Eaton 9135 User manual

Category
Power distribution units (PDUs)
Type
User manual
Eaton Two-in-One
PowerPass Distribution Module
User's Guide
®
®
For use with 9135 Two-in-One
5000/6000 VA UPS Models
Class A EMC Statements
FCC Part 15
NOTE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at his own expense.
ICES-003
This Class A Interference Causing Equipment meets all requirements of the Canadian Interference Causing
Equipment Regulations ICES‐003.
Cet appareil numérique de la classe A respecte toutes les exigences du Reglement sur le matériel brouilleur du
Canada.
EN 50091-2
Some configurations are classified under EN 50091-2 as “Class‐A UPS for Unrestricted Sales Distribution.” For
these configurations, the following applies:
WARNING This is a Class A‐UPS Product. In a domestic environment, this product may cause radio interference, in
which case, the user may be required to take additional measures.
Eaton and PowerPass are registered trademarks of Eaton Corporation or its subsidiaries and affiliates.
Greenlee is a registered trademark of Greenlee Textron.
ECopyright 2009 Eaton Corporation, Raleigh, NC, USA. All rights reserved. No part of this document may be
reproduced in any way without the express written approval of Eaton Corporation.
Requesting a Declaration of Conformity
Units that are labeled with a CE mark comply with the following harmonized standards and EU directives:
S Harmonized Standards: EN 62040-1-1 (2004-12) and EN 62040-2 (2006-6); IEC 60950 Third Edition
S EU Directives: 2006/95/EC, Council Directive on equipment designed for use within certain voltage limits
2004/108/EC, Council Directive relating to electromagnetic compatibility
The EC Declaration of Conformity is available upon request for products with a CE mark. For copies of the EC
Declaration of Conformity, contact:
Eaton Power Quality SAS
110, Rue Blaise Pascal
38334 St ISMIER
FRANCE
Phone: +33 476 00 66 66
Special Symbols
The following are examples of symbols used on the UPS or accessories to alert you to important
information:
RISK OF ELECTRIC SHOCK - Indicates that a risk of electric shock is present and the
associated warning should be observed.
CAUTION: REFER TO OPERATOR'S MANUAL - Refer to your operator's manual for
additional information, such as important operating and maintenance
instructions.
This symbol indicates that you should not discard the UPS or the UPS batteries
in the trash. This product contains sealed, lead‐acid batteries and must be
disposed of properly. For more information, contact your local recycling/reuse or
hazardous waste center.
This symbol indicates that you should not discard waste electrical or electronic
equipment (WEEE) in the trash. For proper disposal, contact your local
recycling/reuse or hazardous waste center.
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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Table of Contents
1 Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Warnings 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Installation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Equipment 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PPDM Setup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UPS Shutdown 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PPDM Setup 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardwired PPDM Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug-Receptacle PPDM Installation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PPDM Startup 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UPS Startup 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug-Receptacle PPDM Rear Panels 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Operation 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Maintenance Bypass 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Specifications 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PPDM Schematics 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Service and Support 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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Chapter 1 Introduction
The PowerPass
®
Distribution Module (PPDM) is designed to operate
with a 5000/6000 VA Eaton
®
9135 uninterruptible power system (UPS).
The PPDM allows you to:
S Replace or upgrade the UPS without losing power to the protected
equipment (see “Using Maintenance Bypass” on page 35).
S Provide surge protection if the UPS is not present.
S Provide extra surge protection when the UPS is present.
Safety Warnings
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that you should follow during installation and
maintenance of the UPS and PPDM. Please read all instructions before operating the
equipment and save this manual for future reference.
D A N G E R
This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by
AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS
inside the UPS.
C A U T I O N
S To reduce the risk of fire or electric shock, install this UPS in a temperature and humidity
controlled, indoor environment, free of conductive contaminants. Ambient temperature
must not exceed 40°C (104°F). Do not operate near water or excessive humidity
(95% maximum).
S For PPDM models with hardwired outputs, overcurrent protection for the output AC
circuit(s) is to be provided by others.
S For PPDM models with hardwired outputs, suitably rated disconnect switches for the
output AC circuit(s) are to be provided by others.
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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Chapter 2 Installation
This section explains:
S Equipment inspection
S UPS setup
S PowerPass Distribution Module (PPDM) installation
S PPDM rear panels
Inspecting the Equipment
If any equipment has been damaged during shipment, keep the shipping
cartons and packing materials for the carrier or place of purchase and file
a claim for shipping damage. If you discover damage after acceptance,
file a claim for concealed damage.
To file a claim for shipping damage or concealed damage: 1) File with
the carrier within 15 days of receipt of the equipment; 2) Send a copy of
the damage claim within 15 days to your service representative.
NOTE Check the battery recharge date on the shipping carton label. If the date has passed
and the batteries were never recharged, do not use the UPS. Contact your service
representative.
PPDM Setup
The 9135 UPSs are designed for flexible configurations and can be
installed in a rack or as a standalone cabinet.
If the UPS is already installed and operating, shut down the UPS before
installing the PPDM. See the following section, “UPS Shutdown.”
For new UPS installations, continue to “PPDM Setup” on page 15.
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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UPS Shutdown
If the UPS is already installed and operating, shut down the UPS:
1. Prepare your equipment for shutdown.
2. Press the
button for approximately three seconds.
The UPS beeps once, and the load is no longer protected by the
UPS. It is powered by utility power. If the UPS is set in frequency
converter mode, the equipment will not be powered.
If the utility power is out of tolerance, the UPS will generate a
10 ms output calibrated break.
3. For a full shutdown of UPS and connected load, the upstream
circuit breaker (not included) should be set to the OFF position.
4. Continue to the following section, “PPDM Setup.”
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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PPDM Setup
To set up the PPDM with the 9135 UPS:
1. For tower configurations, continue to Step 2; for rack
configurations, continue to Step 7 on page 17.
2. Tower configuration only. Install pedestal extenders for each
additional cabinet:
For two cabinets, insert the extender into position 3 on the pedestal
(see Figure 1).
For three cabinets or more, insert the extender into position 4 on
the pedestal (see Figure 2).
1
2
3
4
1
2
3
4
Figure 1. Extending the Pedestals for Two Cabinets
1
2
3
4
1
2
3
4
1
2
3
4
Figure 2. Extending the Pedestals for Three or More Cabinets
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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NOTE Eaton recommends a minimum of 150 mm (5.9”) free space behind the UPS rear
panel, and a distance of 450 mm (17.7”) between the tower stands.
3. Carefully position the cabinet upright with the UPS indicators at the
top and place in the pedestals (see Figure 3).
4. Adjust the pedestals to the size of the UPS and secure the
pedestals with the captive screws.
UPS Indicators
150 mm
(5.9”)
450 mm
(17.7”)
Figure 3. Tower Position with Two Cabinets
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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5. Align each joining bracket with the adjacent cabinet screw holes
and secure with the supplied screws (see Figure 4).
NOTE Joining brackets are required for installations with two or more cabinets.
Joining Bracket
Figure 4. Installing the Joining Brackets
6. Continue to “Hardwired PPDM Installation” on page 19, or
“Plug-Receptacle PPDM Installation” on page 26.
7. Rack configuration only. Install the PPDM below the UPS and EBM
as shown in Figure 5.
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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Figure 5. Typical 9135 UPS Installation with EBM and PPDM
8. Continue to “Hardwired PPDM Installation” on page 19, or
“Plug-Receptacle PPDM Installation” on page 26.
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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Hardwired PPDM Installation
W
A R N I N G
Only qualified service personnel (such as a licensed electrician) shall perform the electrical
installation. Risk of electrical shock.
C A U T I O N
S For PPDM models with hardwired outputs, overcurrent protection for the output AC
circuit(s) is to be provided by others.
S For PPDM models with hardwired outputs, suitably rated disconnect switches for the
output AC circuit(s) are to be provided by others.
NOTE Do not make unauthorized changes to the UPS or PPDM; otherwise, damage may
occur to your equipment and void your warranty.
The hardwired PPDM models require a dedicated branch circuit that
meets the following requirements:
S 40A minimum circuit with short circuit and overcurrent protection
S 200–240 Vac
S Single phase
S 50/60 Hz
S The breaker must be wallmounted and be readily accessible to the
operator
S Flexible metal conduit (recommended for ease of service and
maintenance)
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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Figure 6 shows the operation of the UPS with the EPPDMG6000-3U-HW
model, and Figure 7 shows the EPPDMG-6000-3U-HWEU model. For a
more detailed schematic, see Figure 21 on page 40 or Figure 22 on
page 41.
Terminal 1
L1 In
UPS
In Out
Bypass Switch
Voltage Switch
PPDM
240
208
Terminal 6
UPS Output L1
Terminal 7
UPS Output L2
Terminal 2
L2 In
L1
L2
L1
L2
PPDM
Input Cord
PPDM
Output Cord
120
120
N
240
Terminal 4
Load Output 120V (isolated)
Terminal 5
Load Output Neutral (isolated)
Terminal 3
Load Output 120V (isolated)
Figure 6. UPS with EPPDMG6000-3U-HW PPDM Block Diagram
Terminal 1
L1 In
UPS
In Out
Bypass Switch
Voltage Switch
PPDM
240
230
Terminal 6
UPS Output L1
Terminal 7
UPS Output L2/N
Terminal 2
L2 In
L1
L2
L1
L2
PPDM
Input Cord
PPDM
Output Cord
240
Terminal 3
Load Output 230–240V (isolated)
Terminal 4
Load Output 115–120V (isolated)
Terminal 5
Load Output Neutral (isolated)
Figure 7. UPS with EPPDMG-6000-3U-HWEU PPDM Block Diagram
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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To hardwire the PPDM:
1. Switch off utility power at the distribution point where the PPDM
will be connected. Be absolutely sure there is no power.
2. Verify that the PPDM output circuit breaker is in the OFF position
(see Figure 9 on page 23).
3. Verify that the bypass switch on the PPDM is in the NORMAL
position (see Figure 8).
Bypass Switch Voltage Switch
Figure 8. PPDM (with Front Cover Removed)
4. Changing the PPDM voltage switch setting. When the PPDM voltage
switch is set to the 240V position (the default) with 240V input, the
output voltage is 240/120V. When set to the 208V position with
208V input, the output voltage is 208/120V. See Table 1 for a list of
PPDM input/output voltage settings. Figure 8 shows the voltage
switch.
NOTE In most applications, the voltage switch does NOT need changing.
To change the switch position, remove the bracket screw and turn
the switch. Flip the bracket around to fit the new position and
reinstall.
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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Table 1. Hardwired PPDM Input/Output Voltage Settings
Input Voltage
(from UPS)
EPPDMG6000-3U-HW Models Output Voltage
208V Switch Position Default 240V Switch Position
HV (T6-7) LV HV (T6-7) LV
208 208 120 208 104
220 220 126 220 110
230 230 131 230 115
240 240 138 240 120
Input Voltage
(from UPS)
EPPDMG-6000-3U-HWEU Models Output Voltage
230V Switch Position Default 240V Switch Position
HV (T6-7) LV HV (T6-7) LV
220 230 115 220 110
230 240 120 230 115
240 250 125 240 120
5. Remove the wiring access cover and the conduit landing plate and
retain (see Figure 9).
Punch holes in the conduit landing plate for the input and output
conduit using a Greenlee
®
punch or similar device.
6. Pull the input and output wires through separate conduit, leaving
approximately 0.5m (2 ft) of exposed wire. Attach a flexible metal
fitting to the end of each conduit.
7. Insert each conduit through a wiring access entry and attach the
conduit fitting to the panel. Strip 9 mm (0.35) of insulation from the
end of each incoming wire.
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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PPDM Input Cord
PPDM Output Cord
PPDM Output
Circuit Breaker
RPO Connector
Communication Port
USB Port
Wiring Access Cover
Conduit Landing Plate
RJ-11 Connector
Figure 9. UPS and Hardwired PPDM Installation
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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8. Connect the input and ground wires to the terminal block according
to the PPDM model:
S For the EPPDMG6000-3U-HW model, see Figure 10 and Table 2.
S For the EPPDMG-6000-3U-HWEU model, see Figure 11 and
Table 2.
9. Connect the output and ground wires to the terminal block
according to the PPDM model:
S For the EPPDMG6000-3U-HW model, see Figure 10 and Table 2.
S For the EPPDMG-6000-3U-HWEU model, see Figure 11 and
Table 2.
UPS Output Line 2, 208–240V
Load Output Neutral (isolated)
Output
Ground
Source Input Line 1
Source Input Line 2
Input
Ground
Load Output 120V (isolated)
Load Output 120V (isolated)
UPS Output Line 1, 208–240V
E4 1 2 3 4 5 6 7 E5
Figure 10. EPPDMG6000-3U-HW Model Terminal Block
Load Output Neutral (isolated)
Output
Earthing
Source Input Line 1
Source Input Line 2/N
UPS Output Line 2/N, 230–240V
Input
Earthing
Load Output 115–120V (isolated)
Load Output 230–240V (isolated)
UPS Output Line 1, 230–240V
E4123 4567E5
Figure 11. EPPDMG-6000-3U-HWEU Model Terminal Block
INSTALLATION
EATON Two-in-One PPDM (5000/6000 VA) User's Guide S 164201820 Rev 1 www.eaton.com/powerquality
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Table 2. PPDM Wiring Specifications
Terminal
Position
PPDM Wire Function
Terminal Wire
Size Rating*
Tightening
Torque
EPPDMG6000-3U-HW EPPDMG-6000-3U-HWEU
1 Source Input Line 1 Source Input Line 1
2–17 mm
2
(14–6 AWG)
1.8 ±0.22 Nm
(16 ±2 lb in)
2 Source Input Line 2 Source Input Line 2/N
3 Load Output 120V (isolated) Load Output 230–240V (isolated)
4 Load Output 120V (isolated) Load Output 115–120V (isolated)
5 Load Output Neutral (isolated) Load Output Neutral (isolated)
6 UPS Output Line 1, 208–240V UPS Output Line 1, 230–240V
7 UPS Output Line 2, 208–240V UPS Output Line 2/N, 230–240V
E4 Input Ground Input Earthing
2–5 mm
2
(14–10 AWG)
8 mm
2
(8 AWG)
17 mm
2
(6 AWG)
2.26 ±0.22 Nm
(20 ±2 lb in)
2.82 ±0.22 Nm
(25 ±2 lb in)
3.95 ±0.22 Nm
(35 ±2 lb in)
E5 Output Ground Output Earthing
* Use 2.0 mm
2
(14 AWG) 75_C copper wire minimum.
10. Replace the wiring access cover and the conduit landing plate.
11. Continue to “PPDM Startup” on page 28.
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