PowerPak PDU Installation and Operation

PowerPak PDU Installation and Operation
WaveStar®
PowerPak
Power Distribution Unit
50 – 300 kVA
Installation and Operation
Ctrl Nr: PM375118
Revision: 001
PowerPak PDU 50-300 kVA
Thank you for your recent purchase of a PowerPak Power Distribution Unit from Power Distribution,
Inc.
For safety reasons as well as to ensure optimal performance of your PowerPak Power Distribution
Unit, please carefully read the instructions before trying to install, operate, service, or maintain the
system.
For any questions regarding the installation, operation, service, or maintenance of your PowerPak
Power Distribution Unit, please contact us:
Power Distribution, Inc. | 4200 Oakleys Court | Richmond, VA 23223
+1 804 737 9880 | +1.800.225.4838
pdicorp.com | service@pdicorp.com
WaveStar® PowerPak Power Distribution Unit
Installation and Operation
Ctrl Nr: PM375118 Revision: 001
Release Date: February 2017
© 2017 Power Distribution, Inc. All rights reserved.
Cover Photo: PowerPak PDU with Two 21-inch Side Cars
PDI, WaveStar, JCOMM, Powercube, QUAD-WYE, QUIKSWITCH, DynaCool On-demand Cooling
System, are registered trademarks of Power Distribution, Inc. Other trademarks are held by their
respective owners.
Power Distribution, Inc. (PDI)
Power Distribution, Inc. (PDI) designs, manufactures, and services mission critical power distribution, static switches, and
power monitoring equipment for corporate data centers, alternative energy, industrial and commercial customers around the
world. For over 30 years, PDI has served the data center and alternative energy markets providing flexible solutions with the
widest range of products in the industry.
.
2
Contents
Contents
Safety ............................................................................................8
1
2
Introduction ..........................................................................9
1.1
PowerPak PDU Summary .................................................................... 9
1.2
Standards ........................................................................................ 9
1.3
Environmental Requirements ............................................................ 10
Installation Planning: PDU Layouts .....................................11
2.1
3
4
PDU Enclosure ................................................................................ 11
2.1.1
PDU Dimensions ................................................................... 11
2.1.2
Spacers ............................................................................... 11
2.2
PDU Weights .................................................................................. 11
2.3
Mounting Options ............................................................................ 12
2.4
Clearances ..................................................................................... 12
2.5
PDU Layouts ................................................................................... 12
2.6
PDU Service Access Configurations .................................................... 18
2.6.1
Front Access Only ................................................................. 18
2.6.2
Front and Side Access Only .................................................... 19
2.6.3
Front and Rear Access Only .................................................... 19
2.6.4
Front, Rear, and Side Access .................................................. 20
Installation Planning: Electrical .......................................... 21
3.1
PDU Electrical Specification............................................................... 21
3.2
Transformer ................................................................................... 21
3.2.1
Transformer Parameters and Options ...................................... 21
3.2.2
Transformer BTUs ................................................................. 22
3.2.3
Transformer Voltage Compensation Taps ................................. 22
3.2.4
Transformer Temperature Alarms ........................................... 22
3.2.5
Infrared Scan Windows .......................................................... 23
3.2.6
Front-Facing Transformer ...................................................... 23
3.3
One-Line Overview .......................................................................... 23
3.4
Main Input Circuit Breaker ................................................................ 23
3.5
Surge Protective Devices .................................................................. 23
3.6
Subfeed and Panelboard Capacity...................................................... 25
Installation: Placing the PDU .............................................. 26
4.1
Receiving and Unpacking the PDU ..................................................... 26
4.2
Placing the PDU .............................................................................. 26
4.3
Pre-Placement Inspection ................................................................. 27
4.4
Placing Directly on Floor or Raised Floor ............................................. 27
3
PowerPak PDU 50-300 kVA
4.5
5
6
7
8
Installation: Power Cabling ................................................. 32
5.1
Input Power Cabling ........................................................................ 32
5.2
Input Power Junction Box Option ....................................................... 39
5.3
Input Power Wiring .......................................................................... 41
5.4
Distribution Cabling ......................................................................... 42
5.4.1
Subfeeds ............................................................................. 42
5.4.2
Square D I-Line Subfeed Panelboards ...................................... 42
5.4.3
Distribution Panelboards ........................................................ 42
PDU Initial Start-Up ............................................................ 44
6.1
PDU Post-Installation Inspection ....................................................... 44
6.2
Initial Start-Up Procedure ................................................................. 44
PDU Procedures ..................................................................46
7.1
Normal Start-Up ............................................................................. 46
7.2
Normal Shutdown Procedure ............................................................. 46
7.3
Automatic Shutdown Signals ............................................................ 46
7.4
Manual or Automatic Restart ............................................................. 46
7.5
Changing Transformer Taps .............................................................. 47
Monitoring: Components ..................................................... 49
8.1
Monitoring Component Summary ...................................................... 49
8.2
Customer Connections ..................................................................... 49
8.3
PDU Board and Contractor Boards ..................................................... 50
8.4
8.5
8.6
9
Placing PDU on Optional Floor Stand .................................................. 27
8.3.1
PDU M4G Board .................................................................... 50
8.3.2
Basic Contractor Board .......................................................... 53
8.3.3
Enhanced Contractor Board .................................................... 54
8.3.4
PDU M4G Board Points List ..................................................... 55
Branch Circuit Monitoring System (BCMS) .......................................... 55
8.4.1
Panelboard and Subfeed Monitoring ........................................ 55
8.4.2
BCMS Points Lists ................................................................. 56
Dry Contact Network ....................................................................... 57
8.5.1
Dry Contacts for Subfeed Circuit Breakers (optional) ................. 58
8.5.2
Surge Protective Device Status ............................................... 58
Subfeed Circuit Breaker Trip ............................................................. 58
Monitoring: PDU Network .................................................... 60
9.1
Color Monitor and Protocols .............................................................. 60
9.2
Customer Network Connections ........................................................ 60
9.3
Modbus Addressing ......................................................................... 60
9.4
Color Monitor Network Connections ................................................... 61
4
Contents
9.5
9.4.1
Modbus RTU Ports ................................................................. 63
9.4.2
Modbus RTU 2-Wire vs. 4-Wire Configuration ........................... 63
Modbus RTU Cables ......................................................................... 64
9.5.1
Cable Specification ................................................................ 64
9.5.2
Cable Biasing and Termination................................................ 64
9.6
Ethernet Cables .............................................................................. 64
9.7
Setting Color Monitor Network Parameters ......................................... 64
9.8
9.7.1
Downstream Modbus Device Chain Setup ................................. 65
9.7.2
Modbus RTU Setup ................................................................ 65
9.7.3
TCP/IP and Modbus TCP/IP Setup ........................................... 66
9.7.4
SNMP Setup ......................................................................... 67
Device Settings ............................................................................... 67
9.8.1
9.9
10
11
Device Readings.............................................................................. 68
Monitoring: Alarms .............................................................. 70
10.1
Summary Alarm Indicators ............................................................... 70
10.2
Alarm Screen and Alarm List............................................................. 70
10.3
Alarms by Device Type..................................................................... 72
10.3.1
Color Monitor Alarms ........................................................... 72
10.3.2
PDU Alarms ........................................................................ 72
10.3.3
Enhanced Subfeeds ............................................................. 75
10.3.4
BCMS Panelboard—Typical Alarms ......................................... 76
Manual Dual PDU Option ..................................................... 77
11.1
Initial Status: Circuit Breakers and Kirk Keys ...................................... 77
11.2
Permissive Signal Options ................................................................ 78
11.3
Customer Wiring for Permissive Signals ............................................. 78
11.3.1
Internal Permissive Signal .................................................... 78
11.3.2
External Permissive Signals .................................................. 78
11.3.3
Dry Contact External Permissive Signal .................................. 78
11.3.4
120VAC External Permissive Signal ....................................... 79
11.4
Using Cam Locks with Alternate Power Source (Optional) ..................... 79
11.5
Dual Input Source Transfer Procedures .............................................. 80
11.6
12
PDU Device Settings .............................................................. 67
11.5.1
Transfer Procedure: Internal Permissive Signal Only ................ 80
11.5.2
Transfer Procedure: External Permissive Signal Only ............... 82
11.5.3
Transfer Procedure: External Plus Internal Permissive Signals... 83
Open Transition Transfer .................................................................. 84
Service ................................................................................ 86
12.1
Start Up ......................................................................................... 86
5
PowerPak PDU 50-300 kVA
12.2
Service Contracts ............................................................................ 86
12.2.1
Standard Warranty .............................................................. 86
12.2.2
Extended Warranty ............................................................. 86
12.3
Maintenance Contracts ..................................................................... 86
12.4
Time and Materials .......................................................................... 87
12.5
Spare Parts Kits .............................................................................. 87
Bibliography ................................................................................ 88
Glossary ...................................................................................... 89
Tables
Table 1 PDU Dimensions by Enclosure Type ....................................................................................... 11
Table 2 Sample PDU Weights .............................................................................................................. 11
Table 3 Transformer Parameters .......................................................................................................... 22
Table 4 BTUs per Hour for Selected K13 Transformers ....................................................................... 22
Table 5 PDU Subfeed Capacities by Amperage ................................................................................... 25
Table 6 PDU Panelboard Capacities at 208VAC .................................................................................. 25
Table 7 PDU Panelboard Capacities at 480VAC .................................................................................. 25
Table 8 Square D I-Line Subfeed Circuit Breaker Capacities ............................................................... 25
Table 9 Input Cable Entry Options ........................................................................................................ 33
Table 10 Power J-Box and Power Cable Sizing Chart ......................................................................... 40
Table 11 Dry Contact Signals ............................................................................................................... 59
Table 12 Pin-Out for Modbus Headers ................................................................................................. 63
Table 13 Spare Parts Kits for PowerPak PDU ...................................................................................... 87
Figures
Figure 1 Main Cabinet with 3-in Side Spacer ........................................................................................ 11
Figure 2 PDU 50-150 kVA Main Cabinet with Panelboards (Example) ................................................ 13
Figure 3 PDU 200-300 kVA with 9-in Side Car and Four Panelboards (Example)............................... 14
Figure 4 PDU 200-300 kVA with 21-in Side Car and Front-Facing Transformer Taps (Example) ....... 15
Figure 5 Main Cabinet and 12-in Side Car with 1000A I-Line Panelboard (Example) ......................... 16
Figure 6 Front-Access PDU: Main Cabinet and Extension with 1000A I-Line Panelboard (Example) . 17
Figure 7 PowerPak Front-Access PDU with Two 21-in Side Cars ....................................................... 18
Figure 8 PowerPak PDU, Front and Rear Access, Main Cabinet with Two Panelboards, Doors Off .. 19
Figure 9 One-Line for PDU with Single Main Input Circuit Breaker ...................................................... 24
Figure 10 PDU Floor Stand with Height Options .................................................................................. 29
Figure 11 PDU Floor Stand Detail ........................................................................................................ 30
Figure 12 Mounting PDU on Floor Stand .............................................................................................. 31
Figure 13 Bottom Cable Entry to Terminal Block with Compression Lugs ........................................... 34
Figure 14 Bottom Rear Cable Entry to Terminal Block with Mechanical Lugs ..................................... 35
Figure 15 Bottom Rear Cable Entry through Floor Stand ..................................................................... 36
Figure 16 Bottom Front Cable Entry to Staggered Busbars ................................................................. 37
Figure 17 Top Cable Entry .................................................................................................................... 38
Figure 18 Power J-Box.......................................................................................................................... 39
Figure 19 Ground Connections for Front-Access Only PDU ................................................................ 41
Figure 20 Distribution Ground and Neutral Busbars ............................................................................. 42
Figure 21 Underfloor Junction Box for 1000A I-Line Panelboard in 12-in Side Car ............................. 43
6
Contents
Figure 22 Transformer Taps ................................................................................................................. 47
Figure 23 Open Controls Compartment ................................................................................................ 49
Figure 24 PDU (M4G) Board................................................................................................................. 51
Figure 25 Basic Contractor Board ......................................................................................................... 53
Figure 26 Enhanced Contractor Board ................................................................................................. 55
Figure 27 BCMS HV Board ................................................................................................................... 57
Figure 28 SPD/TVSS Status Lights ...................................................................................................... 58
Figure 29 Color Monitor Network Connections ..................................................................................... 61
Figure 30 Internal PDU Network, Modbus Addressing, Example ......................................................... 62
Figure 31 Color Monitor SETUP Screen ............................................................................................... 64
Figure 32 Modbus RTU Setup .............................................................................................................. 65
Figure 33 Modbus TCP/IP and SNMP Setup........................................................................................ 66
Figure 34 Settings: PDU Device ........................................................................................................... 68
Figure 35 Readings: PDU ..................................................................................................................... 69
Figure 36 Alarm and Warning Summary Status Icons .......................................................................... 70
Figure 37 ALARM Screen with an Alarm List........................................................................................ 71
Figure 38 Finding the Circuits in an Alarm Condition ........................................................................... 72
Figure 39 PDU Internal Panel, Kirk Keys .............................................................................................. 77
Figure 40 Dry Contact External Permissive Signal Connection ............................................................ 79
Figure 41 120V External Permissive Signal Connection ...................................................................... 79
Figure 42 Optional Cam Locks for Second Power Source ................................................................... 80
Figure 43 Color Monitor Synch Screen ................................................................................................. 81
Figure 44 Transfer Procedure Using Internal Permissive Signal .......................................................... 81
Figure 45 Two-Stage Permissive Signal: External plus Internal ........................................................... 83
Figure 46 One-Line Manual Dual PDU with Permissive Signal Wiring Variations................................ 85
7
PowerPak PDU 50-300 kVA
Safety
Please pay special attention to the use of “Danger” symbols throughout this manual indicating
electrical or other safety hazards. Following these safety instructions is extremely important to avoid
possible injury or death.
The PowerPak Power Distribution Unit must be installed by licensed
electricians or by PDI-authorized technicians.
Follow safe electrical work practices:





Read, understand, and follow the instructions before installing this product.
Electrical equipment should be installed, operated, serviced, and maintained only by qualified
personnel and in accordance with all local safety codes. Power Distribution, Inc. assumes no
responsibility for any consequences arising out of the use of this manual. This document should
not be viewed as sufficient by otherwise non-qualified personnel to operate, service, or maintain
the equipment discussed.
Disconnect and lock-out all power supplying equipment before working on or installing
components. Use a properly rated voltage sensing device to confirm power is OFF.
Install device in an appropriate electrical enclosure per local regulations.
ESD sensitive equipment. Ground yourself, discharge any static charge and ensure that the
device is effectively grounded before handling the unit.
DANGER!
Severe or fatal injury can result from electrical shock during contact with high
voltage conductors, monitoring PCBs, or similar equipment.
Disconnect power before drilling holes, attaching conduit, or connecting power
cables or control wiring.
Use Lock Out/Tag Out procedures.
Wear suitable personal protective clothing and use protective equipment for
performing mechanical and electrical installations.
Leave ample space for attaching and routing wires.
8
Introduction
1 Introduction
1.1 PowerPak PDU Summary
The WaveStar® PowerPak Power Distribution Unit (PDU) is a versatile and highly configurable 50300 kVA PDU. Features and options include the following:










50-300 kVA DOE transformer with a choice of transformer sizes, vectors, taps, and options,
including the option of non-DOE efficiency standards for exempt and non-US customers.
Wide variety of electrical, panelboard, and circuit breaker configurations.
Top, bottom rear, and bottom front cable entry/exit.
Manual dual PDU configuration with Kirk Key lockouts and choice of different permissive signals.
Oversized neutrals.
Optional Surge Protective Devices (SPDs) (or Transient Voltage Surge Suppressor (TVSS)) on
input and output.
Front- and side-facing Side Cars:
o Up to (10) panelboards or (420) 1P branch circuits can be installed with Side Cars.
o Up to (12) 250A subfeeds can be installed with Side Cars.
o Square D I-Line subfeed panelboards (800A, 1000A, and 1200A) can be installed in
specially designed Side Cars or Main Cabinet Extensions.
Physically configurable for service access as front-only, front-and-rear, or front-rear-side(s).
Can be integrated with WaveStar® Static Transfer Switches in Primary or Secondary Systems.
Extensive monitoring capabilities:
o WaveStar® Color Monitor as local PDU display.
o Monitoring for transformer, main power feeds, subfeeds, panelboards, and other PDU
functions.
o Integration with the PDI family of Branch Circuit Monitoring System (BCMS) monitoring
products.
o Support for Modbus RTU, Modbus TCP/IP, and SNMP protocols through the Color
Monitor, providing communications with Building Management Systems and Data Center
Infrastructure Management (DCIM) Systems.
o Extensive dry contact network.
You should consult with your PDI sales representative and with PDI Applications Engineering to
select a PDU package that meets your application needs.
1.2 Standards
The PowerPak PDU is certified through ETL for the following standards:
 UL 60950-1
 CS 22.2
In addition, the PowerPak PDU is designed, manufactured, tested, and installed in compliance with
the following standards:
 UL67
 UL50
 UL489
 UL 891
 UL1561
 NFPA
9
PowerPak PDU 50-300 kVA








IEEE 519-1991
ANSI C33.4
NEMA ST-20
NEMA AB-1
NEMA-PB-1
NEC
ISO 9001
CS57.12.91
The PowerPak PDU complies with the latest FCC Part 15 EMI emission standard for Class A
computing devices.
1.3 Environmental Requirements
Environmental Operating Limits:



Operating ambient temperature range: 0⁰C to 40⁰C (32⁰F to 104⁰F).
Relative humidity range from 0% to 95% non-condensing.
Maximum altitude 6,600 ft. For installation above 6,600 ft., consult with the factory for de-rating
information.
Acceptable PDU storage (non-operating) temperature is -36⁰C to +70⁰C (-33⁰F to 158⁰F).
10
Installation Planning: PDU Layouts
2 Installation Planning: PDU Layouts
2.1 PDU Enclosure
The PDU has a NEMA 1 enclosure with removable front, side, and rear panels. A NEMA 3R
enclosure is optional. Advanced door catches ensure positive door closure.
2.1.1
PDU Dimensions
Table 1 below gives dimensions for the various PDU frames. Because frames are combined in
different configurations, your actual PDU dimensions will vary by side car options and transformer
size. Your submittal package will include drawings for your PDU’s layout. To determine your PDU’s
footprint, you must also account for clearances (see below, Section 2.4 Clearances).
Table 1 PDU Dimensions by Enclosure Type
Main Cabinet (with ˂ 200 kVA transformer)
Main Cabinet (with 200–300 kVA transformer)
21" Front-Facing/Side-Facing Side Car add-on
9" Side-Facing Side Car add-on
12" Side-Facing Side Car (I-Line Panelboards) add-on
36.5"W x 32.75"D x 74.75"H*
36.5"W x 39.00"D x 74.75"H*
21.00"W x 32.75"D x 74.75"H*
9.00"W x 32.75"D x 74.75"H*
12.00"W x 32.75"D x 74.75"H*
Main Cabinet extension for 1200A I-Line Panelboards
46.75"W x 32.75"D x 74.75"H*
* Includes height of PDU with casters.
Note: See sample PDU layout drawings (Figures 2-6) for dimensions on several PDU configurations.
12" side cars and the Main Cabinet extension can also be used for larger
400A panelboards.
2.1.2
Spacers
In some cases spacers are used to extend the PDU enclosure:


A 6.25" rear spacer is added for larger transformers, 200-300 kVA (see
above, Table 1).
A 3" side spacer is used for monitoring components when a dense
PDU configuration leaves no room inside the Main Cabinet (Figure 1).
Your submittal drawings will show dimensions for your specific PDU.
Figure 1 Main Cabinet
with 3-in Side Spacer
2.2 PDU Weights
PDU weight varies by configuration, especially by transformer size.
Table 2 Sample PDU Weights
PDU Configuration
Main Cabinet, no side cars, 2 panelboards
Main Cabinet, 1 x 9" side car, 2 panelboards
Main Cabinet, no side cars, 4 subfeeds
Main Cabinet, 1 x 9" side car, 4 panelboards
Transformer
75 kVA
125 kVA
150 kVA
150 kVA
Approximate Weight
(LBS)
1300
1610
1705
1785
11
PowerPak PDU 50-300 kVA
PDU Configuration
Approximate Weight
(LBS)
Main Cabinet, no side cars, 6 subfeeds,
225 kVA
2010
Main Cabinet, 1 x 9" side car, 2 panelboards
225 kVA
2205
Main Cabinet, 1 x 21" side car, 6 subfeeds
300 kVA
2470
Main Cabinet, 1 x 21" side car, 6 subfeeds
300 kVA
2695
Main Cabinet, 1 x 21" side car, 2 subfeeds, 4 panelboards
300 kVA
2840
Note 1: Weights are from actual shipments. Weights vary by the PDU’s component characteristics.
Note 2: Floor stands are not included in the PDU weight. Floor stand weights in the above examples
are about 200-400 lbs.
Transformer
PDU shipping weight is given on the bill of lading.
2.3 Mounting Options
The PDU can be installed on both fixed floor or on a floor stand in a raised floor environment. The
PDU alone or the PDU with floor stand conforms to seismic zone four requirements, California
standard, per IBC 2010. The following mounting options are available:



Heavy duty casters and leveling feet are standard on the Main Cabinet. Casters can support the
weight of the PDU.
An optional universal floor stand is available with heights from 11-76"H to match raised floor
height. See Section 4.5 Placing PDU on Optional Floor Stand. Fixed height floor stands are
also available for 8-11" heights.
An optional skirt provides air closure around the PDU.
2.4 Clearances



Ventilation clearance: recommended 6" minimum ventilation clearance on rear and both sides;
18" overhead clearance also recommended.
Service clearance: 36" required front access; 36" required side clearance for Side Cars with side
access. 36" service clearance is also required in PDU rear to access transformer taps and
infrared scanning unless the transformer is rotated.
Cabling: 12" underfloor cabling clearance is recommended for raised floor.
2.5 PDU Layouts
The PDU has many possible configurations as Main Cabinet only or Main Cabinet plus Side Cars on
either side or with a Main Cabinet Extension. Figures 2-6 show selected layouts.
12
Installation Planning: PDU Layouts
PDUs with distribution
PDUs with have prepanelboards
panelboards
punched
cablehave
exit prepunched cable trays.
trays.
Pre-holes are
7/8" dia.
Pre-punched
knockfor 1/2"
dia. dia.
holes.
outs
are 7/8"
for
1/2" dia. conduit.
Customer connects input power to PDU
terminal block, shown here with
mechanical lugs.
Figure 2 PDU 50-150 kVA Main Cabinet with Panelboards (Example)
13
PowerPak PDU 50-300 kVA
PDUs with 200-300
kVA transformers have
6.25" rear spacers.
PDUs with distribution
panelboards have prepunched cable exit
trays.
Pre-punched knockouts are 7/8" dia. for
1/2" dia. conduit.
Figure 3 PDU 200-300 kVA with 9-in Side Car and Four Panelboards (Example)
14
Installation Planning: PDU Layouts
PDUs with 200-300
kVA transformers have
6.25" rear spacers.
PDUs with subfeeds
have solid cable trays
above or below the
subfeeds. Customers
provide their own
conduit or cable cutouts.
Side Cars can be installed on one or both
sides of the Main Cabinet.
9" and 12" Side Cars are side-facing only.
21" Side Cars are both front- and sidefacing and can be used as front-only.
Neutral and ground bus bar are
installed in the Side Car for subfeed
connections. Holes are 3/8" or 1/2" dia.
Figure 4 PDU 200-300 kVA with 21-in Side Car and Front-Facing Transformer Taps (Example)
15
PowerPak PDU 50-300 kVA
PDUs with 200300 kVA
transformers
have 6.25" rear
spacers.
12" Side Cars can accommodate 800A or 1000A
Square D I-Line Panelboards.
1000A I-Line Panelboards require an underfloor
junction box for distribution because of space
limitations in the Side Car. Neutral and ground
output bus bars are placed in the junction box.
See Figure 17.
36" front clearance is required. (Door swing
clearance is not sufficient service access
clearance.)
Figure 5 Main Cabinet and 12-in Side Car with 1000A I-Line Panelboard (Example)
16
Installation Planning: PDU Layouts
PDUs with
200-300 kVA
transformers
have 6.25"
rear spacers.
A Main Cabinet Extension can accommodate 1000A and 1200A I-Line
Panelboards without an underfloor distribution junction box. Neutral and
ground busbars are contained in the Extension.
The Main Cabinet Extension can
also be used to provide frontaccess to Square D I-Line
Panelboards, for customers
needing a front-access-only PDU.
36" front clearance is required.
(Door swing clearance is not
sufficient service access
clearance.)
Figure 6 Front-Access PDU: Main Cabinet and Extension with 1000A I-Line Panelboard (Example)
17
PowerPak PDU 50-300 kVA
2.6 PDU Service Access Configurations
The PDU can be flexibly configured for different service access requirements:




Front access only PDU
Front and side access only (one or both sides)
Front and rear access only
Front, side, and rear access PDU (one or both sides)
2.6.1
Front Access Only
The PDU can be made front-access for routine maintenance, including easy circuit breaker
replacement, and extension of circuit breaker capacity.
The transformer can as an option be turned 180⁰ making transformer taps and infrared scanning
front-accessible. Distribution should be in the Side Cars. Rear service access is not required; only 6"
ventilation clearance is required at the rear or sides.
Outer lockable
doors.
Dead front panels
over panelboards
and panelboard
main feeds
Dead panels on
front-facing
transformer.
Front split doors
reduce door swing.
Figure 7 PowerPak Front-Access PDU with Two 21-in Side Cars
Front access PDUs can have the following:



Main Cabinet should have front-facing transformer for front access to taps and infrared scanning.
21” front- and side-facing Side Cars, using front access only to Side Cars.
(Optional) Main Cabinet Extension for 1000A or 1200A Square D I-Line panelboards.
18
Installation Planning: PDU Layouts
2.6.2
Front and Side Access Only
Front and side-access PDUs (one or both sides) can have the following:




Main Cabinet with front-facing transformer.
21” front- and side-facing Side Cars, requiring 36" side service clearance if side access is used.
9" side-facing Side Car(s), requiring 36" service clearance on sides with this Side Car.
12" side-facing Side Car for I-Line panelboards.
2.6.3
Front and Rear Access Only
Front and rear access PDUs can have the following:


Main Cabinet with rear-facing transformer taps
21" Side Car(s), if side access is not used.
9" and 12" Side Cars are not allowed.
Controls Compartment
Main Input Circuit Breakers
WaveStar Color Monitor
Panelboard Main Circuit Breakers
42-Pole Panelboards
Component Mounting Plate
(Note: With Component Mounting
Plate, transformer is rear-facing.)
Neutral and Ground Strips
Distribution Cable Tray with Knock-outs
Figure 8 PowerPak PDU, Front and Rear Access, Main Cabinet with Two Panelboards, Doors Off
19
PowerPak PDU 50-300 kVA
2.6.4
Front, Rear, and Side Access
Front, side (one or both sides), and rear access PDUs:


Main Cabinet with rear-facing transformer
All Side Car configurations and Main Cabinet Extension configurations are allowed.
20
Installation Planning: Electrical
3 Installation Planning: Electrical
3.1 PDU Electrical Specification






Input: 3-phase, 3 wire plus ground
Input Voltage
o @ 50 Hz: 415VAC or 380VAC
o @ 60 Hz: 600, 480 or 208V
Output: 3-phase, 4 wire plus ground
Output Voltage
o @ 50 Hz: 575, 415/240, or 380/220V
o @ 60 Hz: 600, 575, 480, or 208/120V
Output:
o Neutral: computer grade neutrals for subfeeds and panelboards
 200%-rated neutral busbars
 173%-rated panelboard neutrals
o Ground: Computer-grade single point safety ground
o Isolated ground available as option
Emergency Power Off (EPO) button on front-mounted Color Monitor bezel
3.2 Transformer
3.2.1
Transformer Parameters and Options
The PDU is fed from an integral 3-phase, copper or aluminum, high isolation transformer. The
transformer is specifically designed for the PDU and its applications, providing voltage transformation,
voltage adjustment, high isolation, conditioning, and shielding. Each transformer is complete with
electrostatic shielding and uses a universal footing template inside the PDU to secure the transformer
to its base.
Each transformer is tested to the C57.121.91 standard.
Standard transformers with DOE2016 efficiency and K-Factor K13 are offered at 150, 225, and 300
kVA. Table 3 lists transformer parameters.


Standard transformer parameters are applicable to all standard transformers at 150, 225, and 300
kVA.
Non-DOE2106 transformer efficiency standards are offered for customers outside the US and for
certain exempt categories in the US.
21
PowerPak PDU 50-300 kVA
Table 3 Transformer Parameters
Parameter
Input Voltage
Output Voltage
Frequency
Impedance
Efficiency
Standard Transformer
480V Delta
208 /120V Wye
60 Hz
2.5 – 5%
DOE2016
K-Factor
Conductor Material
Inrush
Taps (150-300 kVA)
K13
Copper (CU)
8 – 10x
+2, -4 x 2.5%
Temperature Rise
Vector
150⁰C
Delta-Wye
Average sound level
Applicable Standard
NEMA ST-20
DOE2016, UL-1561
IEEE Standard C57.12.01
240⁰C Class S
Insulation
3.2.2
Options
400 – 600V
208 – 600V
50 Hz
Up to 6%
Non-DOE2016 or non-TP1 offered for
certain exempt categories, CEC,
CSA, NEMA Premium, or customerrequested efficiency values.
K4, K9, K20
Aluminum (AL)
5x
±2 x 2.5%, custom taps or no taps
designs also available
115⁰C, 130⁰C
Delta Zig-Zag
Delta Quad-Wye
NEMA ST-20
IEC 60076, CSA22.2 No 66, CEC
400
Transformer BTUs
Transformers generate heat, which should be considered in placing the PDU. The following table
shows transformer BTU output at the kVA values offered for standard K13-rated transformers:
Table 4 BTUs per Hour for Selected K13 Transformers
kVA
150
225
300
3.2.3
BTUs/Hour
14,296
20,536
22,483
Transformer Voltage Compensation Taps
The PDU has six (6) transformer voltage compensation taps (4FCBN, 2FCAN). Section 7.6 Changing
Transformer Taps has the procedure for changing taps.
3.2.4
Transformer Temperature Alarms
A standard transformer has six (6) thermal overload devices to monitor core temperature in each
winding.

180⁰F warning: The first set of thermal devices is calibrated to 180⁰F, the warning threshold.
If any winding reaches 180⁰C core temperature, the thermal overload protection device
closes a set of contacts for annunciation of a potential over-temperature condition.
22
Installation Planning: Electrical


3.2.5
195⁰F shutdown: The second set of thermal devices is calibrated to 195⁰F, the shutdown
threshold. If any winding reaches 195⁰F core temperature, the thermal overload protection
device closes a set of contacts for annunciation of an over-temperature condition and
initiates an automatic PDU shutdown.
Settings adjustment: Temperature warning and alarm levels can be adjusted by PDI at
customer request.
Infrared Scan Windows
Optional 3" infrared scan windows are available for side or rear transformer thermal scanning.
3.2.6
Front-Facing Transformer
The transformer can be rotated 180⁰ to make transformer taps and transformer infrared scanning
accessible from the front of the PDU. Only 6" rear ventilation clearance is required instead of 36"
service clearance. Because the main cabinet’s Component Mounting Plate is removed, distribution
must be placed in side cars. Alternatively, a half-height Component Mounting Plate can be provided,
allowing (1) 250A panelboard or up to (3) 250A subfeeds in the Main Cabinet.
3.3 One-Line Overview
Figure 9 is a general one-line diagram showing the most common electrical layout with optional
SPD/TVSS devices and input wire specifications.
One-line diagram for manual dual PDUs showing permissive signal connections for the Solenoid Key
Release Unit (SKRU) is in Chapter 11, Manual Dual PDU Option (Figure 46).
3.4 Main Input Circuit Breaker
The standard Main Input Circuit Breaker is as follows:


˂ 225kVA: thermal magnetic circuit rated 80% at 480VAC with 35 kAIC and matched to the
transformer size.
225kVA – 3000 kVA: fixed (non-adjustable) electronic trip circuit breaker rated 80% at 480VAC
with 35 kAIC and matched to the transformer size.
The PDU has many Main Input Circuit Breaker options with different PDU voltages, amperages, kAIC
ratings, and trip settings. Consult with your sales representative or PDI Applications Engineering for
options.
3.5 Surge Protective Devices
SPD/TVSS devices can optionally be installed on the primary and/or secondary sides of the
transformer. SPDs are listed to UL 1449 3rd Edition and have the following ratings:


LEA SP100 providing 100,000 Amps maximum surge current dissipation per phase.
LEA SP200 providing 200,000 Amps maximum surge current dissipation per phase.
See SPD/TVSS locations in Figure 9, “One Line for PDU with Single Main Input Circuit Breaker.”
23
PowerPak PDU 50-300 kVA
Figure 9 One-Line for PDU with Single Main Input Circuit Breaker
24
Installation Planning: Electrical
3.6 Subfeed and Panelboard Capacity
The following tables provide general guidance on PDU physical configuration possibilities. PDU
capacity depends both on physical configurability and on the electrical limits of the transformer.
Table 5 PDU Subfeed Capacities by Amperage
250A Subfeeds
Main cabinet
6
9" Side-facing side car
6
21" Front-and-side facing side car
9
Maximum total PDU capacity
12
Note: Subfeed circuit breakers are all 600V rated.
400A Subfeeds
4
4
4
8
Table 6 PDU Panelboard Capacities at 208VAC
225A Panelboards at
400A Panelboards at
208VAC
208VAC
Main cabinet
2
2
9" Side-facing side car
2
2
21" Front-and-side facing side car
4
2
Maximum total PDU capacity
8
6
Note: Each panelboard is protected by a 3-pole secondary main circuit breaker.
Table 7 PDU Panelboard Capacities at 480VAC
225A Panelboards at
400A Panelboards at
480VAC
480VAC
Main cabinet
1
1
9" Side-facing side car
1
1
21" Front-and-side facing side car
0
0
Maximum total PDU capacity
3
3
Note: Each panelboard is protected by a 3-pole secondary main circuit breaker.
Table 8 Square D I-Line Subfeed Circuit Breaker Capacities
225A Frame Circuit Breakers
800A MLO (12" side-facing side
car)
1000A MLO (12" side-facing
side car)
(includes underfloor power
junction box)
1200A MLO (requires 46.7"W
main cabinet front-facing
extension frame)
400A Frame Circuit Breakers
10
N/A
11
8
11
8
25
PowerPak PDU 50-300 kVA
4 Installation: Placing the PDU
4.1 Receiving and Unpacking the PDU
PowerPak PDUs are shipped as fully assembled units with optional side cars attached and internal
cabling completed. Units are strapped to shipping pallets, but not bolted to pallets, and are protected
by two layers of external plastic covering. The PDU is first covered by a large plastic bag and then
shrink-wrapped.
1. Upon receiving a PowerPak PDU pallet and before removing packaging, inspect the
packaging for visible damage that could affect the PDU. If damage is evident notify PDI and
the shipping company (see below).
2. Carefully remove the outer layer of protective shrink wrap from the unit, but leave the interior
plastic covering intact. Use care to not puncture or scratch the PDU cabinets with cutting
tools. NOTE: Do not cut the retaining bands until the PDU has been moved on its pallet close
to its installation location.
3. After removing the outer external packaging, check the unit’s exterior panels and doors for
any visible damage such as scratches dents, cracks. If any damage is noted, please call PDI
Service at (800) 225-4838.
4. If any damage is evident during unpacking, notify the shipping company and PDI:
a. File a claim with the shipping company at the time of delivery. Damage must be noted
on the bill of lading. Failure to properly document all damages may result in the unit’s
warranty being voided.
b. Notify PDI Service at
Power Distribution Inc.
4200 Oakleys Court
Richmond, Virginia 23223
(800)-225-4838
service@pdicorp.com
4.2 Placing the PDU
Danger!
Do not remove the retaining bands securing the PDU to its pallet until the PDU
is near its final position and you are ready to remove the PDU from its pallet.
Retaining bands are under tension; cut them carefully. Wear protective
clothing and use eye, face, and hand protection when cutting bands.
1. Move the PDU, still secured to its pallet, to as near its operating position as is practicable with
a forklift truck or pallet jack.
2. Carefully cut the safety bands, making sure that they do not scrape the exterior of the unit or
scratch the paint. Use eye, face, and hand protections to guard against injury when bands are
cut.
3. Remove the PDU from its pallet using a fork-lift truck. Take care that the unit is properly
centered on the forks.
26
Installation: Placing the PDU
4. Once the unit is completely off the pallet, carefully remove the large plastic bag covering the
PDU. The unit is now ready to be placed in its final position and prepared for installation.
If you have questions or need further assistance, call PDI Service at (800) 225-4838.
4.3 Pre-Placement Inspection
The installer should perform a complete internal inspection of the PDU after the PDU has been
placed in its approximate operating position and before electrical hookup. The following items must
be included in the inspection checklist:
1. Transformers: Inspect the transformers for any loose connections or displacement during
shipment. Check to make sure all terminal lugs are tight and secure.
2. Internal feeders: Ensure all lug connections are tight and secure.
3. Main input feeder:
a. Check the main input feeder connections at the main breaker to be sure vibration has
not loosened the terminal screws.
b. Check the feeders from the load side of the main breaker to the primary side of both
transformers.
4. Check all other lugs (i.e. neutral bus, ground bus, terminal blocks, etc.).
4.4 Placing Directly on Floor or Raised Floor
The PDU can be moved on a fork lift or pallet jack and placed directly on a floor or raised floor. The
floor must be capable of supporting the PDU’s weight. See Section 2.2 PDU Weights for approximate
weights. PDUs are weighed when shipped and actual PDU weight is given on the bill of lading.
Check that required clearances are met when the PDU is placed in its operating position (see Section
2.4 Clearances).
4.5 Placing PDU on Optional Floor Stand
The PDU can be placed on an optional floor stand that will support the PDU’s weight. Floor stands are
available in several heights to match the height of your installation’s raised floor, ranging from 11" to
76".
Each floor stand provides a height range and is adjustable within that range. Center supports are
provided on the larger floor stands (48", 60", and 72" height). (See Figures 10-11.) Fixed-height floor
stand are also available in 8-11" heights. At time of order, select the floor stand that matches your
raised floor height.
To install, follow these steps:
1. Remove floor tiles and/or make floor tile cutouts to match the width and depth of the floor
stand (Figure 10).
2. Place the floor stand within the raised floor opening and bolt feet securely to the subfloor. See
leg detail in Figure 11.
3. To adjust the floor stand height, adjust the bottom height-adjustment screws. To prevent air
flow escaping around the base of the PDU, choose one of these options:
a. Option 1: Reduce the height of the floor stand so that the top of the floor stand is
about 1½" below the top of the raised floor. When the PDU is placed on the floor
stand, the PDU base should be even with the floor.
27
PowerPak PDU 50-300 kVA
b. Option 2: Match the floor stand to your raised floor height. Install an optional PDU
skirt to minimize loss of air flow.
4. The floor stand has removable front and rear cover plates for cable entry/exit and air flow. To
provide adequate air flow, remove cover plates before placing the PDU on the floor stand.
(See Figure 11, “PDU Floor Stand Detail.”)
5. To stabilize the PDU on the floor stand, there are two options:
a. Option 1: Remove the PDU leveling feet, allowing the PDU to rest on its casters. (The
casters rotate 360⁰ but do not lock.) Bolt the PDU to the floor stand using 1/2" allthread (Figure 11). Some customers invert the removed leveling feet and use them to
attach the PDU to the floor stand.
b. Option 2: Adjust the main cabinet leveling feet so that they all rest firmly on the floor
stand (Figure 12).
6. With a fork lift or pallet jack, carefully position the PDU over the floor stand. The main cabinet
should be centered directly over the floor stand. If you are using the main cabinet leveling
feet, they should all be positioned within the borders of the floor stand’s top plate.
28
Installation: Placing the PDU
Important!
To provide adequate air
flow, remove cover plates
before placing the PDU on
the floor stand.
Figure 10 PDU Floor Stand with Height Options
29
PowerPak PDU 50-300 kVA
Important!
To provide adequate air flow,
remove cover plates before placing
the PDU on the floor stand.
Figure 11 PDU Floor Stand Detail
30
Installation: Placing the PDU
To stabilize the PDU on the floor stand:
Remove leveling feet and bolt the PDU to the
floor stand, OR
Adjust PDU leveling feet so that the PDU rests
firmly on floor stand and does not move.
Casters do not lock.
Figure 12 Mounting PDU on Floor Stand
31
PowerPak PDU 50-300 kVA
5 Installation: Power Cabling
DANGER!

Severe or fatal injury can result from electrical shock during contact
with high voltage conductors, monitoring PCBs, or similar equipment.

A licensed electrician must install each unit.

Wear suitable personal protective clothing and use protective
equipment for performing mechanical and electrical installations.

Disconnect power before drilling holes, attaching cables or conduit, or
connecting PDUs to other power distribution equipment.

Use Lock Out/Tag Out procedures.

Leave ample space for attaching and routing wires.
Important!
Power wiring must comply with NEC and applicable local codes
and should be wired by licensed electricians.
Reference your submittal package for 1-line drawings specific to your PDU configuration.
Refer to NEC (2014) 310.16 and your local codes for wiring standards for phase and neutral wiring.
Customer-supplied cable connections should be 75⁰C copper wire.
Refer to NEC (2014) 250.122 and your local codes for ground wiring standards.
Important!
Grounding for this equipment must comply with NEC and local
building and electrical codes.
5.1 Input Power Cabling
Input cable entry to the PDU can be from the bottom rear, bottom front, or top.
Input power cables can be landed in several ways:




To an terminal block in the top right of the Main Cabinet. Input cables are terminated to
mechanical lugs or optionally to compression lugs.
To staggered busbars, for front bottom cable entry.
For manual dual PDUs, directly to the main input circuit breakers.
To an optional J-Box (junction box) that can be up to 6' from the PDU. The J-Box is in turn cabled
to the PDU’s input terminal block or input busbars.
32
Installation: Power Cabling
Table 9 Input Cable Entry Options
Cable Entry Location
in PDU
Cable/Conduit Entry
Holes
Cable Landing
Comments
Bottom Rear
Three (3) pilot holes
provided in bottom
rear. Customer can
enlarge pilot holes to
match conduit size.
Terminal Block in top
right of PDU:
 Compression lugs
or
 Mechanical Lugs
Typically used when
main cabinet has
panelboards and
bottom front cable tray
has pre-punched holes
for distribution.
Top
Solid plate provided in
top of PDU. Customer
makes own cut-outs for
cable/conduit entry.
Terminal Block in top
right of PDU:
 Compression lugs
or
 Mechanical Lugs
Bottom Front
Solid plate provided in
bottom of PDU.
Customer makes own
cut-outs for
cable/conduit.
Staggered busbar with
mechanical or
compression lugs on
right front of PDU.
Manual Dual PDU,
choose from these
options:
 Bottom Rear
 Top
Choose from above
according to cable
entry location.
Directly to Main Circuit
Breakers
Commonly used with
front-facing
transformers.
For wire recommendations, see Figure 9, “One Line for PDU with Single Main Input Circuit Breaker.”
33
PowerPak PDU 50-300 kVA
Figure 13 Bottom Cable Entry to Terminal Block with Compression Lugs
34
PowerPak PDU 50-300 kVA
Customer can enlarge pilot
holes in bottom rear of PDU.
Mechanical lugs are standard
for the PDU cable entry
terminal block (shown in this
diagram).
Compression lugs are optional.
Transformer is shown facing
rear of PDU.
Figure 14 Bottom Rear Cable Entry to Terminal Block with Mechanical Lugs
35
PowerPak PDU 50-300 kVA
Figure 15 Bottom Rear Cable Entry through Floor Stand
36
Installation: Power Cabling
For front bottom
access, phase
cables are landed
to staggered
busbars allowing
2-hole
compression or
mechanical lugs.
Front bottom
access is most
often used with
forward-facing
transformer taps
(shown).
Customer makes
own cable entry
cutouts in bottom
front solid plate.
Figure 16 Bottom Front Cable Entry to Staggered Busbars
37
PowerPak PDU 50-300 kVA
Top cable entry plate is solid
plate. Customers must make
their own cut-outs.
Mechanical lugs are standard for the PDU cable entry terminal block
(see Figure 12). Compression lugs are optional.
PDU is shown with frontfacing transformer taps.
Figure 17 Top Cable Entry
38
Installation: Power Cabling
5.2 Input Power Junction Box Option
PDI offers an input power junction box (J-Box) as an option (Figure 18). The J-Box provides an
intermediate connection point between building power and the PDU. Customers may wish to connect
building power to the J-Box before the PDU is installed, possibly shortening installation time.
DANGER!
A power J-Box and power cable assembly must be installed in accordance with all
applicable NEC and local electrical codes.
The power J-Box must be installed by a qualified electrician.
Disconnect power before drilling holes, attaching conduit, or attaching the J-Box to
a PDU, building power, or to other power distribution equipment.
Use Lock Out/Tag Out procedures.
Wear suitable personal protective clothing and use protective equipment for
performing mechanical and electrical installations.
Leave ample space for attaching and routing wires.
H x W x D correspond to dimensions of the J-Box
given in the sizing chart (Table 8).
Figure 18 Power J-Box
39
PowerPak PDU 50-300 kVA
The power J-Box must be located within six (6) feet of the PDU and should remain accessible after
the PDU has been installed. If the PDU has its rear panel against a wall, the power J-Box must be
installed at least 36" away from the wall and must allow future accessibility.
The J-Box should not restrict the positioning of any power cabling and should not obstruct the floor
tiles located directly above the power J box.
PDI recommends that power cables from the power J-Box enter the PDU through the floor tile
cutouts. If cable entry to the PDU uses bottom rear cable entry, the one or more pilot holes are
enlarged for conduit coming from the J-Box.
J-Boxes come in three sizes. Wire size must be matched to Main Input Circuit Breaker amperage and
conduit to wire size as given in Table 10.
Table 10 Power J-Box and Power Cable Sizing Chart
Main Input Input Power Cable
Circuit
Wire Size
Breaker
Phase & Ground
Size (Amps)
(# - Size)
Input Power Cable
Conduit Size
(# - Size)
Junction Box Size
(H x W x D)
Input Junction Box
Terminal Block Size
(# Poles - Wire Range)
25
1 x 8 AWG
1 x 1"
12" x 10" x 5"
4 Pole - # 12 x 2/0
30
1 x 6 AWG
1 x 1"
12" x 10" x 5"
4 Pole - # 12 x 2/0
40
1 x 6 AWG
1 x 1"
12" x 10" x 5"
4 Pole - # 12 x 2/0
50
1 x 6 AWG
1 x 1"
12" x 10" x 5"
4 Pole - # 12 x 2/0
60
1 x 6 AWG
1 x 1"
12" x 10" x 5"
4 Pole - # 12 x 2/0
70
1 x 4 AWG
1 x 1 1/4"
12" x 10" x 5"
4 Pole - # 12 x 2/0
80
1 x 4 AWG
1 x 1 1/4"
12" x 10" x 5"
4 Pole - # 12 x 2/0
90
1 x 3 AWG
1 x 1 1/4"
12" x 10" x 5"
4 Pole - # 12 x 2/0
100
1 x 3 AWG
1 x 1 1/4"
12" x 10" x 5"
4 Pole - # 12 x 2/0
110
1 x 2 AWG
1 x 1 1/4"
12" x 10" x 5"
4 Pole - # 12 x 2/0
125
1 x 1 AWG
1 x 1 1/2"
12" x 10" x 5"
4 Pole - # 12 x 2/0
150
1 x 1/0 AWG
1 x 1 1/2"
12" x 10" x 5"
4 Pole - # 12 x 2/0
175
1 x 2/0 AWG
1 x 2"
16" x 14" x 6"
4 Pole - # 6 x 350 MCM
200
1 x 3/0 AWG
1 x 2"
16" x 14" x 6"
4 Pole - # 6 x 350 MCM
225
1 x 4/0 AWG
1 x 2"
16" x 14" x 6"
4 Pole - # 6 x 350 MCM
250
1 x 250 MCM AWG
1 x 2 1/2"
24" x 18" x 6"
4 Pole - # 6 x 350 MCM
300
2 x 3/0 AWG
1 x 3"
24" x 18" x 6"
4 Pole - # 6 x 350 MCM
350
2 x 4/0 AWG
2 x 2"
24" x 18" x 6"
4 Pole - # 4 x 500 MCM
400
2 x 4/0 AWG
2 x 2"
24" x 18" x 6"
4 Pole - #4 x 500 MCM
500
2 x 250 MCM AWG
2 x 2 1/2"
24" x 18" x 6"
4 Pole - #4 x 500 MCM
40
Installation: Power Cabling
Main Input Input Power Cable
Circuit
Wire Size
Breaker
Phase & Ground
Size (Amps)
(# - Size)
Input Power Cable
Conduit Size
(# - Size)
Junction Box Size
(H x W x D)
Input Junction Box
Terminal Block Size
(# Poles - Wire Range)
600
2 x 350 MCM AWG
2 x 3"
24" x 18" x 6"
4 Pole - #4 x 500 MCM
700
2 x 500 MCM AWG
2 x 3"
24" x 18" x 6"
4 Pole - #4 x 500 MCM
800
3 x 300 MCM AWG
3 x 2 1/2"
Special
Special
5.3 Input Power Wiring
Customers must make their own cut-outs for input cable and conduit. Pull input power conduit through
cut-outs. Connect input phase and ground cables to the PDU input terminal block or, for Manual Dual
PDUs, directly to main input circuit breaker lugs. Torque lugs to the circuit breaker manufacturer’s
specification, which are typically given on the circuit breaker.
For top cable entry, input and output share the same plate, which for input may have solid plate and
for output solid plate or panelboard knockouts (KOs).
Front bottom cable input:
Staggered busbars are
provided for input phase
cables.
With a front-facing transformer, there is no
Component Mounting Plate. Customer ground
connection is typically provided in the Main
Cabinet input cable tray.
Customers can alternatively ground to
the PDU Input Terminal Block.
NOTE: Cut-outs behind PDU Input Terminal
Block and the front-facing transformer facilitate
infrared scanning.
Figure 19 Ground Connections for Front-Access Only PDU
The customer safety ground is typically connected to the Component Mounting Plate in the Main
Cabinet with mechanical lugs. Busbar ground connections can be optionally specified.
41
PowerPak PDU 50-300 kVA
For front-access transformers, the Component Mounting Plate is removed. A ground connection is
typically provided in the input cable tray. Alternatively, ground connection can be made to the PDU
Input Terminal Block (Figure 19).
5.4 Distribution Cabling
5.4.1
Subfeeds
Neutral busbars are rated 200%. Neutral wires must be
twice the size of phase cables.
Neutral and ground busbars have two-hole compression
lug connections. Holes can be 3/8" dia. or 1/2" dia.
(Figure 20).
Location of busbars depends on customer’s top or
bottom cable exit.
Solid plate is provided at the bottom or top of the main
cabinet or side car for cable exit. Customers must
execute their own cut-outs for solid plate cable exit trays.
5.4.2
Square D I-Line Subfeed Panelboards
Figure 20 Distribution Ground and Neutral
Busbars
Square D I-Line subfeed panelboards are also available, requiring at minimum their own 12" side
cars.
800A and 1000A I-Line Panelboards can be installed in 12" side cars. 1000A I-Lines require an
underfloor junction box for distribution cabling. The junction box has the neutral and ground busbars
for the Side Car and cable exit panels on three sides (Figure 21).
1000A and 1200A I-Line Panelboards can be installed in a Main Cabinet Extension (Figure 6). Neutral
and ground busbars are located in the Extension and no underfloor junction box is required.
5.4.3
Distribution Panelboards
Standard panelboards are Square D or GE bolt-on or snap-on circuit breaker panels.
Square D and GE 225A panelboards for 208VAC or 480VAC are protected by a 3-pole 225A
secondary main circuit breaker. 400A panelboards for 208VAC or 480VAC are protected by a 3-pole
400A secondary main circuit breaker.
Panelboards have 173%-rated neutrals.
42-position ground and neutral strips are provided for each multiple of a 42-circuit panelboard.
Optional 42-position isolated ground strips are available.
Pre-punched cable exit trays are provided at the top or bottom of the main cabinet or side car housing
the panelboard(s). Pre-punched distribution cable exit holes are 7/8" dia. for 1/2" dia. conduit.
42
Installation: Power Cabling
Junction box height
matches floor
stand height.
Junction box has
removable panels on
three sides for
distribution cables.
Neutral and ground
busbars for the Side
Car are located in
the junction box.
Figure 21 Underfloor Junction Box for 1000A I-Line Panelboard in 12-in Side Car
43
PowerPak PDU 50-300 kVA
6 PDU Initial Start-Up
Important!
At the initial startup of the PDU, a PDI factory-authorized technician
must validate correct operation of the PDU. The product warranty may
be voided if the correct start-up procedures are not followed.
When applying utility power to the PDU for the first time, a PDI factory-authorized technician
must validate correct operation of the PDU. PDU start-up typically includes the following
procedures.
6.1 PDU Post-Installation Inspection
After placing the PDU and attaching cables, re-inspect the PDU, as follows:
1. Visually inspect for and remove any debris that may have fallen into the PDU during
installation.
2. Transformer: Inspect the transformer for any loose connections or displacement during
shipment. Check to make sure all terminal lugs are tight and secure.
3. Internal feeders: Ensure all lug connections are tight and secure.
4. Main input feeder:
a. Check the main input feeder connections at the main breaker to be sure vibration has not
loosened the terminal screws.
b. Check the feeders from the load side of the main breaker to the primary side of the
transformer.
5. Check all other lugs (i.e. neutral bus, ground bus, terminal blocks, etc.).
6.2 Initial Start-Up Procedure
Warning!
Steps 1-4 below must be executed before applying incoming power
to the PDU.
Energizing the PDU can create inrush! Verify that the upstream UPS
is in bypass mode or can handle inrush from the PDU.
1. Confirm that the PDU’s main input circuit breaker (or both breakers for Manual Dual PDU) is
in the OFF position.
2. Ensure that all of the PDU’s output circuit breakers are in the OFF position.
3. Verify that the input voltage to the unit matches the input voltage rating of the unit as identified
on the PDU nameplate found on the outside of the front door.
4. Ensure that the input voltage has proper phase rotation and safe grounding practices.
5. Apply building power to the unit.
44
PDU Initial Start-Up
6. Measure for correct PDU input voltage, which should match the unit’s rating within + 5% to
-10% of nominal rating.
7. Check for correct phase rotation (clockwise) and voltage.
8. Energize the PDU by setting the Main Input Circuit Breaker to the ON position.
Note: If the main breaker trips when energized, it may indicate a fault in the unit.
Contact PDI Service at (800) 225-4838 for diagnostic assistance.
9. Perform an EPO check: Depress the external EPO button and verify that the Main Input
Circuit Breaker shunt trips.
10. Manually reset the Main Input Circuit Breaker to the ON position. You may have to first
manually trip the lever all the way to the OFF position.
11. Verify that the output voltages are correct for the PDU.
12. Sequentially turn ON the distribution circuit breakers.
Note: Equipment energized by the PDU may require special start-up procedures.
Consult the equipment manufacturer’s instructions for start-up procedures.
45
PowerPak PDU 50-300 kVA
7 PDU Procedures
7.1 Normal Start-Up
After initial PDU startup, you can use the following abbreviated procedure to start up the PDU and its
downstream equipment:
Confirm that the PDU’s main input circuit breaker is in the OFF position.
Confirm that all of the PDU’s output circuit breakers are in the OFF position.
Apply power to the unit.
Set the Main Input Circuit Breaker to the ON position. You may have to first manually trip the
lever all the way to the OFF position.
5. Sequentially energize the distribution output circuit breakers, following any special procedures
required by equipment attached to the PDU. Consult the individual manufacturer’s
instructions for these requirements.
1.
2.
3.
4.
7.2 Normal Shutdown Procedure
1. Shutdown equipment connected to the PDU’s distribution output circuits, following any special
procedures that the equipment manufacturer has specified.
2. Turn off the Distribution Output Circuit Breakers feeding the load equipment.
3. When ALL output circuit breakers have been turned OFF, turn the Main Input Circuit Breaker
to the OFF position.
7.3 Automatic Shutdown Signals
The PDU can be shut down by the PDU M4G Board with a signal to trip the Main Input Circuit
Breaker. The trip signal is sent using either the 170VDC or 24VDC output connections.
The PDU board will shunt-trip the main breaker if it receives any of the following signals (refer to
Figure 24, “PDU M4G Board”, for connections):




Local EPO signal to the PDU board from the front panel EPO button.
Remote EPO (REPO) signal from the Contractor Board to the PDU Board. The customer REPO
signal is terminated at the Contractor Board.
Thermal wires registering a temperature in the PDU transformer core that exceeds the
transformer temperature limit specified.
Optional shutdown signals: the customer can elect to shut down the PDU on the following
conditions. These optional shutdown conditions are programmed into the PDU M4G Board in
manufacturing and should be selected at time of order:
o Output over-voltage or under-voltage on pre-programmed limits.
o Improper phase rotation.
o Ground fault interrupt: ground fault current rises above programmed levels.
o Building alarm. A 10-second time delay for shutting down the PDU can also be set.
7.4 Manual or Automatic Restart
The Restart Switch on the PDU board determines if restart is automatic after a voltage loss. The
170VDC output connection on the PDU M4G Board must be connected to the main breaker trip unit
46
PDU Procedures
for the Restart Switch to function —the Restart Switch does not work with the 24VDC voltage
connection.



If the Restart Switch is set to Manual (down or away from the PDU Board transformer), the main
breaker is tripped when the PDU loses voltage. When the PDU receives voltage again, the main
breaker must then be manually reset and closed to power up the PDU and resume operation.
This is the default position: the PDU is shipped with the Restart Switch set to Manual.
If the Restart Switch is set to Automatic (up or towards the PDU Board transformer), the main
breaker is not tripped on a voltage loss. The PDU resumes operation if voltage is in the correct
range.
See Section 7.3.1 PDU M4G Board and associated illustration for location of the Restart Switch.
7.5 Changing Transformer Taps
Transformers have jumper cables on each phase connecting one tap position to another. Changing
the tap jumper cable connection changes the transformer voltage output by a predefined percentage.
Each transformer has a label showing the voltage adjustment provided by a specific tap connection.
Default connection is 100% of the transformer rating.
Default tap connection is 100% of
transformer rated voltage.
The Tap Adjustment Table is found on the
transformer label.
Torque connections to 72-in-lbs or 6 ft-lbs.
Tap connection numbers are clearly labeled.
Figure 22 Transformer Taps
To change transformer taps on the PDU follow these steps (To change transformer taps on PDU with
front-facing taps, the procedure is the same except that the customer need only open front panel
doors.):
1.
2.
3.
4.
Make sure that the PDU is powered off.
Lock out power to the PDU at main circuit breaker(s).
Remove rear panels or, if transformer is front-accessible, open PDU front doors.
Read label on transformer and select the voltage adjustment that is closest to the adjustment
you require.
5. Disconnect one or both jumper ends as needed to match tap jumper numbers, retaining bolts
and nuts.
47
PowerPak PDU 50-300 kVA
6. Reconnect jumpers to correct numbered positions. Jumpers use 1/4-20 x 1” hex head bolts.
Torque bolts to 72 inch-pounds or 6 foot-pounds. Apply torque seal. The bolt size and torque
specifications are the same for all standard transformers.
7. Replace panels or close doors.
48
Monitoring: Components
8 Monitoring: Components
8.1 Monitoring Component Summary
WaveStar monitoring components include the following:




PDU M4G Board sets PDU parameters and monitors the transformer. Each PDU has a
Contractor Board which is an extension of the PDU Board.
Branch Circuit Monitoring System (BCMS) PCBs collect readings from CT strips on
panelboard current transformer (CT) strips and subfeed CTs and voltage measurements.
A Resistor Board is intermediate between subfeed CTs and a BCMS PCB. It is used only with
subfeeds.
The WaveStar® Color Monitor displays power information about monitored PDU devices and
passes their points list information to upstream Modbus master devices, such as a Building
Management System or Data Center Infrastructure Management (DCIM).
Monitoring components are mostly located in the Controls Compartment at the top of the Main
Cabinet. BCMS PCBs are also placed in Side Cars for monitoring panelboards or subfeeds in the
Side Car.
The PDU also has an extensive dry contact network. See Table 11, “Dry Contact Signals.”
SKRU
PDU M4G Board
SPD
Color Monitor Backpanel
Contractor Board
Figure 23 Open Controls Compartment
8.2 Customer Connections
Customer connections are made only to the following:


A Contractor Board, for Modbus RTU network connections, REPO, and remote relays. (See
Figure 25, Basic Contractor Board,” and Figure 26, “Enhanced Contractor Board.”)
Color Monitor backpanel for Ethernet cable connection (see Figure 29, “Color Monitor Network
Connections.”
49
PowerPak PDU 50-300 kVA


Other dry contact connections (see Table 11, “Dry Contact Signals”).
External permissive signals (see Section 1.3 Customer Wiring for External Permissive
Signals.)
Customers can also specify specific values, such as Digital Inputs or Alarms, which are programmed
by PDI in manufacturing.
Other information in this chapter is provided for reference.
8.3 PDU Board and Contractor Boards
The PDU (M4G) Board sets PDU parameters and monitors the PDU’s transformer.
Every PDU also has a Contractor Board, which functions as a terminal block to the PDU Board and
is directly connected by a ribbon cable to the PDU Board. The customer has a choice of two (2)
Contractor Boards, which act as an extension of the PDU M4G Board for making customer
connections for remote control and monitoring:


Basic Contractor Board
Enhanced Contractor Board, which can connect twice as many output relays and building alarms
Internal PDU signaling, such as the four Digital Inputs, is terminated to the PDU (M4G) Board.
External signaling, such as the customer’s REPO signal, is terminated to the Contractor Board:
Setup of the PDU and Contractor Boards is performed during manufacturing. These boards can be
programmed through a USB programming board the PDU Board.
The PDU Board’s points list values are also accessible through the customer’s BMS, but most points
cannot and should not be set by the customer, as incorrect settings can cause PDU malfunctions.
Measurements values in the points list can also be viewed on the Color Monitor.
8.3.1
PDU M4G Board
For the following connections, reference Figure 24, “PDU M4G Board”.
Transformer CT (current) and voltage connections (top edge of Figure 24):







CT connections, output current (ABC), Output 1 and Output 2
CT Connection G-N:
Pins 1-2: Ground CT connection
Pins 3-4: Neutral CT connection
Input 1 Voltage-G connection: Input Delta connection is 3-wire plus ground (no neutral).
Output 1 Voltage-N connection: Output Wye connection is 4-wire plus ground.
Input 2 or Output 2 Voltage provides a configurable second input or output voltage, used with dual
input or output PDUs.
Power and Power Signals



120VAC Input Power connection provides power to the PDU M4G Board.
24VDC Output Power connection provides power to WaveStar Color Monitor or Monitor
Power Off Controls:
50
Monitoring: Components
o
o
o

Remote EPO connection from the Contractor REPO Connection (J6), see Figure 25.
Customer REPO dry contact connection is to the Contractor Board.
Local EPO connection
Thermal wires for transformer temperature measurements, which can cause PDU
shutdown.
Shunt Trip: The board outputs two voltages for tripping the Main Breaker Shunt Trip:
o 170VDC: 170 VDC is rectified from 120VAC input power; 170VDC must be used for
Restart Switch to function.
o 24VDC
CT Measurements
G-N CT
Connection
Output 2
Current
ABC
Output 1
Current
ABC
Input 1
Voltage-G
Input 2 or
Output 2
Voltage
Output 1
Voltage-N
120VAC
input from
PDU
transformer
power to
170VDC
shunt trip.
Transformer
Restart Switch
Down (away
from
transformer)
= Manual
24VDC
Output
for Shunt
Trip to
Main
Breaker
Processor
Up=Auto
170VDC
Output
signal for
Shunt Trip
to Main
Breaker
24VDC Output
Power to Color
Monitor
Output relay
to release
SKRU key
for Manual
Dual PDU
.switching
4 Digital
Inputs
24VDC Output also powers the
Enhanced Contractor Board, if
installed.
Setup
USB
Connection
RJ12 Upstream /
Downstream
Modbus Connections to
Color Monitor
Ribbon Cable Connection to
Contractor Board
Thermal Wires
Local EPO
Remote EPO
Figure 24 PDU (M4G) Board

The Restart Switch determines whether restart is automatic or manual after a voltage loss.
51
PowerPak PDU 50-300 kVA
o
o
o
o
Switch down (away from on-board transformer): PDU restart must be done manually after
voltage is restored.
Switch up (towards on-board transformer): PDU restart is automatic after power is
restored.
See section 7.4 Manual or Automatic Restart for additional information.
NOTE: The Restart Switch requires 170VDC input to the main breaker shunt trip to
function. It is not operable with the 24VDC input to the main breaker shunt trip.
Other Input and Output Signals


Four Digital Inputs or Alarms: Digital Inputs or Alarms are used for signalling internal to the
PDU, such as a Door Open condition. Digital Inputs can be assigned by PDI during PDU M4G
Board setup, when names can also be assigned to the inputs. These inputs turn on bits in PDU
M4G Board Points List, Modbus Registers 90-91.
o Default assignments for single input PDU are as follows:
 Digital Input 1: Unassigned
 Digital Input 2: SPD Primary Device 1 not operational (if installed)
 Digital Input 3: SPD Secondary Device 2 not operational (if installed)
 Digital Input 4: Door Open
o Default assignments for Manual Dual PDU are as follows:
 Digital Input 1: Main Input Circuit Breaker 1 is closed.
 Digital Input 2: Main Input Circuit Breaker 2 is closed.
 Digital Input 3: SPD Secondary Device 1 or 2 not operational (if installed)
 Digital Input 4: Door Open
Output Relay: On a Manual Dual PDU, this relay is triggered when prerequisite conditions for a
transfer are met and the operator presses the KEY RELEASE button on the Color Monitor’s Sync
screen. The relay signal is transmitted to the Solenoid Key Release Unit (SKRU). A phase
synchronization check is performed before enabling the relay. (See Section 11.5 Dual Input
Source Transfer Procedures and Figure 43, “Transfer Procedure Using Internal Permissive
Signal”.)
Setup/USB Connection: Used by PDI representatives to program setpoints, contractor board relays,
etc., in the PDU M4G and Contractor Boards. PDU board setpoints cannot be altered through normal
Modbus register access to prevent registers being accidentally altered. See PDU M4G Board points
list for further information. (See Bibliography for information on downloading points lists.)
RJ12 Modbus Connections on the PDU M4G board are to/from the Color Monitor.
52
Monitoring: Components
8.3.2
Basic Contractor Board
(4) Building Alarms: NO
Dry Contact Connections
from Customer
Modbus Upstream
to Customer BMS
Remote EPO
Connection to PDU
M4G Board
Ribbon Cable to PDU
M4G Board
Modbus
Downstream to
Devices in Monitor
Chain
(4) Remote Relays, NO Dry
Contacts
Remote EPO NO Dry
Contact Connection
from Customer
Leftmost relay is triggered by
PDU Summary Alarm by
default.
Figure 25 Basic Contractor Board
The Basic Contractor Board has these connections (Figure 25):
Inputs:

Remote EPO: Customer dry contact connection point for input of an REPO signal. Connect
external dry contacts to terminals marked +24V EPO RET (Figure 25). The external REPO signal
is passed to the PDU Board via the REMOTE EPO connection, which is not a customer
connection point. A small indicator light can be powered from the +24V and the return.
Warning!
Connecting a voltage to the +24V EPO RET dry contact connection
can cause damage to the unit.

Four (4) Building Alarms (Figure 25). Alarm names can be specified by PDI in PDU Board setup.
Building alarms turn on alarm bits in the PDU M4G Board points list (Modbus registers 88-89), but
do not shut down the PDU. However, the customer can specify that a specific building alarm
shuts down the PDU. The shut-down option must be programmed into the PDU M4G Board in
manufacturing. (See Section 7.3 Automatic Shutdown Signals.)
Outputs:

Four (4) remote relays that output dry contact (NO) signals (Figure 25).
53
PowerPak PDU 50-300 kVA
o
o
Relays are programmable using the USB setup connection on the PDU M4G Board. PDI
programs the relay inputs, usually in in manufacturing. So for example, a relay can be
programmed to turn on when a specific Building Alarm, such as a fire alarm, is received.
The building management system or other control system receives the relay input and
can cause PDU shutdown with an REPO signal.
By default, the first, left-most relay is programmed to close when the PDU Summary
Alarm, PDU Board points list, Modbus Register 70, is in alarm (Figure 25).
Modbus Connections: The board has customer connections for upstream and downstream 4-wire
Modbus (Figure 21, J3 and J4). 2-wire Modbus can be set with jumpers on the Color Monitor and
other boards in the Modbus RTU chain.
8.3.3
Enhanced Contractor Board
The Enhanced Contractor Board (Figure 22) provides twice as many relays and building alarms as
the Basic Contractor Board. The Enhanced Contractor Board is used in other PDI products and many
of the connectors are not used on PDUs.
24VDC Power Input: Unlike the Basic Contractor Board, the Enhanced Contractor Board has a
processor and uses 24VDC power from the PDU M4G Board.
Inputs:

Remote EPO: Dry contact connection point for input of a REPO signal to system. Connection of
voltage to this point can cause damage to the unit. Connect external dry contacts to terminals
marked +24V EPO RET (Figure 26). The REPO signal is sent to the PDU Board via the REMOTE
EPO connection, which is not a customer connection point. A small indicator light can be powered
from the +24V and the return.
Warning!
Connecting a voltage to the +24V EPO RET dry contact connection
can cause damage to the unit.

Eight (8) Building Alarms (Figure 26). Alarm names can be specified by PDI in PDU Board setup.
Building Alarms turn on alarm bits in the PDU M4G Board points list (Modbus registers 88-89), but
do not shut down the PDU. However, the customer can specify that a specific Building Alarm
shuts down the PDU. The shut-down option must be programmed into the PDU M4G Board in
manufacturing. (See section 7.3 Automatic Shutdown Signals.)
Outputs:

Eight (8) remote relays that output dry contact (NO) signals (Figure 26).
o Relays are programmable using the USB setup connection on the PDU M4G Board. PDI
programs the relay inputs, usually in in manufacturing. So for example, a relay can be
programmed to turn on when a specific Building Alarm, such as a fire alarm, is received.
The building management system (BMS) or other control system receives the relay input,
receives the signal and can cause PDU shutdown with an REPO signal.
o By default, the first relay RR1 is programmed to close when the PDU Summary Alarm,
PDU Board points list, Modbus Register 70, is in alarm.
Modbus Connection: 4-wire configuration connection is located on the customer connection terminal
block.
54
Monitoring: Components
24VDC power from
PDU M4G Board
Outputs:
- Remote Relays
- RR1-RR8
- Dry contacts (NO)
Input:
- Remote EPO
Connection (Dry
contacts (NO))
REPO signal to
PDU M4G Board
Inputs:
-Building Alarms
BA1-BA8 (Dry
contacts (NO))
Modbus
Upstream
(RJ12 to Color
Monitor)
Modbus
Upstream:
paralleled
connectors
Modbus
Downstream
(RJ12 to Color
Monitor)
Modbus
Downstream:
paralleled
connectors
NOTE: Customer connections are all at the bottom of the board.
Figure 26 Enhanced Contractor Board
8.3.4
PDU M4G Board Points List
The PDU M4G Points List contains measurements and setpoints for the PDU M4G Acquisition Board
and its associated Contractor Board. It has two groups of data:


Measurements and Alarms
o Current and voltages measurements from the critical load transformer
o Alarms from PDU M4G Board and Contractor Board
Setpoints for
o Alarm thresholds
o Contractor board setup, such as enabling building alarms and specifying names
PDI representatives must specify Modbus register setpoints or Contractor Board setup options using
a special setup program connected to the M4G USB port.
The PDU M4G Board points list can be downloaded from the PDI website (see Bibliography).
8.4 Branch Circuit Monitoring System (BCMS)
8.4.1
Panelboard and Subfeed Monitoring
A single BCMS PCB can monitor



(2) x 42-pole panelboards, or
(1) x 84-pole panelboard, plus
The main feed(s) associated with each panelboard.
55
PowerPak PDU 50-300 kVA

Two sets of up to (14) subfeeds (or up to (10) subfeeds if neutrals are monitored).
Panelboards must have CT strips covering each panelboard circuit. Subfeeds must have CTs
connected to an intermediate Resistor Board.
Layout of a BCMS HV board (BCMS PCB) is shown in Figure 27.
8.4.2
BCMS Points Lists
Points lists are loaded onto BCMS PCBs at the factory. Only one kind of points list can be loaded into
a BCMS PCB at the same time, but the PCB can monitor more than device that uses that points list.
A 42-pole panelboard is represented by a single panelboard points list. An 84-pole panelboard is
represented by two (2) panelboard points lists. Panelboard points lists include the following:



BCMS Normal panelboard points list allows customization of circuit breaker alarms and warnings
for each panelboard circuit.
BCMS KWH points list provides accumulated KWH measurements and other detailed power
information for each panelboard circuit.
BCMS IEC panelboard points list is for IEC format panelboards with 36 or 72 1P circuits.
Subfeeds (including I-Line subfeeds) use this points list:
 BCMS Enhanced Subfeeds (ESF) points list for subfeeds.
See the Bibliography for information on downloading points lists from the PDI website.
56
Monitoring: Components
Modbus
Connection
USB
M
P
BC CT Cable
Harness
Panelboard 2B
EVEN
Main or SD CT
Cable Harness 1
CP
Main or SD CT
Cable Harness 2
CP
BC CT Cable
Harness
Panelboard 2A
ODD
CP
BC CT Cable
Harness
Panelboard 1B
EVEN
CP
BC = branch circuit
CP= current processor
CT= current transformer
MP= main processor
SD = subdistribution
Programming
Connections
CP
BC CT Cable Harness
Panelboard 1A
ODD
CP
120-277V C
Neutral
120-277V B
Neutral
120-277V A
VOLTAGE SOURCE #2
120-277V ANBNC
Power Input
VOLTAGE SOURCE #1
12VAC/12VAC/Ground
Figure 27 BCMS HV Board
8.5 Dry Contact Network
In addition to the internal Modbus RTU network, the PDU has a network of dry contacts providing
input signals and alarm and status annunciation. Dry contact connections to the Color Monitor, PDU
57
PowerPak PDU 50-300 kVA
M4G Board, and Contractor Board(s) are standard. Optional dry contacts for subfeed circuit breaker
(trip, trip alarm, and aux status) and SPD/TVSS status are also available.
Table 11 lists available dry contact input and output signals.
8.5.1
Dry Contacts for Subfeed Circuit Breakers (optional)
Subfeeds can have optional dry contacts to


present a trip alarm, or
present circuit breaker status.
A set of terminal blocks can be installed in the monitoring compartment providing an intermediate
connection point between the circuit breakers and the customer’s dry contact network.
8.5.2
Surge Protective Device Status
The PDU allows optional SPD/TVSS devices on input and/or output. Each SPD/TVSS incorporates a
remote signaling dry contact and visual status lights.
The dry contact is closed when the SPD is powered and functional. (See Table 11, “Dry Contact
Signals.”) The dry contact is typically wired at the factory to a PDU M4G Board Digital Input.
The optional SPDs are mounted in the Controls Compartment
of the main cabinet.
Status Lights are on the device. You must open the front
compartment door to see the lights:
- A green status light indicates normal operation.
- A red status light indicates loss of protection and SPD may
need replacing.
- Non-illuminated status light indicates loss of power.
Status Lights for
each phase ABC
Figure 28 SPD/TVSS Status Lights
8.6 Subfeed Circuit Breaker Trip
A subfeed circuit breaker can optionally be tripped using an applied voltage, 120VDC or 24VDC.
24VDC is recommended.
58
Monitoring: Components
Table 11 Dry Contact Signals
Device
Input Signals
Output Signals
Signal Meaning
Dry Contact Spec
NA=Not Applicable
Color Monitor
Summary Alarm
An alarm is present on a device
in the Monitor’s device chain.
0.5A @ 120VAC
0.5A @ 30VDC
PDU board
4 Digital Inputs
Signals internal to PDU with
assignable meanings. Digital
Input 4 = PDU door open
(default assignment).
NA
Contractor
Board
Remote
Emergency
Power Off
(REPO)
Signal to immediately power
down PDU.
NA
Contractor
Board
4-8 Building
Alarms
Assignable meanings.
NA
Customer can elect to shut
down the PDU on a specific
building alarm. See Section 7.3
Automatic Shutdown Signals.
Contractor
Board
4-8 Remote Relays
Assignable meanings
Up to 2A/250V
Relay 1 = Summary Alarm for
PDU by default
Subfeed
breaker(s)
(optional)
Breaker trip alarm
Subfeed circuit breaker has
tripped or has been reset
Max 5A/600V
24VDC
recommended
Subfeed
breaker(s)
(optional)
Auxiliary contacts
Subfeed circuit breaker contacts
have changed state (open or
closed)
Max 5A/600V
24VDC
recommended
Surge
Protective
Device (SPD)
(optional)
OK/not OK signal
NC contact is closed when SPD
is functional and powered.
600V wire
required. Contact
ratings:
0.3 A @ 125VDC
0.3 A @ 110 VDC
1.0 A @ 30 VDC
Manual Dual
PDU External
Dry Contact
Signal
SPD dry contact is usually wired
to a Digital Input on the PDU
M4G Board. See “Digital Inputs”
in Section 8.3.1 PDU M4G
Board.
External signal;
may be issued
from UPS
Enable the Color Monitor’s
internal permissive signal.
59
PowerPak PDU 50-300 kVA
9 Monitoring: PDU Network
The PDU’s network is centered on the Color Monitor, which stands at the dividing point between the
PDU’s internal or downstream network and the network upstream or external to the PDU.
9.1 Color Monitor and Protocols
The Color Monitor is the Modbus master device to all devices in the PDU that use WaveStar
monitoring. All of these devices are downstream of the Monitor. Upstream Modbus master devices,
such as the Building Management System (BMS), request data from the PDU’s monitored
components only through the Color Monitor. The Monitor communicates to these upstream Modbus
requesters using any of the following protocols, which can all be used simultaneously.
Downstream Protocol The downstream PDU device network has fixed parameters of Modbus RTU,
9600 baud, EVEN parity.
Upstream Protocols The Monitor has separate upstream ports for Modbus RTU and Ethernet,
supporting these protocols:


Modbus RTU
Ethernet port
o TCP/IP, used by the Color Monitor’s web page server
o Modbus TCP/IP
o SNMP Version 1
For in-depth information on the Color Monitor, including setup, networking, commands and replies,
screens, and web pages, see WaveStar® Color Monitor, Setup and Operation, PM375103.
9.2 Customer Network Connections
Customer Modbus RTU network connections are made to the Contractor Board. See 8.3.2 Basic
Contractor Board and 8.3.3 Enhanced Contractor Board.
The Customer Ethernet connection is made to the Color Monitor backpanel. See 9.4 Color Monitor
Network Connections.
9.3 Modbus Addressing
Refer to Figure 30, “Internal PDU Network, Modbus Addressing, Example,” with the following bullet
points:



The internal PDU network uses Modbus RTU protocol to connect the PDU board and BCMS
PCBs to the Color Monitor.
The Color Monitor is the Modbus master to its downstream devices. The upstream Modbus
master (such as the BMS) cannot directly address these devices, but rather addresses them
through the Monitor. Upstream and downstream from the Monitor are separate Modbus
segments.
The Monitor’s upstream address can be set to from 1 to 255, but you must leave enough
addressing capacity for downstream devices. The monitor will not respond to a command sent to
address 0. The address is set during Monitor Setup.
60
Monitoring: PDU Network



The Monitor’s downstream devices must be assigned consecutive addresses starting at address
1 for the PDU Board. Modbus addresses must be assigned in BCMS setup and will be done
initially at the factory. Modbus addresses cannot be assigned by, for example, the BMS.
For upstream addressing these device addresses are remapped as successor addresses to the
Monitor. (This is often confusing, but it is important to understand.) If the Monitor has upstream
address 30, the downstream addresses 1, 2, 3, 4, 5, 6, 7 are remapped to 31, 32, 33, 34, 35, 36,
37 as seen from the BMS or other Modbus Master.
Modbus addressing is the same for Modbus RTU and Modbus TCP/IP.
9.4 Color Monitor Network Connections
The Color Monitor’s backpanel has Modbus RTU and Ethernet ports (Figure 29).
Modbus RTU backpanel connections are typically made in manufacturing. (Customer Modbus RTU
connections are made to a Contractor Board.) However, the customer’s Ethernet cable is connected
directly to the Monitor’s Ethernet port.
Jumper W1, W2 for
2-wire Modbus upstream
J1: Modbus RTU
Upstream
Connection
Ethernet Port
Jumper W3, W4 for
2-wire Modbus
downstream
J3: Modbus RTU
Downstream
Connection
Figure 29 Color Monitor Network Connections
61
PowerPak PDU 50-300 kVA
PDU Main Cabinet
12" Side Car
24" Side Car
PDU M4G Board/
Contractor Board
To upstream
Modbus
master (BMS,
DCIM, etc.)
Color
Monitor
Points List =
Color
Monitor
Points List = PDU
BCMS PCB
Points List =
ESF
BCMS PCB
Points List =
KWH
BCMS PCB
Points List =
KWH
BCMS PCB
Points List =
ESF
Modbus RTU
Resistor Board
Resistor Board
(30)
1-8 Subfeeds
1
2
PB1 PB2
3
4
PB3 PB4
5
6
1-8 Subfeeds
7
Downstream Modbus addresses must be assigned to each device consecutively from 1.
These addresses are
visible from the upstream
Modbus master:
Monitor’s Upstream
Modbus Segment
30
31
32
33
34
35
36
37
Monitor’s Upstream Address (30) is added to each device’s downstream address for upstream addressing.
Monitor is Modbus master on its Downstream Modbus Segment.
Figure 30 Internal PDU Network, Modbus Addressing, Example
62
Monitoring: PDU Network
9.4.1 Modbus RTU Ports
Pin
J1, J3
1
Ground
2
RX-
3
RX+
4
TX-
5
TX+
Table 12 Pin-Out for Modbus Headers
The Color Monitor has two (2) paralleled Modbus ports:



J1 and J3 are header/plug connections for connecting to most devices.
J1 is the upstream port.
J3 is the downstream port.
The Modbus RTU interface is isolated, and pin designations are given in Table 12.
9.4.2 Modbus RTU 2-Wire vs. 4-Wire Configuration
PDI devices have two (2) jumpers near their Modbus ports for configuring 2-wire vs. 4-wire Modbus
RTU (see Figure 29). The Monitor’s 2-wire configuration jumpers are W1 and W2 (upstream) and W3
and W4 (downstream). Upstream and downstream chains can be differently configured.
For 2-wire configuration:




At least one device in a device chain must have both jumpers jumped on its Modbus connection.
If any device in the chain has jumpers installed for 2-wire, all of the device chain is 2-wire. To
avoid confusion when troubleshooting, all of the devices in the chain should be jumped in the
same way.
TX+ or RX+ on the Monitor (either one, because the on-board 2-wire jumpers short them
together) wires to TX+ or RX+ on downstream devices.
TX- or RX- on the Monitor wires to TX- or RX- on downstream devices.
The + and - signal wires should comprise of a (twisted) wire pair residing in the same shield.
For 4-wire configuration:






All of these jumpers must be removed from every device in the chain.
TX+ on the Monitor’s PCB or on the customer Building Management System (BMS) wires to RX+
on a device PCB (Figure 25).
TX- from the Monitor or BMS wires to RX- on device PCB (Figure 25).
A second pair of wires connects the other pair of TX+ / RX+ & TX- / RX-.
The TX+ & TX- going to the RX+ & RX- should be in the same shield. Do not run the +'s in one
shield and the -'s in another. Doing so may lead to sporadic communication.
Run a dedicated ground wire with the signal wires and only ground the shield at one end.
63
PowerPak PDU 50-300 kVA
9.5 Modbus RTU Cables
9.5.1 Cable Specification
RS485/RS422 cable length can be up to 4000 ft. if you use the proper cable:



The cable resistance should be ≤ 27 ohms/1000ft @ 1 kHz and the mutual capacitance
should be ≤ 14pf/ft. @ 1 kHz.
4-wire cabling:
o RS422 is typically 4-wire.
o Use a shielded cable with two (2) twisted pairs and a shield/ground wire.
o The two transmit lines must be in one twisted pair and the two receive lines in the
other twisted pair.
2-wire cabling:
o RS485 is typically 2-wire and is slower than RS422.
o Use a shielded cable with one (1) twisted pair and a shield/ground wire.
9.5.2 Cable Biasing and Termination
PDI devices have soft biasing (27K pull-up and pull-down resistors) on the + and – transmit and
receive lines. Therefore, if the customer’s Master device allows for control, PDI recommends that the
user turn on biasing and turn off termination, which may “fight” the biasing. Biasing the Master
device’s lines is not critical because the Color Monitor is already biasing the lines. If termination is
needed because of an extremely long cable run, PDI recommends that a small capacitor be put in
series with the terminating resistor.
9.6 Ethernet Cables
The maximum length of Ethernet cable depends upon the customer’s choice of Ethernet cable.
9.7 Setting Color Monitor Network Parameters
The Color Monitor must be set up to match the customer’s physical network. Touch SETUP on the
Color Monitor HOME screen to display buttons for network setup (Figure 31).
Network setup screens
Touch buttons in the initial SETUP
screen to link to miscellaneous setup
functions:
PASSWORD: Keyboard appears, enter
password, then type new password.
HORN DISABLED: Toggle Monitor’s
audible alarm to ENABLED/DISABLED.
BANNER: Banner setup (here shown
as “PDI DISPLAY”) is on same screen
as Modbus setup (Figure 7).
TIME & DATE: Set time and date; used
on HOME screen and alarm
timestamps.
CALIBRATE GUI: See next figure.
Figure 31 Color Monitor SETUP Screen
64
Monitoring: PDU Network
A password is required to access and change setup parameters. Enter the password (default is
“PDI”). The user can navigate through any of the screens and come back to SETUP without having to
re-enter the password for 10 minutes. Touch PASSWORD to change to a new password.
Warning!
Improper configuration of a WaveStar Color Monitor may conflict with other
monitors or devices on the network.
9.7.1 Downstream Modbus Device Chain Setup
To set Modbus device chain parameters, touch DEVICES/MODBUS (Figure 32):



Number of Devices should equal the number of devices in the Monitor’s device chain. Up to
twenty (20) devices are allowed. The Monitor uses this number to determine how many devices to
search for in its downstream chain.
When you add new devices, increment this counter, then press “ENTER”. The Monitor will
automatically start a new search and find all of the downstream devices. The devices will then be
listed in the DEVICES Screen, where the added devices will initially show up as generic device
names.
For each new device the user should then enter a unique device name. Unique device names are
needed to isolate alarms and measurements to specific devices.
On SETUP screen, touch DEVICES/MODBUS.
The DEVICES/MODBUS screen defines the Modbus
network and device chain as well as set the banner
name for the header.
Modbus Device Chain:
Banner Name displayed on top line.
Number of Devices should equal
number of devices connected in
Monitor’s downstream device chain.
Upstream Modbus:
Address of Monitor on upstream side
Baud rate (9600/19200/38400)
Parity (even/odd/none)
Downstream Modbus Network
characteristics are fixed and cannot
currently be modified.
Figure 32 Modbus RTU Setup
9.7.2 Modbus RTU Setup
Downstream Modbus settings cannot be changed.
Upstream Modbus provides network characteristics on the upstream side of the Monitor.
65
PowerPak PDU 50-300 kVA


Address is the address that the upstream Modbus master, such as the Building Management
System (BMS), uses to address the Monitor. The downstream device addresses are incremented
sequentially from this address. So if the Monitor has address 20, the next three devices will
appear 21, 22, and 23 to the upstream master device. (See Figure 30, “Internal PDU Network,
Modbus Addressing, Example.”)
Upstream Modbus settings for Baud rate and Parity must match those for the upstream Modbus
master.
9.7.3 TCP/IP and Modbus TCP/IP Setup
For TCP/IP, the customer must provide an Ethernet cable connected to the Ethernet port (RJ45
header J11) on the Monitor. (See Figure 29, “Color Monitor Network Connections”.)
On the SETUP screen, touch NETWORK/SNMP to display the network parameters for TCP/IP
(Figure 13).
The following must be specified for Modbus TCP/IP:



IP Address
Subnet Mask
Gateway
Each connected monitor must be assigned a unique address. DHCP is not supported.
Touch RESTART WITH NEW SETTINGS if any parameter is changed on this screen. The processor
will reboot and search the network for connections.
TCP/IP Setup: Set for TCP/IP,
Modbus TCP/IP, and SNMP
Load configuration from SD card
Set for SNMP
Figure 33 Modbus TCP/IP and SNMP Setup
66
Monitoring: PDU Network
9.7.4 SNMP Setup
To use SNMP, the customer must connect an Ethernet link to the RJ45 header J11 (see Figure 4) on
the Monitor using a standard Ethernet cable.
For SNMP setup, on the SETUP screen, touch NETWORK/SNMP to display the network parameters
for SNMP (Figure 33).
In addition to the TCP/IP specification, the following must be specified for SNMP:





Specify the Trap Server IP address
Toggle ENABLED/DISABLED for the trap server.
Touch SEND TEST TRAP to verify operation.
Get Community security string for Get operations.
Set Community security string for Set operations.
Touch RESTART WITH NEW SETTINGS if any parameter is changed on this screen. The processor
will reboot and search the network for connections.
9.8 Device Settings
A “device” is a points list (or Modbus register map) representing a physical monitored entity, such as a
panelboard. Each points list instance has a single Modbus address.
Each device has a SETTINGS screen for changing device name, software version, and device
configuration. These settings provide information to the Monitor in addition to each device’s own
internal setup. Device settings are usually entered by PDI manufacturing or service representatives,
but can be entered by customer administrators.
9.8.1
PDU Device Settings
Use the DEVICES screen to show each device in the Color Monitor’s chain. By selecting a device in
the list, you can change the generic name (e.g. “PDU”) to a name meaningful to your installation.
Accessing the PDU device name is shown below.
67
PowerPak PDU 50-300 kVA
Touch PDU (generic name) in device list. Device
name turns blue when selected.
Touch SETTINGS to set device name or software
versions.
Set NAME:





Touch NAME field (“PDU” in this
example):
A keyboard appears.
User may be requested to enter
password (default is “PDI”).
Type in device name (up to 16
characters); touch ENTER.
Device Name is put in header
under banner and in DEVICES
screen device list.
Figure 34 Settings: PDU Device
To change device parameters on other devices in the PDU, such as panelboards or subfeeds, consult
the WaveStar® Color Monitor, Setup and Operation, PM375103.
9.9 Device Readings
Each device in the Monitor’s device chain has a READINGS screen chain, providing power
monitoring information.


Select (touch) DEVICES to see the device list and then READINGS.
Use PREVIOUS/NEXT to step through the screen chain.
As an example, READINGS from the PDU are power measurements at input to and output from the
PDU transformer (Figure 35).
Screens for device readings for all devices that can be monitored by the Color Monitor are shown and
described in WaveStar® Color Monitor, Setup and Operation, PM375103.
68
Monitoring: PDU Network
Select (touch) PDU device name in the device list. Device
name turns blue when selected and device name displays
in header.
PDU is the default generic device name.
Users can change the device name in SETTINGS.
Touch READINGS to see PDU power monitoring data.
INPUT to the PDU transformer:
Voltage: AB BC CA
THD (total harmonic distortion):
AB BC CA
Frequency: in Hz
Current A B C (optional)
THD
A B C (optional)
Ground Current
OUTPUT from the PDU transformer:
Instantaneous measurements:
Voltage: AB BC CA AN BN CN
ABC(N) phase readings and totals:
Current
KW
KVA
KVAR
PF
Cumulative Measurement:
KWH
Touch Clear to set KWH to 0.
Figure 35 Readings: PDU
69
PowerPak PDU 50-300 kVA
10 Monitoring: Alarms
The Color Monitor displays alarms and warnings for all devices in the Monitor’s device chain. The
Monitor reads the alarms and warnings from the points list (Modbus register map) of each device.
Because the Monitor receives power from the line side of the Main Circuit Breaker, it can be used to
monitor power and diagnose power events, both during PDU Start-up or after an outage.
10.1 Summary Alarm Indicators
There are two Summary Alarms:


PDU Remote Relay Summary Alarm signals that an alarm is present for the PDU M4G Board or
Contractor Board.
Color Monitor Summary Alarm signals that an alarm is presented on any of its downstream
connected devices, including the PDU and Contractor Boards and all of the PDU’s BCMS
devices. It does not include auxiliary contacts for circuit breakers.
The Color Monitor indicates that there are extant alarms with three general indicators:

The summary count of warnings and alarms for the Monitor’s entire device chain is shown on
every screen (Figure 36).
When there are no alarms or warnings, a green check
mark is displayed.
When alarms are present on any device, a red and yellow
icon is displayed with the alarm and warning counts.
Figure 36 Alarm and Warning Summary Status Icons


There is also a light under the screen that glows green if none of the devices in the Monitor’s
chain has warnings or alarms and red if there are outstanding warnings or alarms (See Figure
21).
In addition, the Monitor has a dry contact (NO) connection on the backpanel that signals a
summary alarm whenever any alarm is present in the Monitor’s device chain (See Monitor
backpanel, Figure 29).
10.2 Alarm Screen and Alarm List
On any screen, touch the ALARM button to show the ALARM screen.
The ALARM Screen (Figure 37) lists all outstanding warning and alarms by device name with a datetime stamp in a scrollable list. If no alarms are outstanding, there will be only one line, “No Alarms”.
The warning or alarm gives the device name and locates the device component that is the alarm
source. For example, for a BCMS panelboard device, the alarm may be located to

the panelboard, such as “Over Current PB”, or
70
Monitoring: Alarms


the main voltage feed to the panelboard, such as “Over Volt Main,” or
the individual panelboard circuit, such as “CB 19 Zero Current”.
To further investigate individual circuits in warning/alarm state (Figure 38):
1. Note the device name and the warning/alarm.
2. Touch the DEVICES button to show the device list.
3. In the device list, scroll to the device name that has the warning/alarm. Touch the device
name to show the device’s circuit list.
4. Step through the device’s screen chain with PREVIOUS/NEXT to find the ALARM heading.
5. Scroll within the circuit list on the first device screen to find circuit or other component in
warning/alarm. An alarm may apply to a circuit or to the entire device, such as “Under Current
PB.”
Touching CLEAR ALL clears
all outstanding warnings and
alarms on screen and resets
corresponding Modbus
registers in the device points
list. It takes several seconds
for alarms to clear.
If a warning/alarm condition
remains outstanding, the
warning/alarm will remain on
the ALARM screen.
Device Name
BCMS KW = device (generic panelboard
device with KWH points list).
Device Name should be changed from
generic name to user-specified name on
the device’s SETTINGS screen.
Alarm or Warning Name
“Under Volt Main” locates
the problem to the main
voltage source to the
panelboard.
Touching SILENCE
HORN silences the Color
Monitor’s audible alarm,
which sounds when an
alarm is issued.
Figure 37 ALARM Screen with an Alarm List
71
PowerPak PDU 50-300 kVA
Touch DEVICES button to display the device list.
Find the Device Name noted in the alarm in the
device list.
Touch the Device Name to display its screen chain.
Step through the device’s screen
chain (using NEXT) to find the
screen with the ALARM column.
Scroll through the device’s circuits to
find the component in alarm. (Alarm
shows as ACTIVE under ZERO,
WARNING, or ALARM.)
Review information for that circuit on
all of the device’s screens.
Figure 38 Finding the Circuits in an Alarm Condition
10.3 Alarms by Device Type
Each device has its own alarm set based on its points list. Warnings and alarms that can be viewed
on the Monitor are listed below. The Monitor does not display setpoints from the points lists, such as
alarm thresholds.
10.3.1 Color Monitor Alarms
DISPLAY Comm. N Error (N is device number from 1-20): Communication error with one of the
devices in the Monitor’s downstream device chain
Alarm
Alarm Description
DISPLAY Comm. N
Error (N is device
number from 1-20):
Communication error with one of the devices in the Monitor’s downstream
device chain
10.3.2 PDU Alarms
General PDU Alarms
Warning or Alarm
Alarm Description
EPO
Emergency Power Off on PDU has been engaged. When EPO button is
pushed, the alarm is activated and the unit’s main input circuit breaker will
then be shunt-tripped off line.
72
Monitoring: Alarms
Warning or Alarm
Alarm Description
Remote EPO
Remote EPO on PDU can be activated in by closing the contacts on the
contractor board. When Remote EPO button is activated, the alarm is
activated and the unit’s main input circuit breaker will then be shunt-tripped
off line.
Thermal Overtemp
Stage 1 transformer temperature alarm: 180⁰F or higher temperature
registered in the transformer windings.
Thermal Hightemp
Stage 2, PDU shutdown on transformer temperature alarm by tripping main
PDU input circuit breaker when 195⁰F or higher temperature is registered
in the transformer windings. (Temperature threshold can vary by
transformer and PDU.)
Phase Rotation
Input phase rotation is incorrect.
S1-S2 Phase Angle
Dual input sources are not synchronized; cannot shutdown one source and
transfer load to the alternate source.
Ground Curr Trip
Ground current above preset level (10A) causes breaker trip (normally
disabled, enable as option).
Phase Rotation Trip
Incorrect phase rotation causes breaker trip (normally disabled, enable as
option).
Over Voltage Trip
Over voltage causes breaker trip (normally disabled, enable as option).
Under Voltage Trip
Under voltage causes breaker trip (normally disabled, enable as option).
PDU Transformer Input
Alarm
Alarm Description
NOTE: If the PDU is configured for dual inputs, “Input 1” or “Input 2” will prefix the alarm instead of
“Input.”
Input Voltage AB High
Input voltage AB measures above threshold level in points list.
Input Voltage AB Low
Input voltage AB measures below threshold level in points list.
Input Voltage BC High
Input voltage BC measures above threshold level in points list.
Input Voltage BC Low
Input voltage BC measures below threshold level in points list.
Input Voltage CA High
Input voltage CA measures above threshold level in points list.
Input Voltage CA Low
Input voltage CA measures below threshold level in points list.
Input Frequency High
Input frequency measures above threshold level.
Input Frequency Low
Input frequency measures below threshold level.
Input Current A High
Input current phase A measures above threshold level (optional).
73
PowerPak PDU 50-300 kVA
Input Current A Low
Input current phase A measures below threshold level (optional).
Input Current B High
Input current phase B measures above threshold level (optional).
Input Current B Low
Input current phase B measures below threshold level (optional).
Input Current C High
Input current phase C measures above threshold level (optional).
Input Current C Low
Input current phase C measures below threshold level (optional).
PDU Transformer Output
Alarm
Alarm Description
NOTE: If the PDU is configured for dual outputs, “Output 1” or “Output 2” will prefix alarm instead of
“Output.”
Output Voltage AB High
Output voltage AB measures above threshold level in points list.
Output Voltage AB Low
Output voltage AB measures below threshold level in points list.
Output Voltage BC High
Output voltage BC measures above threshold level in points list.
Output Voltage BC Low
Output voltage BC measures below threshold level in points list.
Output Voltage CA High
Output voltage CA measures above threshold level in points list.
Output Voltage CA Low
Output voltage CA measures below threshold level in points list.
Output Voltage AN High
Output voltage AN measures above threshold level in points list.
Output Voltage AN Low
Output voltage AN measures below threshold level in points list.
Output Voltage BN High
Output voltage BN measures above threshold level in points list.
Output Voltage BN Low
Output voltage BN measures below threshold level in points list.
Output Voltage CN High
Output voltage CN measures above threshold level in points list.
Output Voltage CN Low
Output voltage CN measures below threshold level in points list.
Output Current A High
Output current phase A measures above threshold level in points list.
Output Current A Low
Output current phase A measures below threshold level in points list.
Output Current B High
Output current phase B measures above threshold level in points list.
Output Current B Low
Output current phase B measures below threshold level in points list.
Output Current C High
Output current phase C measures above threshold level in points list.
Output Current C Low
Output current phase C measures below threshold level in points list.
Output KW A High
Output KW phase A measures above preset level.
74
Monitoring: Alarms
Alarm
Alarm Description
Output KW B High
Output KW phase B measures above preset level.
Output KW C High
Output KW phase C measures above preset level.
Output KW Total High
Output KW total measures above threshold level in points list.
Output KVA A High
Output KVA phase A measures above preset level.
Output KVA B High
Output KVA phase B measures above preset level.
Output KVA C High
Output KVA phase C measures above preset level.
Output KVA Total High
Output KVA Total measures above preset level.
Neutral Current High
Neutral current measures above preset level.
Neutral Current Low
Neutral current measures below preset level.
Ground Current High
Ground current measures above preset level.
Ground Current Low
Ground current measures below preset level.
Contractor Board Alarms
Alarms
Alarm Description
Build N (N = 1-8)
Building alarms, customizable names up to 8 characters can be set in
software.
Digit N (N = 1-4)
Digital alarms, customizable names up to 8 characters can be set in
software.
10.3.3 Enhanced Subfeeds
Alarm
Alarm Description
CB N Zero Current
(N = 1-14)
Circuit N has lost current after previously measuring a minimum current.
CB N High Current
Warning (N = 1-14)
Circuit N has exceeded current warning threshold.
CB N High Current
Alarm (N = 1-14)
Circuit N has exceeded current alarm threshold.
Over Voltage
Over voltage measured to ESF board as specified in points list.
Under Voltage
Under voltage measured to ESF board as specified in points list.
75
PowerPak PDU 50-300 kVA
10.3.4 BCMS Panelboard—Typical Alarms
Circuit Alarms
Alarm
Alarm Description
Note: The Color Monitor can number panelboard circuits sequentially for up to 336 circuits (8 x 42circuit panelboards) as specified in device setup. Circuit alarms are identified by this number.
CB N Zero Current (N =
1-336)
Circuit N has lost current after measuring a minimum current.
CB N High Current
Warning (N = 1-336)
Circuit N exceeds high current warning threshold.
CB N High Current
Alarm (N = 1-336)
Circuit N exceeds high current alarm threshold.
Panelboard Alarms
Alarm
Alarm Description
Over Current PB
Current feeding one panelboard is above alarm threshold.
Under Current PB
Current feeding one panelboard is below alarm threshold.
Over Curr both PBs
A common circuit feeding both panelboards is over alarm threshold.
Under Curr both PBs
A common circuit feeding both panelboards is under alarm threshold.
Over Volt Main
Over voltage measured on main voltage source to panelboard.
Under Volt Main
Under voltage measured on main voltage source to panelboard.
Over Volt Alt
Over voltage measured on alternate voltage source to panelboard.
Under Volt Alt
Under voltage measured on alternate voltage source to panelboard.
76
Manual Dual PDU
11 Manual Dual PDU Option
A Power Pak PDU can optionally be configured in manufacturing as a Manual Dual PDU. A Manual
Dual PDU has two independent voltage sources, each with its own main input circuit breaker and with
lock-outs provided by Kirk Keys. The output load can be manually transferred from one source to the
other in a make-before-break closed transition transfer.
11.1 Initial Status: Circuit Breakers and Kirk Keys
The two main input circuit breakers have mechanical interlocks using Kirk Keys controlling access to
the breakers and the Solenoid Key Release Unit (SKRU). There are three (3) locks (Figure 39) and
two (2) keys. The starting breaker and lock settings for a transfer are as follows:




Active power source: circuit breaker = closed; Kirk Key lock = unlocked; key in lock.
Inactive power source: circuit breaker = open; Kirk Key lock = locked; no key in lock.
Solenoid Key Release Unit (SKRU): Kirk Key lock = locked; key in lock.
SKRU key is released by a “permissive signal” to the SKRU
Both power sources must be synchronized to perform the transfer.
Solenoid Key Release
Unit (SKRU) Lock
Bar
extended
Key Lock, Main
Circuit Breaker 1
Kirk Key Mechanism Locked
Key Lock, Main
Circuit Breaker 2
Bar
retracted
Kirk Key Mechanism Unlocked
Figure 39 PDU Internal Panel, Kirk Keys
77
PowerPak PDU 50-300 kVA
11.2 Permissive Signal Options
The first step in a make-before-break transfer is sending a “permissive signal” to the SKRU to unlock
its key. The PDU can be configured for any one of several mutually exclusive methods for providing a
permissive signal. Each method must be selected at time of order and is wired in manufacturing:



Internal signal. An internal permissive signal is generated through the Color Monitor’s Sync
Screen. The PDU M4G Board detects that both input sources are synchronized and can be
switched, allowing the operator to release the SKRU key using the Color Monitor.
External signal. An external permissive signal provides the SKRU key release directly. The PDU
does not check to see that the two power sources are synchronized. Detecting that both power
sources are synchronized is the customer’s responsibility.
2-Stage External/Internal signal. An external signal (dry contact or 120VAC) enables the
internal signal. The PDU then determines whether both sources are synchronized and, if so, the
operator uses the Color Monitor Sync Screen to release the SKRU key.
11.3 Customer Wiring for Permissive Signals
11.3.1 Internal Permissive Signal
An internal permissive signal requires no wiring at the customer site whether used alone or in the
two-stage external/internal system.
11.3.2 External Permissive Signals
Customer wiring for an external permissive signal is the same whether the external signal is used
alone to release the SKRU key or it is used in a two-stage system to enable the internal signal.
The customer connects either a dry contact or external applied 120VAC connection to a terminal
block near the main breakers’ Kirk Keys. The choice of dry contact or 120VAC connection must be
selected at time of order.
The customer must independently determine that the sources are synchronized. Typically the external
signal is sent from an Uninterruptible Power Supply (UPS).
11.3.3 Dry Contact External Permissive Signal
The dry contact must be a normally open (NO) dry contact. Closing the contact enables the signal
(Figure 40).
In a two-stage external/internal system, if the dry contact is not connected to the terminal block, you
can install a jumper in the terminal block to keep the external permission permanently enabled. This
effectively reduces the two-stage system to an internal permissive signal only system.
78
Manual Dual PDU
Normally Open (NO)
Dry Contact
Connections
In a two-stage internal/external
system, you can keep the
external permissive dry contact
signal permanently enabled by
installing a jumper in the terminal
block.
Figure 40 Dry Contact External Permissive Signal Connection
11.3.4 120VAC External Permissive Signal
The 120VAC external signal is connected to a terminal block in the PDU, similarly to the dry contact
connection. The 120VAC neutral and hot wires should be connected as shown in Figure 41.
Neutral wire connection (white)
Hot wire connection (black)
Note for Two-Stage Systems:
If there is no 120V input, installing a
jumper from the neutral terminal to the
hot terminal will not provide a
permanently enabled external permissive
signal.
Figure 41 120V External Permissive Signal Connection
11.4 Using Cam Locks with Alternate Power Source (Optional)
Both power sources are usually hard-wired to the two main circuit breakers. However, some
customers optionally elect to connect an alternate power source via cam locks. Cam locks have
ABCG input power connections and are color-coded for correct phase and ground connections.
79
PowerPak PDU 50-300 kVA
Figure 42 Optional Cam Locks for Second Power
Source
G
A
B
B
C
When cables are connected to the cam locks, the PDU
M4G board will check that all ABC voltages are within
specification (usually ±10%) and then check for correct
phase rotation. The PDU will issue an input phase
rotation error if the operator has incorrectly connected
the cables, such as inserting B-phase into C-phase.
WARNING!
If the customer is using cam locks to connect an alternate power
source, it is not recommended that they select the option to shut down
the PDU on phase rotation error. If the operator incorrectly wires the
phase cables into the cam locks, the PDU will shut down immediately.
11.5 Dual Input Source Transfer Procedures
There are three closed transition transfer procedures:



Internal permissive signal using Color Monitor to release the SKRU key
External permissive signal using dry contact or 120V input, bypassing Color Monitor
Two stage permissive signal: external signal enables internal signal
Select the procedure suitable for your configuration.
11.5.1 Transfer Procedure: Internal Permissive Signal Only
The Monitor checks voltage readings for both sources from the PDU M4G board to determine if the
two sources are synchronized. When both voltage sources are in synch, the operator can signal the
SKRU to release its key using the Monitor Sync Screen (Figure 43). The operator then removes the
SKRU key and inserts it into the Kirk Key lock for the inactive power source, allowing that breaker to
be closed.
80
Manual Dual PDU
To display this screen, select
Home  Devices  PDU  Readings
This Sync screen appears as the first “Readings” screen.
Circuit breaker status: closed
(red) or open (green).
Outstanding input
voltage alarms prevent
release of the SKRU
key. Check the Alarm
screen and clear.
Voltage 1: voltage and
frequency
Voltage 2: voltage and
frequency
Touch Key Release to
release the SKRU key.
Phase difference between
sources must nominally be
≤ 20 degrees to release
SKRU key. Phase difference
maximum can be set during
PDU board setup.
Figure 43 Color Monitor Synch Screen
To manually switch the load from one power source to the other using the Monitor, use the following
procedure:
Figure 44 Transfer Procedure Using Internal Permissive Signal
1. From the Color Monitor Home screen, go to
Alarm screen and clear voltage alarms.
2. From the Home screen, touch Devices.
3. Select the PDU device (customer may have
renamed the PDU device to a different
name).
4. Touch Readings.
5. Sync screen appears.
Active power source shows a closed circuit
breaker (red).
Inactive power source shows an open circuit
breaker (green).
81
PowerPak PDU 50-300 kVA
6. When the Sync screen is displayed, the
active source breaker should be closed (red)
and the inactive source breaker open
(green). If both sources look to be in sync,
touch KEY RELEASE to release the SKRU
key.
The SKRU will not release the key if
 any input voltage alarms are present, or
 the phase difference between sources is
greater than 20 degrees (value can be
set in PDU M4G Board setup).
7. The operator should turn the SKRU
(solenoid) key and remove it.
8. The operator should then
8.1. insert the SKRU key into the circuit
breaker lock for the inactive power
source (the open circuit breaker, in this
example, Source 2);
8.2. turn the key; and
8.3. close (turn on) the breaker.
Note: At this point, both synchronized voltage
sources are feeding the PDU and both
breakers will show closed (red) on the Sync
screen.
9. Make the previously active source inactive.
9.1. Open the circuit breaker for the
previously active power source that you
are turning off.
9.2. Turn the key to lock the breaker.
10. Move the key from this breaker to the SKRU
(solenoid):
10.1. Remove the key from the breaker.
10.2. Insert it into the lock for the SKRU.
10.3. Turn the key.
7
10
9
Assume Source 1 has
been the active power
source.
8
Assume Source 2
has been the
inactive source.
Note: Source 2 is now the only active source and
shows red on the SYNC screen. Source 1 is
locked open (off) and shows green on the SYNC
screen.
11.5.2 Transfer Procedure: External Permissive Signal Only
If an external permissive signal is to release the SKRU key, power source synchronization must be
independently verified. The PDU does not check sources for synchronization through the SYNC
screen; however, the operator must still touch the SYNC screen button to release the SKRU key.
Assuming the active source = Source 1, follow these steps:
1. An external permissive signal must be issued to enable the SKRU key release.
2. The operator should
2.1. bring up the Color Monitor SYNC screen,
82
Manual Dual PDU
2.2. touch KEY RELEASE on the Color Monitor SYNC screen to release the SKRU key, and
2.3. turn the SKRU key and remove it.
3. The operator should then
3.1. insert the key in the lock for the main breaker of the inactive power source (Source 2),
3.2. turn the key, and
3.3. close the breaker.
Note: At this point, both synchronized voltage sources are feeding the PDU.
4. Open the circuit breaker on Source 1.
4.1. Open the circuit breaker for the previously active power source that you are turning off.
4.2. Turn the key to lock the breaker.
5. Remove the key from the Source 1 circuit breaker, insert it into the SKRU lock, and turn the
key.
At this point only Source 2 is feeding the PDU, and Kirk Key locks prevent any inadvertent change of
sources.
11.5.3 Transfer Procedure: External Plus Internal Permissive Signals
The PDU can be also be configured with a two-stage permissive signal (Figure 45):
Stage 1. An external permissive signal (120V or dry‐contact signal) enables or disables the internal
permissive signal to the SKRU key release signal via the Color Monitor.
Stage 2, internal permissive signal. The PDU checks sources for synchronization. The an operator
uses the Color Monitor Sync Screen to release the SKRU key. Use procedure described in Section
10.5.1 Transfer Procedure: Internal Permissive Signal Only.
External
Permissive
Signal
Dry contact (NO)
Closed = enable
OR
120 VAC signal
ON = enable
Enable/disable
Color Monitor synch signal
Internal
Permissive
Signal
ColorMonitor:
Monitor:
Color
Checkfor
for
1.1.Check
synchronization.
synchronization.
Operator
2.2.Operator
releases
SKRU
releases SKRU
key using Sync
Screen.
Figure 45 Two-Stage Permissive Signal: External plus Internal
83
PowerPak PDU 50-300 kVA
11.6 Open Transition Transfer
During maintenance you may wish to switch power sources in an open transition break-before-make
transfer. Power continuity from one source to the other is not maintained. The load is dropped. The
SKRU key is not used.
To do an open transition transfer from the primary to the alternate source, follow these steps:




Open (turn off) the primary source circuit breaker.
Turn the key of the primary circuit breaker lock to extend the bar, locking the breaker. Remove the
key.
Insert the key into the alternate source circuit breaker lock and turn the key to retract the bar.
Close the alternate circuit breaker, applying power to the PDU from the alternate source voltage.
Warning!
Closing the alternate circuit breaker to re-energize the PDU can result in
inrush on the upstream power sources, such as a UPS. Verify that your
upstream power sources can handle the inrush or put the upstream UPS in
bypass mode.
84
Manual Dual PDU
Dry Contact Permissive Signal
120VAC Voltage Applied Permissive Signal
Figure 46 One-Line Manual Dual PDU with Permissive Signal Wiring Variations
85
PowerPak PDU 50-300 kVA
12 Service
12.1 Start Up
PDI START UP is mandatory for all purchased PDU’s and is a sure way of getting your power
equipment up and running as you need it. PDI START UP services provide the following:


A factory-trained customer support engineer to certify that the PDU is functioning correctly in your
installation.
A factory-trained customer support engineers to assist with operational training.
12.2 Service Contracts
12.2.1 Standard Warranty
Standard products manufactured by PDI are warranted to be free from defects in workmanship and
material for a period of twelve (12) months from initial startup or eighteen (18) months from date
of shipment, whichever comes first. After the end of the warranty period, service requests are
handled on a time and material basis unless a preventative maintenance contract is in effect.


U.S. – Full Coverage of Parts and Labor
International – Parts Only Coverage Standard
12.2.2 Extended Warranty
Please contact a PDI service representative for detailed information about extended warranties.
Tel: (800) 225-4838 | Email: service@pdicorp.com
12.3 Maintenance Contracts
PDI offers maintenance contracts to help ensure the ongoing reliability of critical power systems.
Maintenance contracts are customizable to meet specific needs (number of PM visits per year, scope
of coverage (e.g. parts not included), length of contract, etc.).
Maintenance contracts include the following:



Rapid Service Response
o PDI Maintenance Service responds 24 hours a day, 7 days a week without additional
costs for weekends, nights or holidays.
Two comprehensive Preventative Maintenance Visits Annually
o Infrared Scanners provide information that can determine impending failures on
connections and busing.
o Harmonic Analyzers provide real time information on the effects of harmonic currents on
the power distribution system.
Other services include:
o Thorough visual inspection of all parts (bulbs, displays, missing hardware and
cleanliness)
o Inspection of load balance, KVA usage and building alarms
o Test and analysis report
86
Service

Guaranteed Parts Availability
o PDI guarantees parts availability to service customer equipment in timely fashion.
Please contact a PDI service representative for detailed information about Preventative Maintenance
Contracts.
Tel: (800) 225-4838 | Email: service@pdicorp.com
12.4 Time and Materials
In most cases the customer will be covered by START UP service or Maintenance Contracts;
however, there may be times when the customer needs PDI service and lacks the benefits that these
two packages provide. Therefore, PDI provides Time and Material coverage for those in need of our
customer support engineers.
12.5 Spare Parts Kits
Spare Parts are available for the PowerPak PDU in three kit levels: A , B, C. To order, call (800) 2254838 or email service@pdicorp.com.
Table 13 Spare Parts Kits for PowerPak PDU
Qty
5
1
5
5
5
5
2
2
2
1
1
5
1
1
1
1
1
1
1
Spare Parts Kit Components
Assorted Fuses
Control Power Transformer
South-co Panel Retainer
South-co Panel Clip
South-co Panel Fastener
South-co Panel Washer
Panel Guide
Panel Latch
Panel Slide Latch
WaveStar® Data Acquisition Card
Audible Alarm Horn
Emergency Power Off Assembly
WaveStar® Color Monitor
WaveStar® Contractor Board
Second Source Board
Complete Set of Ribbon Cables (6)
BCMS Board
Data Module Transformer
Split Core Hot Fix Board with 6 CT’s
Option
A
B
C
87
Bibliography
Bibliography
Points Lists
Points lists for PDUs can be downloaded from the PDI website. Go to Service Software
Downloads:
http://www.pdicorp.com/brands/pdi/services/customer-service/service-softwaredownloads
For the PDU M4G Board points list, download Wavestar® PDU Customer CD, a zip
file. Unzip the file and open the directory \Wavestar PDU Customer CD to find the
following points lists and use the latest revision given:
PDU M4G Board points list is “M4G acquisition points list”.
For BCMS points lists, download BCMS II Customer CD Info, a zip file. Unzip the file
and open the directory \Points List for BCMS Version to find the following points lists
and use the latest revision given:
o
o
o
o
BCMS ESF (Enhanced Subfeeds) points list is “BCMS Points List Fourteen Sub”.
BCMS Normal panelboard points list is “BCMSII points list”.
BCMS KWH panelboard points list is “BCMSII plus points list Power KWH”.
BCMS IEC panelboard points list (for IEC format panelboards with 36 or 72 1P circuits) is
“72 BCMSII plus points list Europe KWH”.
Manuals for Related Products
WaveStar® Color Monitor, Setup and Operation, PM375103
PowerPak 2 PDU Installation and Operation PM375116
WaveStar® Power Hub 2, Power Distribution Unit 300 – 625 kVA, Installation and
Operation, DOC15315
Modular Compact Remote Power Panel, Installation and Operation, PM375115
PowerWave 2™ Bus System 250A – 800A Installation and Operation, PM375106
PowerWave 2™ Bus System Branch Circuit Monitoring System, Setup and Operation,
PM375107
88
Glossary
Glossary
ANSI
American National Standards Institute
BCMS
Branch Circuit Monitoring System
BMS
Building Management System
DCIM
Data Center Infrastructure Management
EPO
Emergency Power Off
FIPS
Federal Information Processing Standards
kAIC
Kilo amps interrupting capacity
KWH
Kilowatt hour
M4G
PDU (M4G) Board
NEC
National Electrical Code
NEMA
National Electrical Manufacturer’s Association
NC
Normally Closed (dry contact)
NO
Normally Open (dry contact)
PDU
Power Distribution Unit
REPO
Remote Emergency Power Off
TVSS
Transient Voltage Surge Suppressor (preferred term=Surge Protective Device or
SPD)
SKRU
Solenoid Key Release Unit
SPD
Surge Protective Device
UBC
Uniform Building Code
UL
Underwriters Laboratories
89
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising