Powerware 400-230V, 415-240V, 380-220V, 208-120V User Manual

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Powerware® Energy Management System (EMS)

Upgrade Kit (208/120V, 380/220V, 400/230V, 415/240V)

User’s Guide

Requesting a Declaration of Conformity

Units that are labeled with a CE mark comply with the following harmonized standards and EU directives:

SHarmonized Standard: IEC 61010−1:2001−02

S EU Directives:

2006/95/EC, Council Directive on equipment designed for use within certain voltage limits

 

2004/108/EC, Council Directive relating to electromagnetic compatibility

The EC Declaration of Conformity is available upon request for products with a CE mark. For copies of the EC Declaration of Conformity, contact:

Eaton Power Quality Oy

Koskelontie 13

FIN−02920 Espoo

Finland

Phone: +358−9−452 661

Fax: +358−9−452 665 68

Eaton, Powerware, Power Xpert, and X−Slot are registered trademarks of Eaton Corporation or its subsidiaries and affiliates. HyperTerminal is a registered trademark of Hilgraeve. Kirk is a registered trademark of the Kirk Key Interlock Company. Microsoft and Windows are registered trademarks of Microsoft Corporation in the United States and/or other countries. Modbus is a registered trademark of Schneider Electric. National Electrical Code and NEC are registered trademarks of National Fire Protection Association, Inc. Phillips is a registered trademark of Phillips Screw Company. All other trademarks are property of their respective companies.

ECopyright 2008 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any way without the express written approval of Eaton Corporation.

Special Symbols

The following are examples of symbols used on the UPS or accessories to alert you to important information:

RISK OF ELECTRIC SHOCK − Observe the warning associated with the risk of electric shock symbol.

CAUTION: REFER TO OPERATOR’S MANUAL − Refer to your operator’s manual for additional information, such as important operating and maintenance instructions.

This symbol indicates that you should not discard waste electrical or electronic equipment (WEEE) in the trash. For proper disposal, contact your local recycling/reuse or hazardous waste center.

Three−phase alternating current

PROTECTIVE CONDUCTOR TERMINAL

Do not apply around or remove from hazardous live conductors.

Table of Contents

1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

 

Inspecting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

 

Unpacking the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

 

Checking the Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

 

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

 

Installing the Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

 

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

 

Initial Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

 

Installing the Software Configuration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

 

Initial System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

 

Initial Panel and Breaker Configuration (Using the Software Configuration Tool) . . . . . . . . . . . . . . . . . . . . . .

31

 

Initial Panel and Breaker Configuration (Using the Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

 

Advanced Metering Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

3

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

 

Reset Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

 

Breaker Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

 

Control Panel Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

 

Display Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

 

Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

 

Setup Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

 

Control Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

 

Accessing Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

 

Configuring Panels Containing Branch Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

 

Configuring Panels Containing Subfeed Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

 

Configuring Branch Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

 

Viewing Panel Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

 

Viewing Breaker Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

i

TABLE OF CONTENTS

4

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

 

Installing Communication Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

 

Communication Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

 

Serial Port (Service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

 

X−Slot Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

 

Control Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

 

Relay Output Contacts (Alarm Relay) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

 

Programmable Signal Inputs (Building Alarms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

 

Recycling the Used Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

 

Updating the Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

 

Replacing the Power Xpert Gateway Series 1000 Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

 

Rewiring and Reconfiguring the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

 

Typical Alarms and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

 

Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

8

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

 

Limited Factory Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

ii EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

Chapter 1

Introduction

Eaton’s Powerware® Energy Management System (EMS) Upgrade Kit (EMS−UGK) is designed to monitor energy usage of existing power distribution panelboards, remote power panels, or power distribution units. Providing outstanding performance and reliability, the EMS−UGK’s unique benefits include the following:

SMonitors up to 42 (single panel) or 84 (dual panel) circuits in a standard three−phase panelboard. Measures and stores energy parameters for each of the individual monitored circuits, letting you manage power with greater precision.

SFunctions in a wide variety of applications supporting various data center loads that may require a power distribution monitoring solution, especially where power needs are changing and backup architecture must be scalable.

SCan be mounted on a wall with the included mounting bracket and customer−supplied fasteners appropriate for the type of wall.

SChoice of voltage sensing installation: connection to an unoccupied circuit breaker using included transition harnesses or connection to an occupied circuit breaker using included wire taps.

SIncludes a software tool for easy configuring of settings and options.

SAll harnesses supplied except for optional external ground.

SNo preventive maintenance required other than verifying the hardware and wiring are clear of debris. The EMS−UGK does not require an annual calibration.

SAdvanced Metering monitoring system, providing communication options such as network connectivity through the Power Xpert® Gateway Card installed in the X−Slot® communication bay.

SIntended for continuous duty operation.

SBacked by worldwide agency approvals.

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

1

INTRODUCTION

The following options for the EMS−UGK are available:

SSingle panel (42 circuits) or dual panel (84 circuits)

S208/120V or 380/220V, 400/230V, 415/240V rating

SLiquid crystal display (LCD) for local indication of energy usage

SConduit box for enhanced harness protection

SMain input monitoring (three phases and one neutral rated to measure currents up to 400A; up to 100A for input ground)

The following accessories for the EMS−UGK are available:

SSubfeed breaker monitoring, rated to measure currents up to 400A

S100A branch circuit breaker monitoring

STemperature and humidity monitoring with the optional Environmental Monitoring Probe (EMP) that is used with the Power Xpert Gateway Series 1000 Card installed in the EMS−UGK

The EMS−UGK includes an externally−mounted enclosure with an optional display. Current transformers (CTs) provide branch circuit monitoring of installed panelboards. Figure 1 shows an example installation of an EMS−UGK.

Figure 1. Typical EMS−UGK Installation (Dual Panel Shown with Optional Display)

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INTRODUCTION

Safety Warnings

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important instructions that you should follow during installation and operation of the EMS−UGK. Please read all instructions before operating the equipment and save this manual for future reference.

D A N G E R

This EMS−UGK contains LETHAL VOLTAGES. All repairs and service should be performed by AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS inside the EMS−UGK.

C A U T I O N

STo reduce the risk of fire or electric shock, install this EMS−UGK in a temperature and

humidity controlled, indoor environment, free of conductive contaminants. Ambient temperature must not exceed 40°C (104°F). Do not operate near water or excessive humidity (95% maximum).

SUse the branch circuit breakers to disconnect hazardous voltage from the EMS−UGK. Turn off the breaker before disconnecting the voltage measuring circuit cables, or hazardous voltage may be present at the exposed end of the cable.

SInstallation or use of the equipment in a manner not specified by the manufacturer may impair the protection provided by the equipment.

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

3

INTRODUCTION

Consignes de sécurité

CONSIGNES DE SÉCURITÉ IMPORTANTES

CONSERVER CES INSTRUCTIONS

Ce manuel contient des instructions importantes que vous êtes invité à suivre lors de toute procédure d’installation et de fonctionnement de EMS−UGK. Veuillez consulter entièrement ces instructions avant de faire fonctionner l’équipement et conserver ce manuel afin de pouvoir vous y reporter ultérieurement.

D A N G E R !

Cet EMS−UGK contient des TENSIONS MORTELLES. Toute opération d’entretien et de réparation doit être EXCLUSIVEMENT CONFIÉE A UN PERSONNEL QUALIFIÉ AGRÉÉ. AUCUNE PIÈCE RÉPARABLE PAR L’UTILISATEUR ne se trouve dans la EMS−UGK.

A T T E N T I O N !

SPour réduire les risques d’incendie et de décharge électrique, installer la EMS−UGK uniquement à l’intérieur, dans un lieu dépourvu de matériaux conducteurs, où la

température et l’humidité ambiantes sont contrôlées. La température ambiante ne doit pas dépasser 40 °C. Ne pas utiliser à proximité d’eau ou dans une atmosphère excessivement humide (95 % maximum).

4 EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

INTRODUCTION

Sicherheitswarnungen

WICHTIGE SICHERHEITSANWEISUNGEN

AUFBEWAREN

Dieses Handbuch enthält wichtige Hinweise, welche Sie bei der Installation und Wartung des EMS−UGK beachten sollten. Bitte lesen Sie alle Anweisungen des Handbuches bevor sie mit dem Gerät arbeiten. Bewaren Sie das Handbuch zum Nachlesen auf.

W A R N U N G

Die EMS−UGK führt lebensgefährliche Spannungen. Alle Reparatur− und Wartungsarbeiten sollten nur von Kundendienstfachleuten durchgeführt werden. Die EMS−UGK enthält keine vom Benutzer zu wartenden Komponenten.

A C H T U N G

SUm die Brandoder Elektroschockgefahr zu verringern, diese EMS−UGK nur in Gebäuden

mit kontrollierter Temperatur und Luftfeuchtigkeit installieren, in denen keine leitenden Schmutzstoffen vorhanden sind. Die Umgebungstemperatur darf 40°C nicht übersteigen. Die EMS−UGK nicht in der Nähe von Wasser oder in extrem hoher Luftfeuchtigkeit (max. 95 %) betreiben.

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

5

INTRODUCTION

Advertencias de Seguridad

INSTRUCCIONES DE SEGURIDAD IMPORTANTES

GUARDE ESTAS INSTRUCCIONES

Este manual contiene instrucciones importantes que debe seguir durante la instalación y el funcionamiento de la EMS−UGK. Por favor, lea todas las instrucciones antes de poner en funcionamiento el equipo y guarde este manual para referencia en el futuro.

P E L I G R O

Este EMS−UGK contiene VOLTAJES MORTALES. Todas las reparaciones y el servicio técnico deben ser efectuados SOLAMENTE POR PERSONAL DE SERVICIO TÉCNICO AUTORIZADO. No hay NINGUNA PARTE QUE EL USUARIO PUEDA REPARAR dentro de la EMS−UGK.

P R E C A U C I Ó N

SPara reducir el riesgo de incendio o de choque eléctrico, instale este EMS−UGK en un

lugar cubierto, con temperatura y humedad controladas, libre de contaminantes conductores. La temperatura ambiente no debe exceder los 40°C. No trabaje cerca del agua o con humedad excesiva (95% máximo).

6 EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

Chapter 2

Installation

This section explains:

SEquipment inspection

SUnpacking

SParts list

SRequired tools

SInstallation and wiring

SInitial configuration

SAdvanced Metering installation

Inspecting the Equipment

If any equipment has been damaged during shipment, keep the shipping cartons and packing materials for the carrier or place of purchase and file a claim for shipping damage. If you discover damage after acceptance, file a claim for concealed damage.

To file a claim for shipping damage or concealed damage: 1) File with the carrier within 15 days of receipt of the equipment; 2) Send a copy of the damage claim within 15 days to your service representative.

Unpacking the Cabinet

Use care when moving and opening the carton. Leave the components packaged until ready to install.

To unpack the cabinet:

1.Open the outer carton and remove the items packaged with the cabinet.

2.Carefully lift the cabinet out of the outer carton.

3.Discard or recycle the packaging in a responsible manner, or store it for future use.

Place the cabinet in a protected area that has adequate airflow and is free of humidity, flammable gas, and corrosion.

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

7

INSTALLATION

Checking the Parts List

Verify that the following items are included with the EMS−UGK.

All models

Electronics module (display optional)

Mounting bracket (installed on electronics module)

EMS Configuration Tool CD for setup and calibration

EMS configuration cable (DB−9 to RS−232 serial)

This user’s guide

Power Xpert Gateway Series 1000 Card (installed on electronics module)

Card configuration cable (RJ−45 to RS−232 serial)

Ethernet cable

Power Xpert Gateway Series 1000 Card registration card

Power Xpert Gateway Series 1000 Card Quick Start Instructions

NOTE For more detailed information, download the Power Xpert Gateway Series 1000 Card User’s Guide from the Documentation page on the Power Xpert card once the card is accessible on the user’s network or from www.eaton.com/powerxpert.

All models (for each panel ordered)

(2) Branch circuit harnesses, each with one 28−position circular connector and 21 two−position connector plugs

(44) Branch current transformers (CTs), split−core, 75A, 1V output, with two−position connector receptacle (includes 2 spares) (optional)

(1) Voltage harness, with one 7−position circular connector, three spade connectors (A, B, C), and two ferrule connectors (Neutral, Ground)

NOTE Dual panel option only. Voltage harness V2 does NOT include a connector for Ground.

(10) Wire taps:

(5) 4.0 mm2 (12 AWG), yellow

(5) 0.75–2.5 mm2 (18–14 AWG), blue

(3) Wire tap transition harnesses, each with a quick disconnect receptacle and a ferrule connector

8 EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

INSTALLATION

Main input monitoring option only (one set for each panel if ordered)

(1) Main input harness, with one 28−position circular connector and five 2−position connector plugs (A, B, C, Ground, Neutral)

(4) Main CTs, split−core, 400A, 1V output, with 2−position connector receptacle

(1) Input ground CT, split−core, 100A, 1V output, with 2−position connector receptacle

Conduit box option only (if ordered)

Conduit box, left side

Conduit box, right side, with installed DB−9 extender cable

Subfeed Accessory Kit only (if ordered)

(3) Subfeed transition harnesses, each with 2 two−position connector plugs

(3) Branch CTs, split−core, 400A, 1V output, with two−position connector receptacle

100A Split−Core CTs Accessory Kit only (if ordered)

(10) Branch CTs, split−core, 100A, 1V output, with two−position connector receptacle

75A Split−Core CTs Accessory Kit only (if ordered)

(5) Branch CTs, split−core, 75A, 1V output, with two−position connector receptacle

NOTE Accessory kits may be shipped in separate cartons.

Tools Required

To assemble the components, the following tools may be needed:

SPhillips® #2 screwdriver

SPliers or other appropriate tool for installing wire taps

SDrill or other appropriate tool for installing customer−supplied wall anchors

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

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INSTALLATION

Installing the Hardware

NOTE Review the wiring planning requirements in Step 3 on page 14 as an aid to locating an appropriate site for the EMS−UGK.

To install the EMS−UGK on a wall:

1.Verify that the wall on which the EMS−UGK is to be mounted meets the recommendations listed in Table 1.

Table 1. Wall Specifications (Customer−Supplied Components)

Component

Specification

 

 

Wall surface and

Sufficient to support the weight of the EMS−UGK and installed

wall anchors

cables (see Table 12 on page 57 for weight specifications)

 

 

Clearance around

Above: 102 mm (4") [152 mm (6") recommended]

electronics module

Below: 102 mm (4")

 

Sides: 152 mm (6")

 

 

2.Loosen the four front screws, and remove the four rear screws. Remove the mounting bracket from the electronics module. Retain the bracket and four removed screws. See Figure 2.

M4 10 screws (8 places)

Figure 2. Mounting Bracket and Electronics Module (with Optional Display)

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INSTALLATION

3.Attach the mounting bracket to the wall with appropriate wall anchors (not supplied). See the mounting template in Figure 3.

Verify that at least two wall anchors attach to studs within the wall.

 

 

376.5 mm

 

 

 

 

 

 

(14.82")

 

 

 

 

 

 

 

152.4 mm

 

 

 

 

 

 

 

152.4 mm

 

 

 

16.8 mm

(6.00")

 

 

 

 

(6.00")

 

 

 

 

 

 

 

 

 

(0.66")

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12.7 mm

5.3 mm

(0.50") TYP

(0.21") TYP

226.0 mm

283.5 mm

(8.90")

(11.16")

Figure 3. Mounting Template

4.Slide the loosened front screws on the electronics module into the slots on the mounting bracket.

5.Verify all screw holes are aligned. Reinstall the four screws removed in Step 2, but do not fully tighten. See Figure 2.

6.If installing the optional conduit box, continue to Step 7. Otherwise, proceed to Step 11.

7.Remove the front plate from each conduit box. Retain the plates and screws for later reinstallation. See Figure 4.

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

11

INSTALLATION

8.If installing a right conduit box, connect the DB−9 extender cable (installed on the extended serial port on the inside of the right conduit box) to the serial port (Service) on the electronics module.

Figure 4 shows the location of the two serial ports.

9.Slide the conduit box into place on one side of the electronics module. Loosen the mounting bracket screws further if needed.

If installing conduit on both panels, repeat for the other conduit box. Tighten the mounting bracket screws to secure the conduit box(es).

Serial Port

Extended

(Service)

Serial Port

Front

Plate

Left Conduit

Box

 

 

Front

2" Bushing

 

 

Plate

 

 

 

 

Card Cover Plate

Mounting

 

 

1.5" Bushing

 

 

 

Slots

 

 

1" Bushing

(4 places)

Mounting Bracket

 

 

 

 

Ground Bonding Screw

Screws (8 places)

Right Conduit Box

 

 

 

Figure 4. Conduit Box Option

10.Optional but recommended. Attach the conduit box(es) to the wall with appropriate wall anchors (not supplied). Use one or more of the four available mounting slots in each conduit box.

11.Verify that all hardware is mounted and aligned properly, then tighten all screws. Verify the hardware is attached safely and securely to the wall.

12.Continue to the following section, Electrical Connections."

12 EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

INSTALLATION

Electrical Connections

W A R N I N G

SOnly qualified service personnel (such as a licensed electrician) shall perform the electrical installation. Risk of electrical shock.

SAlways follow all personal protective equipment (PPE) and other safety rules when working around electricity.

C A U T I O N

SUse the branch circuit breakers to disconnect hazardous voltage from the EMS−UGK. Turn off the breaker before disconnecting the voltage measuring circuit cables, or hazardous voltage may be present at the exposed end of the cable.

STo prevent mechanical damage, coil and secure any excess cable away from the floor.

The EMS−UGK is designed for quick and easy installation. Labels on the harnesses describe where to connect the CTs and wire taps. Keyed circular connectors provide a quick and secure installation to the electronics module.

To connect the wiring for the EMS−UGK:

C A U T I O N

Before wiring the EMS−UGK, disconnect the load and shut down the host equipment. Refer to the user’s guide for the host equipment for shutdown instructions.

1.Verify that no circuits on which the EMS−UGK will be installed are energized. Be absolutely sure there is no power.

2.Optional. Connect the ground cable (not supplied) from the host equipment to the M5 ground bonding screw on the bottom of the electronics module. Figure 4 shows the location of the ground bonding screw.

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

13

INSTALLATION

3.Plan the wiring route from the electronics module to the monitored breaker panel(s). See Table 2 through Table 4, Figure 5, and use the following guidelines.

S Mount the electronics module within 3.05m (10 ft) of a disconnect device.

S If installing conduit (not supplied), plan for adequate conduit routing. Follow National Electrical Code® (NEC®) and local guidelines for conduit length and bending radius. Installed width of the EMS−UGK with both conduit boxes is 633 mm (24.9"). Remove conduit box hole plugs as needed for conduit.

S Follow NEC and local guidelines for filling wiring space and maintaining the thermal performance of the equipment.

S Plan the location and installation of the CTs and wire taps to allow for adequate bending radius of wiring. If necessary, support the CTs to avoid undue strain on wiring.

Table 2. Current Transformer Sizing

Type of CT

Rating

CT Dimensions

Lead Length

Maximum Wire Insulation

 

(W H

D)

Outside Diameter

 

 

 

 

 

 

 

 

 

 

 

 

Branch CT

75A

25.4

 

38.1

25.4 mm

0.91m (36.0")

10.16 mm (0.40")

 

 

(1.0" 1.5" 1.0")

 

 

 

 

 

 

 

 

 

 

Branch CT

100A

41.0

 

51.0

30.0 mm

1.00m (39.4")

16.00 mm (0.63")

(separate accessory)

 

(1.6"

2.0"

1.2")

 

 

 

 

 

 

 

 

 

Main CT (phases A,

400A

96.0

100.0

46.0 mm

0.91m (36.0")

22.86 mm (0.90")

B, C, and Neutral)

 

(3.8"

3.9"

1.8")

 

 

 

 

 

 

 

 

 

 

Input Ground CT

100A

66.0

 

70.0

33.0 mm

0.91m (36.0")

15.24 mm (0.60")

 

 

(2.6" 2.8" 1.3")

 

 

 

 

 

 

 

 

 

Subfeed CT

400A

96.0

100.0

46.0 mm

0.91m (36.0")

22.86 mm (0.90")

(separate accessory)

 

(3.8"

3.9"

1.8")

 

 

 

 

 

 

 

 

 

 

Table 3. Wire Tap Sizing

Housing Color

Wire Size

 

 

Blue

0.75–2.5 mm2 (18–14 AWG)

Yellow

4.0 mm2 (12 AWG)

NOTE Use wire taps ONLY on thermoplastic insulation (PVC).

14 EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

INSTALLATION

Table 4. Harness Sizing

Harness

Bundled Length

Connection

Lead Length

 

 

 

 

 

 

Voltage

3.05m (10 ft)

Phases (A, B, C)

0.91m (3 ft)

 

 

 

 

 

 

Ground (V1 only), Neutral

1.83m (6 ft)

 

 

 

 

Main Input

2.74m (9 ft)

Phases (A, B, C), Neutral, Ground

304.8 mm (12")

 

 

 

 

Branch Circuit

2.74m (9 ft)

Circuit Breakers 1/1 – 14/28*

304.8 mm (12")

 

 

 

 

 

 

Circuit Breakers 15/8 – 28/35*

203.2 mm (8")

 

 

 

 

 

 

Circuit Breakers 29/15 – 42/42*

101.6 mm (4")

 

 

 

 

Wire Tap Transition

N/A

Three−Phase Circuit Breaker

101.6 mm (4")

 

 

 

 

Subfeed Transition

N/A

Subfeed Breaker

50.8 mm (2")

 

 

 

 

 

* Circuit breaker numbering: NEMA/Standard (See Breaker Numbering" on page 37.)

NOTE Voltage harness

shown installed with wire

Main CTs

(A, B, C)

taps on an occupied

 

branch circuit breaker

 

(20A maximum).

 

Branch CTs

Wire Taps

Neutral

Input Ground CT

Branch Circuit Harnesses

Voltage Harness

Main Harness

Electronics Module

CT1

CT2

CTM V2

External Ground (optional)

Panel Connections:

Branch CTs (CT1)

Branch CTs (CT2)

Main CTs (CTM)

Voltage (V1)

Panel Connections and

Communication Features (see Figure 20 on page 49)

Figure 5. Wiring Overview (Example Installation)

EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

15

INSTALLATION

4.Connect the circular connector of each harness to the electronics module. Verify the harness label matches the connector label on the electronics module. See Figure 6 and Table 5. Figure 7 shows a detailed view of both panels.

NOTE To connect a harness to the electronics module, align the polarizing keys and keyways and insert the plug into the receptacle. Rotate the attached coupling ring clockwise until it snaps into position.

Branch Circuit Harness CT1

CT1

CT1

Branch Circuit Harness CT2

CT2

CT2

Main Input Harness CTM

CTM

CTM

Voltage Harness V1

V1

V2

Figure 6. Harness Connections at the Electronics Module

Table 5. EMS−UGK Harness Connections

Connection

Description

 

 

 

 

CT1

Branch circuit harness from Panel 1 / Input 1 to Panel 1 breaker poles 1–21.

 

Dual panel option only. Branch circuit harness from Panel 2 / Input 2 to Panel 2 breaker poles 1–21.

 

 

CT2

Branch circuit harness from Panel 1 / Input 1 to Panel 1 breaker poles 22–42.

 

Dual panel option only. Branch circuit harness from Panel 2 / Input 2 to Panel 2 breaker poles 22–42.

 

 

CTM

Main input monitoring option only. Main input harness from Panel 1 / Input 1 to Panel 1 main

 

connections.

 

Dual panel option only. Main input harness from Panel 2 / Input 2 to Panel 2 main connections.

 

 

V1

Voltage harness from Panel 1 / Input 1 to Panel 1 reference voltage connection.

 

 

V2

Dual panel option only. Voltage harness from Panel 2 / Input 2 to Panel 2 reference voltage

 

connection.

 

 

 

16 EATON Powerware® Energy Management System (EMS) Upgrade Kit User’s Guide S 164201724 Rev 1 www.powerware.com

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