PowerPak Operations Manual

PowerPak Operations Manual
WaveStar®
PowerPak
Power Distribution Unit
Permissive Signals for Manual Dual Redundant System
Ctrl Nr: DOC15029
Revision: 002
PowerPak Manual Dual Redundant PDU
Thank you for your recent purchase of a WaveStar® PowerPak Power Distribution Unit from Power
Distribution, Inc.
For safety reasons as well as to ensure optimal performance of your 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 Power
Distribution Unit, please contact us:
Power Distribution, Inc. | 4200 Oakleys Court | Richmond, VA 23223
+1.800.225.4838 | PDICorp.com | pdiservice@pdicorp.com
WaveStar® PowerPak Power Distribution Unit/Permissive Signals for Manual Dual Redundant
System
Document Control Number: DOC15029 Rev 002
©Smiths Power 2014. All rights reserved.
DynaCool On-demand Cooling System, i-CON Modular Data Center, JCOMM, PDI, PDIQ,
Powercube, Quad-Wye, QuikSwitch, ToughRail Technology, and WaveStar are registered trademarks
of Power Distribution Inc. All 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.
Smiths Power
Smiths Power is a leading supplier of power distribution, conditioning, protection and monitoring solutions for data centers,
wireless communications and other critical or high-value electrical systems.
As a family of brands, PDI, Onyx, PolyPhaser, Transtector, LEA and RO Associates unite under one umbrella to Transform,
Distribute, Monitor and Protect™ power in global networks and systems. Our companies provide expertise in consulting, design
and manufacturing of power transformers and distribution systems, static switches, power monitoring, RF, AC, DC, data signal
and EMP protectors as well as power quality engineering services.
Smiths Power is part of the Smiths Interconnect division of Smiths Group (www.smiths.com), a global leader in applying
advanced technologies for markets in threat and contraband detection, energy, medical devices, communications and
engineered components. Smiths Group employs around 23,000 people in more than 50 countries.
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Contents
Contents
Safety ............................................................................................5
1
Permissive Signals ................................................................6
1.1
Kirk Key Circuit Breaker Locks ............................................................ 6
1.2
Permissive Signal Configurations ......................................................... 6
1.3
Wiring External Permissive Signals ...................................................... 7
1.4
1.5
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1.3.1
Dry Contact External Permissive Signal ...................................... 7
1.3.2
120V External Permissive Signal ............................................... 8
1.3.3
External Permissive Signal Only ................................................ 8
Dual Input Power Source Transfer Procedures ....................................... 9
1.4.1
Using the Internal Permissive Signal ......................................... 9
1.4.2
Transfer Procedure: Internal Permissive Signal Only.................... 9
1.4.3
Transfer Procedure: External Plus Internal Permissive Signals .... 11
1.4.4
Transfer Procedure: External Permissive Signal Only ................. 11
Open Transition Transfer .................................................................. 12
3
PowerPak Manual Dual Redundant PDU
Figures
Figure 1 PDU Internal Panel, Kirk Keys .................................................................................................. 6
Figure 2 Dry Contact External Permissive Signal Connection ................................................................ 8
Figure 3 120V External Permissive Signal Connection .......................................................................... 8
Figure 4 Monitor Sync Screen ................................................................................................................ 9
Figure 5 Manual Power Source Transfer Procedure ............................................................................ 10
Figure 6 Two-Stage Permissive Signal: External plus Internal ............................................................. 11
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Safety
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.
DANGER!
This symbol is used throughout this manual to indicate the presence of high
voltages, representing a hazard for electric shock, burn or explosion. Follow the
instructions carefully to avoid serious or fatal injury.
Follow safe electrical work practices:
 Disconnect and lock-out all power supplying equipment before working on or installing
PDU components. Use a properly rated voltage sensing device to confirm power is OFF.
 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.
 Read, understand, and follow the instructions before installing this product.
 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.
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WaveStar Manual Dual PDU Permissive Signals
1 Permissive Signals
The PowerPak Manual Dual PDU has dual inputs. The output load can be manually transferred from
one source to the other using the main circuit breakers.
1.1 Kirk Key Circuit Breaker Locks
The two main input circuit breakers have mechanical interlocks using Kirk Keys controlling access to
the breakers. There are three locks (Figure 1):



The breaker for the active power source is closed with a key in its lock.
The breaker for the inactive power source is locked open without a key in its lock.
The third lock is in the Solenoid Key Release Unit (SKRU), which has a key that is released
by a “permissive signal” to the solenoid. The operator removes the key and inserts it into the
lock for the inactive power source, allowing that breaker to be closed, enabling the closed
transition transfer.
Both power sources must be synchronized to perform the closed-transition, Make-Before-Break
transfer.
Solenoid Key Release
Unit 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 1 PDU Internal Panel, Kirk Keys
1.2 Permissive Signal Configurations
The PowerPak Manual Dual PDU can have two types of permissive signal for unlocking the SKRU
lock:

Internal signal. An internal permissive signal is generated through the Monitor’s Sync
Screen. The Monitor detects that sources are synchronized, allowing an operator to generate
a permissive signal to release the solenoid’s key.
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Permissive Signals

External signal. An external signal can optionally be used as a permissive signal, using an
external dry contact or 120VAC connection to a terminal block in the PDU.
There are three configurations for permissive signals:
1) Internal permissive signal only. The Monitor Sync Screen provides the SKRU (solenoid) key
release.
2) External permissive signal only. An external signal unlocks the SKRU key. The internal
permissive signal—the Monitor Sync Screen—is not used. Synchronizing power sources must be
done independently of the PDU.
The external signal is wired from a PDU terminal block directly to the solenoid key release,
bypassing the Monitor. The external signal can be either
a) a 120V applied external signal OR
b) a dry contact signal.
2) External permissive signal plus internal permissive signal. This is a two-stage permission
system, where the external permissive signal enables the internal permissive signal, the Monitor
Sync Screen. The external signal can be either
a) a 120V applied external signal OR
b) a dry contact signal.
See section 1.4 Dual Input Transfer Procedures for information on how external and internal
permissive signals are used.
1.3 Wiring External Permissive Signals
1.3.1 Dry Contact External Permissive Signal
A terminal block for connecting an external dry contact permissive signal is installed inside the PDU,
typically near the main breakers and Kirk Keys for the main breakers (Figure 2).
The dry contact must be a normally open (NO) dry contact. Closing the contact enables the signal.
If the external dry contact terminal block is installed but the dry contact is not connected, you can
install a jumper in the terminal block in place of a dry contact connection, to keep the external
permission permanently enabled.
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WaveStar Manual Dual PDU Permissive Signals
Normally Open (NO)
Dry Contact
Connections
To keep the external permissive
dry contact signal permanently
enabled, install a jumper in the
terminal block.
Figure 2 Dry Contact External Permissive Signal Connection
1.3.2 120V External Permissive Signal
The 120VAC external signal is connected to a terminal block in the PDU, similarly to the dry contact
connection. The 120V neutral and hot wires should be connected as shown in Figure 3.
Neutral wire connection (white)
Hot wire connection (black)
Note:
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 3 120V External Permissive Signal Connection
1.3.3 External Permissive Signal Only
The customer may choose to use only an external permissive signal to release the SKRU key. In this
case, the dry contact or 120V external permissive signal is wired directly to the solenoid, bypassing
the Monitor Sync Screen. Wiring is done at the factory.
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Permissive Signals
The external permissive signal provides the key release directly. Typically the external signal is sent
from an Uninterruptible Power Supply (UPS).
The PDU does not check to see that the two power sources are synchronized. The customer must
independently determine that the sources are synchronized.
1.4 Dual Input Power Source Transfer Procedures
1.4.1 Using the Internal Permissive Signal
The Monitor checks voltage readings for both sources from the PDU M4G board to determine if the
two sources are synchronized. For switching sources, the Monitor has a Sync screen. (When the
WaveStar Monitor is installed on a Manual Dual Redundant PDU, the first screen (Figure 4) after the
initial Banner/Alarm screen is the Sync screen.)
When sources are in synch, an operator can, from the Monitor Sync Screen, signal the solenoid to
release its key. The operator removes the key and inserts it into the Kirk Key lock for the other power
source, allowing that breaker to be closed.
Source 1: voltage,
frequency, and harmonic
distortion
Source 2: voltage,
frequency, and harmonic
distortion
“SYNC OK” = Sources are
synchronized and it is OK
to release the SKRU
(solenoid) key.
Circuit breaker status:
closed or open
Press right arrow button
to release solenoid key.
Figure 4 Monitor Sync Screen
The Sync screen has a mimic diagram of the circuit breaker status for both sources and other
information regarding the two sources:




Availability of both sources (Source reads “OK”)
Voltage and frequency measurements from both sources
Circuit breaker status (open/closed) on both sources
“Sync OK” allows signal to the Key Release Solenoid to release its key
1.4.2 Transfer Procedure: Internal Permissive Signal Only
To manually switch the load from one power source to the other using the Monitor, use the following
procedure:
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WaveStar Manual Dual PDU Permissive Signals
Figure 5 Manual Power Source Transfer Procedure
1. From the Banner/Alarm screen, press Enter
to display the Sync screen. The Sync screen
appears.
2. When the Sync screen displays “SYNC OK,”
the operator can press the right arrow key
(˃), signalling the SKRU to release its key. If
the sources are not synchronized, the screen
reads “SYNC BAD.”
Note: Both voltage sources must be
synchronized to make the closed transition
transfer.
3. The operator should turn the SKRU
(solenoid) key and remove it.
3
4. The operator should then
4.1. insert the SKRU key into the circuit
breaker lock for the inactive power
source (the open circuit breaker, in this
example, Source 1);
4.2. turn the key; and
4.3. close (turn on) the breaker.
Note: At this point, both synchronized voltage
sources are feeding the PDU and both
breakers will show closed on the Sync
screen.
5. Open the circuit breaker for the previously
active power source that you are turning off.
6. Move the key from this breaker to the SKRU
(solenoid):
4
Assume Source 1 has
been the inactive
power source.
6
5
Assume Source 2
has been the active
power source.
6.1. remove the key from the breaker,
6.2. insert it into the lock for the SKRU, and
6.3. turn the key.
Note: Source 1 is now the only active source.
Source 2 is locked open (off).
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Permissive Signals
1.4.3 Transfer Procedure: External Plus Internal Permissive Signals
The PDU can be also be configured with a two-stage permissive signal (Figure 6):
Stage 1. An external permissive signal (120V or dry‐contact signal) enables or disables the Monitor’s
solenoid key release signal (internal permissive signal).
Stage 2. An operator uses the Monitor Sync Screen to release the SKRU (solenoid) key as described
in the previous section, 1.4 Power Source Transfer Procedure.
External
Permissive
Signal
Dry contact (NO)
Closed = enable
OR
120 VAC signal
On = enable
Enable/disable
Monitor SKRU (solenoid key release)
Internal
Permissive
Signal
Monitor:
1. Power source
synchronization
check
2. SKRU
(solenoid) key
release command
Figure 6 Two-Stage Permissive Signal: External plus Internal
1.4.4 Transfer Procedure: External Permissive Signal Only
If an external permissive signal is used alone to release the SKRU (solenoid) key, power sources
must be independently verified to be synchronized. Once the external permissive signal releases the
SKRU key, follow these steps, the same as steps 3-6 in 1.4 Power Source Transfer Procedure:
Internal Permissive Signal
1. The operator should turn the SKRU key and remove it.
2. The operator should
2.1. insert the key in the lock for the main breaker of the inactive power source,
2.2. turn the key, and
2.3. close the breaker.
Note: At this point, both synchronized voltage sources are feeding the PDU.
3. Open the circuit breaker on the first source.
4. Remove the key from the first (previously active) breaker, insert it into the lock for the SKRU
(solenoid), and turn the key.
At this point only the second power source is feeding the PDU, and Kirk Key locks prevent any
change of sources.
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WaveStar Manual Dual PDU Permissive Signals
1.5 Open Transition Transfer
During maintenance you may wish to switch power sources in an open transition transfer. Power
continuity from one source to the other is not maintained. The load is dropped. The solenoid and
SKRU key are not used.
To do an open transition transfer to the other source, simply swap the key from one breaker to the
other:




Open (turn off) the primary breaker.
Turn the key and remove it from the primary breaker lock to extend the bar.
Insert the key in the alternate breaker lock and turn the key to retract the bar.
Close the alternate 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.
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Permissive Signals
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