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

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:

S Harmonized Standard: IEC 61010−1:2001−02

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

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

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

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:

S Monitors 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.

S Functions 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.

S Can be mounted on a wall with the included mounting bracket and

customer−supplied fasteners appropriate for the type of wall.

S Choice 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.

S Includes a software tool for easy configuring of settings and options.

S All harnesses supplied except for optional external ground.

S No preventive maintenance required other than verifying the

hardware and wiring are clear of debris. The EMS−UGK does not
require an annual calibration.

S Advanced Metering monitoring system, providing communication

options such as network connectivity through the Power Xpert
Gateway Card installed in the X−Slot® communication bay.

S Intended for continuous duty operation.

S Backed 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:

S Single panel (42 circuits) or dual panel (84 circuits)

S 208/120V or 380/220V, 400/230V, 415/240V rating

S Liquid crystal display (LCD) for local indication of energy usage

S Conduit box for enhanced harness protection

S Main 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:

S Subfeed breaker monitoring, rated to measure currents up to 400A

S 100A branch circuit breaker monitoring

S Temperature 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)

2

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

Safety Warnings

INTRODUCTION

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

S To 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).

S Use 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.

S Installation 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

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.

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.

S Pour réduire les risques d’incendie et de décharge électrique, installer la EMS−UGK

CONSIGNES DE SÉCURITÉ IMPORTANTES

CONSERVER CES INSTRUCTIONS

D A N G E R !

A T T E N T I O N !

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

Sicherheitswarnungen

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.

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.

S Um die Brand- oder 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.

INTRODUCTION

WICHTIGE SICHERHEITSANWEISUNGEN

AUFBEWAREN

W A R N U N G

A C H T U N G

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

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.

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.

S Para 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).

GUARDE ESTAS INSTRUCCIONES

P E L I G R O

P R E C A U C I Ó N

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:

S Equipment inspection

S Unpacking

S Parts list

S Required tools

S Installation and wiring

S Initial configuration

S Advanced 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 mm

− (5) 0.75–2.5 mm

2

(12 AWG), yellow

2

(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:

anchors

®

#2 screwdriver

S Phillips

S Pliers or other appropriate tool for installing wire taps

S Drill or other appropriate tool for installing customer−supplied wall

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

9

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
wall anchors

Clearance around
electronics module

Sufficient to support the weight of the EMS−UGK and installed
cables (see Table 12 on page 57 for weight specifications)

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

10

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

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
(6.00")

∅ 12.7 mm
(0.50") TYP

152.4 mm
(6.00")

∅ 5.3 mm
(0.21") TYP

226.0 mm
(8.90")

16.8 mm
(0.66")

283.5 mm
(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).

Front
Plate

Left Conduit
Box

Mounting
Slots
(4 places)

Ground Bonding Screw

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."

Mounting Bracket
Screws (8 places)

Figure 4. Conduit Box Option

Serial Port
(Service)

Front
Plate

Right Conduit Box

Extended
Serial Port

2" Bushing

Card Cover Plate

1.5" Bushing

1" Bushing

12

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

Electrical Connections

S Only qualified service personnel (such as a licensed electrician) shall perform the

S Always follow all personal protective equipment (PPE) and other safety rules when

S Use the branch circuit breakers to disconnect hazardous voltage from the EMS−UGK. Turn

S To 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.

INSTALLATION

W

A R N I N G

electrical installation. Risk of electrical shock.

working around electricity.

C A U T I O N

off the breaker before disconnecting the voltage measuring circuit cables, or hazardous
voltage may be present at the exposed end of the cable.

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
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

Branch CT 75A 25.4 38.1 25.4 mm

Branch CT
(separate accessory)

Main CT (phases A,
B, C, and Neutral)

Input Ground CT 100A 66.0 70.0 33.0 mm

Subfeed CT
(separate accessory)

100A 41.0 51.0 30.0 mm

400A 96.0 100.0 46.0 mm

400A 96.0 100.0 46.0 mm

CT Dimensions

H D)

(W

1.5" 1.0")

(1.0"

2.0" 1.2")

(1.6"

3.9" 1.8")

(3.8"

2.8" 1.3")

(2.6"

3.9" 1.8")

(3.8"

®

(NEC®) and local

Lead Length

0.91m (36.0") 10.16 mm (0.40")

1.00m (39.4") 16.00 mm (0.63")

0.91m (36.0") 22.86 mm (0.90")

0.91m (36.0") 15.24 mm (0.60")

0.91m (36.0") 22.86 mm (0.90")

Maximum Wire Insulation

Outside Diameter

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
taps on an occupied

Main CTs
(A, B, C)

Electronics Module

branch circuit breaker
(20A maximum).

External Ground

Branch CTs

(optional)

Panel Connections:

Branch CTs (CT1)

Wire Taps

Neutral

Branch CTs (CT2)
Main CTs (CTM)
Voltage (V1)

CT1
CT2

CTM
V2

Panel Connections
and
Communication Features
(see Figure 20 on page 49)

Input Ground CT

Branch Circuit Harnesses

Voltage Harness

Main Harness

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

Branch Circuit Harness CT2

Main Input Harness CTM

Voltage Harness V1

CT1

CT2

CTM

V1

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.

CT1

CT2

CTM

V2

16

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