Eaton Series

Battery Upgrade Instructions

For use with the Eaton® 93E (20–60 kVA)

p/n: P-164000967
Revision 01
 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS
This manual contains important instructions that you should follow during installation and maintenance
of the UPS and batteries. Please read all instructions before operating the equipment and save this
manual for future reference.

CONSIGNES DE SÉCURITÉ IMPORTANTES — CONSERVER CES INSTRUCTIONS

Ce manuel comporte des instructions importantes que vous êtes invité à suivre lors de toute
procédure d'installation et de maintenance de la UPS. Veuillez consulter entièrement ces instructions
avant de faire fonctionner l'équipement et conserver ce manuel afin de pouvoir vous y reporter
ultérieurement.

Eaton reserves the right to change specifications without prior notice. Eaton is a registered trademark of Eaton. All other trademarks are
property of their respective companies.

©Copyright 2020 Eaton, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any way without the
express written approval of Eaton.
Chapter 1 Introduction
1.1 Introduction
Upgrade kit P-106000220 facilitates replacing one existing two-row battery tray assembly with two single-row
battery assemblies.
The replacement trays contain nine batteries each, such that it takes two single-row trays to complete one
string. Each single-row battery tray has one circuit.
Each kit (P-106000220) includes two single-row battery trays and two harness adapters. Only one harness
adapter is needed for the installation; the second harness adapter is a spare.

Figure 1. Upgrade Kit P-106000220 (Two Cartons) Includes Two Single-Row Battery Trays and Two
Wiring Harness Adapters

Figure 2. Wiring Harness Adapter P-152001881

Battery Upgrade Instructions for 93E (20–60 kVA) P-164000967—Rev 01 1

Introduction

2 Battery Upgrade Instructions for 93E (20–60 kVA) P-164000967—Rev 01

Chapter 2 Upgrade Instructions
2.1 Battery Upgrade Instructions
READ THIS ENTIRE PROCEDURE BEFORE PERFORMING ANY WORK

WARNING
This procedure involves interacting with components that may be energized.
Any and all work can involve hazards when working on electrical equipment. The work must be done in
accordance with all applicable local, federal, or other safety requirements and must be performed by qualified
personnel.

1. Review and inspect the parts within the battery upgrade kit (Part Number: P-106000220)

! IMPORTANT
In the event of input power failure while performing this procedure, battery backup will not be available.

2. Follow the instructions in the Eaton 93E UPS Installation and Operation Manual to place the 93E UPS in
bypass and in maintenance bypass. However, if the UPS cannot be placed in maintenance bypass, this
procedure can still be performed.
3. Remove the UPS front panel door
4. Open breakers:

! IMPORTANT
Ensure the UPS is in Maintenance Bypass before opening the Input and Bypass Breakers; otherwise a Load
Loss will occur.

• Input Breaker
• Bypass Breaker
• Battery Breaker - Extended Battery Cabinet (EBC)
• Battery Breaker - UPS (if EBC capable)
• Module Output Breaker (if parallel configuration)

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Figure 3. Eaton 93E 30 kVA and 60 kVA UPS Breaker Locations

Input Breaker

Battery Breaker
(EBC capable
option only.)

93E 30 kVA UPS 93E 60 kVA UPS

5. Follow appropriate Lock Out /Tag Out (LOTO) and electrical safety procedures
6. Remove dead front panels:

• 30 kVA, upper and lower panels

• 60 kVA lower two panels
7. Disconnect all internal battery trays (note battery wiring configurations)

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 Battery Upgrade Instructions

Figure 4. Eaton 93E 30 kVA and 60 kVA Battery Tray and Cabinet Wiring

WARNING
All battery trays must be disconnected before proceeding.

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Battery Upgrade Instructions

8. Follow appropriate protocols to verify the UPS is electrically isolated / de-energized by using a certified
Digital Multi-Meter to verify the absence of AC voltages within the UPS
9. Remove the internal battery trays and label them as “old”
10. Install all the new battery trays

! IMPORTANT
Before connecting ANY battery trays, verify and orient yourself with ALL battery harnesses

11. Attach the Wiring Adaptor Harness to the existing UPS cabinet wiring harness for each battery shelf (one
shelf at a time) (red–to–red and black–to–black).

WARNING
The 2-circuit connectors should ALWAYS mate with a battery tray connector, NEVER with a 2-circuit connector
in another UPS harness. Arc-flash incident may occur when incorrectly mated.

a. Install the adapter on each UPS cabinet battery harness. Connect the adapter to the UPS cabinet
wiring harness (red–to–red and black–to–black).

Figure 5. Wiring Harness Adapter

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 Battery Upgrade Instructions

Figure 6. Wiring Harness Connection Detail

Battery Tray Shelf

Battery Tray Battery Tray Battery Tray Battery Tray

Battery Tray Battery Tray

Wiring Adapter
Wiring Wiring
Harness
Black Black White
Wire Red Red

Red Red Black Black

*Battery Tray
Cabinet
Connection Wiring
Only Harness
Connector Black Black
Sleeving

Red Red

*Cabinet Harness
Connection Only

b. Verify the absence of DC voltage on the harness (use precautions when verifying the voltage readings)

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Battery Upgrade Instructions

Figure 7. Wiring Harness Adapter — DC Voltage Testing

c. Slowly push the black sleeving over the cabinet harness Anderson connectors until centered
Tie wrap each end of the sleeving

Figure 8. Battery Wiring Adapter Harness — Sleeving Detail

Wiring Adapter
Harness

Tie Wraps
Cabinet
Wiring
Harness

Connector
Sleeving

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 Battery Upgrade Instructions

Figure 9. Connector Sleeving Installed

12. Repeat step 11 until all UPS cabinet battery harnesses are connected to a Wiring Harness Adapter
13. Once all of the UPS cabinet battery harnesses are connected to the Wiring Harness Adapter, proceed to
2.1.1 Internal Battery Voltage Polarity Verification Procedure

2.1.1 Internal Battery Voltage Polarity Verification Procedure

! IMPORTANT
Checking string polarity must be conducted separately for each battery string (pair of battery trays). These
checks also assure that all battery-to-battery jumpers in the battery tray assemblies are connected. Be sure to
disconnect the current battery tray pair before moving to the next pair. Strings should not be connected in
parallel until after each and every string polarity has been verified. Failure to do this could result in a serious arc-
flash injury

1. Utilizing one shelf at a time, attach the Wiring Harness Adapter to the left most battery string cables

Battery Upgrade Instructions for 93E (20–60 kVA) P-164000967—Rev 01 9

Battery Upgrade Instructions

Figure 10. Battery Wiring Adapter Connection to Battery Tray Cabling

Verify battery voltage polarity at the battery fuses (Gen 1 & 2) and the UPS battery breaker (Gen 3, top side
on the breaker). The measured voltage is around “+230vdc”

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 Battery Upgrade Instructions

Figure 11. Eaton 93E 30 kVA UPS Fuse Location Detail

Battery Upgrade Instructions for 93E (20–60 kVA) P-164000967—Rev 01 11

Battery Upgrade Instructions

Figure 12. Eaton 93E 60 kVA UPS Fuse Location Detail

2. Disconnect the new harness from the right most battery string cables and connect the second new
harness to the left most battery string cables
Verify battery voltage polarity at the battery fuses (Gen 1 & 2) and the UPS battery breaker (Gen 3)
3. Disconnect the new harness from the left most battery string cables
4. Repeat these steps for the remaining battery shelves, once all battery strings have been successfully
tested, proceed to

2.1.2 Battery Tray Connection and Wrap Up

1. Connect the new harnesses to the batteries for each shelf
2. Verify the battery voltage at the battery fuses (Gen 1 & 2) and battery breaker (Gen 3)
3. Before the battery dead front panel is reinstalled, the battery harnesses for each battery shelf must be
formed by hand
• 30 kVA

a. Push most of the battery harness between the right most battery and the frame

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 Battery Upgrade Instructions

Figure 13. Eaton 93E 30 kVA UPS — Battery Shelf Cabling Clean Up

b. Leave some stress relief for installing the battery dead front panel
c. Use tie wraps to help secure the battery harness
d. Press the battery harness as close to the batteries and next to the battery shelf (the red mark on
the battery is an example for the CSE to use as an example noting the shipping bracket lower
edge on the dead front panel)
e. Form the battery cables as close to the batteries and the shelf as possible
Use tie wraps as needed
• 60 kVA
a. Shelf 1 wire forming is different. Push most of the harness between the battery and the UPS
frame. Use tie wraps and tie wrap mounting pads as needed to anchor the battery harness to
ensure it is not touching the battery fuse nor the side frame of the UPS. (Gen 3 UPS are shipped
with tie wrap mounting pads)

Battery Upgrade Instructions for 93E (20–60 kVA) P-164000967—Rev 01 13

Battery Upgrade Instructions

Figure 14. Eaton 93E 60 kVA UPS — Battery Shelf Cabling Clean Up

Leave some stress relief for installing the battery dead front panel
b. Repeat step “a” for the remaining battery shelves
c. Press the battery harness as close to the batteries and next to the battery shelf (the red mark on
the battery is an example [30 kVA] picture for the CSE to use as an example noting the shipping
bracket lower edge on the dead front panel)
d. Form the battery cables as close to the batteries and the shelf as possible
Use tie wraps as needed

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 Battery Upgrade Instructions

4. Install the appropriate new wiring labels

• 30kVA, label P/N - P-138000552
• 60kVA, label P/N - P-138000553
5. Reinstall the battery dead front panel
As you install the panel, you may feel some slight resistance. The shipping bracket on the dead front panel
is pressing on the battery harness
Reinstall slowly to ensure you are not pinching any battery cables. If you feel as though it is too much
resistance, reform the wires and reinstall the dead front panel
6. Reinstall remaining dead front panels
7. Refer to the Eaton 93E UPS Installation and Operations Manual instructions to return the UPS to normal
and supporting the load

Battery Upgrade Instructions for 93E (20–60 kVA) P-164000967—Rev 01 15

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