1.1 Low Voltage PW 9355 30kVA Spare Parts Kit A P/ N

106711170
Component Description UM Qty
1021278 PCBAS CONTROL BOARD EA 1
1024053 PCBAS K30 LV 3PH I/O BOARD EA 1
1024049 PCBAS K30 LV 3PH PWR BOARD EA 1
1021994 IGBT 3X94A 600V HB SKIIP2 EA 3
103004890 SUBAS K15 DISPLAY PANEL EA 1
101073763 EMI BOARD EA 1
128308001-012 FUSE, 200 A, 500 VAC EA 1
1024057 BYPASS BOARD EA 1
129400054-002 THERMAL INTERFACE PAD EA 6
143319005-001 SCR, DUAL, MODULE, 160A, 1600V EA 3

Parts 9355 20 30 kVA

8052457 160A 240V 160LET Fuse EA 3
1024046 FAN 119x119x39 51l/s 115VAC UL EA 2
129400066-001 THERMAL INTERFACE PAD, IGBT EA 6
10.1.2 High Voltage PW 9355 30kVA Spare Parts Kit A P/ N

1021278 PCBAS CONTROL BOARD EA 1
PCBAS K30 LV 3PH I/O BOARD EA 1
PCBAS K30 LV 3PH PWR BOARD EA 1
IGBT 3X94A 600V HB SKIIP2 EA 3
103004890 SUBAS K15 DISPLAY PANEL EA 1
EMI BOARD EA 1
128308001-012 FUSE, 200 A, 500 VAC EA 1
BYPASS BOARD EA 1
129400054-002 THERMAL INTERFACE PAD EA 6
SCR, DUAL, MODULE, 160A, 1600V EA 3
8052457 160A 240V 160LET Fuse EA 3
1024046 FAN 119x119x39 51l/s 115VAC UL EA 2
129400066-001 THERMAL INTERFACE PAD, IGBT EA 6
10.2 PW 9355 30kVA UPS Subassemblies

10.2.1 LV Electronic Module
P/N DESC QTY
1021278 PCBAS CONTROL BOARD 1
103004890 SUBAS K30 DISPLAY PANEL 1
1021994 IGBT 3X94A 600V HB SKIIP2 9
1024046 FAN 119X119X39 51L/S 115VACUL 6
157809032 TRAY, BATTERY 24
101073763-001 9355 30kVA EMI / MOV PCB 1
1024049 PCBAS, POWER BOARD 3K30LV 3
1024053 PCBAS, IO BOARD 3K30LV 1
1024057 PCBAS, BYPASS BOARD 3K30LV 1
122129008-001 CIRCUIT BREAKER, 2 POLE, 200 A 1
122161004-001 CIRCUIT BREAKER, 3 POLE, 125 A 1
123118002-001 CONT, 115A, 480VAC,3 POLE, NO 1

9355 20 30 kVA Parts
P/N DESC QTY

123118002-002 CONT, 130A, 480VAC,3 POLE, NO 2
128308001-012 FUSE, 200 A, 500 VAC 3
129400054-002 THERMAL INTERFACE PAD 3
129400066-001 THERMAL PAD, SKIIP2 PACKAGE 9
143319005-001 SCR, DUAL, MODULE, 160A, 1600V 3
145205027-001 SWITCH, SELECTOR, 100 A, 600 V 1
145301073-001 SWITCH, PUSHBUTTON, SPST, N.O. 1
151201040-004 AIR FILTER, STRATADENSITY 1
151501017-001 FAN GUARD, 4.125" MOUNT 6
58700036-001 BATTERY, 12V, 9 AH 108
10.2.2 HV Electronic Module

P/N DESC QTY
1021278 PCBAS CONTROL BOARD 1
SUBAS K30 DISPLAY PANEL 1
IGBT 3X94A 600V HB SKIIP2 9
FAN 119X119X39 51L/S 115VACUL 6
TRAY, BATTERY 24
9355 30kVA EMI / MOV PCB 1
PCBAS, POWER BOARD 3K30LV 3
PCBAS, IO BOARD 3K30LV 1
PCBAS, BYPASS BOARD 3K30LV 1
CIRCUIT BREAKER, 2 POLE, 200 A 1
CIRCUIT BREAKER, 3 POLE, 125 A 1
CONT, 115A, 480VAC,3 POLE, NO 1
CONT, 130A, 480VAC,3 POLE, NO 2
FUSE, 200 A, 500 VAC 3
THERMAL INTERFACE PAD 3
THERMAL PAD, SKIIP2 PACKAGE 9
SCR, DUAL, MODULE, 160A, 1600V 3
SWITCH, SELECTOR, 100 A, 600 V 1
SWITCH, PUSHBUTTON, SPST, N.O. 1
AIR FILTER, STRATADENSITY 1
FAN GUARD, 4.125" MOUNT 6
BATTERY, 12V, 9 AH 108

10.3 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 part number and/or research a
previously listed part number on any Powerware product.
10.3.1 Requirements:
a. Access to Eatons Powerware Division Intranet:
http://poweratwork/usa/
b. An assembly number where the parts are located.
A CTO Number
10.3.2 Procedure
Once you have the assembly or CTO number, you can break it down and
retrieve the part number using the following steps:
NOTICE
The PRMS system may be slow, depending on the number of Logins and time of day.
If at any time during this process you receive a web page message
stating that it is not available, your session has timed out and you will
have to start over.
1. Go to http://poweratwork/usa/
2. Under Applications on the right hand side, select PRMS
ACCESS.
3. For User enter LSGINQ (upper or lower case)
4. For Password enter ky9ag (upper or lower case)
5. Leave all other entries blank.
6. At top left of the next page select ENTER (at top left).
7. Select ENTER two more times (to bypass the Sign On and
Display Messages pages.)
8. In the Option block, enter 1 and press ENTER for Production
Utility.
9. In the Option block, enter 1 and press ENTER for Product
Structure Inquiry.

9355 20 30 kVA Parts
At this point you have some options:

a. Option One:
- To simply break down an assembly to its various
components (part numbers), go to step 10.
b. Option Two
- To break down the assembly to its various component
parts from a previous date, (an earlier product release) go
to step 11.
c. Option Three:
- If you have a part number to a part, other than the one
you want, but it is in the same assembly, you can look up
a where used. You can then look for the part number of
the component youre looking for. Go to step 12.
d. Option Four:
- To look up assembly and component (part) numbers using
the Configuration to Order (CTO) number, go to step 13.
10. In the assembly block enter the assembly number and press
ENTER. (Use the buttons at the bottom of the web page to
navigate to the next pages containing additional components for
that assembly. If More... is shown on bottom of right column,
click the Next Page button to see the remaining parts. The last
page of parts will show Bottom.)
11. In the assembly block enter the assembly number and in the
effective date block enter a previous date (format mmddyy) and
press ENTER.
12. Select F2 at the bottom of the web page. In the Component
block enter the part number and press ENTER. The system will
provide you with the assembly numbers on every unit where that
part is used. If it is a common part across platforms you will have
several pages of information.
13. In the assembly block enter the CTO number and press ENTER.
(You must use the buttons at the bottom of the web page to
navigate to the subsequent pages containing additional
components for that assembly.)
NOTICE
If you need to look up another assembly number, or a sub-assembly of

the assembly you just looked up, you must use the F buttons near the
bottom of the web page, not the F keys on your keyboard.


11
Prints
PW 9355 20 - 30 kVA Prints Table Of Contents
PAGE DRAWING SHT CATEGORY DESCRIPTION REV
1 1024051 1 Schematic Power Board 30kVA LV 2
2 1024055 1 Schematic I/O Board 30kVA B
3 2
4 3
5 1024056 1 Silkscreen I/O Board B
6 1024059 1 Schematic Bypass Board 30kVA LV 3
7 1024062 1 Silkscreen Bypass Board 3
8 110720620 1 Drawing 9355 EMI Filter A00
9 110720639 1 Schematic Top Level 30kVA 9355 LV 1
10 110720676 1 Schematic 9355 Options Cabinet C00
11 2
12 3
13 4
14 5
15 6
16 7
17 8
18 110720683 1 Drawing 9355 30kVA EMI Filter B00
19 110720684 1 Drawing 9355 30kVA EMI Filter A00
20 110720687 1 Drawing 9355 30kVA Input EMI Filter A00
21 121102093 1 Drawing Rectifier/Inverter Choke A00
22 121102094 1 Drawing Battery Choke A00
23 CTO Chart 1 Table 110577093 C00
24 2

Prints 9355 20 30 kVA
This page was left blank intentionally

1024055B.sch-1 - Wed Dec 28 10:01:09 2005
1024055B.sch-2 - Wed Dec 28 10:01:14 2005
1024055B.sch-3 - Wed Dec 28 10:01:23 2005
Page 5
10240593.sch-1 - Mon Nov 21 08:40:23 2005
Page 7
1 1
9355 30kVA Option Cabinet
120V
120V
120V
9355-30 Options cabinet - 208/208, 480/208, 600/208 Bypass Transformer
1 8
9355-30 Options Cabinet - MBS only
2 8
120V
120V
120V
9355-30 Options cabinet - 208/208, 480/208, 600/208 Mains Input transformer
3 8
T1
277V
277V 208V
208V
277V
208V
9355-30 Options Cabinet - 208/480 Output Transformer
4 8
9355 30kVA UPS Cabinet
120V
120V
120V
9355-30 Options Cabinet - System - Single feed 208/208, 480/208, or 600/208
5 8
9355-30 Options Cabinet - System - Single feed, MBS only
6 8
9355 30kVA Option Cabinet 9355 30kVA Option Cabinet
120V
120V
120V
T1
277V
277V 208V
208V
277V
208V
9355-30 Options Cabinet - System - Single feed 480/480
7 8
9355 30kVA Option Cabinet 9355 30kVA Option Cabinet
120V
120V
120V
120V
120V
120V
9355-30 Options Cabinet - System - Dual feed 208/208, 480/208, or 600/208
8 8
NOTES:
1. Materials/com ponents shall meet RoHS regulations per Eaton Power Quality
RoHS specification 164080496.
2. Bulk packaging shall indicate contents are RoHS com pliant.
3. Docum entation indicating m aterials/components are RoHS com pliant
(Certificate of Compliance and M aterial Analysis) shall be available upon request.
NOTES:
1. M aterials/com ponents shall meet RoHS regulations per Eaton Power Quality
RoHS specification 164080496.
2. Bulk packaging shall indicate contents are RoHS com pliant.
3. Docum entation indicating m aterials/components are RoHS com pliant
(Certificate of Compliance and M aterial Analysis) shall be available upon request.
1 2 3-4 5 6 7 8 9 10 11 12 13 14 15
Model Type Product Family UPS KVA Rating Application Battery Configuration UPS Configuration Comm Option (Slot 1) Future Option Future Option Future Option Future Option Future Option OEM Future Option
9355-15
PW9355
K A (See
110577092)
R/T 120/208V in/out

3x battery shelves
B 9355-30 20 20 KVA 1 (no output breaker) 3 1 50/60 Hz 0 None 0 None 0 None 0 None 0 None 0 None 1 Eaton 0 None
9Ah (108 batteries)
(Factory default) Autodetect
127/220V in/out
Note: Selections in this column Parallel Connect UPS-
can't be 0-4, 6, 7,D, S, L. 30 30 KVA 2 2 50/60 Hz 3
(no output breaker) X Web/SNMP
Autodetect
R/T with
3 4 Modbus Card
output breaker
Parallel with
4 5 Relay Card
output breaker
Industrial Relay
6
Card
7 Modem Card
Only Slot 1 populated

from factory
Notes:
1
Supporting Documents:
Schematic - 30kVA UPS 110720639

Schematic - 30kVA EBC 110720675 Description: CTO CHART, 9355 30KVA UPS
Option Cabinet CTO 110577094
OBJECT ID:
Created By: HARDY_J Date: 05-JAN-06
Modified By: Date:

110577093
Checked By: WALLACE_T Date: 21-MAR-06 ECN 9355-0164 Revision: C00
Approved By: HARDY_J Date: 21-MAR-06 Status: RELEASED Sheet 1 of 2

These Drawings and Specifications Are the Property Of Eaton / Powerware and Shall Not be Reproduced or
Copied or Used as the Basis for Manufacture of Sale of Apparatus Without Permission
Position 1 2 3-4 5 6 7 8 9-12 13 14 15
Model Product UPS KVA Future Future

Type Family Rating Application Battery Configuration UPS Configuration Comm Option Option OEM Option
Base unit BOM BOM BOM BOM BOM
20 or 1
3
K B 103004897 R/T 103005372 103004887 (12x) 1 0 None NA 1 103004888
30 (no output breaker)
3 battery shelves
103002974-5501
3 Connect UPS-X
2 103002511-551
103005372
Parallel 2 4 Modbus Card + 103002818
(no output breaker)
+ 101073663-001
+ 164201376
5 Relay Card 1018460
3 6 Industrial Relay 103002686
R/T with 103005373 4
output breaker
Card + 164201433
7 Modem Card 1019017

4 103005373
Parallel with 5
output breaker
+ 101073663-001
Only Slot 1 populated from factory

Options
REPO 103002939
103002687-001
Remote Monitor
+ 103003055
Wall mount MBS 124100026-001
Parallel Tie Cabinet 124100026-001
External battery (4 strings) 103004868

External battery (2 strings) 103005183
kVA Upgrade 20 to 30 103004901
Parallel Upgrade Kit 103005160
Seismic Kit 103004896
X-slot Communication Options (Order separate, field install)

Parallel (CAN Bridge) 103004336 Description: CTO CHART, 9355 30KVA UPS
Connect UPS-X Web/SNMP 103002974-5501
Modbus Card 103002510-5501 OBJECT ID:
Relay Card 1018460 Created By: HARDY_J Date: 05-JAN-06
Industrial Relay Card 103003055 110577093
Modified By: X Date:
Modem Card 1019017
Checked By: WALLACE_T Date: 21-MAR-06 ECN 9355-0164 Revision: C00
Approved By: HARDY_J Date: 21-MAR-06 Status: RELEASED Sheet 2 of 2
These Drawings and Specifications Are the Property Of Eaton / Powerware and Shall Not be Reproduced or
Copied or Used as the Basis for Manufacture of Sale of Apparatus Without Permission

9355 30kVA Service Manual - A02

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Powerware 9355

Notwithstanding the foregoing, Eaton Electrical assumes NO

The information contained herein is proprietary to Eaton Electrical and

Periodically, changes are made to the contents herein. Please contact

The equipment provided by Eaton Electrical contains areas that

2006 - Eaton Corporation

2006 - Eaton Corporation i

Operational Inspection 3-7

ii 2006 - Eaton Corporation

4.5.1 Introduction & Overview 4-31

4.13 Bypass Board System Overview 4-64

6.3 Power Distribution Unit (PDU) 6-18

2006 - Eaton Corporation v

Figure 48. MODBUS Communications Card............................................................ 6-9

2006 - Eaton Corporation vii

164201621 Change sheet

viii 2006 - Eaton Corporation

1.1.1 Single Module Systems

Figure 1. EATON-Powerware 9355 2030kVA UPS

Figure 2. PW9355 30kVA Basic Single Module System

A digital signal processor (DSP) is used to provide all software functionality

1-2 2006 - Eaton Corporation

A single module operates independently, providing conditioned and

2006 - Eaton Corporation 1-3

1.2 Single ModuleReverse Transfer (RT) Modes of Operation

1.2.1 NORMAL Mode

Bypass Input Input TB

Figure 3. PW 9355 NORMAL Mode (single feed)

1-4 2006 - Eaton Corporation

Figure 4. PW 9355 NORMAL Mode (dual feed)

The inverter produces three phase AC output to a customers critical load

1.2.2 BATTERY Mode

Figure 5. PW 9355 BATTERY Mode (single feed)

1-6 2006 - Eaton Corporation

Figure 6. PW 9355 BATTERY Mode (dual feed)

2006 - Eaton Corporation 1-7

1.2.3 Power Share Operation

1.2.4 BYPASS Mode

1-8 2006 - Eaton Corporation

Figure 7. PW 9355 BYPASS Mode (single feed)

Figure 8. PW 9355 BYPASS Mode (dual feed)

2006 - Eaton Corporation 1-9

The internal bypass is comprised of a solid-state Silicon Controlled Rectifier

1-10 2006 - Eaton Corporation

Figure 9. PW9355 Service Position

Figure 10. PW9355 Maintenance Bypass Position

2006 - Eaton Corporation 1-11

1.3 Parameter Settings

1.3.1 Parameter List

3 Horn enable 1 0 Horn is disabled No

1-12 2006 - Eaton Corporation

10 Disable control 0 0 Control commands from X-Slot1 No

2006 - Eaton Corporation 1-13

37 Reset to factory NA 1 Resets all parameters on this No

1-14 2006 - Eaton Corporation

42 Auto-sense input 1 0 Do not auto-sense input YES

51 Force xcp sub- 0 0 Parallel unit accepts system

2006 - Eaton Corporation 1-15

1.4 Input Isolation Transformer (60 Hz Only)

1.5 Seismic Capability

1.6 External Battery Cabinets

1.7 Remote Emergency Power Off (REPO)

1.8 Environmental Monitoring Probe (EMP)