Rittal PMC 7857.361, User Manual

Page 1: ...Rittal PMC USV Manual 7857 361 7857 363 7857 365 Modular n 1 redundant 3phase UPS System 10 40kVA A3346302IT74 GB ...

Page 2: ...ration for the Input Cabling 10 3 6 3 Earthing 10 3 6 4 Connection of the Mains Supply 10 3 6 5 Single Input Feed 11 3 6 6 Dual Input Feed 11 3 6 7 Preparation for the Output Cabling 12 3 6 8 Connection of the Load 12 3 6 9 Output Cabling 12 3 7 INTERNAL BATTERY MODULES 16 3 8 EXTERNAL BATTERY CABINET AND BATTERY CONNECTION 16 3 8 1 External Battery Configuration 16 3 8 2 Connection of External Ba...

Page 3: ...BINET CONFIGURATION 42 6 1 CONCEPT OF MULTI CABINET CONFIGURATION 42 6 2 INSTALLATION INSTRUCTIONS 43 6 2 1 Introduction 43 6 2 2 Paralleling of UPS Cabinets 43 6 2 2 1 Connection of Parallel Communication Cables BUS lines 43 6 2 2 2 Parallel Adapater and DIP Switch SW2 2 44 6 2 3 DIP Switch SW1 1 and SW1 9 Settings 44 6 2 4 ON OFF Main Buttons 45 6 2 5 Parallel Isolator IA2 45 6 2 6 Maintenance B...

Page 4: ...A3346302IT74 GB 4 9 5 1 Why is UPS Management important 53 9 5 2 Power Modular Concept Software Shutdown and Monitoring Software 53 9 6 SNMP CARD ADAPTER FOR NETWORK MANAGEMENT REMOTE MONITORING 55 ...

Page 5: ...Y DUE TO INCORRECT OPERATION OR MANIPULATION OF THE UPS HIGH LEAKAGE CURRENT MAKE SURE THAT THE EARTHING IS CARRIED OUT CORRECTLY BEFORE YOU CONNECT THE MAINS POWER SUPPLY THE POWER MODULAR CONCEPT 10 40 kVA IS CLASS A UPS PRODUCT ACCORDING TO EN 50091 Part 2 IN A DOMESTIC ENVIRONMENT IT MAY CAUSE RADIO INTERFERENCE IN SUCH AN ENVIRONMENT THE USER MAY BE REQUIRED TO UNDERTAKE ADDITIONAL MEASURES R...

Page 6: ...ULAR CONCEPT MODELS The Power Modular Concept PMC Series consists of three Lines PMC BASIC The PMC Basic 10 40kVA cabinet consists of only one UPS Module and a standard battery PMC TWIN The PMC Twin 10 30kVA cabinet consists of two UPS Module and a standard battery PMC EXTENDED TWIN The PMC Extended Twin 10 40kVA cabinet consists of three UPS Module 2 3 SINGLE PARALLEL MODULES AND SINGLE MULTI CAB...

Page 7: ... will at its sole option repair or replace the UPS or parts of it All repaired or replaced parts will remain the property of RITTAL or of the authorized service centre RITTAL is not liable for any costs such as loss of profits or revenue loss of equipment loss of data or software cost of substitutes claims by third parties or otherwise As general policy RITTAL GmbH Co KG does not recommend the use...

Page 8: ...nt of the UPS Check if it corresponds to the purchased material mentioned in the delivery note 3 2 UNPACKING When unpacking the UPS observe the FRAGILE and ARROW on the packing container Perform the following steps to unpack the UPS Cut wrappers and remove packing container by pulling it upwards Remove the plastic cover from the UPS Remove pallet from the UPS Retain the packaging materials for fut...

Page 9: ...n cool environment in their original packaging If the packing container is removed protect the batteries from dust and humidity 3 5 POSITIONING The PMC is a compact and light UPS and can easily be moved to the final position All parts of the PMC are accessible from the front and rear making it a service friendly and maintenance friendly UPS The UPS should be located where Humidity and temperature ...

Page 10: ...itted with circuit breakers or other kind of protection The circuit breakers will be connected between the mains supply and the UPS and will provide additional protection to the UPS in the event of overloads and short circuits 3 6 3 Earthing ALL THE OPERATIONS IN THIS SECTION MUST BE PERFORMED BY AUTHORISED ELECTRICIANS OR BY QUALIFIED TRAINED INTERNAL PERSONNEL To ensure protection of personnel d...

Page 11: ...ck according to the following table MAINS INPUT CABLE UPS TERMINAL Phase L1 1L1 Phase L2 1L2 Phase L3 1L3 NEUTRAL 1N EARTH PE For minimum recommended Input Cable Sections and Fuse Ratings for the PMC Extended Twin see table in Figure 3 4 Under the connection terminal of the UPS there is a cable fixing rail to ensure that the cables have been fastened properly 3 6 6 Dual Input Feed To achieve corre...

Page 12: ... the prescribed IEC Standards or with the local regulations Under the connection terminal of the UPS there is a cable fixing rail to ensure that the cables have been fastened properly Ensure that the earthing is performed in accordance with the prescribed IEC Standards or with the local regulations 3 6 8 Connection of the Load ALL THE OPERATIONS IN THIS SECTION MUST BE PERFORMED BY AUTHORISED ELEC...

Page 13: ...x25 5x25 3x63A 3x10 15 15 3x100 5x25 3x100 4x25 5x25 3x100A 3x25 15 15 15 3x100 5x25 3x100 4x25 5x25 3x125A 3x35 20 3x100 5x25 3x100 4x25 5x25 3x63A 3x10 20 20 3x100 5x25 3x100 4x25 5x25 3x125A 3x35 20 20 20 3x100 5x25 3x100 4x25 5x25 3x160A 3x50 30 3x125 5x35 3x125 4x35 5x35 3x80A 3x16 30 30 3x125 5x35 3x125 4x35 5x35 3x125A 3x35 30 30 30 3x125 5x35 3x125 4x35 5x35 3x200A 3x70 40 3x200 5x70 3x200...

Page 14: ...ev 03 18 05 04 dz Control Panel 2 JD2 SNMP SW1 1 F2 JD1 JD7 JD4 JD2 SNMP SW1 1 F2 JD1 JD7 JD4 Control Panel 3 JD2 SNMP SW1 1 F2 JD1 JD7 JD4 Control Panel 1 UPS Module Rated Power Bypass Fuse F2 A 10 15 kVA 32A 14x51 pronorm 20 30 kVA 50A 14x51 pronorm SW1 9 JD8 In Out Terminal Block Mains Input Single Feed Remove Link for Dual Input Feed Additional Batteries Separate Bypass Dual Feed Output Load 1...

Page 15: ...N ON OFF ON 4 ON ON OFF ON 5 ON ON OFF ON 6 ON ON OFF ON 7 ON ON OFF ON 8 ON ON OFF OFF 9 ON OFF OFF ON SW1 1 Module Type LOW Single Module HIGH Parallel Module Power Modular Concept EXTENDED TWIN 120kVA TS 8 Front View Rev 02 18 05 04 dz N _ Common battery distribution optional Control Panel 2 UPS Module 3 JD2 SNMP SW1 1 F2 JD1 JD7 JD4 X1 M X2 M X3 M UPS Module 2 JD2 SNMP SW1 1 F2 JD1 JD7 JD4 X1 ...

Page 16: ...TWIN 10 30KVA 5x24 5x24 5x24 empty UPS 3 5x24 5x24 5x24 UPS 3 5x24 5x24 5x24 5x24 5x24 5x24 5x24 5x24 5x24 UPS 2 5x24 5x24 5x24 UPS 2 5x24 5x24 5x24 5x24 5x24 5x24 5x24 5x24 5x24 UPS 1 5x24 5x24 5x24 UPS 1 5x24 5x24 5x24 5x24 5x24 5x24 5x24 5x24 5x24 Distribution 90kVA 5x24 5x24 5x24 Distribution 90kVA PMC EXTENDED TWIN 40KVA 5x24 5x24 5x24 5x24 5x24 UPS 3 5x24 5x24 5x24 5x24 5x24 UPS 2 5x24 5x24 ...

Page 17: ...e each UPS Module with its own separate battery In this way the redundancy is extended also to the batteries In the Figure 3 7 the drawing shows how to connect the batteries in the external battery cabinet and the PMC Extended Twin If the three battery batches are desired to be used as one common battery for all three UPS Modules then Battery Links may be connected as shown below External Battery ...

Page 18: ...rm following steps 1 Make sure that the fuses feeding the UPS in the input Distribution Board are all open and no power is fed to the UPS 2 Make sure the MAINTENANCE BYPASS IA1 is open position OFF 3 Make sure the battery fuses in the external battery cabinet are open 4 Connect Earth PE between the UPS and external battery cabinet 5 Connect the corresponding N terminals between UPS and external ba...

Page 19: ...rminal will display a message For details see our Monitoring Package PMC Software The Fig 3 8 and 3 9 shows how to connect a PC to the UPS a Fig 3 8 in case the PC has a 9 pin serial port b Fig 3 9 in case the PC has a 25 pin serial port a Interface Cable UPS End Interface cable Computer End 9 Pin D Type Male 9 Pin D Type Female Connects to UPS Connects to SMART PORT Computer Figure 3 8 Connector ...

Page 20: ...al Function 1 NO Mains failure 2 NC ALARM MAINS_OK Mains present 3 C Common 4 NO Load on inverter 5 NC Message LOAD_ON_INV 6 C Common 7 NO Battery low 8 NC ALARM BATT_LOW Battery OK 9 C Common 10 NO Load on Mains BYPASS mode 11 NC Message LOAD_ON_MAINS 12 C Common 13 NO Common Alarm 14 NC ALARM COMMON_ALARM No Alarm Condition 15 C Common 16 19 NC Not Connected 20 Customer in 21 GND Customer in GND...

Page 21: ...afety of any personnel Additionally the manufacturer s warranty is immediately invalidated if the UPS is put into use before it has been correctly commissioned 4 2 CONTROL PANEL The user friendly control panel is composed of three parts POWER MANAGEMENT LCD DISPLAY PMD LED INDICATORS KEYS Figure 4 1 Control Panel 4 2 1 Power Management Display PMD The 2 x 20 character LCD simplifies the communicat...

Page 22: ...d off INV GREEN RED OFF Load on inverter Inverter fault or load not transferable to inverter Inverter not operating switched off BATTERY GREEN RED Flashing GREEN Battery OK Battery fault or battery is discharged Battery in discharge or battery fuse open 4 2 3 Keys The keys allow the user to operate the UPS to perform settings and adjustments to start up and shutdown the UPS to monitor on the LCD d...

Page 23: ...D of the respective UPS Modules you can read P01 Master P02 slave and P03 Slave 4 2 6 Definition of a Single Multi Cabinet Chain DIP Switch SW1 9 By means of the DIP Switch SW1 9 which is located on the front of a Cabinet it is possible to determine the position of the Cabinets in Multi Cabinet Chain First in the Multi Cabinet Chain Middle in the Multi Cabinet Chain there may be more than one Last...

Page 24: ... Cabinet system and 03 stands for the third Cabinet SLAVE in the Multi Cabinet system The definition of the Cabinet Position is achieved in the Menu Service Set Up 4 3 2 Main Menu Screen DESCRIPTION LCD DISPLAY 1 Logging Control A log of the last 64 events is stored in the Power Management Display EVENT LOG MEASUREMENTS 2 In Menu Measurements monitor voltages power frequencies currents autonomy et...

Page 25: ...ctive Output Power of all three phases ACTIVE POWER KW 00 00 00 00 00 00 12 Reactive Output Power of all three phases REACTIVE POWER kVAr 00 00 00 00 00 00 13 Apparent Output Power of all three phases APPARENT POWER KVA 00 00 00 00 00 00 14 Output Power of all three phases OUTPUT POWER 00 00 00 00 00 00 15 Battery capacity BATT CAPACITY 00 00 4 3 5 Commands Screen DESCRIPTION LCD DISPLAY 1 Transfe...

Page 26: ...R OP NO MORE SETTINGS BATT CHARGE LOCK YES NO BYPASS LOCK YES NO 4 3 8 Set Up Service DESCRIPTION LCD DISPLAY 1 This Menu is reserved for authorized service engineers It is not to be used by End Users SET UP SERVICE PASSWORD 2 Type in password PASSWORD Password is necessary to enter NOTE Apart from the adjustment of voltages frequencies currents power and autonomies in the SET UP Service it is als...

Page 27: ...Mode OFF LINE ECO or BYPASS MODE In the OFF Line Mode the load is supplied from the mains through the static bypass Using the control panel see figure 4 1 the UPS may be easily transferred to Bypass Mode When the UPS is operating in Bypass Mode the efficiency of the system is higher In the event of a mains failure the load will automatically be transferred from mains to inverter within 5 msec this...

Page 28: ...the Bypass Mode or ECO Mode IF THE UPS IS OPERATING IN THE MAINTENANCE BYPASS MODE THROUGH THE BYPASS SWITCH THE LOAD WILL NOT BE PROTECTED IN THE EVENT OF A MAINS FAILURE IT IS THEREFORE STRONGLY RECOMMENDED TO SWITCH OVER TO THE ON LINE MODE INV ON OR BYPASS MODE OFF LINE MODE AS SOON AS POSSIBLE 4 4 4 Parallel Isolator IA2 Every UPS unit module is provided with an output parallel isolator IA2 w...

Page 29: ...ition HIGH 8 Check the Position of the DIP Switches SW1 9 This is a Single Cabinet Configuration and the DIP Switches SW1 9 must be set according to positions shown in Table of Paragraph 4 2 6 Start up procedure of PMC Extended Twin 1 Insert fuses for the supply of UPS System in the Input Distribution The LED indicators LINE 1 and battery on UPS Module is lit green On LCD Display LOAD OFF SUPPLY F...

Page 30: ...e is now UPS power and on all three LCD s LOAD PROTECTED will appear 13 Load transfer to Maintenance Bypass Go to Menu COMMANDS and choose command LOAD TO BYPASS and transfer the load to mains on control panel of any one of the three UPS modules Close Maintenance Bypass Switch IA1 position ON On LCD MANUAL BYP IS CLOSED will appear and the LED indicator will indicate as shown below LED Indicator C...

Page 31: ...isconnected and does not need any power supply PRESSING ON ALL MODULES BOTH ON OFF BUTTONS SIMULTANEOUSLY DURING NORMAL OPERATION WILL SWITCH OFF THE UPS OUTPUT AND NO LONGER SUPPLY POWER TO THE LOAD 1 Verify that the loads are shutdown and that there is no need for power supply to the load 2 If the loads are all disconnected press simultaneously both ON OFF Buttons on UPS Control Panel on all thr...

Page 32: ... select the COMMANDS menu and choose command LOAD TO BYPASS and transfer the load to mains on control panel of any one of the three UPS modules On LCD panel LOAD NOT PROTECTED will appear 2 Close Maintenance Bypass Switch IA1 position ON On LCD MANUAL BYP IS CLOSED will appear and the mimic panel will show LED Indicator Colour LINE 1 Green LINE 2 Green BYPASS Green INVERTER RED BATTERY Green 3 Pre...

Page 33: ...el will show LED Indicator Colour LINE 1 Green LINE 2 OFF BYPASS OFF INVERTER OFF BATTERY Flashing Green 3 Close Parallel Isolators IA2 1 IA2 2 and IA 3 and check message PARALLEL SW CLOSED on LCD of each module 4 Press simultaneously the two ON OFF buttons on the UPS control panel PMD on all three control panels Unit will start up and after about 60 seconds the mimic panel will show LED Indicator...

Page 34: ... Module The audible noise will stop If the Alarm condition persists the LED Indicator ALARM will remain red it means that there is a fault in the UPS Module 2 If the load is supplied by the mains in Bypass Mode Eco Mode the Maintenance Bypass IA1 may be closed by turning it to position ON NOTE If the load is on inverter then before closing the Maintenance Bypass IA1 transfer load to bypass by mean...

Page 35: ...E PROTECTION COVER RITTAL WILL NOT TAKE RESPONSIBILITY OR BE LIABLE FOR PERSONNEL INJURIES OR MATERIAL DAMAGES CAUSED BY IMPROPER MANIPULATION OF THE UPS OR BY INCORRECT CABLING THE PROPER INSTALLATION AND USAGE INSTRUCTIONS OF THE UPS ARE DESCRIBED WITHIN THIS MANUAL AND MUST BE STRICTLY ADHERED TO If your PMC Extended Twin consists of only one single UPS Module then perform following steps to fi...

Page 36: ...en 9 Transfer load to mains and inverter for testing using submenu COMMANDS 10 Transfer Load to Bypass Mode by means of COMMAND LOAD TO BYPASS 11 Verify the status Load on Bypass Eco Mode by checking the LED indicators as shown below LED Indicator Colour LINE 1 Green LINE 2 Green BYPASS Green INVERTER OFF BATTERY Green 12 Close Parallel Isolator IA2 13 Open Maintenance Bypass IA1 by turning it to ...

Page 37: ...the Alarm condition and RESET the Alarm The audible noise will stop If the Alarm conditions persists the LED Indicator ALARM is red there is a fault in the UPS Module 2 Verify that load is supplied by inverter of the other modules running by checking the LCD indication LOAD PROTECTED Verify load measures on the operating modules 3 Turn the faulty module OFF by pressing simultaneously both ON OFF b...

Page 38: ...LCD LOAD OFF SUPPLY FAILURE will appear and the LED indicator will indicate as shown below LED Indicator Colour LINE 1 Green LINE 2 OFF BYPASS OFF INVERTER OFF BATTERY Flashing Green 6 Make sure the bypass fuse F2 is inserted front of Module 7 Close external battery fuses breaker of the new Module 8 Press both ON OFF Buttons simultaneously to start up UPS 9 Wait 60 seconds LCD panel must display L...

Page 39: ... experiences a fault and there is not enough capacity left to protect the load by the remaining operating UPS Modules the load will automatically be transferred to bypass Bypass Mode or Eco Mode and will continue to be supplied by the mains power supply To extract the faulty module from the UPS Frame in a Capacity Multi Module System proceed as follows 1 Identify the faulty Module with the Alarm c...

Page 40: ... out the module from the UPS Frame The weight of a 40 kVA module is 56kg 10 kVA module 52kg 12 Insert new UPS Module or cover the opening UPS Module Compartment with appropriate protection cover immediately and fix with four screws WHILE THE UPS IS OPERATING IN THE MAINTENANCE BYPASS MODE THE LOAD IS NOT PROTECTED AND IN THE EVENT OF A MAINS FAILURE THE LOAD SUPPLY WILL BE INTERRUPTED AND THE LOAD...

Page 41: ...u COMMANDS 10 Transfer Load to Bypass Mode by means of COMMAND LOAD TO BYPASS 11 Verify the status LOAD ON BYPASS LED Indicator Colour LINE 1 Green LINE 2 Green BYPASS Green INVERTER OFF BATTERY Green 12 Verify that the remaining UPS Modules are also on Bypass 13 If all three UPS Modules are on Bypass Close Parallel Isolator Switch IA2 of New Module position ON on LCD should appear PARALLEL SW IS ...

Page 42: ... parallel Isolator IA2 which when opened isolates the corresponding unit from the parallel system Once the parallel isolator IA2 of a unit is open that unit module is isolated from the rest of the parallel system and therefore does not provide power to the output For example if you perform the command LOAD TO BYPASS on any unit all the units will transfer the load simultaneously to mains and if yo...

Page 43: ... PHASE1 UPS2 PHASE1 UPS n WHEN CABLING THE UPS s MAKE SURE THAT THE UPS s ARE COMPLETELY VOLTAGE FREE CHECK THAT THE MAINTENANCE BYPASSES IA1 AND ALL PARALLEL ISOLATOR IA2 ARE OPEN OFF ON ALL CABINETS 6 2 2 Paralleling of UPS Cabinets 6 2 2 1 Connection of Parallel Communication Cables BUS lines For the correct performance of different parallel functions and operations the parallel units communica...

Page 44: ...witch SW1 1 The DIP Switch SW1 1 is located on every UPS Module and serves to define if the UPS Module is a single or parallel Module SW1 1 has two positions HIGH Parallel the Module is in a parallel system LOW Single the Module is a single UPS In the case of parallel cabinet configurations the SW1 1 on all Modules is always in position HIGH Parallel SingleUnit First Unit Middle Unit Last Unit SW ...

Page 45: ... Module IN A MULTI Module SYSTEM ONLY THAT PARTICULAR UPS Module WILL SHUTDOWN TO SHUTDOWN THE COMPLETE SYSTEM PRESS BOTH ON OFF BUTTONS ON EVERY UPS MODULE OF A MULTI MODULE SYSTEM 6 2 5 Parallel Isolator IA2 Every UPS unit is provided with a parallel isolator IA2 The parallel isolator is an important element of the UPS unit that allows the isolation of a unit from the parallel system without the...

Page 46: ...RMED BY AUTHORISED ELECTRICIANS OR BY QUALIFIED INTERNAL TRAINED PERSONNEL BY OPENING OR REMOVING THE UPS MODULES AND MODULE COVERS YOU RUN RISK OF EXPOSURE TO DANGEROUS VOLTAGES BEFORE REMOVING A UPS MODULE MAKE SURE THE INTERNAL DC CAPACITORS HAVE BEEN DISCHARGED FOR AT LEAST 2 MINUTES DO NOT EVER LEAVE THE UPS MODULE COMPARTMENT WITHOUT AN APPROPRIATE PROTECTION COVER RITTAL WILL NOT TAKE RESPO...

Page 47: ...any power supply To perform a complete shutdown of a Multi Cabinet Configuration proceed in analogy to the shutdown procedures described in Paragraph 4 6 of Chapter 4 6 3 3 Replacement of a Faulty UPS Module in a Multi Cabinet Configuration If in a Multi Cabinet Configuration a UPS Module fails proceed in replacing the UPS Module in analogy with the replacement procedures described in Chapter 5 of...

Page 48: ...issioning field service engineer will attach a service record book to the front of the UPS and this will be used to record the full service history of the UPS Preventative maintenance inspections involve working inside the UPS which contains hazardous AC and DC voltages Only RITTAL trained or agreed service personnel and authorised field service engineers are fully aware of all of the hazardous ar...

Page 49: ...rs to be OK check the input circuit breakers etc supplying the UPS OUTPUT SHORT There is a short circuit at the output of UPS on load side Check all output connections and repair as required OVERLOAD Load exceeds the UPS rated power Identify which piece of equipment is causing the overload and remove it from the UPS Do not connect laser printers photocopiers electric heaters kettles etc to the UPS...

Page 50: ...e emergency stop port X1 is located at the front of the PMC module See Figure 3 5 for location drawing In order to allow removal maintenance or testing of any remote emergency stop facility without disturbing the normal operation of the UPS it is recommended that a terminal block with linking facilities be installed between the UPS and the stop button 1 Use a screened cable with 1 pair section of ...

Page 51: ...or UPS on bypass 3 INVERTER GREEN OFF Load supplied by inverter Inverter supply not available 4 LOAD GREEN RED FLASHING Load is supplied Load is not supplied 5 ALARM RESET Push button Silence the audible alarm 6 ALARM RED OFF Alarm condition check other LEDS for indication of mains and or UPS status UPS is in normal operation condition 7 BYPASS RED OFF Load is supplied by mains Load is supplied by...

Page 52: ... Fig 9 3 Connection of Remote Signalling Panel RSP Details of all Dry Port connections are shown in Figure 3 10 9 4 GENERATOR ON FACILITIES The generator ON facility must use a normally open contact that closes to indicate that a generator is running and supplying input power to UPS When used this facility disables the UPS static bypass and prevents the UPS from transferring the load onto the gene...

Page 53: ...und it important to have a complete solution for its UPS and is able to offer a wide range of monitoring remote controls for assuring the maximum protection degree to the RITTAL customers 9 5 2 Power Modular Concept Software Shutdown and Monitoring Software Power Modular Concept PMC Software is an external monitoring and shutdown software which was designed to operate with all RITTAL UPS products ...

Page 54: ...rver shutdown under NT UNIX and other operating systems The service programs are generally delivered as a single licence To use a single CD ROM to shutdown multiple servers you have to purchase additional CD license keys Parallel redundant UPS systems are also manageable by the software The main principle is let introduce a shutdown of a Server only when strictly necessary A correct Parallel Handl...

Page 55: ...w residual battery autonomy time downtime or by a countdown timer which is started at the beginning of the alarm A shut down is therefore possible without extra input from the operator and is fully software controlled The small 125x70 mm External SNMP adapter comes with following interfaces 1 RJ 45 connector for 10 100 Base T autoswitchable 2 Serial Port for configuration COM2 or optional ModBus i...