Powerware Series

Eaton 9155/9355 8-15 kVA Preventive Maintenance Procedure

Uninterruptible Power Supply System

p/n: 164700802
Revision A00
January 13, 2010
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Eaton 9155/9355 8-15 kVA Preventive Maintenance Procedure

Copyright © 2010, Eaton Corporation, Raleigh, NC, USA.
Company Confidential.
All rights reserved. Produced in the United States of America.

No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form
or by any means, electronic, mechanical, photocopying, or otherwise, without the prior written per-
mission of the publisher, UPS Service Documentation Department, Eaton Corporation.

Eaton Corporation, UPS Service Documentation, 3401 Spring Forest Road, Raleigh, North Carolina
27616. e-mail: E-ESSDocumentation@Eaton.com
Eaton 9155 / 9355 8−15 kVA UPS
System Preventive
Maintenance Procedure
1.1 Preventive Maintenance Procedure Purpose
The preventive maintenance (PM) process is an important component in the
overall service level that we provide to our customers. Not only does it improve
our customer’s confidence in the equipment, it also allows the service
organization several opportunities to provide an increased level of support to our
customers.
The primary goal of the PM process is to reduce emergency calls by:
• Identifying potential problems with the UPS and battery.
• Ensuring a clean environment and proper airflow through the unit.
• Addressing known issues through the implementation of FSBs.
• Addressing previously identified site issues in a less stressful setting.
• Establishing an up-to-date operating status and historical reference data.
The site visit with the customer is as important as the mechanical and technical
aspects of the PM. Building a strong relationship with your customer is important
for the success of the service business.
• Take the time to discuss any issues that are identified in the alarm history.
• Review the number of times the unit has protected the load or operated on
battery.
• Discuss any potential changes or upgrades that could be beneficial to the
customer, and allow them to see that Eaton is concerned for the site power
quality and is there to help them.
Establishing a positive tone during the PM helps to build a strong relationship
with the customer. After all, customer loyalty is the single most valuable asset of
a service organization.

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9155/9355 8-15 kVA PM Procedure Preparing to Complete a PM

1.2 Preparing to Complete a PM

Prior to scheduling the site visit, review the customer’s service history and
check for any FSBs that need to be implemented. During this preliminary work,
prepare any procedures and parts that are necessary. This practice will reduce
or eliminate follow-up visits to address issues.

After the PM is complete, attach the downloaded files and complete notes to the
ticket/FAR upload. This practice ensures that there is an accessible record for
reference by technical support and other service personnel. The site history will
be reviewed by the next technician to the site, enabling Eaton representatives to
make better decisions about what the customer needs.

2 © 2010. Eaton Corporation. Company Confidential.

PM Procedure 9155/9355 8-15 kVA PM Procedure

1.3 PM Procedure
Eaton 9155/9355 8-15 kVA System Preventive Maintenance Procedure.

1.3.1 Required Materials

• Flash files (latest version for each processor)
• XCP tool (latest version)
• Computer
• DB9 Male to DB9 female cable
• Printer with cables if required
• CSE Tool Kit
• Oscilloscope
• HyperTerminal
• PM Form
• Service Manual
• Installation and Operation Manual
Note: If the unit to be inspected is equipped with remote monitoring, unplug the
modem phone line or network connection (Ethernet cable) to prevent false
outcall notifications. Pulling the web card from its internal connection will: 1)
stop any events created while performing the PM from being sent out after the
Ethernet connection is restored 2) possibly prevent a load shutdown if the
customer has a shutdown client operating that monitors DC Voltage or the
battery breaker status.

1.3.2 Download and Save

• EEPROM Reports
• Unit Configuration Report
• Meters Report
• Use HyperTerminal to capture event history by entering ESC L
• Use HyperTerminal to capture battery test info by entering ESC B

1.3.3 Review Alarm / Event Queue with Customer

• Note any alarm repeated in the Alarm/Event Queue.
• Note most frequent reoccurring alarm(s).
• Does the alarm occur at the same time of day or week?
• Does the alarm correlate to the utility behavior?

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9155/9355 8-15 kVA PM Procedure PM Procedure

• Does the alarm correlate to the load? If yes, what kind of equipment is the
UPS supplying?
• Has load been added to the UPS since installation?
– If load has been added, were there any problems? If yes,
explain on the PM forms.
• Does the UPS supply any motor loads? What kind?
• Review unit configuration and options with the customer.
• Explain how E-Notify works (EMP must be installed for proper operation).

1.3.3.1 Customer Site and Unit Performance Discussion

Use this discussion to focus on problem areas and probe for more information.
• Note past visits to the site and any problems or concerns the customer has
regarding the UPS.
• Note any panel meter discrepancies such as input kW lower than output
kW or negative battery current.
• Note unit sounds and overall impression of unit health when supporting the
load.
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1.3.4 Review Unit Statistics with Customer

• Note any abnormalities.

1.3.5 Review Battery Diagnostic with Customer

• Did the battery string(s) perform ok on last outage?
• Note any anomalies in performance or any comments/concerns from the
customer.

1.3.6 Inventory Spare Parts Kits

• Complete an inventory of the customer’s spare parts kits. Use the
customer’s inventory sheet or the spare kit list in the service manual.
• Update the firmware of spare boards, if applicable.
• Order parts required to complete the kit.

4 © 2010. Eaton Corporation. Company Confidential.

PM Procedure 9155/9355 8-15 kVA PM Procedure

1.3.7 Verify Modifications / Field Service Bulletins

• Verify applicable modifications or Field Service Bulletins (FSBs) are
completed.

1.3.8 Inspect for Signs of Overheating

NOTICE
Note:notice

Customer Approval is required to transfer the load to bypass.

Use the correct Installation and Operation Manual or Service Manual procedure
to secure the customer’s load before proceeding.

WARNING

If the unit is on internal/Static bypass, then be aware that the following

areas are still powered in the unit and are not accessible without proper
arc flash gear and safety measures:
• Customer connections
• Bypass contactor
• Inverter contactor
• Output sensing path to monitor board
• Bypass power supply
• Any associated harnessing to the above areas/components
1. Transfer the unit to Bypass and then to Maintenance Bypass if
available.
2. Ensure the unit is de-energized before proceeding.
3. Remove dead fronts to access UPS cabinet.
4. Look for darkened or charred areas around all control and power
connections. Note all locations.
5. Inspect control and power wire insulation at all wiring connections for
discoloration. Note locations and wire numbers.

1.3.9 Fan Inspection

• Did Alarm/Event queue indicate any fan failures?
• Fan Dead Front Panel
• Inspect and spin the fans by hand
• Replace any bad / failed fans.
• Install Top Fan Dead Front Panel and Side Bracket; insure fan
connections and Battery Start Switch connection are properly
made.

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9155/9355 8-15 kVA PM Procedure PM Procedure

• Check all fans, including rear fan for proper operation when the
unit is restarted.

1.3.10 Visual and Electrical Inspection

CAUTION
Stored voltages continue to exist in the UPS. Discharge all capacitors and
other energy storage devices. Use caution in the following steps.
1. Isolate the UPS cabinet from all voltages and visually inspect the
following:
• All connections
• All contactors and boards
• Fuses

6 © 2010. Eaton Corporation. Company Confidential.

Battery PM 9155/9355 8-15 kVA PM Procedure

1.4 Battery PM
Perform the following battery PM procedures on all internal and external
batteries.
1. Inform the customer that battery alarms may occur while performing
the battery PM.
2. Establish work area and safety barriers. Record ambient
temperature:________.
3. Don personal protective equipment.
4. Verify that the UPS is in Normal mode.
5. Measure and record the total battery string voltage for each string.
6. Begin battery PM with the internal battery of the UPS.
Note: Whenever two or more strings of batteries are available, take one string
only offline and test at a time.
7. Open the individual battery string breaker.
8. Verify the breaker is open using a DVM.
9. Acknowledge alarms at the UPS to silence the horn and verify the
alarms are correct.
10. Remove any panels or doors blocking access to the battery trays.
11. Label anderson connectors before disconnecting.

NOTICE
Note:

Failure to label connectors could lead to an arc-flash hazard on reassembly.

12. Disconnect anderson connectors for the battery trays as you test
them.
13. Set Canon Load Bank to 120 volt, 15 amps.
14. Connect the load bank to the most positive and most negative ends of
the string.
15. Load test the battery string for 30 seconds at 15 amps.
16. If the load test fails, remove the battery tray and test each battery.
Measure and record the individual jar voltages, impedances, internal
resistance, and conductance to identify the bad battery. Use one of
the methods below:
a. Pull tray of batteries out and measure and record individual jar
voltages/impedance/ internal resistance/ conductance using
Alber Cellcorder or Midtronics.

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9155/9355 8-15 kVA PM Procedure Battery PM

b. Load test each jar utilizing the L-641 Load Bank on the 50 amp
setting for 10 seconds (record reading; bad if below 11 vdc) -
NOTE - LDI is not necessary when this portion is combined with
the internal batteries.
17. Replace battery tray.
18. Reconnect anderson connector.
19. Verify connection with a DVM.
20. Repeat steps 11-19 for each battery tray.
21. Report weak and failed batteries to the customer and recommend
individual or string replacement of batteries.
22. Remove any debris from the cabinet and record the conditions.
23. Install panels and doors that were removed.
24. Secure the battery cabinet.
25. Close the individual battery string breaker.
26. Verify the breaker is closed using a DVM.
27. Clear any alarms on the UPS.
28. Verify that the charger is on and connected to the batteries.
29. Measure and record AC ripple voltage and current.
30. Verify any ground faults and check positive to ground and negative to
ground.
31. Record charger output current.
32. Record any safety deficiencies. Report these to the customer.
33. Notify the customer that battery maintenance is complete. Discuss
findings and make any necessary recommendations.
34. Have the customer sign off on the PM form.
35. Provide report (Battery Net) of test readings within 48 hours.

1.4.1 Metering Verification

1. Using a calibrated DVM and the XCP Service Tool, verify that the
input, output, and DC voltages are calibrated. Refer to the calibration
chapter of the service manual if calibration is required.
2. Ensure that all measured values match the displayed values within
1%. Calibrate any parameter not within 1%.

1.4.2 Cleaning
Because the UPS is small, clean around the logic and other confined areas with
canned air.

8 © 2010. Eaton Corporation. Company Confidential.

Battery PM 9155/9355 8-15 kVA PM Procedure

1.4.3 Returning Unit to Service

1. Notify the customer before transferring the UPS back online.
2. Verify that the unit displays the correct date and time.
3. Verify that the mimic panel reflects accurately system operation.
4. Reconnect network and modem cables and insert X-Slot cards.
5. Verify connectivity.
6. Verify the remote monitor panel is operational.

© 2010. Eaton Corporation. Company Confidential. 9

9155/9355 8-15 kVA PM Procedure Battery PM

1.4.4 Unit Measurements and Metering (while offline)

Rectifier Input (Measured)

A-B Voltage = B-C Voltage = C-A Voltage =
A-G Voltage = B-G Voltage = C-G Voltage =
A Current = B Current = C Current =
Frequency =

Rectifier Input (Metered/Displayed)

A-B Voltage = B-C Voltage = C-A Voltage =
A Current = B Current = C Current =
Frequency =

Bypass Input (Measured)

A-B Voltage = B-C Voltage = C-A Voltage =
A-N/G Voltage = B-N/G Voltage = C-N/G Voltage =
A Current = B Current = C Current =
Frequency =

Bypass Input (Metered/Displayed)

A-B Voltage = B-C Voltage = C-A Voltage =
A Current = B Current = C Current =
Frequency =

Inverter Output (Measured)

A-B Voltage = B-C Voltage = C-A Voltage =

Critical Bus (Measured)

A-B Voltage = B-C Voltage = C-A Voltage =
A-G Voltage = B-G Voltage = C-G Voltage =

A Current = B Current = C Current =

Frequency =

10 © 2010. Eaton Corporation. Company Confidential.

Battery PM 9155/9355 8-15 kVA PM Procedure

Critical Bus (Metered/Displayed)

A-B Voltage = B-C Voltage = C-A Voltage =
A-N/G Voltage = B-N/G Voltage = C-N/G Voltage =

A Current = B Current = C Current =

Frequency =

© 2010. Eaton Corporation. Company Confidential. 11

9155/9355 8-15 kVA PM Procedure Completion & Recommendations

1.5 Completion & Recommendations

1.5.1 Sections waived and why:

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1.5.2 Recommendations

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1.5.3 Sign–off:

Technician: _______________________________________ Date: ________

Customer: ________________________________________ Date: ________

12 © 2010. Eaton Corporation. Company Confidential.