Rittal 7857.433, 7857.434 Assembly And Operation Instructions Manual

Assembly and Operation Instructions

UPS System

Power Modular

Concept

PMC 12

4,5 and 6kVA

7857.433

7857.434

Microsoft Windows is a registered trademark of Microsoft Corporation.
Acrobat Reader is a registered trademark of Adobe Systems Incorporated.

UPS-Manual

2

EN

Table of Contents

IMPORTANT SAFETY INSTRUCTIONS..3

1.1. Documentation Notes........................................3

1.2. Retention of Documents...................................3

1.3. Symbols Used.....................................................3

1.4. Safety Instructions............................................3

1.5. Proper Use .........................................................4

1.6. Storage Instructions..........................................4

2. PRODUCT INTRODUCTION ..........5

2.1. General Characteristics....................................5

2.2. Special Features.................................................5

3. UPS FUNCTIONAL DESCRIPTIONS

6

3.1. UPS Front Panel Display..................................6

3.1.1. Symbols on the LCD DisplayPanel............ 6

3.2. Rear Panel Descriptions ...................................8

3.2.1. UPS input and output.................................8

3.2.2. Battery input...............................................8

3.3. Communication Port Explanation...................9

3.3.1. EPO (Emergency Power Off).....................9

3.3.2. RS232 Port Descriptions............................ 9

4. INSTALLATION ............................10

4.1. Unpacking........................................................10

4.2. Selecting Installation Position........................11

4.3. Assembling of the different System

Components..................................................................12

4.3.1. Tower Assembling steps ..........................12

4.3.2. Rack installation step................................13

4.4. Electrical Installation......................................16

5. OPERATION .................................17

5.1. Start-Up In Normal Mode..............................17

5.2. Start-up in Battery Mode (Cold Start)......... 18

5.3. Check Measured Values & Figures detected
by UPS 19

5.4. UPS Default Data and Special Function

Execution...................................................................... 20

5.5. UPS Default Settings and their alternatives. 22

5.6. UPS Is Off Due to Unknown Reason and It’s

Trouble Shooting......................................................... 22

5.7. Shut Off........................................................... 23

5.8. Maintenance Bypass Mode............................ 23

6. TROUBLESHOOTING GUIDE .....24

6.1. Troubleshooting.............................................. 24

7. BUNDLED SOFTWARE

INSTALLATION GUIDE ......................... 25

7.1. Hardware Installation.................................... 25

7.2. Software Installation...................................... 25

8. OPTIONAL COMMUNICATION

CARD......................................................25

8.1. SNMP Adapter............................................... 25

8.2. Internal SNMP Adapter................................ 26

9. HOT SWAPPABLE BATTERY

REPLACEMENT..................................... 27

10. CUSTOMER SERVICE................. 27

11. TECHNICAL DATA ...................... 28

Important Safety Instructions

UPS-Manual

3

EN

Important Safety Instructions

1.1. Documentation Notes

The audience for this guide is the technical
specialist familiar with the assembly, installation
and operation of the PMC12 UPS-System.
You should read this operating guide prior to
commissioning and store the guide so it is
readily accessible for subsequent use.
Rittal cannot accept any liability for damage
and operational malfunctions that result from
the non observance of this guide.

1.2. Retention of Documents

This guide and all associated documents are
part of the product. They must be given to the
operator of the unit and must be stored so they
are available when needed.

1.3. Symbols Used

The following safety and other notes are used
in this guide:

Symbol for handling instructions:

• This bullet point indicates that you should
perform an action.

Safety and other notes:

Danger!

Immediate danger to health and
life!

Warning!

Possible danger for the product
and the environment!

Note!

Useful information and special
features.

1.4. Safety Instructions

1. Assembly and installation of the UPS, in

particular for wiring the enclosures with
mains power, may be performed only by
a trained electrician. Other tasks asso­ciated with the UPS, such as the as­sembly and installation of system com­ponents with tested standard connec­tors, and the operation and configura­tion of the PMC12 UPS-System may be
performed only by instructed personnel.

2. Do not open the case, as there are no
serviceable parts inside. Your warranty
will be void.

3. Do not try to repair the unit yourself;
contact your local supplier or your war­ranty will be void.

4. If liquids are spilt onto the UPS or for­eign objects dropped into the unit, the
warranty will be null and void.

5. Do not install the UPS in an environ­ment with sparks, smoke or gas.

6. The batteries inside the external
packages of these ups can have a
strengthened gas emission of hydrogen
in case of a fire or technical fault.
Please refer to EN 50272-2 for
references for battery ventilation.

7. This UPS is equipped with an EMI filter.
To prevent potential leakage current
hazard, ensure that the AC main supply
is securely grounded.

8. This UPS is designed to be installed
and commissioned in a sheltered, con­trolled environment as follows:

- Operating temperature 0-40°C
and 30-90% non-condensing
humidity.

- Always avoid contact with direct
sunlight.

- Do not install the UPS in
inflammable or hazardous
environment.

- Dusty, corrosive and salty envi­ronments can do damage to any
UPS.

- Install the UPS indoors as it is
not designed for installation out­doors.

9. To prevent any overheating of the UPS,
keep all ventilation openings free from
obstruction, and do not place anything
on top of the UPS. Keep the UPS rear
panel 20 cm away from the wall or other
obstructions.

10. The battery will discharge naturally if the
system is unused for any length of time.

11. Install the UPS away from objects that
give off excessive heat and areas that
are excessively wet.

12. Always switch off the UPS and discon­nect the batteries when relocating the
UPS.

13. It should be recharged every 2-3
months if unused. If this is not done,
then the warranty will be null and void.
When installed and being used, the
batteries will be automatically recharged
and kept in top condition.

Important Safety Instructions

UPS-Manual

4

EN

14. Make sure that the AC main supply
outlet is correctly grounded.

15. Please ensure that the input voltage of
the UPS matches the utility supply volt­age. Use a certified input power cable
with the correct plugs and sockets for
the appropriate voltage system.

16. Observe the valid regulations for the
electrical installation for the country in
which the unit is installed and operated,
and the national regulations for accident
prevention. Also observe any company­internal regulations (work, operating and
safety regulations).

17. Use only genuine or recommended
parts and accessories. The use of other
parts can void the liability for any
resulting consequences.

1.5. Proper Use

This UPS is designed for providing power to IT
systems. A use different from that described
here is considered to be an improper use. Rittal
cannot accept any liability for damage resulting
from the improper use or the non-observance
of this guide. The guides for the used
accessories may apply.
Rittal prohibits the use for life-preserving
applications (such as the use in hospitals or the
direct patient care). Rittal expressly does not
sell its products for such applications. Rittal will
not accept any responsibility if a UPS is used in
this area.

1.6. Storage Instructions

For extended storage in moderate climate, the
batteries should be charged for 12 hours at 3
month intervals by connecting the UPS to the
utility supply and switch on input breaker lo­cated at UPS rear panel. Repeat this procedure
every 2 months if the storage ambient
temperature is above 30°C.

Product Introduction

UPS-Manual

5

EN

2. Product Introduction

2.1. General Characteristics

The double-conversion technology in
accordance with the specification VFI-SS-111
guarantees the power supply to connected
terminal devices with a pure sinusoidal voltage.

1. The ultra-efficient PWM technology
achieves a high efficiency for an almost
sinusoidal output voltage. The high crest
factor of the converter filters any switch-on
current peaks without the loading needing
to be modified.

2. A fully digitalised control circuit provides a
high level of protection and enables future
upgrade. In-built communication capability
enhances its ability for remote control and
monitoring.

3. The multi-functional LCD/LED panel will
display various status of the UPS. The LED
display may show UPS working status,
Utility Status and UPS Abnormal status,
whilst the LCD display may show
Input/Output Voltage, Frequency, Load
Status, Inner cabinet temperature, and
Abnormal Phenomenon.

4. To protect the unit from overloading, it
automatically switches to bypass mode in
~160 seconds if loading is at 105% of
rating and in case of overloading of more
than 150% of rating, it switches to bypass
mode immediately. It will automatically
switch back to inverter mode once
overload condition ceases.

5. If a short-circuit occurs at the output, the
UPS switches the system into standby
operation. The UPS issues an audiovisual
alarm and automatically interrupts the
current output until the short-circuit has
been corrected manually.

6. Should the unit become overheated, the
internal thermal switch will detect the heat
and switch to bypass mode and vice versa.

7. Maintenance-free sealed-type battery
minimises after-sales service.

8. The maintenance bypass switch provides
easy and safe troubleshooting or
maintenance function when the utility is
normal.

2.2. Special Features

The transformer-free converter technology with a
housing that can be mounted in a rack or used as
floor-standing enclosure allows the UPS to be
integrated even in environments with restricted
space.

1. The UPS is equipped with an intelligent
microprocessor-based controller and
offers a flexible configuration capability
with remote communication and
comprehensive overload protection.

2. A large 184 V ~ 288 V input voltage
range permits an under voltage and
overvoltage correction without
unnecessary battery discharge and so
ensures an increased battery lifetime.

3. The cold start function ensures that the
UPS can be switched on even when no
mains voltage is present (see chapter

5.2).

4. An optimum battery management
system analyses the charging state of
the battery in order to maximise the
battery lifetime.

5. The "Active Power Factor Correction
(PFC)" control function keeps the "Input
Power Factor (PF)" of the UPS to a
value > 0.99. This allows an excellent
energy efficiency to be attained.

6. Selectable bypass input voltage
tolerance (high/low sensitivity) ensures
that the consumers are not supplied
with under voltage or overvoltage during
bypass operation. The selectable
voltage ranges are:

(i) low sensitivity: 184 ~ 260 V
(ii) high sensitivity: 194 ~260 V.

7. Fixed selectable output voltages
(220/230/240) to satisfy the
requirements for different voltage
systems.

8. The UPS satisfies all relevant EMC
regulations.

UPS Functional Descriptions

UPS-Manual

6

EN

3. UPS Functional Descriptions

3.1. UPS Front Panel Display

① LC Display
② Green LED steadily lights up to indicate that

the utility input voltage is within the
window; the LED flashes flickeringly to
indicate that the utility input voltage is
within the acceptable window.

③ Green LED lights up to indicate Bypass

Input is normal.

④ Green LED lights up to indicate the UPS

has the capability to run under redundancy
mode.

⑤ UPS is working under ECO (Economic,

Line-interactive) mode.

⑥ UPS Fault or Abnormal
⑦ UPS On/Alarm Silence
⑧ UPS OFF Switch
⑨ Special functions log in/out
⑩ Go to next page
⑪ Go to previous page or change the setting

of the UPS.

⑫ To re-confirm the change of UPS Setting

3.1.1. Symbols on the LCD

DisplayPanel

Item Symbol Description

1

LINE

Utility or Bypass
Source

2

Battery Low

3

Battery Abnormal

4 UPS Overloading

5

UPS Working in
Service Mode

1

6

A Blackout
Transfer occurred
in UPS Output

7

Bypass Input
Abnormal, UPS
fails to transfer to
bypass, Bypass
Abnormal at ECO
mode

8

Utility Input
Abnormal

9

OFF

UPS Shutoff

10

LINE OFF

UPS Abnormal
Lock

11 UPS Flow Chart

12

4 Digit
Measurement
Display

13

Indicates the item
desired
to be measured

14

UPS ON Switch or
Alarm Silence

15 UPS OFF Switch

1

The specified modes include Normal mode, ECO mode,

CVCF mode, etc..

UPS Functional Descriptions

UPS-Manual

7

EN

16

Previous Page or
Setting Change

17 Next Page

18

Special Function
Log in /out

19

Enter or
Reconfirmed

20

Utility Input Normal
LED

21

Utility Input Normal
LED

22

UPS under
Redundancy Mode

23

UPS under ECO
Mode

24

UPS Fault or
Abnormal Warning
LED

25

EPO

Emergency Power
Off

26

Er05

Battery Weak or
Dead

27

Er06

Output Short
Circuit

28

Er10

Inverter Over­current

29

Er11

UPS Overheat

30

Er12

UPS Output
Overloading

31

Er15

Wrong Procedure
to Enter
Maintenance Mode

32

Er16

Output Parameters
Set Error in
Parallel System

33

Er17

ID Numbers are in
conflict in Parallel
System or ID
number Error in
single unit

34

Er21

Parallel
communication
error
(communication
wire disconnected
or failure to find
ID1 UPS ) in
parallel system

35

Er24

CVCF mode with
Bypass input

36

Er27

The UPS must be
operated in normal
mode in parallel
s

y

stem

37

Er28

Bypass Overload
Time out and cut
off output

38

Er31

The settings of
both control board
and driver board
are not matched
each other

39

Er**

Other Error Code

UPS Functional Descriptions

UPS-Manual

8

EN

3.2. Rear Panel Descriptions

A Terminal Resistor for Parallel function
B RS232 Port
C EPO Port
D Utility Input Breaker
E CAN Bus Connection Port for Parallel
System
F External Battery Connector
G Cooling Fan
H Utility Input &UPS Output Power Connector

I Customer Options Slot
J Slot

3.2.1. UPS input and output

3.2.2. Battery input

Model Maximum

Current

Conductor

Section

4,5 kVA 24 A 4 mm²

6 kVA 32 A 4 mm²

Model Maximum

Current

Conductor

Section

4,5 kVA 25 A

AWG #10,

6 mm²

6 kVA 25 A

AWG #10,

6 mm²

B A

C

D

G

I

E F

H

J

1 L in
2 N

in

PE
3 L

out

4 N out

UPS Functional Descriptions

UPS-Manual

9

EN

3.3. Communication Port Explanation

The Communication port on the UPS provides
true RS232 type communication with the UPS
software to remotely monitor the power and
UPS status.

The bundled UPS software is compatible with
many operating systems such as Windows 98,
& 2000, ME, NT and XP. For other applications
like Novell, NetWare, Unix, Linux, please
contact your local distributor for a proper
solution.

Highest Priority (in descending order),

1) EPO input port

2) Optional Interface card

3) RS232

3.3.1. EPO (Emergency Power Off)

The Pin assignments of the EPO Input port are:

1 2

1 Æ EPO+
2 Æ Ground

To enable the EPO function, please short Pin 1
& 2.

3.3.2. RS232 Port Descriptions

The RS232 interface shall be set as follows:

Baud Rate 2400 bps
Data Length 8 bits
Stop Bit 1 bit
Parity None

The Pin Assignments of the true RS232 port
are illustrated as follows:

Pin 3: RS232 Rx
Pin 2: RS232 Tx
Pin 5: Ground

1

2

3

4

5

6

7

8

9