Download PowerHub 2 Power Distribution Unit

WaveStar®
PowerHub 2
Power Distribution Unit
300-750 kVA
Installation and Operation
Ctrl Nr: DOC15315
Revision: 004
PowerHub 2 PDU 300-750 kVA
Thank you for your recent purchase of a WaveStar® PowerHub 2 Power Distribution Unit from Power
Distribution, Inc.
For safety reasons as well as to ensure optimal performance of your WaveStar® PowerHub 2 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 WaveStar®
PowerHub 2 Power Distribution Unit, please contact us:
Power Distribution, Inc. | 4200 Oakleys Court | Richmond, VA 23223
+1.800.225.4838 | [email protected]
WaveStar® Power Hub 2
Power Distribution Unit
300 – 750 kVA
Installation and Operation
DOC15315 Rev 004
© 2017 by Power Distribution, Inc. All rights reserved.
DynaCool On-demand Cooling System, 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 switching, 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
General Description .................................................................. 9
1.1
Product Summary .................................................................................. 9
1.2
Electrical Specification ............................................................................ 9
1.3
Environmental Specification ................................................................... 10
1.4
Standards ........................................................................................... 10
1.5
PDU Module Descriptions ....................................................................... 10
PDU Enclosure ........................................................................ 13
2.1
3
4
2.1.1
Panels and Covers...................................................................... 13
2.1.2
Clearances ................................................................................ 13
2.1.3
Front Access PDU ....................................................................... 13
2.2
Cable Landing ...................................................................................... 15
2.3
PDU Mounting ...................................................................................... 15
Transformer ........................................................................... 16
3.1
Standard and Optional Transformer Parameters ....................................... 17
3.2
Transformer Temperature Alarms ........................................................... 17
3.3
Transformer Voltage Adjustment Taps .................................................... 17
Power Distribution ................................................................. 19
4.1
4.2
4.3
5
Enclosure Specifications ........................................................................ 13
Main Circuit Breakers ............................................................................ 23
4.1.1
Main Input Circuit Breaker .......................................................... 23
4.1.2
Main Output Circuit Breaker (Optional) ......................................... 23
Output Subfeed Circuit Breakers ............................................................ 24
4.2.1
Circuit Breaker Frame Type ......................................................... 24
4.2.2
Subfeed Breaker Optional Features .............................................. 25
Transient Suppression .......................................................................... 25
4.3.1
Surge Protective Device .............................................................. 25
4.3.2
Transient Suppression Network ................................................... 25
4.4
Emergency Power Off (EPO) .................................................................. 25
4.5
Fuse Panel ........................................................................................... 26
Monitoring .............................................................................. 27
5.1
Monitoring Overview ............................................................................. 27
5.2
Monitoring Compartment....................................................................... 27
3
PowerHub 2 PDU 300-750 kVA
5.3
WaveStar Monitors ............................................................................... 28
5.4
PDU M4G Board ................................................................................... 28
5.5
5.6
5.4.1
Layout and Connections .............................................................. 28
5.4.2
PDU M4G Board Points List (Modbus Register List) ......................... 31
Contractor Boards ................................................................................ 31
5.5.1
Basic Contractor Board ............................................................... 32
5.5.2
Enhanced Contractor Board ......................................................... 33
5.5.3
BCMS Acquisition Board (HV) ...................................................... 34
BCMS Subfeed Monitoring ..................................................................... 34
5.6.1
5.7
6
Dry Contact Network ............................................................................ 37
5.7.1
Dry Contacts for Subfeed Circuit Breakers (optional) ...................... 37
5.7.2
Surge Protective Device Status .................................................... 39
Manual Dual PDU Configuration ............................................. 41
6.1
Closed-Transition Power Source Transfer ................................................. 41
6.2
Manual Dual PDU Layout and Wiring ....................................................... 41
6.3
Two-Stage or One-Stage Permissive Signal ............................................. 41
6.4
6.5
7
Subfeed Output Circuit Monitoring ............................................... 34
6.3.1
Two-Stage Permissive Signal ....................................................... 41
6.3.1
One-Stage Permissive Signal ....................................................... 46
6.3.2
Connecting the External Dry Contact ............................................ 46
Power Transfer Procedures: Closed Transition .......................................... 46
6.4.1
Manual Transfer Mechanisms ....................................................... 46
6.4.2
Conditions Prerequisite to Initiating a Power Source Transfer .......... 47
6.4.3
Transfer from Primary Source to Alternate Source.......................... 48
6.4.4
Transfer from Alternate Source to Primary Source.......................... 48
Power Transfer Procedure: Open Transition ............................................. 48
Installation Planning: Placement and Power Connections ...... 49
7.1
Placement ........................................................................................... 49
7.2
Raised Floor ........................................................................................ 49
7.3
7.2.1
Raised Floor Loading .................................................................. 49
7.2.2
Cabling ..................................................................................... 49
7.2.3
Raised Floor Cable Entry ............................................................. 49
System Grounding Recommendations ..................................................... 49
7.3.1
Power System Grounding ............................................................ 50
7.3.2
Grounding Conductors ................................................................ 50
4
Contents
7.3.3
7.4
8
Input Power Connections ....................................................................... 51
Installation Planning: PDU Network ....................................... 53
8.1
8.2
8.3
9
Physical Network .................................................................................. 53
8.1.1
Supported Protocols ................................................................... 53
8.1.2
ModBus RTU .............................................................................. 53
8.1.1
Biasing and Termination ............................................................. 53
8.1.2
Wiring ...................................................................................... 54
8.1.3
Customer Network Connections ................................................... 54
8.1.4
Color Monitor Backpanel ............................................................. 54
8.1.5
WaveStar Monitor Backpanel ....................................................... 55
Modbus Addresses ................................................................................ 55
8.2.1
Points List Addresses .................................................................. 55
8.2.2
Monitor Address......................................................................... 56
8.2.3
Address Mapping Downstream of the Monitor ................................ 56
Modbus Commands and Replies ............................................................. 57
8.3.1
Command Packets ..................................................................... 57
8.3.2
Supported Commands and Replies ............................................... 57
8.4
Modbus Registers: Data and Parameters ................................................. 57
8.5
Reading and Writing Modbus Registers .................................................... 58
8.6
SNMP.................................................................................................. 58
PDU Installation ..................................................................... 59
9.1
Receiving and Unpacking....................................................................... 59
9.2
Placing the PDU ................................................................................... 59
9.3
Inspection ........................................................................................... 60
9.4
Output Distribution Cable(s) Installation ................................................. 60
9.5
Torque Specifications ............................................................................ 61
9.6
9.5.1
MCCB’s, MCSW’s, Contactors, and Other Electrical Components ....... 61
9.5.2
Structural Fasteners ................................................................... 62
Torque Value Quick Reference ............................................................... 62
9.6.1
10
High Frequency (RF) Grounding (computer rooms) ........................ 51
Terminal Blocks and Distribution Breakers .................................... 62
PDU Initial Start-Up ............................................................... 63
10.1
PDU Post-Installation Inspection ............................................................ 63
10.2
Start-Up Procedure ............................................................................... 63
5
PowerHub 2 PDU 300-750 kVA
11
12
13
PDU Procedures ..................................................................... 65
11.1
Shutdown Signals................................................................................. 65
11.2
Manual or Automatic Restart .................................................................. 65
11.3
Manual Dual PDU Procedures ................................................................. 65
Alarms and Troubleshooting .................................................. 66
12.1
Reading Alarms with Modbus ................................................................. 66
12.2
Summary Alarms ................................................................................. 66
12.3
Reading Alarms at the WaveStar Display ................................................. 67
12.4
Troubleshooting Guidelines .................................................................... 67
Service ................................................................................... 68
13.1
Start Up .............................................................................................. 68
13.2
Warranty............................................................................................. 68
13.3
Maintenance ........................................................................................ 69
13.4
Time and Materials ............................................................................... 70
Bibliography ................................................................................... 71
Glossary ......................................................................................... 72
Appendix 1: Main Output Circuit Breaker Options ........................... 73
6
Contents
Figures
Figure 1 Front Access to Operator Controls, Components, and Customer Connections ........................... 12
Figure 2 General Assembly Drawing .......................................................................................................... 14
Figure 3 PDU Rear View, Covers Off, Transformer Compartment ............................................................. 16
Figure 4 Transformer Nameplate Sample ................................................................................................... 18
Figure 5 Transformer Taps and Main Circuit Breakers ............................................................................... 18
Figure 6 Power Distribution Components ................................................................................................... 20
Figure 7 PowerHub 2 PDU One-Line Diagram with 480/208VAC .............................................................. 21
Figure 8 PowerHub 2 One-Line Diagram with 230/400 VAC ...................................................................... 22
Figure 9 Fuse Panel .................................................................................................................................... 26
Figure 10 PDU Monitoring Components Part 1: Monitoring Compartment ................................................ 27
Figure 11 WaveStar Monitors Display Screens .......................................................................................... 28
Figure 12 PDU (M4G) Board Connections ................................................................................................. 30
Figure 13 Basic Contractor Board ............................................................................................................... 32
Figure 14 Enhanced Contractor Board ....................................................................................................... 33
Figure 15 BCMS HV Board ......................................................................................................................... 36
Figure 16 PDU Monitoring Components Part 2: Outside the Monitoring Compartment ............................. 37
Figure 17 Dry Contacts for Subfeed Circuit Breakers ................................................................................. 38
Figure 18 Surge Protective Device (SPD) Status ....................................................................................... 39
Figure 19 PowerHub 2 Manual Dual PDU General Assembly Drawing for a 400 kVA PDU ...................... 43
Figure 20 PowerHub 2 Manual Dual PDU One-Line Drawing for a 400 kVA PDU .................................... 44
Figure 21 Schematic for Manual Dual Power Transfer using Kirk Keys ..................................................... 45
Figure 22 Connecting External Permissive Dry Contact ............................................................................. 46
Figure 23 Dual Main Input Breakers and Kirk Key Mechanisms ................................................................ 47
Figure 24 Single Point Ground Conductor Connections ............................................................................. 50
Figure 25 Ground and Neutral Busbars ...................................................................................................... 51
Figure 26 Main Input Breaker with Extended Bus Option ........................................................................... 52
Figure 27 WaveStar Color Monitor Backpanel Connections ...................................................................... 54
Figure 28 WaveStar Monitor Modbus Connections .................................................................................... 55
Figure 29 Network Segmentation with Monitor ........................................................................................... 56
Figure 30 Modbus Upstream Address Remapping with Monitor ................................................................ 57
Tables
Table 1 Transformer Standard and Optional Parameters ........................................................................... 17
Table 2 Main Input Circuit Breaker Sizing by kVA and VAC ....................................................................... 23
Table 3 Main Output Circuit Breaker Characteristics .................................................................................. 23
Table 4 Subfeed Q-frame Circuit Breakers ................................................................................................. 24
Table 5 Subfeed J-frame Circuit Breakers .................................................................................................. 24
Table 6 Subfeed L-frame Circuit Breakers .................................................................................................. 24
Table 7 PDU Dry Contacts Table ................................................................................................................ 40
Table 8 Transfer Initiate Switch Prerequisite Conditions ............................................................................ 48
Table 9 Phase Wire Color Coding .............................................................................................................. 61
Table 10 Structural Fasteners Torque Table .............................................................................................. 62
Table 11 Troubleshooting Guidelines ......................................................................................................... 67
Table 12 Main Output Circuit Breaker UL/IEC Interrupting Ratings ........................................................... 73
7
PowerHub 2 PDU 300-750 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.
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 PDU in an appropriate environment per local regulations.
 ESD sensitive equipment. Ground yourself, discharge any static charge and ensure that the
device is effectively grounded before handling the unit.
8
General Description
1 General Description
1.1 Product Summary
The WaveStar® PowerHub 2 300-750 kVA Power Distribution Unit (PDU) is a large capacity, high-powerdensity central power distribution module:



300 kVA to 750 kVA transformer with a choice of transformer vectors, taps, and transformer
inrush limits
Wide range of circuit breakers and breaker form factors
Integrated Transient Suppression Network (TSN), optional Surge Protective Device (SPD) and
optional lightning arrestor
The PowerHub 2 is a front-accessible PDU (Figure 1) with front-access for these functions:




Operator controls and monitoring
Customer power, network, and dry contact connections
Circuit breakers
Replaceable PCBs, fuses, and other maintenance
The PDU has extensive monitoring capabilities:





WaveStar® monitoring for transformer, main power feeds, subfeeds, and other PDU functions
Integration with the PDI family of Branch Circuit Monitoring System (BCMS) monitoring products
An extensive dry contact network
WaveStar® Color Monitor
Modbus RTU, Modbus TCP/IP, TCP/IP (for Monitor web pages), and SNMP protocols
The PDU design provides customers PDU placement flexibility with a small total space footprint:




The PDU is front-accessible for all maintenance, requiring 36" service clearance only at the front
and 6" ventilation clearance on the back plus one side.
Cable entry to the PDU is from the top or bottom with removable conduit plates.
The PDU can be placed on fixed floor, reinforced raised floor, or floor stand (12"- 48" H).
Welded busbar construction, front-accessibility, and top/bottom cable entry allow the PDU to be
positioned near walls or other equipment, requiring less space and service clearances than
similarly sized PDUs.
The PDU can also be configured as a manual dual redundant PDU with two input sources manually
switched using Kirk Keys (see Chapter 6 Manual Dual PDU Configuration).
1.2 Electrical Specification
The PDU has these electrical characteristics:



kVA rating 300-750 kVA.
Input frequency 60 Hz ± 5 Hz or 50 Hz ± 5 Hz.
Input: 3-phase, 3-wire plus ground
9
PowerHub 2 PDU 300-750 kVA






Input source voltage:
o @ 50 Hz: 380V-415V
o @ 60 Hz: 600, 480 or 208V
Output: 3-phase, 4-wire plus ground
Output Voltage:
o @ 50 Hz: 575, 415/240, or 380/230V
o @ 60 Hz: 600, 575, 480, or 208/120V
All wiring per the National Electrical Code (NEC).
Welded copper bus connections with 200% neutral.
Computer grade single-point ground in accordance with the requirements of the NEC.
1.3 Environmental Specification
The PDU can be stored and operated within the following environmental conditions:



Acceptable temperature ranges:
o Storage temperature -36⁰C to +70⁰C (-33⁰F to 158⁰F).
o Operating temperature 0⁰C to 40⁰C (32⁰F to 104⁰F).
Relative humidity range from 0% to 95% non-condensing.
Altitude to a maximum of 10,000 ft. The PDU is de-rated above 10,000 ft.
1.4 Standards
The PowerHub 2 PDU is listed to the applicable portions of Underwriters Laboratories standards UL1062
(PDU Standard) and UL 1950 and is CSA-certified.
It is also designed and assembled in conformance to all relevant standards of manufacturing and
construction including, but not limited to, the following standards:













UL67
UL50
UL489 Circuit Breaker Enclosures
UL891
NFPA
IEEE 519-1991
ANSI/UL 1449 3rd edition: Surge Protection Device (SPD)
ANSI C33.4
NEMA ST-20
NEMA AB-1
NEMA-PB-1
NEC
IBC 2010, seismic zone 4, California standard
1.5 PDU Module Descriptions
The PowerHub 2 enclosure and functional modules are described in the following chapters:

Chapter 2, PDU Enclosure
10
General Description




Chapter 3, Transformer
Chapter 4, Power Distribution
Chapter 5, PDU Monitoring
Chapter 6, Manual Dual PDU Configuration
Later chapters describe installation and operation of the PDU.
11
PowerHub 2 PDU 300-750 kVA
Circuit breakers are behind locked viewing panels.
Operator controls are all front-accessible.
Front access to monitoring components and to
customer network connections are in the central
Monitoring Compartment on left PDU door.
Customer connections (power, monitoring, dry
contacts, and networking) and replaceable
components are all front-accessible.
Figure 1 Front Access to Operator Controls, Components, and Customer Connections
12
PDU Enclosure
2 PDU Enclosure
2.1 Enclosure Specifications
Dimensions The cabinet enclosure is NEMA-1 rated with these dimensions:


60" W x 84" H x 40" D, if the PDU has the standard transformer, or
60" W x 84" H x 42" D, if required by specific transformer K-factors, conductor materials,
temperature rise, or other specific transformer requirements.
Weight The 500 kVA PDU weighs approximately 3800 lbs. with the standard transformer.
Paint The cabinet enclosure is primed and painted inside and out with a suitable powder coat enamel,
IBM Pearl White or “computer hardware off-white.” Custom paint requirements can be specified by the
customer.
See the General Assembly Drawing, Figure 2, for PDU views with dimensions.
2.1.1 Panels and Covers
Panels All removable panels use captive hardware and either lift off or incorporate ¼-turn latches.
Circuit breaker covers All circuit breakers and switches are mounted behind closed doors with key
access to limit access to only authorized personnel. The PDU has an exterior hinged output circuit
breaker cover door with a transparent window.
The PDU incorporates dead front panels over the output circuit breakers. The dead front panels allow
screw-on plates to cover unused breakers positions.
2.1.2 Clearances
Service clearance: 36" front only access
Ventilation clearances (minimum):


6" both sides, OR
6" rear plus one side
2.1.3 Front Access PDU
The cabinet enclosure is front access only, including





All operator controls and EPO button
Power, network, and dry contact connections
Circuit breakers and PCBs
All routine maintenance
Transformer taps
13
PowerHub 2 PDU 300-750 kVA
Figure 2 General Assembly Drawing
14
PDU Enclosure
2.2 Cable Landing
The PDU is designed for top or bottom cable input and output in the front half of the cabinet. Top and
bottom cable landing panels are removable. The cable landing panels are galvanized solid plate (not prepunched) and are not painted. If aluminum conductors are used, there may be limitations on conduit.
2.3 PDU Mounting
The PDU can be mounted on



Fixed floor
Raised floor (PDI recommends that raised flooring be reinforced.)
Universal floor stand: To match raised floor heights from 12" to 48", the PDU can be mounted on
a floor stand, ranging from 12" to 48" high. The PDU-floor stand combination meets seismic zone
4 requirements, California Standard, IBC 2010.
15
PowerHub 2 PDU 300-750 kVA
3 Transformer
The PDU has an integral three (3) phase, copper-wound, high isolation transformer rated between 300
kVA and 750 kVA.
The transformer is specifically designed for the PDU and its applications and provides the following:





Voltage transformation: several voltage options and vectors
Voltage adjustment: transformer taps
High isolation
Conditioning
Electrostatic shielding
The transformer compartment is the rear module of the PDU and has a large ventilation area (Figure 3).
A universal footing template inside the PDU secures the transformer to its base.
Each transformer is tested to the C57.121.91 standard.
Transformer
Compartment
Ventilation Area
Transformer
Nameplate
Ventilation
Area
Figure 3 PDU Rear View, Covers Off, Transformer Compartment
16
Transformer
3.1 Standard and Optional Transformer Parameters
The standard transformer and options are shown in the following table.
Parameter
Input Voltage
Output Voltage
Frequency
Impedance
Efficiency
Standard Transformer
480V Delta
208 /120V Wye
60 Hz
3 – 5%
DOE2016
K-Factor
Conductor Material
Inrush
Taps
K9
Copper (CU)
8 – 10x
< 750 kVA: ±2 x 2.5-3.5%
≥ 750 kVA: ±1 x 2.5-3.5%
Temperature Rise
150⁰C
Vector
Delta-Wye
Applicable Standard
UL-1561
IEEE Standard C57.12.01
NEMA ST-20
Class 240S
Average sound level
Insulation
Options
208– 600V
208 – 600V
50 Hz
Up to 6%
CEC, CSA, Non-DOE2016 for
certain exempt categories,
NEMA Premium, TP1 (CSA)
K4, K13, K20
Aluminum (AL)
5x
Taps optional. Custom taps
available, percentage subject to
physical location
80⁰C, 115⁰C, 130⁰C, 150⁰C,
175⁰C
Delta Zig-Zag
Delta Quad-Wye
IEC 60076, CSA22.2 No 66,
CEC 400
Table 1 Transformer Standard and Optional Parameters
3.2 Transformer Temperature Alarms
The standard transformer has six (6) thermal overload devices to monitor core temperature in each
winding.


180⁰C Warning The first set of thermal devices is calibrated to 180⁰C, 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.
195⁰C Shutdown The second set of thermal devices is calibrated to 195⁰C, the shutdown
threshold. If any winding reaches 195⁰C 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.
3.3 Transformer Voltage Adjustment Taps
Transformer taps compensate for variation in incoming voltage from the nominal value. Taps on the
transformer primary let you adjust the turn’s ratio, providing a constant value of secondary voltage to the
load.
The transformer nameplate (Figure 4) is located near the transformer (Figure 3) and includes transformer
taps cable connections with the resulting input voltage along with other transformer specifications.
Transformer taps are changed from the front of the PDU (Figure 5).
17
PowerHub 2 PDU 300-750 kVA
Transformer taps cable connections table
for adjusting incoming voltage.
Figure 4 Transformer Nameplate Sample
Main Output Circuit Breaker (from transformer)
Required by NEC if more than (6) distribution breakers
Main Input Circuit Breaker
to transformer
from customer power feed
Transformer Taps are
behind the red panel.
Transformer Taps
obscured behind CT.
Figure 5 Transformer Taps and Main Circuit Breakers
18
Power Distribution
4 Power Distribution
This chapter describes the Power Distribution Module of the PDU, including




Main Input Breakers to transformer and optional Main Output Breaker from the transformer
Subfeed distribution breakers
Transient and surge protection
Emergency Power Off (EPO) and Remote EPO (REPO)
See 1.2 Electrical Specification for voltage and frequency specifications. Grounding and wiring is
described in 7.3 System Grounding Recommendations and 7.4 Input Power Connections. The
following illustration (Figure 6) shows the locations of power distribution components. Typical one-line
electrical diagrams using different input and output voltages are shown in Figures 7 and 8.
19
PowerHub 2 PDU 300-750 kVA
Conduit Plates
Phase ABC
Busbars
Hard Glastic
Separates ABC
Busbar Sets
Distribution Subfeed
Circuit Breakers
(2 columns)
Ground Busbar
Connections
Lightning Arrestor
Surge Protective
Device (SPD)
Main Output Circuit
Breaker (Optional)
200% Neutral
Busbar Connections
(2) Conduit Plates
Customer Input
Power Connections
(Extended Bus
Option Shown)
Main Input Circuit
Breaker
Figure 6 Power Distribution Components
20
Power Distribution
Figure 7 PowerHub 2 PDU One-Line Diagram with 480/208VAC
21
PowerHub 2 PDU 300-750 kVA
Figure 8 PowerHub 2 One-Line Diagram with 230/400 VAC
22
PowerHub 2 PDU 300-750 kVA
4.1 Main Circuit Breakers
The PDU has a Main Input Circuit Breaker to the transformer and an optional Main Output Circuit Breaker
from the transformer to the Distribution Subfeeds (Figures 5-8).
The main input bus is also compatible with a main lug only (MLO) power feed—that is, without a main
breaker.
4.1.1 Main Input Circuit Breaker
Each PDU has a 600V, 480V, or 400V thermal-magnetic main input circuit breaker with optional
electronic trip, sized in compliance with NEC 2011. At 480VAC the Main Input Breaker is a 600A
manually operated, thermal-magnetic breaker with minimum 22 kAIC to maximum 65kAIC. An electronic
trip breaker rated 700A can be substituted if an L-frame breaker is used.
The Main Input Circuit Breaker amperage and kAIC ratings vary by transformer size and input voltage
and are given in the following table:
kVA
300
CB @ 400VAC
(35 kAIC)
600A
CB @ 480VAC
(35 kAIC)
500A (if electronic)
CB @ 600VAC
(22 kAIC)
400A
400
800A
500A
500
1000A
600A (thermal-magnetic)
700A (electronic trip, L-frame only)
800A
625
1200A
1000A
800A
700A
Table 2 Main Input Circuit Breaker Sizing by kVA and VAC
4.1.2 Main Output Circuit Breaker (Optional)
The optional Main Output Circuit Breaker from the transformer to the output subfeeds is required by the
NEC if there are six (6) or more subfeeds. The standard output circuit breaker is from Square D
(Schneider Electric) and its characteristics are given below:
Frame Type
R-Frame
Voltage Rating
600 VAC
Interrupting Rating
65 kAIC@240Vac
35 kAIC@480Vac
18 kAIC@600Vac
Number of Poles
3-Pole
Circuit Breaker Rating
80% Rated
Electronic Trip Unit
Basic (ET1.0I)
Trip Function
Fixed Long-Time Adjustable Instantaneous Trip
Table 3 Main Output Circuit Breaker Characteristics
23
PowerHub 2 PDU 300-750 kVA
600V is the maximum rated voltage of the PDU. A 600VAC circuit breaker can be used with any voltage
less than 600V. Circuit breakers are available in 80% and 100% ratings with other trip options. Other
Main Output Circuit Breakers are also available. See “Appendix 1: Main Output Circuit Breaker Options
and kAIC Ratings.”
4.2 Output Subfeed Circuit Breakers
4.2.1 Circuit Breaker Frame Type
The PDU design accommodates a full line of Schneider Electric output subfeed circuit breakers mounted
in two columns:


Panel-mount circuit breakers (Q-, J-, and L-frame)
L-frame plug-in circuit breakers
Circuit breakers must be of the same frame throughout the circuit breaker column. Electronic trip breakers
are used when available.
The number of circuit breakers that can be installed in the PDU per frame type is given in the following
tables along with amperage sizing and kAIC ratings (the values are for copper conductors unless
otherwise noted). The main output bussing is designed for 65 kAIC minimum at 240VAC.
Q Frame
25/65 kAIC
(Thermal-magnetic only)
Circuit Breaker Frame
Amperage
150
175
225
Circuit Breaker Quantity
14
14
14
Table 4 Subfeed Q-frame Circuit Breakers
Circuit Breaker Frame
Amperage
Circuit Breaker Quantity
J Frame
25/65/100 kAIC
150
175
225
250
16
16
16
16
Table 5 Subfeed J-frame Circuit Breakers
Circuit Breaker Frame
L Frame (65/100 kAIC)
L Frame Plug-in (65 kAIC)
*Numbers in ( ) are for Aluminum conductors.
Amperage
250
400
500
600
Circuit Breaker Quantity
12
12
12 (9)*
9 (7)*
Table 6 Subfeed L-frame Circuit Breakers
24
Power Distribution
4.2.2 Subfeed Breaker Optional Features
Subfeed circuit breakers can have these features:


Output circuit breakers are available in 80% (standard) or 100% (optional) ratings, where
applicable.
Control wiring for all subfeed circuit breakers enabling these features:
 Shunt trip on output breakers
 Dry contact annunciation on shunt trip
 Auxiliary status indicator for circuit breaker
See 5.8.1 Dry Contacts for Subfeed Circuit Breakers (optional) and Table 7 PDU Dry Contacts
Table for more information on subfeed dry contacts.
4.3 Transient Suppression
The PDU has three features for transient suppression:



Input An optional Lightning Arrestor or Surge Protective Device (SPD) protects the input to the
transformer.
Output An optional SPD protects the transformer output to the distribution subfeed circuits.
Integrated The PDU can have an optional integrated Transient Suppression Network (TSN).
4.3.1 Surge Protective Device
As an optional feature, the PDU can incorporate a Surge Protective Device (SPD Type 2) rated either 100
kA or 200 kA on the input to or output from the transformer. The SPD complies with ANSI/UL1449 3rd
edition.
4.3.2 Transient Suppression Network
The PDU can have an optional internal high-energy TSN available for 208VAC Δ, 480VAC Δ, and
600VAC Δ systems. The TSN includes


a solid-state bipolar clamping device that suppresses both positive and negative transients
from either the line or the critical load, and
integral capacitors for noise attenuation.
The TSN has these characteristics:


Total surge capacitance is 40,000 amperes.
The TSN turns on in less than 5 ns.
4.4 Emergency Power Off (EPO)
The PDU has an internally powered 120VAC shunt trip mechanism to operate a local Emergency Power
Off (EPO) and to effectively interface with the WaveStar monitoring system.
25
PowerHub 2 PDU 300-750 kVA
The PDU has a common EPO circuit, designed to accept a normally open (NO) dry contact signal. A
24VDC remote shunt trip signal is available to interface with Remote Emergency Power Off (REPO)
stations.
4.5 Fuse Panel
The Fuse Panel is located in the left-side circuit breaker panel making all fuses readily accessible from
the PDU front. There are 23 fuse positions as shown in Figure 9.
The Fuse Panel is located in the left-side circuit breaker panel.
Fuses F1-F10 are reserved for high voltage and the following
fuse positions are currently assigned:
F1 – Input Voltage Sense Fuse
F2 – Input Voltage Sense Fuse
F3 – Input Voltage Sense Fuse
F4 – Output Voltage Sense Fuse
F5 – Output Voltage Sense Fuse
F6 – Output Voltage Sense Fuse
F7 – Power Supply Input Fuse
F8 – F10 Reserved for future use
Fuses F11-F23 are reserved for low voltage and all are
reserved for future use.
Figure 9 Fuse Panel
26
Monitoring
5 Monitoring
5.1 Monitoring Overview
The PowerHub 2 has a comprehensive set of standard and optional monitoring features:





WaveStar monitoring of the PDU transformer, Contractor Board, and power input to and output
from the transformer
WaveStar Branch Circuit Monitoring System (BCMS) monitoring of subfeeds
Extensive dry contact network
Choice of WaveStar® Monitors
Choice of Modbus RTU, Modbus TCP/IP, or SNMP for communication to Building Management
System (BMS) (see Chapter 7 Installation Planning: PDU Network)
5.2 Monitoring Compartment
PDU M4G Board
WaveStar Color
Monitor
Backpanel
BCMS Board
(spare)
BCMS Board
Enhanced
Contractor Board
The Monitoring Compartment is housed in the left front door
of the PDU.
Figure 10 PDU Monitoring Components Part 1: Monitoring Compartment
27
PowerHub 2 PDU 300-750 kVA
The WaveStar Monitoring Compartment (Figure 10) contains the WaveStar Monitor or Color Monitor and
PDI control and monitoring boards. The compartment is part of the left front PDU door. The panel door of
the compartment swings open for access to PCBs and connections without opening the PDU door,
providing easy access to PCBs and wiring.
5.3 WaveStar Monitors
There are two display choices for WaveStar monitoring (Figure 11):


The WaveStar Color Monitor is the standard PDU monitor: a 7-inch color touchscreen that can
monitor up to twenty (20) downstream devices. For information, see WaveStar® Color Monitor,
Setup and Operation PM375103.
The WaveStar Monitor, a 5.25-in monochrome display with six operator buttons, can be
substituted for the WaveStar Color Monitor. It can monitor up to ten (10) downstream devices. For
information, see WaveStar® Monitor, Setup and Operation DOC15314.
WaveStar Color Monitor screen
7-inch Color Touchscreen
WaveStar Monitor screen
5.25-inch Six-Button Display
Figure 11 WaveStar Monitors Display Screens
WaveStar Monitors can be also used in conjunction with a WaveStar® BCMS Hub, which provides a
consolidated power monitoring station for approximately (70) PDI devices.
5.4 PDU M4G Board
5.4.1 Layout and Connections
For the following connections, reference Figure 12, “M4G Board Layout and Connections.”
Transformer CT (current) and voltage connections (top edge of Figure 12):




CT connections, output current (ABC), Output 1 and Output 2
CT Connection G-N:
o Pins 1-2: Ground CT connection
o 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.
28
Monitoring

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:
o Remote EPO connection from the Contractor REPO Connection (J6), see Figure 12.
Customer REPO dry contact connection is to the Contractor Board.
o Local EPO connection
o 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
o 24VDC
The Restart Switch determines whether restart is automatic or manual after a voltage loss.
o Switch down: PDU restart must be done manually after voltage is restored.
o Switch up: PDU restart is automatic after power is restored.
o See section 10.2 Manual or Automatic Restart for additional information.
o 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.
29
PowerHub 2 PDU 300-750 kVA
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
120 VAC
input
(board
power)
Transformer
Restart
Switch:
Down =
Manual/
Up=Auto
24VDC
Output
for Shunt
Trip
Processor
170VDC
Output
signal for
Shunt Trip
Output
Relay for
switching
input feeds
24VDC Output
Power to
WaveStar Monitor
4 Digital
Inputs
Setup
USB
Connection
24VDC Output also powers the
Enhanced Contractor Board.
Upstream / Downstream
Modbus Connections
Ribbon Cable Connection to
Contractor Board
Thermal Wires
Local EPO
Remote EPO
Figure 12 PDU (M4G) Board Connections
Other Input and Output Signals


Four Digital Inputs or Alarms: Digital inputs or alarms are primarily used for internal PDU
signalling, such as a Surge Protective Device signal or Door Open condition. Digital feeds can be
assigned by PDI during M4G board setup, when names can also be assigned to the inputs.
These inputs turn on bits in the M4G points list. See PDU M4G Board Points List, Modbus
Register 90. Defaults are
o Digital Input 1
o Digital Input 2
o Digital Input 3
o Door Open
Output Relay: Output relay: used with a dual input PDU to signal transfer of input feed to the
other feed; a phase synchronization check is performed before enabling the relay.
30
Monitoring
USB Connection: Used by PDI representatives to program setpoints, contractor board relays, etc., the
PDU M4G and Contractor Boards. PDU board setpoints cannot be altered through normal Modbus
register access to prevent registers being accidentally altered. See M4G points list for further information.
Modbus Connections on the PDU M4G board are to/from the monitor.
5.4.2 PDU M4G Board Points List (Modbus Register 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. See Bibliography for instructions on downloading
points lists.
5.5 Contractor Boards
A Contractor Board is an extension of the PDU M4G Board, functioning as a terminal block to the PDU
Board and connected to the PDU Board by a ribbon cable. It is housed in the WaveStar Monitoring
Compartment with the PDU Board.
Internal PDU signaling, such as the four Digital Inputs, is terminated on the PDU M4G Board. External
signaling is terminated to a Contractor Board:



All dry contact signals for Remote Emergency Power Off (REPO), building alarms, output relays,
communication ports, and other control wiring must be terminated onto a Contractor Board.
All interface wiring (for building alarms, AC alarms, halon alarms, remote power off systems, etc.)
should be run within the PDU cabinet for termination on the Contractor Board.
All interface wiring and contacts are to be provided by others.
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
31
PowerHub 2 PDU 300-750 kVA
5.5.1 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 13 Basic Contractor Board
The Basic Contractor Board has these connections (Figure 13):
Inputs:


Remote EPO: Dry contact connection point for input of an REPO signal. Connect external dry
contacts to terminals marked +24V EPO RET (Figure 13). The REPO signal is sent to the PDU
Board via the REMOTE EPO connection, which is not a customer connection point. Note:
Connection of voltage to this point can cause damage to the unit!
Four (4) Building Alarms (Figure 13). Alarm names can be specified by PDI in PDU Board setup.
Outputs:

Four (4) remote relays that output dry contact (NO) signals (Figure 13). (Note: Remote relays can
accept dry contacts rated up to 2A/250V.)
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,
receives the signal and can cause PDU shutdown with an REPO signal.
32
Monitoring
o
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 13).
ModBus Connection: 4-wire configuration connection is located on the customer connection terminal
block.
ModBus Connections: The board has customer connections for upstream and downstream 4-wire
Modbus (Figure 13).
5.5.2 Enhanced Contractor Board
The Enhanced Contractor Board (Figure 14) 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 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
Modbus
Upstream:
paralleled
connectors
Modbus
Downstream
Modbus
Downstream:
paralleled
connectors
NOTE: Customer connections are all at the bottom of Outputs:
the board.
Figure 14 Enhanced Contractor Board
Remote
Relays
RR1-RR8
NO dry
contacts
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
33
PowerHub 2 PDU 300-750 kVA

marked +24V EPO RET (Figure 14). The REPO signal is sent to the PDU Board via the REMOTE
EPO connection, which is not a customer connection point.
Eight (8) Building Alarms (Figure 14). Alarm names can be specified by PDI in PDU Board setup.
Outputs:

Eight (8) remote relays that output dry contact (NO) signals (Figure 14). (Note: Remote relays can
accept dry contacts rated up to 2A/250V.)
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.
5.5.3 BCMS Acquisition Board (HV)
The PDU can have two BCMS Data Acquisition Boards High-Voltage Boards (Figure 15).
BCMS High Voltage Board Each BCMS is contained on a single PCB. The PCB has one main
processor and six current processors. Current processors process CT readings.
Both main and current processors have software specific to the board type and points lists used on the
board. PCB software is loaded in manufacturing using “Programming Connections.”
The High Voltage BCMS PCB has connectors for the following:






Two voltage sources
Cable harnesses to CTs on two panelboards (odd/even side connections)
Cable harnesses to two main or subdistribution feeds
A Modbus network connection
A USB connection for setup
A power connection
5.6 BCMS Subfeed Monitoring
5.6.1 Subfeed Output Circuit Monitoring
PDU subfeeds are monitored with the following:


Each subfeed can have CTs for monitoring ABC phases and NG.
Resistor Boards: Subfeed CTs are terminated onto a Resistor Board. One Resistor Board can
connect up to (14) 3-phase circuits (ABC) or (10) circuits if neutrals are also monitored (ABCN).
The standard PDU configuration has one Resistor Board for each circuit breaker row. (See Figure
16 for position in PDU.)
34
Monitoring


Branch Circuit Monitoring: the Resistor Boards are both connected to a single Branch Circuit
Monitoring System (BCMS) Acquisition Board. BCMS. A spare BCMS board can be mounted in
the Monitoring Compartment. (See Figure 16 for location in PDU and Monitoring Compartment.)
The BCMS board is loaded with the Enhanced Subfeeds Points List.
BCMS HV board is shown in Figure 15.
35
PowerHub 2 PDU 300-750 kVA
Figure 15 BCMS HV Board
36
Monitoring
Flexible Cable
Carrier for
Monitoring
Connections
Subfeed Circuit
Breakers Dry
Contacts:
- Trip
- Trip Alarms
- Auxiliary
Status
Subfeed Circuit
Breakers Dry
Contacts:
- Trip
- Trip Alarms
- Auxiliary
Status
Current
Transformers
(CTs) for
Subfeeds
Current
Transformers
(CTs) for
Subfeeds
Current
Transformers
(CTs) for
Neutral Bus
Current
Transformers
(CTs) for
Neutral Bus
Resistor Board
Resistor Board
Current
Transformers
(CTs) for Input
Phases
Surge Protective
Device:
- Status Lights
- Dry Contact
Connection
Current
Transformers
(CTs) for Input
Phases
Figure 16 PDU Monitoring Components Part 2: Outside the Monitoring Compartment
5.7 Dry Contact Network
In addition to the Modbus network, the PDU has an extensive network of dry contacts providing input
signals and alarm and status annunciation. Table 7 lists available dry contact input and output signals.
5.7.1 Dry Contacts for Subfeed Circuit Breakers (optional)
Subfeeds have optional dry contacts to


Trip a circuit breaker remotely
Present a trip alarm
37
PowerHub 2 PDU 300-750 kVA

Present circuit breaker status
See Figure 17 for subfeed dry contact layout.
Breaker Trip Signal (input)
- Black = Signal
- White = Neutral
Breaker Trip Alarm (output)
- White = Common
- Blue = Normally open
- Grey = Normally closed
Changes state when breaker is
tripped or reset
Breaker Auxiliary Contact
(output)
- White = Common
- Blue = Normally open
- Grey = Normally closed
Changes state when breaker
contacts change state (open or
close)
Optional Subfeed Dry Contacts
provide a set of dry contacts for
each subfeed circuit breaker.
Each circuit breaker can have a dry
contact set.
Figure 17 Dry Contacts for Subfeed Circuit Breakers
38
Monitoring
5.7.2 Surge Protective Device Status
The optional SPD incorporates a remote signaling contact for inclusion in the PDU dry contact system
and a visual status indicator at the bottom of the right front subfeed breaker panel (Figure 18)
Status Lights for the
optional Surge Protective
Device (SPD) are visible at
the bottom of the right-side
circuit breaker panel.
- Status lights for each
phase ABC
- 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.
Terminal Block for SPD dry contact
connection
Figure 18 Surge Protective Device (SPD) Status
39
PowerHub 2 PDU 300-750 kVA
Device
Input Signals
Output Signals
Signal Meaning
Dry Contact Spec
NA=Not Applicable
Monitors
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
PDU
(Contractor
Board)
Remote
Emergency
Power Off
(REPO)
Signal to immediately power
down PDU.
NA
PDU
(Contractor
Board)
4-8 Building
Alarms
Assignable meanings.
NA
Assignable meanings
Up to 2A/250V
PDU
(Contractor
Board)
Subfeed
breaker(s)
(optional)
4-8 Remote Relays
Relay 1 = Summary Alarm for
PDU by default
Breaker trip
Trip subfeed circuit breaker
Max 5A/600V
24VDC
recommended
Subfeed
breaker(s)
(optional)
Breaker trip alarm
Signals that subfeed circuit
breaker has tripped or has been
reset
Max 5A/600V
24VDC
recommended
Subfeed
breaker(s)
(optional)
Auxiliary contacts
Signals that 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
Stage 1 permissive signal,
enabling SKRU; can be
jumpered to be permanently
enabled (see 6.3 Two-Stage or
One-Stage Permissive
Signal).
NA
External
Permissive
Signal (with
Manual Dual
PDU only)
Enable Solenoid
Key Release
Unit
Table 7 PDU Dry Contacts Table
40
Manual Dual PDU Configuration
6 Manual Dual PDU Configuration
The PowerHub 2 PDU can be configured as a Manual Dual PDU. The dual inputs are switched manually
using Kirk Keys with a transfer initiate switch. A remote dry contact can be used to enable or disable the
transfer initiate switch.
6.1 Closed-Transition Power Source Transfer
The manual dual power source transfer is a closed transition power transfer. This means that power to
the load is never broken or interrupted during the transfer. Both power sources must be synchronized.
When both power sources are synchronized, the alternate power source is enabled, so that both sources
are feeding the PDU and load. The primary source is then taken offline, leaving the alternate source
feeding the load.
6.2 Manual Dual PDU Layout and Wiring
The PowerHub 2 Manual Dual PDU is the same as the standard PDU with these differences:





Two M-frame circuit breakers are Main Input Circuit Breakers for the two main power feeds.
There is no Main Output Circuit Breaker. One M-frame Main Input Breaker occupies the same
location as the in the standard PDU.
Because the NEC requires an output breaker if there are more than six (6) subfeeds, the number
of subfeeds is currently limited to six (6).
The main breakers have Kirk Key locking mechanisms. There is also a Solenoid Key Release
Unit (SKRU), located between the main breakers, which operators use to make the closedtransition, make-before-break power source transfer.
For the external permissive signal, a terminal block is installed in the Monitoring Compartment for
a dry contact connection.
The General Assembly Drawing for the PowerHub 2 Manual Dual PDU is given in Figure 19.
The One-Line Drawing is given in Figure 20.
The Schematic for the sync relay and Kirk Key interlock system is given in Figure 21.
6.3 Two-Stage or One-Stage Permissive Signal
Permissive signals allow the SKRU solenoid key to be released, letting the operator manipulate the main
breakers to execute the power source transfer.
6.3.1 Two-Stage Permissive Signal
The PDU has a two-stage permissive signal for releasing the key from the SKRU key interlock:

Stage 1: An external dry contact signal enables the SKRU transfer initiate switch. The dry contact
signal may originate, for example, from a UPS or the Building Management System.
41
PowerHub 2 PDU 300-750 kVA

Stage 2: An operator initiates the power source transfer using SKRU transfer initiate switch, Kirk
Key locks, and the main breakers.
42
Manual Dual PDU Configuration
Figure 19 PowerHub 2 Manual Dual PDU General Assembly Drawing for a 400 kVA PDU
43
PowerHub 2 PDU 300-750 kVA
400VAC 3PH
3W+G, 50 Hz
400 kVA TRANSFORMER
400Y-400D/230VAC
3W+G, 50 Hz
K13, 150ºC, 50HZ
400VAC 3PH
3W+G, 50 Hz
400VAC 3PH
3W+G, 50 Hz
Figure 20 PowerHub 2 Manual Dual PDU One-Line Drawing for a 400 kVA PDU
44
Manual Dual PDU Configuration
Figure 21 Schematic for Manual Dual Power Transfer using Kirk Keys
45
PowerHub 2 PDU 300-750 kVA
6.3.1 One-Stage Permissive Signal
If the external dry contact signal is not used, the terminal block connection (TB8) should have a jumper
installed to permanently enable the SKRU transfer initiate switch (see Figure 22 below). This creates a
single-stage permissive signal using only the Kirk Key system on the PDU front panel.
6.3.2 Connecting the External Dry Contact
The customer connects the normally open (NO) dry contact for the external permissive signal to TB8 in
the Monitoring Compartment (Figure 22).
If the dry contact signal is not used, the terminal block should be jumpered to create a permanently
enabled signal.
TB8: Connect NO external dry contact permissive
signal to TB8.
If dry contact is not connected, install a jumper at the
connection point for a permanent enabling signal.
Terminal block for connecting
external dry contact
permissive signal is located in
the Monitoring Compartment.
Figure 22 Connecting External Permissive Dry Contact
6.4 Power Transfer Procedures: Closed Transition
6.4.1 Manual Transfer Mechanisms
The two Main Input Circuit Breakers have locks using Kirk Keys controlling access to the breakers with a
Solenoid Key Release Unit (SKRU), shown in Figure 23. There are three locks:


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.
46
Manual Dual PDU Configuration

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.
Kirk Key lock, Source 1
SKRU Key Interlock
Main Input Breaker,
Power Source 1
Transfer Initiate Switch:
Press to initiate transfer
Solenoid Key
Release Unit (SKRU)
Light On = Source 1 available.
Light On = Source 2 available.
Main Input Breaker,
Power Source 2
Kirk Key lock, Source 2
Figure 23 Dual Main Input Breakers and Kirk Key Mechanisms
6.4.2 Conditions Prerequisite to Initiating a Power Source Transfer
For the transfer initiate switch to execute the closed transition transfer, both power sources must be
available and synchronized. These prerequisite conditions are shown in the following table (Table 8),
which is also shown on the schematic drawing (Figure 21).
Primary Power
Available?
Alternate Power
Available?
Both Sources
Synchronized?
Transfer to
Primary Power
Allowed?
Transfer to
Secondary
Power Allowed?
Yes
Yes
Yes
Yes
Yes
Yes
No
—
No
No
No
Yes
—
No
No
Yes
Yes
No
No
No
47
PowerHub 2 PDU 300-750 kVA
Table 8 Transfer Initiate Switch Prerequisite Conditions
6.4.3 Transfer from Primary Source to Alternate Source
The external permissive dry contact signal must be closed to enable the power transfer and the two
power sources must be synchronized.
To transfer power input from the Primary Source to the Alternate Source (see layout, Figure 23):
1. Depress the transfer initiate switch. Unlock and remove the key from the SKRU key interlock.
2. Insert the key into the lock for alternate power source. Unlock alternate source lock and close the
breaker. (Both power sources are now feeding the PDU and load.)
3. Open circuit breaker for the primary source and lock open. Remove the key from primary source
lock.
4. Insert the key into the SKRU key lock and turn to lock.
6.4.4 Transfer from Alternate Source to Primary Source
The external permissive dry contact signal must be closed to enable the power transfer.
To transfer power input from the Alternate Source to the Primary Source (see layout, Figure 23):
1. Depress the transfer initiate switch. Unlock and remove the key from the SKRU (solenoid) key
interlock.
2. Insert the key into the primary source lock. Unlock and close primary source circuit breaker. (Both
power sources are now feeding the PDU and load.)
3. Open circuit breaker for alternate source and lock open. Remove the key from alternate source
breaker lock.
4. Insert the key into the SKRU (solenoid) key interlock and turn to lock.
6.5 Power Transfer Procedure: Open Transition
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:
1.
2.
3.
4.
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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PowerHub 2 PDU 300-750 kVA
7 Installation Planning: Placement and
Power Connections
7.1 Placement
Follow the National Electrical Code (NEC) and local electrical codes for clearance requirements in
addition to PDU clearances given in 2.1.2 Clearances. See 1.3 Environmental Specification for
operating conditions.
7.2 Raised Floor
If the PDU is placed on a raised floor, properly mount the PDU c-channels to the floor mounting supports.
7.2.1 Raised Floor Loading
The PDU at 500 kVA weighs approximately 3800 lbs. The weight of the unit should be considered in
planning the PDU location. Additional floor bracing is recommended for all units. The raised floor system
must be able to support both the PDU as well as any other associated equipment. PDI recommends that
the end user properly compute raised floor loading and supply proper floor bracing when needed.
7.2.2 Cabling
The PDU location should be specified on a floor plan showing distribution cable runs and associated
equipment.
Distribution cable runs should also be recorded on the panelboard schedule. Each schedule identifies the
panelboard circuit and the associated computer or peripheral.
7.2.3 Raised Floor Cable Entry
When applicable, provisions must be made for cable entry through the raised floor once the PDU has
been properly located. The cable entry configuration should be free of any sharp edges and designed to
allow permanent access for the distribution cables and input power cables.
7.3 System Grounding Recommendations
The proper grounding of your PDI PDU is critical to the operation of the unit. Improper grounding of a
system may create unsafe conditions as well as electrical noise that may cause data processing
problems.
49
PowerHub 2 PDU 300-750 kVA
PDI has conducted a great deal of research on system grounding and makes the recommendations in the
following sections.
Important!
Grounding for this equipment must comply with NEC and local
building and electrical codes.
7.3.1 Power System Grounding
The primary concern is to provide a safe system that both complies with the electrical code (NEC article
250 in the USA, Canadian Electrical Code Section, 10, IEEE wiring regulations and chapter 54 in the UK)
and ensures proper and safe equipment operation.
The PDU contains a factory wired, green grounding conductor to a single ground point inside the PDU
cabinet (Figure 24). From this single ground point, each piece of equipment should be separately
grounded via a green grounding conductor within the flexible output computer grade cable.
Neutral Busbars
Single Point Green Grounding
Conductor can be attached to a
neutral busbar at the front lower
left or front lower right.
Figure 24 Single Point Ground Conductor Connections
7.3.2 Grounding Conductors
An isolation grounding conductor identical in size, insulation material, and thickness to the grounded and
ungrounded branch circuit supply conductors should be installed as part of the branch circuit that supplies
the system. This grounding conductor should be marked green (or green with yellow stripe) when using a
four (4) wire system.
This grounding conductor should be grounded at the nearest available grounding electrode in accordance
with all electrical codes. The output cabling receptacles of the PDU should be the same grounding type.
The grounding conductors serving these receptacles should be terminated at the PDU ground bus.
The PDU has ground busbars and neutral busbars symmetrically arranged on the left and right side of the
PDU for grounding circuit breakers and other equipment (Figure 25).
50
Installation Planning: Placement and Power Connections
Ground busbars
Ground busbars
Neutral busbar
Neutral busbar
Figure 25 Ground and Neutral Busbars
7.3.3 High Frequency (RF) Grounding (computer rooms)
In addition to the power grounding system, a reference grounding system for high frequency noise is
desirable (with the two systems being bonded together for the same reference potential). A grid made up
of (2) two foot squares will provide an effective signal reference grounding system. The raised floor can
be used if it has firmly connected metal stringers providing good electrical connections. If raised floor is
not available, a grid can be fabricated by laying a mesh (2 foot square) of braided copper strap directly on
the concrete sub floor (electrically connected at each intersection point). The frames of all the data
processing equipment, including the PDU, should be connected (by the shortest possible distance) to the
reference grid with braided copper. Finally, the reference grid should be bonded to the PDU for a single
point potential ground reference.
For optimum performance all distances for power and high frequency grounding should be kept to an
absolute minimum. To summarize, a radial grounding of this type (utilizing a single ground point) will
ensure that your facility is electrically safe, complies with all code requirements, and will be essentially
free of ground caused computer noise and problems.
7.4 Input Power Connections
Customers can make input power connections directly to the input breaker or with the Extended Bus
Option directly to the Extended Bus. Input wiring is the responsibility of the customer or the Installing
Contractor and must comply with NEC standards.
Extended Busbar Option connections can accommodate double-hole compression lugs and top and
bottom connections to the bus.
Note: Due to high kVA in the PDU, busbar holes for power connection are 1/2" in diameter.
See Figure 26 for input power connection locations.
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PowerHub 2 PDU 300-750 kVA
Extended Bus Option Connections
A
A
B
Main Input Breaker
B
C
C
Conduit Plates (shown
upside down for shipping)
Figure 26 Main Input Breaker with Extended Bus Option
52
Installation Planning: PDU Network
8 Installation Planning: PDU Network
8.1 Physical Network
8.1.1 Supported Protocols
Modbus RTU is the standard protocol both upstream and downstream of the Monitor.
The WaveStar Color Monitor also supports Modbus TCP/IP upstream of the Monitor and the WaveStar
Monitor can use Modbus TCP/IP upstream with a protocol converter.
Both Monitors also support SNMP V1.
8.1.2 ModBus RTU
The standard WaveStar Color Monitor has a 4- or 2-wire plus ground, RS-422/RS-485 compatible
interface. The communications parameters for the interface are


9600 baud (default) with options for 19200 and 38400 baud
8 bit, even parity, and 1 stop are standard with options for odd parity and no parity.
For 4-wire Modbus, all commands are sent to the Monitor on one pair and all replies from the Monitor are
on the other pair. The pair on which the Monitor sends will be in a high impedance state until the Monitor
responds to a command.
For 2-wire Modbus, all commands are sent to the Monitor and all replies from the Monitor are sent on the
same pair. The pair will be in a high impedance state until the Monitor responds to a command. For 2wire communications the transmit + and receive + must be jumpered together as well as the transmit and receive -. You must also verify that the packet is complete before another transmit is initiated. The
interface is isolated.
8.1.1 Biasing and Termination
Because there is only one Modbus master, the master can and should drive its transmit pair continuously
and, of course, never drive the receive line, except in an effort to be 2-wire compatible. However, most
adapters do not drive the transmit pair until the start of the first character sent, and only continue to drive
the transmit pair a few milliseconds after the last character. Consequently, for these adapters the master’s
transmit pair is usually just floating most of the time.
Slaves do not drive the master’s receive pair until they send the master a response. As soon as they are
finished, they must stop driving the master’s receive pair. This is necessary for other slaves to send
responses on the master’s receive pair. Therefore, most of the time the master’s receive pair is just
floating.
PDI devices do not require the Modbus chain to be terminated with a resistor. If other manufacturers’
equipment is connected in the Modbus device chain, consult their termination requirements.
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PowerHub 2 PDU 300-750 kVA
8.1.2 Wiring
RS485/RS422 cable length can be up to 4000 ft if the cable conforms to these specifications:




The cable must be shielded with two (2) twisted pairs and shield/ground.
The two transmit lines must be in one (1) twisted pair and the two (2) receive lines must be in the
other twisted pair.
The cable resistance should be 27 ohms/1000ft @ 1 kHz or less.
The mutual capacitance should be 14pf/ft @ 1 kHz or less.
RS422 is typically 4-wire. RS485 is typically 2-wire and is slower than RS422.
8.1.3 Customer Network Connections
Customer Modbus network connections are made to the PDU’s Basic Contractor (Figure 13) or Enhanced
Contractor Board (Figure 14).
8.1.4 Color Monitor Backpanel
Transformer (*Note: AC 230V is optional and requires a
different transformer.)
Summary alarm dry contact (NO)
RESET button
Modbus
Upstream
Connectors
Fuse
AC
120V/
230V*
Input
24VDC
Input
J11 Ethernet port
Battery
Modbus
Downstream
Connectors
Figure 27 WaveStar Color Monitor Backpanel Connections
54
Installation Planning: PDU Network
The Color Monitor backpanel (Figure 27) has these connections:

Power connections: 120V AC, 230V AC, and 24VDC (230V is optional and requires a different
transformer.)

Modbus connections:

o
Downstream (to Monitor device chain) is always 4-wire Modbus
o
Upstream is 4-wire or 2-wire, jumper selected
Summary Alarm: Dry contact (NO) signals when any device in the Monitor’s device chain has an
alarm condition.
The backpanel also has a RESET button: If the Monitor hangs, you can reset it by pressing this button.
8.1.5 WaveStar Monitor Backpanel
The WaveStar Monitor (monochrome) has Modbus connections and a summary alarm dry contact
connection on its backpanel (Figure 28).
WaveStar Monitor
summary alarm dry
contact connection
WaveStar Monitor
downstream Modbus
connector
WaveStar Monitor
upstream Modbus
connector
Figure 28 WaveStar Monitor Modbus Connections
8.2 Modbus Addresses
8.2.1 Points List Addresses
Each “device” in a Monitor’s chain is a points list with its own Modbus address. A PCB may have more
than one points list or multiple PCBs may be represented collectively by one points list:


The standard WaveStar Color Monitor or the optional WaveStar Monitor is represented by a
single points list.
A PDU M4G board and contractor board are represented by a single points list.
55
PowerHub 2 PDU 300-750 kVA

A BCMS HV Data Acquisition Board can have three points lists with separate Modbus addresses
but typically has two. In the PDU, each subfeed breaker column is represented by one points list.
8.2.2 Monitor Address
Each connected monitor must have a unique Modbus address between 1 and 247. The Monitor assigns
additional sequential addresses for each device in its device chain. The Modbus address of the Monitor
and the number of devices in its device chain are specified in the Monitor’s setup screen.
Note: Improper configuration of a WaveStar monitor may block other monitors or devices on the
chain.
8.2.3 Address Mapping Downstream of the Monitor
Customers should be aware of Modbus addressing differences upstream vs. downstream of a WaveStar
Monitor.
In a Modbus network there can be only one master, typically the BMS, and only the master can poll a
downstream device. However, the Monitor must also poll its downstream devices. Because there cannot
be two Modbus masters, when both a Monitor and a BMS are present, the network must be divided into
segments at the Monitor with one master per segment (Figure 29):
Upstream segment: BMS is master to the Monitor; Monitor is slave to the BMS.
Downstream segment: Monitor is master to its downstream devices.
Figure 29 Network Segmentation with Monitor
The BMS cannot directly address devices downstream of the Monitor because the Monitor is an endpoint
of the BMS’s network segment. Instead, the Monitor maps its downstream device addresses to upstream
segment addresses, sequentially assigned based on its own Modbus address. When the BMS requests
data from a device downstream of a monitor, it addresses the downstream device indirectly through the
Monitor. Downstream devices are only visible to the BMS through these remapped addresses.
The Monitor caches data from its downstream devices. It responds to BMS requests with cached data or
retrieves fresh data from the downstream device.
56
Installation Planning: PDU Network
Plan for downstream Modbus addresses to be remapped based on the Monitor’s address. These
remapped addresses are what the BMS must use to address the downstream BCMS devices (Figure 30).
Figure 30 Modbus Upstream Address Remapping with Monitor
8.3 Modbus Commands and Replies
8.3.1 Command Packets
The Monitor never initiates communications, rather it responds to command packets sent to it. Each
command packet sent to the Monitor has an address byte that includes the address of the destination of
that monitor. It does not respond to packets addressed to “0”.
8.3.2 Supported Commands and Replies
The following commands and replies are typical for both Monitors. See the points list for specifics .
Report slave ID
o Sent Hex: 01 11 C0 2C
o Reply Hex: 01 11 0D EA FE 52 50 50 20 44 69 73 70 6C 61 79 A3 A6
Read holding registers
o Sent Hex: 01 03 00 00 00 01 84 0A
o Reply Hex: 01 03 02 00 00 B8 44
Write single register
o Sent Hex: 01 06 00 00 00 00 89 CA
o Reply Hex: 01 06 00 00 00 00 89 CA
The flag and data numbers shown here are in “human-readable” numbers.
8.4 Modbus Registers: Data and Parameters
A points lists or Modbus register map is a list of sequentially numbered 2-byte Modbus registers. Most
analog channel values are single 2-byte registers representing a parameter such as input voltage,
current, etc. KWH measurements use (2) contiguous 2-byte Modbus registers. Some parameters require
scaling and are so noted in the points list.
The first analog channel or Modbus register in a points list is numbered 1 but, in software, it is accessed
by an index value of 0. Because adjacent registers have similar readings, being one register off is not
57
PowerHub 2 PDU 300-750 kVA
necessarily apparent. Consequently, it is common for a Modbus system to be off one register, and it is
important to verify that the registers are correct early in the configuration procedure.
8.5 Reading and Writing Modbus Registers
A Modbus master communicates with PDI devices using Modbus commands directed at Modbus register
locations in the device’s points list.
A device responds to Modbus commands addressed to any Modbus register in its points list. (If the
device is downstream of a monitor or Hub, the BMS must address the points list using the remapped
Modbus addresses in the monitor or Hub.)
Use standard Modbus read and write commands to retrieve or write registers in the points lists:
1. Retrieve up to 200 bytes or 100 Modbus register values with a single read.
2. Use write commands to alter set points, such as alarm and warning thresholds.
3. Reset alarms and warnings by reading the warning or alarm register and writing it back with the
alarm and warning bits turned off.
4. Separate Modbus requests to a BCMS by at least 400 ms.
8.6 SNMP
When SNMP is used upstream from a Monitor, upstream addresses are not remapped. Use the PDI
SNMP MIB, available from PDI service.
58
PDU Installation
9 PDU Installation
DANGER!

A licensed electrician must install each unit.

Startup by a PDI certified technician is required to validate the warranty.

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 cables or conduit, or
connecting PDUs 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.
9.1 Receiving and Unpacking
PDI carefully packages every PDU to ensure damage-free delivery to your job site. PDI recommends that
you perform the following unpacking and inspection procedures immediately after your PDU has arrived.
Report any damage immediately to your PDI Service Team by calling (800) 225-4838. All freight damage
claims should be initiated with the freight carrier immediately.
1. Remove the outer layer of protective shrink wrap from the unit.
2. Cabinet: Inspect packaging, exterior panels, and doors for any visible damage (i.e. scratches
dents, cracks, or torn packaging). If any damage is noted, please call the PDI Service Team
at (800) 225-4838.
3. Any damages must be noted on the bill of lading with a detailed description of the damages
incurred. A claim should be filed with the freight company at the time of delivery. Failure to
properly document all damages may result in the unit’s warranty being voided.
9.2 Placing the PDU
Note: Do not remove the safety bands securing the PDU to the pallet until all handling by a forklift
or pallet jack is complete and the PDU is near its final position.
1. Move the PDU, still secured to its pallet, to 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.
59
PowerHub 2 PDU 300-750 kVA
3. Remove the PDU from its pallet using a fork-lift truck. Use extreme caution to ensure the unit
is properly centered on the forks.
4. Once the unit is completely off the pallet, carefully remove the under layer of protective shrink
wrap. The unit is now ready to be placed in its final position and prepared for installation. The
PDU has a bottom forklift slot to aid moving it into an MDC.
If any further assistance is needed, please call the PDI Service Team at (800) 225-4838.
9.3 Inspection
The installer or installing contractor should perform a complete internal inspection of the PDU after the
PDU has been placed in its 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.).
9.4 Output Distribution Cable(s) Installation
Warning!
Power distribution cables and assemblies should be installed by a
qualified electrical contractor and/or a factory authorized PDI
representative.
The PDU should be de-energized before attempting to install any
output cables or assemblies.
For assistance call PDI at (800) 225-4838.
The PDU should be in its permanent position with all input power cables properly connected before going
any further. If the unit is resting on raised floor tiles, verify the proper cutouts have been made before
continuing. Be careful not to remove an excessive amount of floor tiles that could cause the flooring to
become unstable.
Optional output distribution cables may have been shipped already attached to the unit. If this is the case,
they should be removed from the pallet and uncoiled. After they are uncoiled, they should be inspected
before installation. Remove necessary floor tiles and lay out the cables to their respective equipment.
After the cables have been properly laid out, replace all removed floor tiles.
60
PDU Installation
With the output cables unattached and the unit in its permanent position, the following procedures should
be followed:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Open the access door to the distribution panelboard or subfeed breaker.
Remove cable entry cover panel.
Install the appropriate circuit breakers, if not factory-installed.
Locate an appropriate sized pre-punched conduit knock out.
Remove locknut from distribution cable end.
Feed cable conductor up through knock out and re-install locknut.
Tighten locknut securely.
Remove the necessary floor tiles and route the cable to its respective equipment.
Replace floor tiles.
Strip insulation approximately 1/2 inch from the end of the cable.
Connect phase wires to the output circuit breaker terminals according to the color-coding
chart below (USA) or according to color coding as per local standards:
Country
Color coding (Phase A,B,C)
United States (208V)
Black, Red, Blue
United States (480V)
Brown, Orange, Yellow
Table 9 Phase Wire Color Coding
12. Connect the ground wire (green or green with yellow tracer) to the distribution panel ground
bus.
13. If the cable requires a neutral wire (white), connect this wire to the distribution panel neutral
bus.
14. Checks to make sure all connections are securely tightened.
15. Reinstall and properly align all panels previously removed.
16. Mark (with pencil) installed breakers on the distribution panel schedule.
17. Check for proper phase rotation and voltage before attaching the other end of cable to its
associated equipment.
Important Considerations on Output Cables:

Output cables on k-rated PDUs must have a neutral wire
that is twice the size of the phase wires.

Special care must be taken when assigning circuit breaker
positions for proper load balancing.

Care should be taken when placing the output cables in the
units to properly align and lace these due to the limited area
for placing cables. Please call the PDI factory for any
assistance needed to insure the placement of these cables.
9.5 Torque Specifications
9.5.1 MCCB’s, MCSW’s, Contactors, and Other Electrical Components
Always tighten electrical component (CBs, contactors, etc.) connections to the manufacturer’s torque
specifications furnished with the component. There are some guidelines for electrical components if no
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PowerHub 2 PDU 300-750 kVA
manufacturer data is available. Tighten connections using Belleville type (spring) washers until washers
are flat.
9.5.2 Structural Fasteners
Structural fasteners are typically used for fastening the PDU to a supplied floorstand or concrete slab. If
structural fasteners are required per assembly instructions, refer to the table below for typical torque
values. Tighten steel hardware parts (except electrical connections) to the values given in the following
table.
Bolt Diameter
1/4”
5/16”
3/8”
7/16”
1/2”
Table 10 Structural Fasteners Torque Table
Tightening Torque (in-lb)
85
201
350
575
875
9.6 Torque Value Quick Reference
Use the following as a reference only. Always check the breaker or component labeling and/or
instructions for proper torque values. DO NOT OVER TORQUE!
Always use the manufacturer’s hardware on CBs, contactors, etc. Once connections are torqued and
sealed, make sure that removable lug covers are reinstalled.
9.6.1 Terminal Blocks and Distribution Breakers
Torque ratings vary depending on item in use. Please refer to label on the item.


3.0 lb-ft of torque is typically required for distribution breakers.
There is a wide variation of torque requirements for terminal blocks with various sizes.
62
PDU Initial Start-Up
10 PDU Initial Start-Up
Note: Before applying utility power to the unit for the first time, the electrician performing the
installation and/or a factory authorized representative should be present to verify that the
following steps are correctly performed.
10.1 PDU Post-Installation Inspection
After installing the PDU and attaching cables, re-inspect the PDU:
1. Visually inspect for and remove any debris that may have fallen into the PDU during installation.
2. Transformers: Inspect the transformers 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 both
transformers.
5. Check all other lugs (i.e. neutral bus, ground bus, terminal blocks, etc.).
6. Output Distribution Cable Assemblies: Cable coils must be inspected for cuts and/or damaged
conduits.
10.2 Start-Up Procedure
1. Confirm that the PDU’s main input circuit breaker is in the “off” position.
2. Ensure that all of the PDU’s output circuit breakers are in the “off” position.
3. The installing contractor or electrician should now 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 as indicated
above.
Warning!
Steps 1-4 must be executed before applying incoming power to the PDU.
5. Apply power to the unit.
6. Measure for the proper PDU input voltage. This should match the units rating (+ 5% to -10% from
nominal rating).
7. Check the phase rotation (clockwise) and voltage.
8. Energize the PDU main breaker by setting the toggle to the “on” position.
Note: If the main breaker trips when energized, 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 breaker shunt
trips.
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PowerHub 2 PDU 300-750 kVA
10. Manually reset the main breaker to the “on” position. This may require that you first manually trip
the lever all the way to the “off” position.
11. Check the output voltages.
12. The PDU is now ready to sequentially energize the branch circuit breakers.
Note: Equipment attached to the PDU may require special start up procedures. Please consult the
individual manufacturers for these requirements.
64
PDU Procedures
11 PDU Procedures
11.1 Shutdown Signals
The PDU can be shut down by the PDU M4G board with a signal to trip the main breaker. The trip signal
is sent using either the 170VDC or 24VDC output connections.
The PDU board will trip the main breaker if it receives any of the following signals (refer to Figure 11 for
connections):



Local EPO signal to the PDU board
Remote EPO (REPO) signal from the Contractor Board to the PDU board: the customer REPO
signal is terminated at the Contractor Board and forwarded to the M4G board.
Thermal wires register a temperature in the PDU transformer core that exceeds the transformer
temperature limit specified.
11.2 Manual or Automatic Restart
The Restart Switch on the PDU board determines if restart is automatic after a voltage loss. For the
Restart Switch to function the 170VDC output connection on the PDU M4G Board must be connected to
the main breaker trip unit—the Restart Switch does not work with the 24VDC voltage connection.


If the Restart Switch is set to Manual (down), 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), the main breaker is not tripped on a voltage loss.
The PDU resumes operation if voltage is in the correct range.
See 5.4 PDU M4G Board Layout and Connections for location of the Restart Switch.
11.3 Manual Dual PDU Procedures
For dual input PDUs, power source transfer procedures are given in these sections:


6.4 Power Transfer Procedures: Closed Transition
6.5 Power Transfer Procedure: Open Transition
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PowerHub 2 PDU 300-750 kVA
12 Alarms and Troubleshooting
Alarms can be issued from the following PDU monitoring components through their points lists:

PDU (M4G) Board, monitors conditions in the critical load transformer and inputs from the
Contractor Board.
 Two BCMS Panelboard points lists (Panelboard 1 and Panelboard 2) monitor the panelboard
main feeds and branch circuits.
 The WaveStar Monitor also has a points list and can present a basic communication alarm for
each device in its Modbus chain.
Alarms can be read in two ways:


Modbus. A BMS or other Modbus master device, such as a WaveStar Hub, can read the points
list for each component.
WaveStar Monitor. Alarms for each device can be displayed on the Alarm Screen.
12.1 Reading Alarms with Modbus
Each device has its own points list with summary alarm Modbus registers indicating that an alarm is
present on that device. The user can check alarm specifics through the BMS or go to the PDU and check
the WaveStar Monitor Banner/Alarm Screen.
The BMS should read these summary alarm registers regularly to be appraised of power conditions
requiring immediate attention.
12.2 Summary Alarms
Monitors Both Monitor options have a summary alarm that is issued whenever a device in its chain has
an alarm or warning. Summary alarms can be issued in these ways:



Dry contact connection on the Monitor backpanel
Modbus Points List, summary alarm point or register: the summary alarm is point is in the Alarm
Register (register 01), which can be read with Modbus RTU.
SNMP trap
When a summary alarm is issued, an operator can go to the Monitor to check the list of active alarms.
Alarms in the Monitor points list are for communication failures with devices in its Modbus chain. These
and the summary alarm are contained in the Alarm Register (register 01).
PDU The PDU M4G Board points list (Rev E) has Summary Alarm and Summary Alarm Latched registers
(registers 70-71). The point list covers both the PDU board and its associated Contractor Board.
Subfeeds The Enhanced Subfeeds points list has a Latched Summary Alarm Register (504).
66
Alarms and Troubleshooting
12.3 Reading Alarms at the WaveStar Display
Alarms for all devices in the Monitor’s Modbus chain are reflected to the Monitor and displayed on the
Alarm Screen. Alarm tables by device type (such as monitor, PDU, subfeeds) are given in the respective
Monitor manual. See WaveStar® Color Monitor, Setup and Operation PM375103 and WaveStar®
Monitor, Setup and Operation DOC15314.
12.4 Troubleshooting Guidelines
SYMPTOM
PROBABLE CAUSE
REMEDY
No power to unit
Unit not connected
to power source.
Main Breaker not
enabled.
Output circuit
breaker and/or cable
are not connected to
PDU.
Main breaker is
turned off or has
tripped
Not able to remotely
communicate to the
monitor
No audible when an
alarm occurs
Cannot see panel
information
No output voltages
or currents are
displayed
No BCMS currents
are displayed on
monitor screens.
Connect unit to power source.
Turn on or reset main circuit
breaker.
Individual output
circuit has no
power.
No output from
unit but indicators
are on
No upstream
communication
No audible
indication
No able to scroll
thru screens
Not able to see
PDU output
readings
Unable to see
BCMS (optional)
panels on front
panel
Connect output circuit to PDU and
energize circuit.
Check LCD Display for active alarms,
then reset main breaker.
Press the ESC key and verify remote
upstream address, baud rate, &
parity are set correctly.
Press the ESC key and verify the
horn is enabled.
Press the enter button firmly to view
PDU information
Once on the input screen, use the
Up or down arrows to access output
screens.
Verify a BCMS is connected to the
downstream port and press the esc
key to setup the number of
additional panelboards added.
Table 11 Troubleshooting Guidelines
67
PowerHub 2 PDU 300-750 kVA
13 Service
13.1 Start Up
PDI START UP is mandatory for all PDU’s purchased and is a sure way of getting your power quality
equipment up and running as you need it. By following our standard START UP procedures, you can be
assured that your power equipment will perform to your requirements. Features and benefits include
these:


PDI START UP services provide a factory-trained customer support engineer to oversee visual
inspection of the installation and system calibration.
PDI START UP service also provides factory-trained customer support engineers to assist with
operational training.
13.2 Warranty
PDI’s Standard Warranty
PDI’s standard warranty covers the PDU for 18 months following shipment or 12 months after initial
system start up, 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
Extended Warranty
Please contact a PDI service representative for detailed information about extended warranties.
Tel: (800) 225-4838 | Email: [email protected]
Warranty Agreement
PDI warrants that its products will perform as specified in PDI publications, providing such products are
properly installed, cared for, and properly operated under the specified environmental conditions.
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 start up or eighteen (18) months from date of
shipment, whichever comes first. Any products which are defective in workmanship or material will be
repaired or replaced at the option of PDI. The obligation of PDI hereunder shall be limited solely to repair
and replacement at its factory of products that fall within the foregoing limitations and shall be conditioned
upon receipt by PDI of written notice within the warranty period of any alleged defects or deficiency. No
products shall be returned to PDI without its prior consent.
Where it is impractical to return suspected faulty equipment to PDI for repair or replacement, PDI will
provide on-site service upon request. Replacement parts and on-site labor necessary for fitting
replacement parts and removal of faulty parts will be undertaken at no charge. Charges will, however, be
made for travel to and from the installation site. Where an on-site warranty is in effect, the no-charge
labor shall be between 8 a.m. and 6 p.m., Monday through Friday, excluding holidays. If the customer
68
Service
requests service outside the above hours, the customer agrees to pay the incremental difference between
PDI's overtime and normal labor rates.
All warranties hereunder are contingent upon the initial start-up being done by PDI trained or other
authorized personnel and upon proper use in the application for which the product was intended and do
not cover products which have been modified or repaired without PDI approval or which have been
subjected to neglect, accident, improper installation or application or on which the original identification
marks have been removed or altered. These warranties will not apply if adjustment, repair or parts
replacement is required because of accident, neglect, misuse, secondary transportation or other causes
other than ordinary use.
PDI's liability under this warranty shall be in lieu of any warranty or condition implied by law as the quality
or fitness for any particular use of the goods, and save as provided in this clause, PDI shall not be under
any liability, whether in contract, tort or otherwise for consequential damages resulting from defects in PDI
products.
This warranty shall apply to all products manufactured by PDI unless this agreement is modified by
addendum.
For questions, please contact the PDI service department at (800) 225-4838 or email us at
[email protected].
13.3 Maintenance
PDI 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:
1. Rapid Service Response
PDI Maintenance Service responds 24 hours a day, 7 days a week without additional costs for
weekends, nights or holidays.
2. Two comprehensive Preventative Maintenance Visits Annually
 Infrared Scanners provide information that can determine impending failures on connections and
busing.
 Harmonic Analyzers provide real time information on the effects of harmonic currents on the
power distribution system.
Other services include:
 Thorough visual inspection of all parts (bulbs, displays, missing hardware and cleanliness)
 Verification of monitor calibration
 Inspection of load balance, KVA usage and building alarms
 Test and analysis report
3. Guaranteed Parts Availability
PDI guarantees parts availability to service customer equipment in timely fashion.
69
PowerHub 2 PDU 300-750 kVA
Please contact a PDI service representative for detailed information about Preventative Maintenance
Contracts.
Tel: (800) 225-4838 | Email: [email protected]
13.4 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.
70
PowerHub 2 PDU 300-750 kVA
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-software-downloads
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 list for
subfeeds and use the latest revision given:
BCMS ESF (Enhanced Subfeeds) points list is “BCMS Points List Fourteen Sub”.
Manuals for Related Products
WaveStar® Color Monitor, Setup and Operation, PM375103
WaveStar® PowerPak Power Distribution Unit, Installation and Operation, PM375118
PowerPak 2 Power Distribution Unit, Installation and Operation, PM375116
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
WaveStar® BCMS Hub, Installation and Operation, PM375108
JCOMM® Installation and Operation PM375100
71
PowerHub 2 PDU 300-750 kVA
Glossary
ANSI
American National Standards Institute
BCMS
Branch Circuit Monitoring System
BMS
Building Management System
EPO
Emergency Power Off
FIPS
Federal Information Processing Standards
Icu
Interrupting capacity ultimate
Lcs
Interrupting capacity service
kAIC
Kilo amps interrupting capacity
KWH
Kilowatt hour
M4G
PDU acquisition board, interfacing to WaveStar Monitor (graphical interface)
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
TSN
Transient Suppression Network
TVSS
Transient Voltage Surge Suppressor
SKRU
Solenoid Key Release Unit
SPD
Surge Protective Device
UBC
Uniform Building Code
UL
Underwriters Laboratories
72
A1: Main Output Circuit Breaker Options
Appendix 1: Main Output Circuit Breaker
Options
The optional Main Output Circuit Breaker from the transformer secondary to the output subfeeds is
required by the NEC if there are six (6) or more subfeeds. For this circuit breaker, PDI provides Square D
(Schneider Electric) circuit breakers in several frame formats and kAIC ratings. For example, the smallest
PowerHub 2 PDU at 300 kVA may use M-frame breakers instead of the standard R-frame circuit breaker.
Main output circuit breakers may be 80- or 100-percent rated and may have different trip options.
Voltage Circuit breakers rated at a certain voltage can be used at any lesser voltage. For example, a
breaker rated at 600V can be used at 400V.
Interrupting ratings kAIC ratings are provided for 60 Hz (UL) and 50 or 60 Hz (IEC) at various voltages
in the table below (Table 12). Interrupting ratings are not available for all voltages because vendors test
only at selected voltages. If a kAIC value is not listed for your output voltage, use the kAIC value for the
next higher output voltage that is listed. The relationship of kAIC to voltage is not necessarily linear;
therefore, do not extrapolate the kAIC value.
Consult with your sales representative and PDI Applications Engineering for circuit breakers appropriate
to your application. The part number of your breaker will be given in your submittals.
Table 12 Main Output Circuit Breaker UL/IEC Interrupting Ratings
UL/CSA Rating (60 Hz)
Square D
Circuit
Breaker
IEC 60947-2 Rating (50/60 Hz)
3 Phase
240 VAC
480 VAC
240 VAC
600 VAC
lcu
380/415 VAC
lcs
lcu
lcs
MG
65 kA
35 kA
18 kA
50 kA
25 kA
35 kA
20 kA
MJ
100 kA
65kA
25 kA
65 kA
35 kA
50 kA
25 kA
PG
65 kA
35 kA
18 kA
50 kA
25 kA
35 kA
20 kA
PJ
100 kA
65 kA
25 kA
65 kA
35 kA
50 kA
25 kA
PK
65kA
50 kA
50 kA
50 kA
25 kA
50 kA
25 kA
PL
125 kA
100 kA
25 kA
125 kA
65 kA
85 kA
45 kA
RG
65 kA
35 kA
18 kA
50 kA
25 kA
35 kA
20 kA
RJ
100 kA
65 kA
25 kA
65 kA
35 kA
50 kA
25 kA
RK
65 kA
65 kA
65 kA
85 kA
65 kA
70 kA
55 kA
RL
125 kA
100 kA
50 kA
125 kA
65 kA
85 kA
45 kA
lcu=Interrupting capacity ultimate; lcs=Interrupting capacity service
73
PowerHub 2 PDU 300-750 kVA
74