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740-01-00 PW9500DPA User Manual Issue 1.0.book

1. 9 i i 10 H 11 12 9 9 11 12 13 MODEM SNMP JD1 USB LEDs JR3 DIP SW JR2 X3 X2 X1 SW1 9 JD8 Slot for optional Modem Ethernet card ONLY Slot for optional SNMP card ONLY Sub D9 female connector RS232 User interface UPS system to computer Standard USB interface UPS system to computer 2 LEDs that indicate the interface board status RJ45 Port RS485 communication for remote panel Module selection used by multidrop configuration RJ45 Port RS485 communication for multidrop cable connected between all the UPS cabinets Used with RJ45 splitter adapter to enable module daisy chaining Terminal block used for external customer inputs Terminal block with volt free outputs for use with customer remote indications panel Castell interlock function 9 pole configuration DIP switch used to configure module for parallel operation Parallel communication bus connector Used in parallel cabinet system only and fitted with parallel adapter board to enable module daisy chaining Figure 7 1 UPS Cabinet customer interface board UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 65 Uninterruptible Power Supplies Ltd T Options A KOHLER COMPANY 7 1 1 Introduction Each UPS cabinet is fitted with a customer inter
2. a Press the UP key once to access the menu system Em b Use the UP DOWN keys to move the cursor so that it is adjacent to COMMANDS and then press the ENTER key c ERE sis c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key LOAD LINE 1 INVERTER m BATTERY d The module control panel will display LOAD PROTECTED L e The module control panel mimic indications should be as shown here T 21 The UPS system is now operating in the on line mode and providing the load with protected power supplied by the modules inverters Functionally check the system control panel 22 Transfer the load to bypass using the Commands function on the system control panel located on the cabinet door 8 Access the HOME screen Press the COMMANDS icon Selectthe Load to bypass command All the UPS modules should change over to the load on bypass state and the system control panel mimic will indicate the load on bypass status see Figure 2 18 amp Oo GU 23 Transfer the load back to inverter using the Commands function on the system control panel 8 Access the HOME screen Press the COMMANDS icon Selectthe Load to inverter command All the UPS modules should change over to load on inverter state and the system control panel mimic will indicate the load on inverter status see Figure 2 18 24 Functionally check the system control panel metering functio
3. Uninterruptible Powerm Supplies Ltd A KOHLER COMPANY Document Control ISSUE DATE REVISION SUMMARY Issue 1 0 01 05 14 Initial issue UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY Uninterruptible Power Supplies Ltd has taken every precaution to produce an accurate complete and easy to understand manual and will therefore assume no responsibility nor liability for direct indirect or accidental personal or material damage due to any misinterpretation of or accidental mistakes in this manual 2014 Uninterruptible Power Supplies Ltd This manual may not be copied nor reproduced without written permission of Uninterruptible Power Supplies Ltd UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Table of Contents Safety 1 1 Description of the safety symbols used in this manual 1 2 User precautions 1 3 Important safety notes 1 4 Storage instructions 1 5 Terminology General Description 2 1 Introduction 2 2 Model range 2 3 Functional description of operation 2 3 1 UPS Module internal operation 2 3 2 UPS Module operational states 2 3 3 UPS system operation 2 3 4 Parallel system operation 2 4 PowerWave 9500 User controls 2 5 Power isolators 2 5 1 PowerWave 9500 cabinet power configurations 2 6 Customer interfa
4. Initial system power up and functional testing Paragraph 4 2 Total system shutdown Paragraph 4 3 Load transfer from inverter to maintenance bypass Paragraph 4 4 Load transfer from maintenance bypass to inverter Paragraph 4 5 Replacing a module in a single module UPS system Paragraph 4 6 2 Replacing a module in a redundant parallel module system Paragraph 4 6 3 Replacing a module in a capacity parallel module system Paragraph 4 6 4 46 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd KOHLER COMPANY 4 Operating Procedures 4 2 Initial system power up and functional testing A WARNING This procedure must be carried out by a trained engineer or service agent approved by UPS Ltd This procedure outlines the steps taken by the commissioning engineer when energising the UPS system for the first time It can also be used to restart the system following a total shutdown Preliminary checks for each UPS cabinet oak wn gt Check the UPS input bypass supply fuses or breakers are open OFF at the distribution board Check that the UPS power cabling has been performed correctly and input phase rotation is correct Check that all the UPS module parallel switches IA2 are open OFF Verify that the maintenance bypass switch IA1 is open OFF Ensure that the battery fuses breakers fitted in the UPS cabinet and external battery cabinets rack
5. Battery The UPS uses sealed maintenance free batteries whose storage capacity depends on the ambient temperature It is important not to store the batteries for longer than 6 months at 20 C 3 months at 30 C or 2 months at 35 C without recharging them For longer term storage the batteries should be fully recharged every 6 months 20 C CAUTION Sealed batteries must never be stored in a fully or partially discharged state Extreme temperature under charge overcharge or over discharge will destroy batteries e Charge the battery both before and after storing e Always store the batteries in a dry clean cool environment in their original packaging e Ifthe packaging is removed you must protect the batteries from dust and humidity 3 5 Planning the installation site and environmental considerations A certain amount of pre planning will help ensure a smooth and trouble free installation of the UPS system The following guidelines should be taken into account when planning a suitable UPS location and operating environment 1 The route to the installation location must allow the equipment to be transported in an upright position 2 The floor at the proposed installation site and en route from the off loading point must be able to safely take the weight of the UPS equipment plus fork lift during transit 3 Avoid locations with high ambient temperature moisture or humidity a The installation site humidity should be lt 95 non condensing b Th
6. default display The display turns on automatically when the first UPS is energised and after a few seconds of initialisation it displays the default module mimic screen shown in Figure 2 14 2 8 4 Display header bar A navigation and status bar is displayed in the header area of every screen EE ntm AA mi A Home Accesses the HOME screen B Mimic diagram Accesses the MIMIC diagram screen C Warning The warning symbol is only visible in the presence of an alarm or monitored events Touching this icon will silence the audible alarm and open the EVENTS screen D Date Current date indication Set in the user menu and used to date stamp the alarms events log Time Current time indication Set in the user menu and used to timestamp the alarms events log F Module selection Accesses MODULE SELECTION screen from where it is possible to select a particular module and exercise the navigation status and measurements at module level G UPS number Each UPS module is given a sequential number in a parallel system The number shown here is used to identify a particular module e g P901 indicates the UPS number 01 This can be used to identify the module associated with the conditions displayed on the screen e g identify a faulty module H System status System status indicates that the user is in the system level navigation OR Load Status Load status displays whether or not the load is protected when the user is in the module navigation le
7. 7 2 2 WAVEMON Shutdown and Management Software Uninterruptible Eventilst System Serial communication restored Supplies Ltd 09 12 39 System Serial communication lost KOHLER cor 09 12 35 System Connected to UPS System S Available UPS Figure 7 7 Monitoring screen image WAVEMON is a software application designed to operate with many of the systems supplied by Uninterruptible Power Supplies Ltd and features both UPS monitoring and automatic UPS server shutdown facilities It comprises a bespoke software package which is installed on a local PC and communicates with the UPS via USB or a standard RS232 serial cable of up to 15m in length It is only required when an SNMP card or adapter box is not purchased Uninterruptible Power Supplies Ltd offer suitable monitoring software with SNMP functionality for NetWare OS 2 all Windows NT systems on INTEL and ALPHA network platforms The main features of WAVEMON are On screen autonomy time battery time countdown On screen server log off and shutdown procedure Time and date stamp event log Extensive logging of all UPS activity and power quality data Permits alarm warnings to be monitored remotely via email Scheduled UPS service mode and other systems status Graphical user interface for Windows compatible platforms Automatic unattended local shutdown Special modules for MS Office software to close and save open documents Compa
8. UPS Data UPS Data Serial Number Manufacturing Firmware Version Hardware Version Display Version User UPS Settings Language Date Time Battery Test Repeat Test Generator Operation Service UPS Measurements Output Voltage V Output Power 96 Active Power L3 KW Inverter Voltage V Rectifier Temperature 9C Udc Gain Output Current A Active Power L1 KW Reactive Power kVAr Bypass Voltage V Inverter Temperature 9C Output Frequency Hz Active Power L2 kW Apparent Power kVA Bypass Frequency Hz Udc Gain Battery Run Time Voltage V Voltage V Charge Current A Discharge Current A Temperature C Battery Offset Capacity V Battery Offset V Battery Offset Autonomy min Type Blocks Cells Floating Voltage V Minimum Threshold Common Battery Start Fast Charge Stop Fast Charge Offset P Load Offset L1 P Load Offset L2 P Load Offset L3 Q Load Offset L1 Q Load Offset L2 Q Load Offset L3 Inverter DC L1 Inverter DC L2 Inverter DC L3 Output DC L1 Output DC L2 Output DC L3 Inverter Offset L1 Inverter Offset L2 Inverter Offset L3 Bypass Offset L1 Bypass Offset L2 Bypass Offset L3 Battery Offset V Battery Offset V V Battery Offset UPS Type Power Unit Number Slot ID Cosphi System Parallel Frequency Sync Window Inverter Voltage V Rectifier Voltage V General Alarm Delay Converter Separate Bypass UPS Data Manufacturing Firmware Version Hardware Version
9. Virtual servers may not need a license per vertual server client Please contact Technical Support to discuss you requirements UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 71 8 Specification Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 8 Specification 8 4 Introduction This system comprises a cabinet that can be populated with up to five 100kVA power modules that operate in parallel within the cabinet to provide the cabinet s rated output Each power module is a self contained UPS and incorporates a rectifier inverter and static bypass Six of the cabinets shown can be connected together to form a 3 MVA parallel system 8 2 Mechanical data 8 2 1 UPS Cabinet Maximum cabinet rating 500 kVA 500kW with 5 power modules fitted Dimensions W x D x H mm 1580 x 940 x 1975 UPS Type On line transformerless modular decentralized parallel architecture Parallel capability Up to 6 frames with up to 5 x 100 kVA modules in each frame Battery Not included Performance specification VFI SS 111 Weight 975 kg with five power modules fitted Colour Graphite Grey RAL 7024 Positioning Min 200mm space required at the rear for ventilation Min 1500mm space required at front for access Min 400mm space required at the rear for ventilation Input output power cabling From the top or bottom 72 UPS740 01 00 PowerWave PW9500DPA User Manual Issue
10. battery charger continues to charge the battery via the rectifier DC boost converter The static switch turns on its bypass arm to connect the UPS output to the module s raw mains bypass supply If the UPS module shuts down due to a fault a contactor connected immediately ahead of the UPS output not illustrated will open to fully isolate the UPS from the remainder of the UPS system UPS ON LINE Mode Figure 2 4 illustrates the UPS ON LINE mode which is considered the normal mode of operation The rectifier and DC boost converter are turned on to supply controlled DC power to the inverter input The battery charger charges the battery The inverter converts the DC supplied by the rectifier back into AC suitable for connecting to the load The inverter arm of the static switch is turned on to connect the inverter output to the UPS output terminals to provide the load with processed power UPS ON BATTERY Mode The UPS automatically changes to the ON BATTERY mode if the mains input supply fails during normal ON LINE operation The battery discharges through the DC boost converter which regulates the battery voltage at the level required by the inverter The inverter converts the DC supplied by the boost converter back into AC suitable for connecting to the load The inverter arm of the static switch remains closed to maintain the connection from the inverter to the UPS output load termin
11. 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 8 Specification Remote signalling and alarms Dry port volt free contacts For remote signalling and automatic computer shutdown Smart port RS 232 For monitoring and integration in network management RS485 on RJ45 port For multidrop purposes SNMP card slot For monitoring and integration in network management Signalling input terminals EMERGENCY OFF normally closed GENERATOR ON normally open BATTERY TEMPERATURE SENSOR EXTERNAL BYPASS INTERLOCK 8 2 2 100 kVA UPS Power module Active Sub module Passive Sub module Dimensions W x H x D mm 710 x 178 x 750 Weight kg 55 active module 54 passive module UPS Type On line transformerless modular decentralized parallel architecture 8 3 100 kVA UPS Module data 8 3 1 General Data General data 100 kVA UPS Module Output power factor 1 0 Output rated power 1 0 p f kW 100 Output current In 1 0 p f A 145 400 V Efficiency AC AC up to at Cos 1 0 Load 100 75 0 50 0 25 0 95 6 96 0 96 1 95 8 Eco mode efficiency at 100 load 99 or better Back feed protection Standard UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 73 Uninterruptible Power Supplies Ltd 8 Specification KOHLER COMPANY 8 3 2 Rectifier data Rectifi
12. 4 Inverter data Inverter data 100 kVA UPS Module Output voltage steady state rms V 3x380 220V or 3x400 230V or 3x415 240V Three phase Neutral Output voltage variation 1 5 Normal and battery mode Output waveform Sinewave Output current rms rated A 145 Output frequency Hz 50 Hz or 60 Hz Output frequency tolerance Free running quartz oscillator lt 0 1 Synchronized with mains lt 2 or lt 4 selectable Permissible unbalanced load 100 All 3 phases regulated independently Phase angle tolerance Deg 0 deg With 100 unbalanced load Inverter overload capability 96 110 load for 60 mins 125 load for 10 mins 150 load for 30 secs Output short capability rms A 2 4 x In during 40 ms Output voltage transient recovery time with 100 step load Linear lt 4 Non linear 96 4 EN62040 3 Output voltage distortion THD 100 load normal and battery mode With linear load 96 2 096 With non linear load 96 4 EN62040 3 8 3 5 Static bypass data Static Bypass data 100 kVA UPS Module Transfer break time ms 1 5 Rated current A 160 overload current 96 11096 load for 85 mins 125 load for 65 mins 150 load for 50 mins Bypass short capability RMS A 10 x In during 20 ms UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 75 8 Specification Uninterruptible
13. Aa o 10 11 12 13 11 12 13 MODEM SNMP JD1 USB LEDs JR3 DIP SW JR2 X3 X2 X1 SW1 9 JD8 Slot for optional Modem Ethernet card ONLY Slot for optional SNMP card ONLY Sub D9 female connector RS232 User interface UPS system to computer Standard USB interface UPS system to computer 2 LEDs that indicate the interface board status RJ45 Port RS485 communication for remote panel Module selection used by multidrop configuration RJ45 Port RS485 communication for multidrop cable connected between all the UPS cabinets Used with RJ45 splitter adapter to enable module daisy chaining Terminal block used for external customer inputs Terminal block with volt free outputs for use with customer remote indications panel Castell interlock function 9 pole configuration DIP switch used to configure module for parallel operation Parallel communication bus connector Used in parallel cabinet system only and fitted with parallel adapter board to enable module daisy chaining Figure 2 10 UPS Cabinet interface board UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 13 Uninterruptible Supplies Ltd ta 2 General Description KOHLER COMPANY 2 7 UPS Module control panel The UPS module control panel is used to start stop the individual module as part of the UPS system operating procedures It can also be used to test and set up the modu
14. Connect the battery power cables between the UPS cabinet s battery connection busbars and the corresponding terminals busbars in the battery cabinet or rack 3 8 Multi cabinet parallel control cabling and configuration Mains bypass input supply power connection Output to load m Daralleling communications bus cables m multidrop cables Figure 3 13 Parallel cabinet control cables In order to facilitate various control functions such as load sharing frequency synchronisation and load transfer the electronic control systems within the paralleled UPS cabinets communicate with each other continuously via the parallel communications bus cables that are daisy chained between each cabinet as shown below in Figure 3 15 Once the cables are fitted each cabinet must be configured by means of a DIP switch to define its position in the parallel system In a parallel cabinet system one UPS cabinet acts as a master cabinet with the remaining cabinets acting as slaves If at any time the master goes faulty the next cabinet former slave will immediately take over the master function and the former master will switch off 42 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 3 Installation and Set up 3 8 1 Connecting the parallel communication bus cables FIRST MIDDLE MIDDLE MIDDLE MIDDLE LAST UPS Cabinet 1 UPS Cabinet 2 UPS Cabinet 3
15. GREEN Mains available RED Mains not available LINE 2 GREEN Mains bypass OK RED Mains bypass not OK or not present OFF UPS is turned OFF ALARM OFF No alarm condition RED Alarm condition INVERTER GREEN Load on inverter RED Inverter fault OFF Inverter not operating switched OFF BY PASS GREEN Load on bypass OFF Bypass not operating switched OFF BATTERY GREEN Battery OK RED Battery fault or discharged Flashing GREEN Load On Battery The ALARM LED is a visual indication of an internal or external alarm condition When activated it is accompanied by an audible alarm which can be cancelled by pressing the RESET key On Line On Inverter mode When the UPS module is operating in the On Line mode the load is supplied through the LINE 1 RECTIFIER and INVERTER This is the module s normal mode of operation and provides the highest degree of protection especially in the event of a mains disturbance or failure LINE 2 LINE 1 BY PASS INVERTER 2 r EE BATTERY E LOAD LED Colour LINE 1 Green LINE 2 Green BY PASS OFF INVERTER Green BATTERY Green Figure 2 12 On Line Mode On Bypass Line Interactive mode In the On Bypass Line Interactive mode the load is normally supplied from the bypass mains LINE 2 and the static BYPASS LINE 2 BY PASS Ge RR ion LINE 1 INVERTER EES BATTERY LED Colour LINE 1 Green LINE 2 Green
16. INVERTER UPS Mains s Input UPS AC Output STATIC SWITCH Automatic 49 Batt Switch BATT CHARGER BATTERY Figure 2 2 UPS module functional block diagram EMI Filters The input and output EMI filters reduce the electromagnetic noise generated by the UPS i e reduces radio interference Rectifier The rectifier uses leading edge switched mode techniques which results in a UPS input power factor of almost unity over its operating range 0 99 at full rated linear load It converts the UPS AC mains input to an unregulated DC power source that can satisfy the inverter DC power demands over an input voltage range of between 160V 288V This wide input voltage range means that the battery is not called upon even during substantial power dips brown outs which maximises battery life and availability DC Boost converter The DC boost converter converts the unregulated DC voltage connected to its input from either the rectifier or battery into a regulated DC bus suitable for powering the inverter Battery charger A multi stage battery charger powered from the DC boost converter output charges the battery whenever the input supply is available and the rectifier DC boost converter is turned on The charger uses an intelligent charging profile to obtain the best battery charge discharge performance in order to optimise the battery life Inverter The inverter converts the regulated DC voltage produced by the DC
17. Manual Issue 1 0 Dated 01 05 14 37 Uninterruptible Power Supplies Ltd 3 Installation and Set up A KOHLER COMPANY e Jl 000000000 Front View 000000000 4 000000000 3D View ji Top View PE PE N FST js FPF oe TPT TET FFT PPT 1 L3 5d 242 341 212 Mains Input Connect Mains Input Connect UPS Connect 2 L3 Rectifier To Bypass To Output To 30 99g gSGTUN Phase L1 141 Phase L1 241 Phase L1 3 L1 312 FF FPP Phase L2 1 L2 Phase L2 22 Phase L2 322 313 FF TERETE Phase L3 1 13 Phase L3 2 13 Phase L3 3 L3 Batt TVESTSESESTET Neutral N Neutral N Neutral N Balt eee SPE EET Earth PE Earth PE Earth PE Figure 3 10 Dual input with common battery 000000000 3D View Front View gt 000000000 0000000090 Top View js SUEPRSSSSUE a AINN WOES SS SEE ESS 3 L1 TERS EEESSI 1 L3 2 L1 2 L2 2 L3 3 L1 2o IITIN TUETEPESTSTU 313 OYUTESTSTE Battery connected to each module s battery circuit breaker Figure 3 11 Dual input with separate batteries 38 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 3 Installation and Set up 3 6 4 Parallel cabinet cabling recommendations In order
18. OFF OFF OFF ON 6 OFF ON OFF OFF 7 OFF OFF OFF OFF 8 OFF OFF OFF OFF 9 OFF OFF OFF OFF 3 8 2 Connecting the multidrop cables The multidrop cables are connected between the modules to enable the system to be remotely monitored over ethernet The cables are connected to an RJ45 connector JR2 located on the customer interface board item 8 in Figure 2 10 An RJ45 splitter plug supplied with the fitting kit is required when fitting the cables to the middle cabinets 1 Connect a multidrop cable between PORT JR2 of UPS cabinet 1 and JR2 of UPS cabinet 2 using a splitter plug in cabinet 2 if it is a middle cabinet 2 Connect a multidrop cable between PORT JR2 of UPS cabinet 2 and JR2 of UPS cabinet 3 using a splitter plug in cabinet 3 if it is a middle cabinet 3 Continue with the above steps until a multidrop cable is connected as a daisy chain between all modules 4 n each cabinet set multidrop configuration switch item 7 in Figure 2 10 according to the table below Single Cabinet First Cabinet Middle Cabinet Last Cabinet SW 1 ON OFF OFF ON SW 2 ON ON OFF OFF 5 n each cabinet set jumper JP2 on PCB NW22085D with ROM76 12 or NW22085E or later versions of the customer interface board as shown below Single Cabinet First Cabinet Middle Cabinet Last Cabinet JP2 ON OFF ON ON 44 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 In
19. Ope 17 Ont n the maintenance bypass switch IA1 in all UPS cabinets The module control panel will display MANUAL BYPASS OPEN followed by LOAD NOT PROTECTED The red INVERTER LED will extinguish The module control panel mimic indications should be as shown here he UPS module control panel Press the UP key once to access the menu system Use the UP DOWN keys to move the cursor so that it is adjacent to COMMANDS and then press the ENTER key Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key The module control panel will display LOAD PROTECTED The module control panel mimic indications should be as shown here LINE 2 BY PASS om EE RR LOAD LINE 1 INVERTER BATTERY LINE 2 BY PASS GB RAT LOAD LINE 1 INVERTER ENS BATTERY LINE 2 BY PASS LOAD LINE 1 INVERTER Gl TT m BATTERY L T Note This completes the procedure The UPS is now operating in On Line mode and supply protected load power 4 6 3 Replacing a module in a redundant parallel module system If a UPS module fails in a redundant parallel module system the load will continue to be supplied by the remaining on line modules and the faulty module can be replaced without having to transfer the load to the bypass supply Removing the module 18 Turn OFF the UPS module by pressing both ON OFF buttons simultaneously then a b releasing t
20. PROTECTED e The module control panel mimic indications should be as shown here 16 Close the maintenance bypass switch IA1 in all cabinets LINE 2 BY PASS a The module control panel will display MANUAL BYP IS CLOSED M b The system control panel mimic should show the system running on iud maintenance bypass see Figure 2 18 cid c The module control panel mimic indications should be as shown here BATTERY 48 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 4 Operating Procedures WARNING The next action will apply mains power to the load equipment Check that the load is ready to receive power and that it is safe to do so before you continue 17 Close the UPS output supply fuses breakers at the load distribution panel a Theload is now live and receiving power through the maintenance bypass circuit Transferring the load to the UPS 18 Ensure that the BYPASS LED is green on ALL UPS module control panels 19 Open the maintenance bypass switch IA1 in all UPS cabinets LINE 2 BY PASS a The module control panel will display MANUAL BYPASS OPEN followed mE by LOAD NOT PROTECTED l LOAD b The red INVERTER LED will extinguish INVERTER c The module control panel mimic indications should be as shown here BATTERY 20 On ANY UPS module control panel LINE 2 BY PASS
21. PowerWave 9500 UPS Uninterruptible Power Supplies Ltd can provide maintenance and support on a wide range of different UPS products If you are interested in an extended warranty for your PowerWave 9500 UPS or for any other UPS products you may have please complete the enquiry form shown below and return or FAX it to Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Business Park Tel 01256 386700 Hook 0800 731 3269 24 Hr Hampshire Fax 01256 386701 RG27 9XA Email service upspower co uk 26 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 2 General Description 2 10 Extended Service enquiry form Fax to 01256 386701 www upspower co uk Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Business Park Hook Hampshire RG27 9XA Tel 01256 386700 Names Misses ee eer Pee ea JOD Title gidiciieieancnd eli edhe eens COMPANY Ncc AddresS dueniehinue rue retis EEE EEC te e cs eret te ete Er ee eed esi deep cata PoStCOdO uniensenelescedeniner d fa nre RRMRDADRI INDOOR EOYrRe dan XR PR SERERE AERE MM ZZ e eE a arae E EE E 1o PEE E mail anum a ERII NIMIRUM EADNMESUNEE Please contact me to discuss C Extended Warranty options for my PowerWave 9500 UPS C Extended warranty options for my UPS System as below Man fact re r riirii
22. UPS Cabinet 4 UPS Cabinet 5 UPS Cabinet 6 Parallel Adaptor Parallel Adaptor Parallel Adaptor Parallel Adaptor Parallel Adaptor Parallel Adaptor Ceo uud SW2 2 IU uu SW2 2 VERSER dung SW2 2 CERDO Cun SW2 2 uU Wieso SW2 2 Manel Manse ake SW2 2 JD6 JD6 JD6 JD5 JD6 JD5 DG JD5 JD6 JD5 Parallel Adapter Board Parallel Adaptor fitted to JD8 on UPS customer interface board Master Slave Master Slave Output Input SW2 2 SW2 2 Configuration JD6 JD5 DIP Switch JD6 JD5 Single Cabinet First Cabinet Middle Cabinet Last Cabinet SW 2 1 ON OFF OFF ON SW 2 2 ON ON OFF OFF Figure 3 14 Bus lines connections A WARNING This procedure must be carried out by the approved commissioning engineer 1 To protect personnel during the UPS installation ensure that the following procedure is performed under the following conditions in ALL UPS cabinets a No mains voltage is present at the UPS mains bypass distribution board terminals Allloads are shut down and isolated at the load distribution board The UPS is fully shut down and voltage free The UPS and battery connection busbars are voltage free The UPS maintenance bypass isolator IA1 is open OFF f The UPS modules parallel switches IA2 are open OFF 2 Fita parallel adaptor board over connector JD8 on the customer interface board in all UPS c
23. UPS and computer server 2 In many cases the use of what is referred to as an SNMP adapter is to be preferred in order to integrate the UPS into the network In this case up to 50 computers can be shut down in one RCCMD environment RCCMD remote console command is an additional software module that is used in order to execute a command typically a shutdown command in a remote system 7 2 4 Licensing A licence is issued with every software serial number for use of what is known as the UPS service on a single server in connection with one UPS and an unlimited number of connected WINDOWS workstations For operation with two or more servers a further licence is required for each additional server In this case it is of no importance whether the UPS service on these servers is active or whether the server was stopped by a remote UPS service The same applies to the use of RCCMD with the remote send receive modules for multi server shutdown under NT UNIX and other operating systems The service programs are generally supplied as single licences In order to use a single CD ROM for several multi server shut down units you must acquire additional licence codes 7 2 5 RCCMD Server shutdown In order that remote shutdown of servers can take place initiated by the SNMP card or WAVEMON software further licenses must be purchased The license s for the RCCMD client or listening software that resides in each target server Note
24. UPS modules 500 kW and up to six cabinets can be connected together to offer a parallel system capacity of 3 0 MW Hot swappable modules Enables system expansion and module replacement to be carried out without disturbing the connected load Unity output power factor kKVA kW Blade server friendly No de rating required with leading PF loads Bestin class AC AC efficiency up to 9696 efficiency minimises operational costs TCO Low input power factor 0 99 100 load Cost savings during installation and the entire life cycle TCO Ease of operation A graphical display panel on the front of the UPS cabinet provides the operator with a single point of system level control and also allows the operation of each individual module to be interrogated Flexible battery management Advanced management of battery charging and preventive failure diagnostics avoids premature deterioration of battery life Top or bottom cable entry Allows flexible installation into existing plant infrastructure Very low input current distortion THDi lt 3 5 100 load leads to savings in generator set power and installation costs 4 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 2 General Description 2 2 Model range As described above the PowerWave 9500 UPS cabinet can house up to five 100 kW UPS modules so each cab
25. at the load distribution board 12 Turn OFF each UPS module in sequence by pressing both ON OFF buttons LINE 2 BY PASS simultaneously then releasing them a The module control panel will display LOAD OFF and SUPPLY LOAD FAILURE LINE 1 INVERTER b The module control panel mimic indications should be as shown here 13 Close the parallel switch IA2 for each module EE BATTERY a The module control panel will display PARALLEL SW CLOSED on every module 14 Turn ON each UPS module in sequence by pressing both ON OFF buttons LINE 2 BY PASS simultaneously then releasing them a The UPS modules will all turn on and operate in their on line mode LOAD LINE 1 INVERTER b There is now power at the UPS output terminals although the load is still isolated at the output distribution board c The module control panel will display LOAD PROTECTED EE BATTERY d The module control panel mimic indications should be as shown here L T Transferring the output to maintenance bypass 15 On ANY UPS module control panel LINE 2 BY PASS a Press the UP key once to access the menu system z toko b Use the UP DOWN keys to move the cursor so that it is adjacent to UNE INVERTER R COMMANDS and then press the ENTER key E c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO BYPASS then press the ENTER key EE BATTERY d The module control panel will display LOAD NOT
26. controlled manner and generate a fault alarm and the module mimic panel indications will differ between the failed and healthy module s as shown below LINE 2 BY PASS LINE 2 BY PASS ee 0 LOAD LOAD LINE 1 INVERTER LINE 1 INVERTER HEALTHY MODULE FAULTY MODULE mE BATTERY BATTERY Removing the module 31 Close the maintenance bypass switch IA1 LINE 2 BY PASS a The LCD display on all modules will now indicate MANUAL BYP IS CLOSED LOAD b The system control panel mimic should show the system on qux pened maintenance bypass see Figure 2 18 c The module control panel mimic indications on all modules should be as shown here EE BATTERY UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 57 Uninterruptible Powerm Supplies Ltd 4 Operating Procedures KOHLER COMPANY 32 Open the fault module s parallel switch IA2 a TheLCD display will now indicate LOAD OFF SUPPLY FAILURE 33 Turn OFF the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them a The module control panel will display LOAD OFF and SUPPLY LOAD FAILURE pon INVERTER b The module control panel mimic indications should be as shown here EHE BATTERY 34 In the UPS cabinet open the faulty module s bypass isolator F3 LINE 2 BY PASS a The BATTERY led on the module mimic
27. is applied to any part of the UPS system before it has been fully commissioned and handed over to the customer 4 1 1 Operating procedure summary Under normal circumstances all the UPS modules in a multi module system are running and operating in their on line on inverter mode If a module fails in a redundant module system the faulty module will shut down but will not affect the remaining on line modules which will continue to supply the load with processed power The failed module can then be replaced or tested off line without affecting the remaining working modules If a UPS module fails in a capacity rated or single module system the faulty module is shut down and the load is immediately transferred to the static bypass supply in all modules from where it is supplied with unprotected mains power The UPS cabinet contains a maintenance bypass switch which when closed completely bypasses the UPS modules and connects the cabinet output terminals directly to its bypass mains input When operating via the maintenance bypass switch the UPS modules can be replaced or tested off line as required In the case of a single module installation the load must be transferred to the maintenance bypass to maintain the load power while the UPS module is replaced Note All the switches and control panel operations mentioned in this chapter are identified and described in chapter 2 4 1 2 This chapter contains the following operating procedures
28. load is not protected against any mains input supply Figure 2 6 UPS ON BYPASS disturbances or loss BATT CHARGER 2 3 8 UPS system operation Summary of UPS module operating modes UPS installations are generally categorised as being either On line or Off line On stand by systems and you can configure the PowerWave 9500 to operate as either type The two systems are described below On line UPS system An on line system provides the highest degree of load protection especially in the event of a mains supply disturbance or complete failure and we always recommended its use if the critical load e g computer system will not tolerate even a very brief supply interruption When the PowerWave 9500 is used as an on line UPS it is configured to normally operate in the ON LINE mode as shown in Figure 2 4 In the event of a mains supply failure the UPS changes to its ON BATTERY mode Figure 2 3 without affecting its output supply i e the changeover to battery operation is totally transparent at the UPS output The UPS then continues to provide its rated output until the battery discharges to a low cut off point at which time the UPS will try to switch to bypass and then shut down in a controlled manner An alarm will warn that the battery is discharging to enable the operator to take any necessary intervention to protect the load integrity It is usual especially in larger installations to provide the UPS with an alternat
29. should show the system on LOAD LINE 1 INVERTER maintenance bypass see Figure 2 18 i c The module control panel mimic indications should be as shown here 3 Open the module s parallel switch IA2 mE BATTERY a The LCD display will now indicate LOAD OFF SUPPLY FAILURE 4 Turn OFF the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them a The module control panel will display LOAD OFF and SUPPLY LOAD FAILURE LINE 1 INVERTER b The module control panel mimic indications should be as shown here ENE BATTERY 5 Inthe UPS cabinet open the module s bypass isolator F3 LINE 2 BY PASS a The BATTERY led on the module mimic should change to flashing green ct LOAD b The module control panel mimic indications should be as shown here LINE 1 INVERTER 6 Open the module s bypass isolator F2 a The module is now fully powered down BATTERY 7 Remove the UPS sub modules from the cabinet in accordance with the guidance in paragraph 4 6 1 Fitting the module 8 Fitthe UPS sub module to the cabinet in accordance with the guidance in paragraph 4 6 1 9 Close the UPS cabinet s input bypass supply fuses or breakers at the distribution board and the module s fused bypass isolator F2 10 Close the module s fused bypass isolator F2 LINE 2 BY PASS a The UPS mimic panel LINE 1 LED will be permanent green b The BATTERY LED will be flashing green FO
30. that PARALLEL SW CLOSED status appears on the module control panel Turn ON the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them es 3 a The module will restart automatically and run on bypass in parallel with LOAD other modules LINE 1 INVERTER b The module control panel mimic indications should be as shown here ENE BATTERY Open the maintenance bypass switch IA1 in all UPS cabinets LINE 2 BY PASS a The module control panel will display MANUAL BYPASS OPEN followed gt mE by LOAD NOT PROTECTED l LOAD b The red INVERTER LED will extinguish paal INVERTER c The module control panel mimic indications should be as shown here m BATTERY UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 59 4 Operating Procedures Uninterruptible Supplies Ltd ta KOHLER COMPANY 47 On the UPS module control panel LINE 2 BY PASS a Press the UP key once to access the menu system Em b Use the UP DOWN keys to move the cursor so that it is adjacent to FOAD COMMANDS and then press the ENTER key ee c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key ENH BATTERY d The module control panel will display LOAD PROTECTED L e The module control panel mimic indications should be as shown here T Note This completes the procedure The UPS system is now ful
31. the utility mains supply through a suitable LV Distribution board containing a circuit breaker or fused isolator to provide both overload protection and a means of isolating the UPS from the mains supply when required Similarly the UPS output supply terminals should be connected to the load equipment via a suitably fused load distribution board UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 31 Uninterruptible Supplies Ltd ta 3 Installation and Set up KOHLER COMPANY Input neutral grounding A permanently connected input neutral is required to enable the rectifier to operate correctly and allow the UPS to function properly UPS when operating on battery The input neutral must also be grounded to permit correct operation when the UPS is running on battery Key Point As the input neutral must P be unswitched and connected to the jpg E E E E UPS at all times DO NOT use a 4 ov 230V pole input switch or isolator at the LV Distribution board on a TN S system Figure 3 3 Permanent grounded input neutral 3 6 2 Cable and fuse sizing PowerWave 9500 power configuration The PowerWave 9500 is manufactured with one of four power configurations and it is not possible the change the configuration once the unit is on site The available configurations are Single input supply with common battery see Figure 3 4 Dual input supply with common batter
32. to achieve equal load sharing between the various UPS cabinets in a multi cabinet installation the input cables from the mains distribution board to each UPS cabinet should be of equal length Similarly the UPS output cables to the load distribution board should be of equal length See Figure 3 12 Recommended cable configuration Rectifier Feed Bypass Feed Output to Load Not Recommended cable configuration Bypass Feed Rectifier Feed Output to Load Figure 3 12 Parallel cabinet cabling recommendations UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 39 Uninterruptible Power Supplies Ltd 3 Installation and Set up KOHLER COMPANY 3 7 UPS Cabling procedure WARNING Opening or removing the UPS covers will create a risk of exposure to dangerous voltages if power is connected to the UPS Please ensure you read and understand the following safety notes before you begin the UPS electrical installation Safety notes 1 Do not commence this procedure until the UPS mechanical installation is completed 2 All the cable installation procedures detailed below must be supervised by a qualified electrician 3 Do not connect or operate the UPS if there is water or moisture present 4 When carrying out any installation work on the UPS power cables or terminals you must ensure that the UPS input and load supplies are isolated and locked out at their respective distribution boards Warning not
33. to e X3I11 1 5 mm and maximum length of 100m 2 Connectthe cable as shown in Figure 7 1 3 ios 4 3 X3 Figure 7 5 Generator ON Connection 7 1 4 RS485 Interface for multidrop JR2 Using the Multidrop connection kit the computer interface JR2 is an intelligent RS485 serial port that allows the use of a single SNMP card on several parallel cabinets in parallel 7 1 5 RS485 Interface for remote panel JR3 JR3 is used by the TFT touchscreen display and control unit 68 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY T Options 7 1 6 SNMP Card slots Simple Network Management Protocol SNMP is a world wide standardised communication protocol that can be used to monitor any network connected device via a simple control language and display the results in an application running within a standard web browser The PowerWave 9500 contains two SNMP slots one is designed to house a Modem Ethernet SNMP adapter card and the other a Modem GSM adapter Alternatively SNMP connectivity can also be implemented using an external SNMP adapter connected to the UPS RS232 output JD1 An SNMP Ethernet adapter contains an RJ 45 connector which allows it to be connected to the network using a standard network cable Once connected the UPS Management software agent which is already installed in the SNMP adap
34. 05 14 Powerm Supplies Ltd Uninterruptible KOHLER COMPANY 4 Operating Procedures 40 41 42 43 44 45 46 Turn ON the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them GE m RR a The UPS module will start up over about 60 seconds LOAD b The module control panel display will indicate LOAD DISCONNECTED INVERTER PARALLEL SW OPEN c The module control panel mimic indications should be as shown here Em BATTERY Verify that the remaining modules are also operating in the on bypass mode On the UPS module control panel LINE 2 BY PASS a Press the UP key once to access the menu system Em b Use the UP DOWN keys to move the cursor so that it is adjacent to FOAD COMMANDS and then press the ENTER key ey c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key ENH BATTERY d The module control panel will display LOAD PROTECTED L e The module control panel mimic indications should be as shown here T Turn OFF the UPS module by pressing both ON 0FF buttons simultaneously LINE 2 BY PASS then releasing them a The module control panel will display LOAD OFF and SUPPLY LOAD FAILURE LINE 1 INVERTER b The module control panel mimic indications should be as shown here EHE BATTERY Close the module s parallel switch IA2 and check
35. 5 Pin D Type Male Female Figure 7 2 Connector Cable PC Serial Port 7 1 3 Dry ports customer interface X2 X3 Customer I O interface facilities are made to Phoenix spring terminal blocks cable 0 5 mm to 1 5 mm All voltage free contacts are rated at 250VAC 8A 30VDC 8A 110VDC 0 3A 220VDC 0 12A On the Master board the following ports are active The Input ports X2 The Output port X3 On the Slave boards the following parts are active The Output ports X2 All other input or output ports on the Slave boards are not activated 66 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY T Options Terminal Contact Signal Display Function INPUTS X38 X3 14 Gnd Gnd Battery Temperature Sensing X3A3 In 43 3V If connected this input is battery temperature dependent X312 Gnd Gnd GENERATOR Customer Specific Input 1 X3M4 In 412V OPER ON Default NC Generator on line X3 10 Gnd Gnd Parallel Switch External output circuit breaker x3 9 In 412V OPEN CLOSED When used both the external and the internal IA2 output breakers have to be either open or closed in order to isolate or connect the output of UPS X3 8 Gnd Gnd EXT MAN BYP External Manual Bypass X3 7 In 12V External IA1 X3 6 Out 12V 12Vdc Power source max 200mA load X3 5 Gnd Gnd X3 4 Gnd Gnd REMOTE RSD Remote Shut Down X3 3 In 412V SHUTD
36. AD c The LCD display will indicate LOAD OFF SUPPLY FAILURE pui INVERTER BATTERY 11 In the UPS cabinet close the module s bypass isolator F3 LINE 2 BY PASS a The module control panel display will indicate LOAD OFF SUPPLY FAILURE LOAD b The BATTERY led on the module mimic should change to permanent yeh Misa green c The module control panel mimic indications should be as shown here EHE BATTERY 54 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Su Power A KOHLER COMPANY 4 Operating Procedures P Key Point If this is a new modules the module s configuration data can be entered at this point e g Set Time Date Module ID etc This requires access to a password protected menu area and must be carried out only by an approved engineer 12 Close the module s parallel switch IA2 and check that PARALLEL SW CLOSED status appears on the module control panel 13 Turn ON each UPS module in sequence by pressing both ON OFF buttons simultaneously then releasing them a b c 14 The The UPS modules will start up over about 60 seconds The module control panel will display MANUAL BYP IS CLOSED The system control panel mimic should show the system on maintenance bypass see Figure 2 18 module control panel mimic indications should be as shown here 15 Ensure that the BYPASS LED is green 16
37. BY PASS Green INVERTER OFF BATTERY Green Figure 2 13 Line Interactive Bypass Mode If the UPS module s parallel switch is open see Figure 2 8 the module can be switched between the On Line and On Bypass modes without affecting remaining modules UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 15 Uninterruptible Power Supplies Ltd 2 General Description A KOHLER COMPANY 2 7 3 Power Management display The 2 x 20 character LCD Power Management Display simplifies communication with the UPS and also provides UPS monitoring information See paragraph 2 7 3 The menu driven LCD enables the operator to Access the Event register Monitoring the input and output voltage current frequency amp power Monitoring battery run time Perform commands such as module START and STOP Load transfer between INVERTER to BYPASS Access the module s Diagnostics service mode Carry out module adjustments and testing service mode Status screens DESCRIPTION LCD DISPLAY 1 Load is protected by UPS power supplied by inverter normal operation LOAD z The batteries are connected and OK PROTECTED 2 Load is not protected by UPS power supplied by mains power load on LOAD Fi bypass or it is supplied by the inverter normal operation and the batteries MOT PROTECTED are not OK 3 Load supply interrupted UPS has been switched off by ON OFF butt
38. Display Version Dynamic Password Commands Clear Alarms Service Mode Standby Mode Default Config Tests Inverter Voltage Open K Bypass Close K Bypass UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 25 Uninterruptible Power Supplies Ltd 2 General Description A KOHLER COMPANY 2 9 Warranty The PowerWave 9500 UPS is supplied with a limited warranty that the UPS and its component parts are free from defects in materials and workmanship for a period of one year from the date of commissioning or fifteen months from the date of original delivery whichever is the sooner This warranty is the only warranty given and no other warranty express or implied is provided This warranty is invalidated if the UPS is used without having been commissioned by a fully trained and authorised engineer The warranty does not apply to any losses or damages caused by misuse abuse negligence neglect unauthorised repair or modification incorrect installation inappropriate operating environment accident act of God or inappropriate application If the UPS fails to conform to the above within the warranty period then Uninterruptible Power Supplies Ltd will at its sole option repair or replace the UPS All replaced parts will remain the property of Uninterruptible Power Supplies Ltd As a general policy Uninterruptible Power Supplies Ltd does not recommend the use of its products in life support applica
39. E 1 INVERTER 5 Open the module s parallel switch IA2 6 Open the module s bypass isolator F2 a The module is now fully powered down E BATTERY A WARNING The UPS input bypass and output terminals within the UPS cabinet are still live UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 51 4 Operating Procedures Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 5 Load transfer from maintenance bypass to inverter This procedure returns the UPS to normal on line operation from working on the maintenance bypass If all the UPS modules are running begin this procedure at step 5 otherwise begin at step 1 to turn on any non working module s 1 Close all the battery fuses breakers in the battery cabinet rack 2 Close the module s bypass isolator F3 in the cabinet a The module control panel will display LOAD OFF SUPPLY FAILURE b The BATTERY led on the module control panel mimic should change from flashing to permanent green c The module control panel mimic indications should be as shown here 3 Close the parallel switch IA2 for each module LINE 2 LINE 1 a The module control panel will display PARALLEL SW CLOSED on every module 4 Turn ON each UPS module in sequence by pressing both ON OFF buttons simultaneously then releasing them a The UPS modules will start up over about 60 seconds b The module control panel will
40. EMON Shutdown and Management Software Functional description Licensing RCCMD Server shutdown 8 1 Introduction 8 2 Mechanical data 8 2 1 8 2 2 UPS Cabinet 100 kVA UPS Power module 8 3 100 kVA UPS Module data 8 3 1 8 3 2 8 3 3 8 3 4 8 3 5 8 3 6 General Data Rectifier data Battery data Inverter data Static bypass data Environmental data 8 4 Standards 69 69 70 71 71 71 72 72 72 72 73 73 73 74 74 75 75 76 76 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY IV UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd t A KOHLER COMPANY 1 Safety 7 Safety 1 4 Description of the safety symbols used in this manual WARNING The warning symbol is used where there is danger of an electrical shock equipment damage or personal injury CAUTION The caution symbol is used to highlight important information to avoid possible equipment malfunction or damage 1 2 User precautions WARNING Ensure you read and understand all the safety and hazard warnings contained in this manual before you begin to install this equipment WARNING Keep this manual with the UPS for future reference of the potential shock hazards WARNING Before it is put into service this UPS must be set up and commissioned by a suitably qualified engineer in accordance with the pr
41. HARGE LOCK pue BYPASS LOCK Qu Set Up Service menu screen DESCRIPTION LCD DISPLAY 1 This Menu is reserved for authorized service engineers only 2 Type in password gt FPASSHORD 2 8 System control panel The system control panel contains a microprocessor based TFT touchscreen display which enables the operator to monitor the operational status of the overall UPS system as well as each individual UPS module It also allows the operator to transfer the load between the inverter and bypass All other UPS module level commands must be performed from the individual modules control panel By having both control panels in place working at module and system level the UPS offers full user friendliness without compromising on robustness The touchscreen display enables the operator to Check operational status and measurements Execute operational commands Monitor the power flow through the UPS system Check alarm and events history Silence alarms Adjust programmable parameters Check the status of the batteries UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 1 9 Uninterruptible Supplies Ltd t 2 General Description KOHLER COVPANY L1 230 0 V SE L2 230 0 V 2l H L3 230 0 V inverter Ubatt 528 0 V Temp 20 0 C L1 230 0 V L2 230 0 V L3 230 0 V Time 15 min Figure 2 14 System control panel
42. ION Claims for visible shipping damage must be notified to the carrier immediately on receipt Other Before you accept delivery ensure that the received packages corresponds to the description on the delivery note 3 2 1 Site transportation Please observe the following precautions when you transport the UPS equipment from the off loading point to its intended installation or storage location CAUTION Transportation e When transporting the equipment use an adequate forklift with the forks inserted into the slots provided at the bottom of the packaging or equipment e Do notat any time tilt the UPS cabinet by more than 10 from vertical 28 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 3 Installation and Set up If tilting occurs do not connect the UPS to the mains electrical supply The weight of the UPS battery equipment can cause serious personal injury and or structural damage to the surrounding area if dropped in transit Always take extreme care CAUTION Storage A e The UPS should be stored in the original packing and shipping carton CAUTION Potential dangers A e Ifthe UPS battery cabinet is tilted by more than 10 it could cause internal damage e The recommended storing temperature for the UPS and batteries is between 5 and 40 C e The UPS system and the battery sets must be protected from high humidity which should not e
43. OWN ss Leave jumper JP5 in place if no Remote Shut Down input is connected X3 2 REMOTE RSD Remote Shut Down For external switch X3 1 z SHUTDOWN Max 250VAC 8A 30VDC 8A 110VDC 0 3A 220VDC 0 12A OUTPUTS X2 X2 18 Com Spare Common X2 17 NC function Auxiliary NO X2 16 NO Auxiliary NC X2 15 Com Alarm COMMON Common X2 14 NC ALARM wo Alarm Condition X2 13 NO Common System Alarm active X2 12 Com Status LOAD ON MAINS Common X211 NC No Load On Bypass X2 10 NO Load on Bypass Mains active X2 9 Com Alarm BATT LOW Common X2 8 NC Battery OK X2 7 NO Battery Low active X2 6 Com Status LOAD ON INV Common X2 5 NC Load not On Inverter X2 4 NO Load on Inverter active X2 3 Com Alarm MAINS OK Common X2 2 NC Mains Failure X2 1 NO Mains Present CASTELL INTERFACE X1 X1 2 230Vac EXT MAN BYP Castell Interlock Function X11 N Ei External Manual Bypass closed 230VAC 2AT Figure 7 3 Dry port connection details UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 67 Uninterruptible Power Supplies Ltd T Options A KOHLER COMPANY Remote shutdown emergency stop option On a standard UPS the remote shutdown function is disabled and if this option is required it must be activated by a hardware code on the SETUP SERVICE menu Please contact your distributor to enable this operation Remote shutdown UPS Remote Shutdown Port The remote shutdown facility comprises a normally closed
44. Powerm Supplies Ltd A KOHLER COMPANY 8 3 6 Environmental data Environmental data 100 kVA UPS Module Audible noise at 100 50 load dBA TBA Ambient temperature UPS C 0 to 40 Storage temperature UPS C 25 to 40 Ambient temperature Batteries C 20 recommended Relative air humidity Max 95 non condensing Max altitude above sea level m 1000m 3300ft without de rating Heat dissipation with 100 non linear W 4500 load per module ETUR EN 62040 1 1 2003 15359 Airflow 25 30 C with non linear m h 1200 load per module EN 62040 1 1 2003 Dissipation at no load W 660 8 4 Standards Standards 100 kVA UPS Module Safety EN 62040 1 1 Electromagnetic compatibility EN 62040 2 Emission class C2 Immunity class C3 Performance EN62040 3 Product certification CE Degree of protection IP 20 76 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14
45. Y FAILURE b The BATTERY led on the module mimic should change to permanent green c The module control panel mimic indications should be as shown here LINE 2 BY PASS LOAD LINE 1 INVERTER E BATTERY LINE 2 BY PASS LOAD LINE 1 INVERTER E BATTERY LINE 2 BY PASS LOAD LINE 1 INVERTER EE BATTERY Key Point If this is a new modules the module s configuration data can be entered at this point e g Set P Time Date Module ID etc This requires access to a password protected menu area and must be carried out only by an approved engineer then releasing them a The UPS module will start up over about 60 seconds b The module control panel display will indicate LOAD DISCONNECTED PARALLEL SW OPEN c The module control panel mimic indications should be as shown here LINE 2 BY PASS _ LOAD LINE 1 INVERTER m BATTERY 56 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 4 Operating Procedures 2T 28 29 30 On the UPS module control panel LINE 2 a Press the UP key once to access the menu system Em b Use the UP DOWN keys to move the cursor so that it is adjacent to COMMANDS and then press the ENTER key DINE 1 EN c Use the UP DOWN keys to move the curs
46. abinets item 13 in Figure 2 10 The parallel adapter board contains a DIP switch SW2 2 and two ribbon connectors JD5 amp JD6 3 Set DIP switch SW2 2 on each parallel adaptor board according to the position of the UPS cabinet in the parallel configuration as shown in Figure 3 14 if there is only one cabinet set the switch selection to Single Cabinet 4 Connecta parallel bus cable between PORT JD6 of UPS cabinet 1 and PORT JD5 of UPS cabinet 2 parallel adaptor 5 Connecta parallel bus cable between PORT JD6 of UPS cabinet 2 and PORT JD5 of UPS cabinet 3 parallel adaptor 6 Continue with the above steps until a parallel bus cable is connected to all modules as shown in Figure 3 14 Oo QO oO Parallel configuration DIP switch selection DIP Switch SW1 9 on the UPS customer interface board item 12 in Figure 2 10 must be set to indicate the position of the cabinet in the parallel chain The three options are First cabinet Middle cabinet there may be several middle cabinets Last cabinet UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 43 Uninterruptible Power Supplies Ltd 3 Installation and Set up A KOHLER COMPANY In each cabinet set Switch SW1 9 according to the table below SW1 9 Single Cabinet First Cabinet Middle Cabinet Last Cabinet 1 OFF OFF OFF OFF 2 OFF OFF OFF OFF 3 OFF OFF OFF OFF 4 OFF OFF OFF OFF 5
47. al damage caused by the application of electrical power to this equipment before it has been fully commissioned 3 2 Taking receipt of the UPS The UPS Modules UPS Cabinet Batteries Battery Cabinets and accessories are packaged and delivered on purpose designed pallets that are easy to off load and move using a forklift or suitable pallet jack CAUTION Observe the following precautions when off loading and moving the UPS e Always keep the packages in an upright position Do not drop the equipment Due to the high energy batteries involved and heavy weight do not stack the pallets The packing container protects the UPS from mechanical and environmental damage during transit This protection is further increased by wrapping the PowerWave 9500 UPS with a plastic sheet Upon receiving the UPS you should carefully examine the packing container for any sign of physical damage The external TILTWATCH FRAGILE and ARROW indicator should be intact if the equipment has been correctly transported in an upright position If the packaging has been ruptured in transit or if the Tip amp Tel indicator is suspect inform both the carrier and Uninterruptible Power Supplies Ltd immediately shipping damage claims must be filed immediately when found and the carrier must be informed within a maximum of 7 days following receipt of the equipment If shipping damage is discovered store all packing materials for further investigation i CAUT
48. als Bypass Line AC DC PFC RECTIFIER DC BOOST CONVERTER DC AC INVERTER UPS Mains UPS AC Input Output STATIC SWITCH Automatic Batt Switch BATT CHARGER BATTERY Figure 2 3 UPS OFF Bypass Line AC DC PFC DC BOOST DC AC RECTIFIER CONVERTER INVERTER UPS Mains UPS AC Input Output STATIC SWITCH Automatic JO Batt Switch 6 BATT CHARGER BATTERY Figure 2 4 UPS ON LINE Bypass Line AC DC PFC RECTIFIER DC BOOST CONVERTER DC AC INVERTER UPS AC Output STATIC SWITCH Automatic Batt Switch BATT CHARGER BATTERY Figure 2 5 UPS ON BATTERY UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 7 2 General Description Uninterruptible Power Supplies Ltd A KOHLER COMPANY UPS ON BYPASS Mode This mode can be selected by the operator as part of the system operating procedure It is also entered following certain fault occurrences such as a UPS Bypass Line AC DC PFC RECTIFIER CONVERTER INVERTER DC BOOST DC AC output overload UPS Mains d UPS AC The load is connected to the raw mains input Input Output supply through the bypass arm of the static FERET STATIC utomatic 49 Switch Batt Switch b SWITCH The rectifier and inverter remain powered up and operational in readiness to be brought into use BATTERY When operating in this mode the
49. and alarms are indicated with their date and time of appearance Measurements menu screen 10 11 12 13 DESCRIPTION Battery Runtime UPS Output Frequency Bypass Frequency Battery Voltage Battery Charger Current Battery Discharge Current Rectifier Input Voltage all three phases Bypass Input Voltage all three phases Output Voltage all three phases Output Current all three phases Active Output Power all three phases Reactive Output Power all three phases Apparent Output Power all three phases LCD DISPLAY gei BS 16 8e i4 32 LOAD TO INWY aa BS 16 65 i4 32 2 LOAD TOBY LCD DISPLAY BATT RUM TIME MIM Bah Berm OUTPUT FREQUENCY HZ E EHE BATTERY VOLTAGE v 5 65 6 6 BATT CHARGE CUR iA 8 8 0 5 mm DISCHARGE CURRENT CA3 E BE RECTIFIER VOLTAGE v3 BES Bee Bee BYPASS VOLTAGE W Bee pic Ei QUTFPUT VOLTAGE EWI aaa gaa ABE OUTPUT CURRENT AGG a a go na E ACTIVE POHER CEBM2 REACTIVE POHER ks Fir 2 APPARENT POWER KYA UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 17 2 General Description Uninterruptible Supplies Ltd uw KOHLER COMPANY 14 Output Power all three phases 15 Battery capacity 16 Rectifier Input Voltage all three phases Commands m
50. arances shown are required to permit the necessary cooling air flow irrespective of whether top or bottom cable entry is used 30 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 3 Installation and Set up BATTERY CABINET UPS CABINET X 200 mm Y 1500 mm Z 100 mm TOP 400 mm BATTERY UPS CABINET CABINET Figure 3 2 Clearances Battery installation It is recommended that the battery is installed in a purpose designed battery cabinet s positioned adjacent to the UPS cabinet The external battery cabinet can be placed on either side of the UPS unit but it is recommended to install it on the right hand side If the batteries are to be mounted on external battery racks rather than cabinet mounted the battery must be sized to take into account the voltage drop between the battery and UPS Contact your local office or manufacturer s authorized agent for installation advice and support if necessary 3 6 Planning the installation cabling considerations 3 6 1 General requirements The information in this section should help with the preparation and planning of the UPS power cabling It is the customer s responsibility to provide all external fuses isolators and cables that are used to connect the UPS input and output power supplies The UPS input and bypass terminals should be connected to
51. ars on top This item displays the full set of measurements for each functional block of the UPS detailed below Command In this menu the user can change the operating mode of the UPS Once the command is executed the user is immediately directed to the mimic diagram where the new status of the UPS is indicated detailed below D Ups Data Gives information regarding the identity of the UPS module detailed below User Enables the adjustment of data such as date and time automatic battery test etc detailed below F Service This password protect facility enables the service technician to adjust several UPS parameters detailed below Figure 2 19 Home display screen Measures UPS Measurements Output Voltage V Output Current A Output Frequency Hz Output Power 96 Active Power KW Reactive Power kVAr Apparent Power kVA Inverter Voltage V Bypass Voltage V Bypass Frequency Hz Rectifier Voltage V Booster Temperature C Inverter Temperature C Ude Gain Ude Gain Battery Measurements Temperature C Discharge Current A Charge Current A Voltage V Run Time Capacity 24 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 2 General Description Commands Available commands Load to inverter Load to bypass Battery test Deep battery test Abort battery test Perform alarm test
52. ble F Battery Cabinet UPS CABINET 1 500 kW Fuse A Cable A Max Input Cable D Nom output Fuse E Cable E Agl CB mm current mm current Agl CB mm 3x800A 5x 2x240 835A 5x 2x240 725A Bespoke Bespoke or or 5x 3x120 5x 3x120 Recommended values only Battery fuses and cabling are bespoke to the installation Figure 3 6 Single input supply with separate batteries UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 3 Installation and Set up Uninterruptible Supplies Ltd ta KOHLER COMPANY Cable C UPS AC Fuse C Output BYPASS Input Cable D Cable B E use RECTIFIER Input i Load Fuse F Cable F Battery Cabinet a Fuse F Cable F Battery Cabinet Cle Fuse F Cable F Battery Cabinet E Fuse F Cable F Battery Cabinet E Fuse F Cable F UPS CABINET 1 500 kW Battery Cabinet E Ratings for fully populated cabinet 500 kW Cable B Max Rect Fuse C Cable Max Bypass Cable Nom output Fuse E Cable E i Agl CB mm current Agl CB mm input current mm current Agl CB mm 3x800A 5x 2x240 835A 3x800A 4x 2x240 732A 5x 2x240 725A Bespoke Bespoke or or or 5x 3x120 4x 3x120 5x 3x120 Recommended
53. boost converter into a sinusoidal AC output voltage suitable for connecting to the load In addition to providing output voltage regulation the inverter control logic also provides various levels of overload protection frequency regulation and synchronisation and output voltage error detection Static switch The static switch provides a means of connecting the UPS AC output terminals to either the inverter or the bypass line which is connected directly to the raw UPS mains input supply The static switch control logic will automatically transfer the load from the inverter to the bypass supply in the event of an overload or UPS inverter malfunction A no break transfer will take place if the inverter frequency and the bypass supply frequency is synchronised 6 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 2 General Description Automatic battery switch If UPS mains input supply fails the battery is automatically connected to the input of the DC boost converter by means of an electronically controlled switch This enables the inverter to continue its normal operation and maintain the UPS output load supply from battery power 2 3 2 UPS Module operational states UPS OFF Figure 2 3 shows the internal operation of the UPS module when the inverter is turned OFF from the module control panel If the mains input supply is still available the
54. c Selectthe Load to bypass command The system control panel mimic indicates the load on bypass see Figure 2 18 e The module control panel will display LOAD NOT PROTECTED f The module control panel mimic indications should be as shown here EEE BATTERY 2 Close the maintenance bypass switch IA1 in ALL cabinets LINE 2 BY PASS a The module control panel will display MANUAL BYP IS CLOSED b The system control panel mimic should show the system on LOAD LINE 1 INVERTER maintenance bypass see Figure 2 18 a mi c The module control panel mimic indications should be as shown here EHE BATTERY Note The system is now operating in the maintenance bypass mode with the UPS modules running but totally off line If you want to shut down any or all the modules continue with the procedure as follows To power down a UPS module 3 Turn OFF the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them a The module control panel will display LOAD OFF and SUPPLY LOAD FAILURE LINE 1 INVERTER b The module control panel mimic indications should be as shown here EEE BATTERY 4 nthe UPS cabinet open the module s bypass isolator F3 LINE 2 BY PASS a The BATTERY led on the module mimic should change to flashing green ee ee ee LOAD b The module control panel mimic indications should be as shown here LIN
55. ce board 2 7 UPS Module control panel 2 7 1 Operator keys 2 7 2 Module mimic leds 2 7 3 Power Management display 2 8 System control panel 2 8 1 Display header bar 2 8 2 Mimic Diagram system level 2 8 3 Module selection screen 2 8 4 Home screen 2 9 Warranty 2 9 1 Extended warranty 2 9 2 Additional service maintenance support 2 10 Extended Service enquiry form Installation and Set up 3 1 Introduction 3 2 Taking receipt of the UPS 3 2 1 Site transportation 3 3 Unpacking the equipment 3 4 Storage 3 5 Planning the installation site and environmental considerations U NNa o 1000 A A 10 11 13 14 14 14 16 19 20 21 22 24 26 26 26 27 28 28 28 28 29 30 30 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 6 Planning the installation cabling considerations 31 3 6 1 General requirements 31 3 6 2 Cable and fuse sizing 32 3 6 3 Power cable terminations 37 3 6 4 Parallel cabinet cabling recommendations 39 3 7 UPS Cabling procedure 40 3 7 1 Connecting the UPS input cables 40 3 7 2 Connecting the UPS output cables 41 3 7 3 Connecting the battery cables 41 3 8 Multi cabinet parallel control cabling and configuration 42 3 8 1 Connecting the parallel communication bus cables 43 3 8 2 Connecting the multidrop cables 44 3 8 3 Module customer interface facilities 45 Operating Procedures 46 4 1 Introductio
56. cessary WARNING When working inside the UPS cabinet there is a risk of exposure to potentially lethal AC and DC voltages During a preventative maintenance inspection the field service engineer will check the following Site environment conditions Integrity of electrical installation Cooling airflow Rectifier operation and calibration Inverter operation and calibration Static switch operation Battery status Load characteristics Integrity of alarm and monitoring systems Operation of all installed options Key Point Preventative maintenance inspections form an integral part of all Extended Warranty Agreements maintenance contracts offered by Uninterruptible Power Supplies Ltd For further details on Extended Warranty Agreements see page 27 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 61 5 Maintenance Uninterruptible Power Supplies Ltd A KOHLER COMPANY 5 4 Battery maintenance The battery maintenance shall be done by an authorized Service Partner Batteries contain dangerous substances that can harm the environment An batteries removed from the system must be disposed of in a safe manner in accordance with local regulations If in doubt call qualified national and local organizations for battery disposal and recycling 5 5 Battery testing The battery test which can be performed from the system control panel takes approximately three minutes t
57. circuit connected between terminal X3 3 and X3 4 on the customer interface card located on the PowerWave 9500 front frame see Figure 7 4 7X33 If this option is used it is recommended that a terminal Terminal block block with linking facilities is installed between the UPS and the remote emergency stop button as shown in order to allow the removal maintenance or testing of the remote emergency stop circuit without disturbing the normal UPS operation 1 Use a screened cable with a single pair 0 5 mm to Figure 7 4 Remote emergency stop cabling 1 5 mm and maximum length of 100m 2 Connect the cable as shown in Figure 7 4 this case the standard remote shutdown option is disabled and the remote shutdown emergency stop operation must be designed into the external building facilities system and include a means of opening the bypass path when operated P Key Point In a single module installation the UPS is provided with an automatic emergency bypass facility In Generator ON facilities The generator ON facility must use a normally open contact which closes when a standby generator is running and supplying the UPS input power This volt free switched input can be used to inhibit the static bypass and battery charger whilst the UPS is being from the generator Generator Alarm Panel UPS Generator Port X3 12 1 Use a screened cable with a single pair 0 5 mm
58. cted in parallel With five UPS modules installed in all six cabinets the PowerWave 9500 parallel system can ultimately operate as a 3 MW 5x6x500 KW parallel system In order to enable such a complex system to operate correctly a parallel communication bus is connected to each UPS module s electronic control system as illustrated in Figure 2 7 to ensure that The UPS modules are always frequency synchronised to each other and the bypass supply when present The UPS modules equally share the load current The static bypass operation is synchronised such that for example if the operator selects Bypass mode the static switch in ALL the modules change over in unison To UPS CABINET 3 UPS Module 05 UPS Module 10 UPSModule04 1 UPS Module 09 UPS Module 08 UPS Module 01 UPS CABINET 1 UPS CABINET 2 Figure 2 7 Parallel system control UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 9 2 General Description Uninterruptible Power Supplies Ltd A KOHLER COMPANY System expansion Some UPS applications present a low initial power requirement which increases over time as the application grows and it is therefore essential that the installed UPS system can be expanded to meet the growing demand without compromising the existing load This situation is easily managed by a PowerWave 9500 system which allows further 100 kW UPS modules to be added to the system without having
59. d 100 mm 4 in at each side of the UPS to allow adequate airflow from the ventilation fans The UPS is must be installed in a sheltered and controlled environment away from direct sunlight The operating temperature should be between 0 C and 40 C ideally in the range 20 C to 25 C with a maximum relative humidity of 9596 non condensing Before installing the equipment you must check to ensure that the UPS input voltage stated on the UPS data plate on the back of the unit matches your local utility supply voltage The UPS warranty will be rendered void and the manufacturer reserves the right to refuse replacement or compensation in the following events Accidental damage to the UPS Ingress of liquids or foreign bodies Damage or malfunction due to installing the UPS in an environment that fail to meet the conditions specified in this manual Damage or malfunction due to improper installation configuration or maintenance carried out by an unauthorised person 1 4 Storage instructions If you intend to store the UPS for an extended period in a moderate climate the batteries should be charged for 12 hours every 6 months by connecting the UPS to the utility supply If the ambient temperature at the storage location is above 30 C this should be carried out every 2 months 2 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 1 Safety 1 5 Ter
60. display MANUAL BYP IS CLOSED c The system control panel mimic should show the system on maintenance bypass see Figure 2 18 d The module control panel mimic indications should be as shown here 5 Ensure that the BYPASS LED is green on ALL UPS module control panels 6 Open the maintenance bypass switch IA1 in all UPS cabinets a The module control panel will display MANUAL BYPASS OPEN followed by LOAD NOT PROTECTED b Thered INVERTER LED will extinguish c The module control panel mimic indications should be as shown here 7 On ANY UPS module control panel a Press the UP key once to access the menu system b Use the UP DOWN keys to move the cursor so that it is adjacent to COMMANDS and then press the ENTER key c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key d The module control panel will display LOAD PROTECTED e The module control panel mimic indications should be as shown here LINE 2 BY PASS LOAD INVERTER EES BATTERY BY PASS LINE 1 LINE 2 LOAD INVERTER EEE BATTERY BY PASS LINE 1 LINE 2 LINE 1 LOAD INVERTER m BATTERY BY PASS LOAD INVERTER z2 r EEN BATTERY L T Note This completes the procedure The UPS is now operating in On Line mode and supply protected load power 52 UPS740 01 00 PowerWave PW9500DPA User Manual Issu
61. e 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 Operating Procedures 4 6 UPS module replacement 4 6 1 General information WARNING This procedure must be carried out by a trained engineer or service agent approved by UPS Ltd WARNING The UPS sub modules weigh up to 54 kg and require at least two persons to lift safely WARNING When removing a sub module from the cabinet withdraw it sufficiently to disconnect it from its power connectors then wait 5 minutes to allow its internal DC capacitors to discharge before fully extracting it from the cabinet PPP Each UPS module comprises an active and a passive sub module and although these sub modules are not operationally matched if a UPS develops a fault it is usual to replace both sub modules together Within the UPS cabinet the sub modules are mounted on rails with the passive sub module located immediately below the active module and secured in place by four screws attached through the modules facia plate When a module is removed from the cabinet a blanking plate must be fitted to the front of the cabinet using the same four screw fixing to ensure that the airflow to the remaining working modules is not degraded The sub modules plug into electrical connectors fixed on the back of the cabinet mounting rack and when inserting a module into the cabinet you must ensure that it is firmly pushed fully home to engage the connecto
62. e prescribed ambient temperature is 20 C to 25 C An ambient temperature of 20 C is recommended to achieve a long battery life c Any specified cooling air flow must be available The air entering the UPS must not exceed 40 C d The air conditioning system must be able to provide a sufficient amount of cooling air to keep the room within the prescribed temperature range 4 The following environmental conditions should also be considered a Local fire protection standards must be respected b The location must be free of dust and corrosive explosive gases c The location must be vibration free UPS cabinet installation 1 If the UPS is located in bayed enclosures partition walls must be installed 2 Before moving the UPS to its final position carry out any necessary pre installation cabling power and control to ensure that full cable access is available once the UPS is placed in situ Top or bottom cable access is permitted 3 The available space must permit the minimum cabinet clearances shown below Note When several UPS cabinets and or battery cabinets are installed they can be positioned immediately adjacent to each other without leaving a gap between them However due to the cabinet s door furniture if the partition or wall at the end of the cabinet suite extends beyond the front of the cabinet a space of 100mm must be provided between the cabinet and the wall in order to allow the cabinet door to fully open The rear and top cle
63. enai ataa iaae Model Ne eeror a a Rating KVA eite t Re PEE reaa ERR C Replacement Batteries eeciseeseee entente innen C Others derem arn ranean eter ERR UE aE Ei deen ste please specify Thank you for your enquiry which will receive our prompt attention If you need to contact us immediately call free on Freefone 0800 731 3269 or E mail us on service upspower co uk www upspower co uk UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 27 3 Installation and Set up Uninterruptible Supplies Ltd ta KOHLER COMPANY Installation and Set up 3 4 Introduction This chapter contains essential information concerning the safe unpacking positioning installing and cabling of the PowerWave 9500 UPS system WARNING All cabling operations must be supervised by an authorised electrician or other suitably A qualified person All installation and operating procedures must be carried out in strict accordance with the instructions contained in this manual Uninterruptible Power Supplies Ltd will take no responsibility for any personal injury or material damage caused by the incorrect installation cabling or operation of this product WARNING Once the UPS equipment is installed it must be commissioned by an engineer approved by Uninterruptible Power Supplies Ltd before it is powered up Uninterruptible Power Supplies Ltd will take no responsibility for any personal injury or materi
64. entified in the Module selection screen as described in paragraph 2 8 3 Proceed as follows 1 Silence the audible alarm by pressing the RESET button 2 Identify the cause of the alarm condition by means of the events register in the main menu See paragraph 2 7 3 3 If the alarm event is shown in the table in Chapter 6 2 follow the actions provided in that table If the event is not shown in the table or you have any doubts as to how to carry out the instructions given then please contact Uninterruptible Power Supplies Ltd on 0800 731 3269 At the UPS module level Fault events are displayed in date time order on the module control panel as described in paragraph 2 7 3 To access the module control panel events log 1 Press the UP key once to access the menu system 2 Usethe UP DOWN keys to move the cursor so that it is adjacent to EVENTS 3 Press the ENTER key 4 Step through the logged events up to 64 using the UP DOWN keys and make a separate note of each alarm condition as this will assist in identifying any problems UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 63 6 Troubleshooting Uninterruptible Power Supplies Ltd A KOHLER COMPANY 6 2 Fault identification and rectification The interpretation and suggested solutions for the major alarm condition that you are most likely to encounter are shown in the table below If the encountered alarm is not shown in the table or
65. enu screen OUTPUT POHER c33 BATT CAPACITY 3 RECTIFIER VOLTAGE v BEE BEE Bee 1 Transfer Load to inverter 2 Transfer Load to bypass 3 Battery Test UPS Data menu screen gt LOAD TO INVERTER LOAD TO BYPASS gt LOAD TO BYPASS PERFORM BATT TEST gt PERFORM BATT TEST 1 These general UPS Data are installed at the manufacturing plant 2 Manufacturing date 3 EPROM Version 4 Actual Date and Time Set Up Service menu screen UPS SER TAL HUMBER nm Tnmnnn DATE OF RAMU AC TURE 15 83 09 EPROM YERS ITOH VE DATE TIME cici Tim esed hhmm SS 1 This Menu is reserved for authorized service engineers only 2 Type in password gt SET UP SERVICE FRSSIH RTI gt PhRSSH RD 18 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 2 General Description Set up User menu screen DESCRIPTION LCD DISPLAY 1 Set up language SET LANGUAGE SET DATE AND TIME ENGL ISH FRANCAIS POLISH 2 Set up Date and Time gt SET UP DATE TIME SET UF BATT TEST Dn Mh 7 HH PhPhH 252 3 Set up battery test gt SET UP BATT TEST SET UP GEM SET OPER DAY OF MONTH 1 315 HOUF OF DAY Ce REPETITIVE YAM BES 4 Setup operation with Gen Set Libia il Palris BATT C
66. er data 100 kVA UPS Module Nominal input voltage V 3x380 220V N 3x400V 230V N 3x415 240V N Three phases Neutral and Earth required Input voltage tolerance V 23 to 1596 for 100 load ref to 3x400 230V for loads in 96 30 to 15 for 80 load 40 to 15 for 60 load Input frequency Hz 35 90 nominal 50 Input power factor PF 0 99 100 load Inrush current lt 100 of rated current limited by soft start Input distortion THDI lt 3 5 100 load Max input current with rated output A 152 power and charged battery output p f 1 0 Max input current with rated output A 167 power and discharged battery output p f 1 0 8 3 3 Battery data Battery data external Technology VRLA vented lead acid NiCd Number of 12V blocks even and odd 380 220V or 400 230V output 40 to 50 415 240V output 42 to 50 Charger capability each module A 60 0 Ripple current rms lt 2 0 Floating voltage VDC 2 25 VLRA 1 4 NiCd End of discharge voltage VDC 1 65 VLRA 1 05 NiCd Temperature compensation Standard Battery test Automatic and periodic selectable Max input current with rated output A 167 power and discharged battery output p f 1 0 74 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 8 Specification 8 3
67. face board as shown in Figure 7 1 which enables various external monitoring and control applications to be connected to the UPS system to satisfy particular site requirements These interfaces are described below Two leds are located on the customer interface board to indicate its status The green led indicates the UPS cabinet s master slave status flashing twice sec interface is master 1st cabinet of a parallel system flashing once sec Interface is slave 2nd 5th cabinet of a parallel system Thered indicates a board malfunction and possible replacement required 7 1 2 Serial RS 232 USB Computer interface JD1 amp USB Smart Port JD1 is a standard 9 pin D Type female socket which provides an intelligent RS 232 serial port that enables the UPS to be connected to a computer When used in conjunction with the optional WAVEMON software this port allows the connected computer to continuously monitor the input mains voltage and UPS status and display a message in the event of any UPS system changes The USB port adjacent to JD1 is effectively in parallel with JD1 and provides an alternative means of connecting to a computer Figure 7 2 shows the cable wiring suitable for PC s with a 9 pin or 25 pin serial port respectively Note that the maximum length for the interconnecting RS232 cable is 15m 9 Pin D Type Male 9 Pin D Type Female Interface Cable Interface Cable UPS end Computer end 9 Pin D Type 2
68. g are shown in vertical columns representing each UPS cabinet This diagram illustrates the display for a fully populated 4 cabinet system Module 12 for example represents the module on the second rack from the bottom of cabinet 3 Figure 2 17 Module selection display screen 22 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd Ww KOHLER COMPANY 2 General Description Module System operational status mimic When a UPS module level screen is accessed it s display is similar to the default system level screen except that the mimic display and metering refers specifically to the selected UPS module Module System ON LINE This is the normal mimic indications for a standard On Line UPS 1 The rectifier and inverter are working normally 2 The battery is charging 3 The parallel switch is closed and connecting the UPS output to the load 4 The bypass line is live and available Module System ON BYPASS This is the normal mimic indications if the UPS is operating in ECO mode In the case of a standard On Line UPS it indicates that either the UPS has a fault overload which has transferred its output to the bypass or the number of off line modules has exceeded the system redundancy The rectifier is working normally The battery is charging The inverter is turned OFF The pa
69. hem The module control panel will display LOAD OFF and SUPPLY FAILURE The module control panel mimic indications should be as shown here LINE 2 BY PASS LOAD LINE 1 INVERTER m BATTERY UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 55 4 Operating Procedures Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 19 20 21 22 Open the module s parallel switch 1A2 a TheLCD display will now indicate LOAD OFF SUPPLY FAILURE In the UPS cabinet open the module s bypass isolator F3 a The BATTERY led on the module mimic should change to flashing green b The module control panel mimic indications should be as shown here Open the module s bypass isolator F2 a The UPS module is now fully powered down Remove the UPS sub modules from the cabinet in accordance with the guidance in paragraph 4 6 1 Fitting the module 23 Fitthe UPS sub modules to the cabinet in accordance with the guidance in paragraph 4 6 1 24 25 26 Turn ON the UPS module by pressing both ON OFF buttons simultaneously Close the module s fused bypass isolator F2 a The UPS mimic panel LINE 1 LED will be permanent green b The BATTERY LED will be flashing green c TheLCD display will indicate LOAD OFF SUPPLY FAILURE In the UPS cabinet close the module s bypass isolator F3 a The module control panel display will indicate LOAD OFF SUPPL
70. ices should be posted to prevent any inadvertent operation of the UPS mains supply isolators 5 Before you connect the UPS input cables ensure that the customer provided fuses and cables are suitably rated in accordance with the prescribed IEC standards or local regulations e g BS7671 2008 see figures 3 4 to 3 7 6 Once the electrical installation is completed the UPS must be commissioned by an engineer authorised by the manufacturer before it is brought into use A WARNING Do not apply electrical power to the UPS before it has been commissioned 7 When installing the UPS cables ensure that the connection procedures are performed under the following conditions a No mains voltage is present at the UPS mains bypass distribution board terminals b Allloads are shut down and disconnected at the load distribution board c The UPS is fully shut down and voltage free d The UPS maintenance bypass isolator IA1 is open OFF e The UPS modules parallel switches IA2 are open OFF 3 7 1 Connecting the UPS input cables 1 Gain access to the UPS power connection busbars by removing the covers in the right hand UPS Cabinet 2 Connectthe earth cable from the mains distribution board to the protective earth PE busbar as shown in Figure 3 8 to Figure 3 11 Single Input Feed 3 Refer to the schematic drawing and connection table in Figure 3 8 common battery system or Figure 3 9 separate battery system 4 Connect the UPS input supp
71. inet can be rated up to 500 kW in 100 kW increments UPS Module 05 E UPS Module UPS Module 04 een ees Active sub module UPS Module 03 See eee Passive sub module e UPS Module 02 EE UPS Module 01 feme eats Figure 2 1 PowerWave 9500 System hardware Each UPS module comprises two sub modules one is known as the Active sub module and the other as the Passive sub module These are mounted in the UPS cabinet in pairs with the Active sub module located on top of the Passive sub module The first module to be installed in the cabinet must be fitted to the bottom position with subsequent modules fitted in the next lowest available space Each module is assigned an ID number when it is installed in the cabinet to allow it to be identified by the system control logic for purposes such as monitoring and event logging etc The modules fitted in the first cabinet should be identified as illustrated in Figure 2 1 In a multi cabinet installation the modules in the second cabinet are given an identity 06 to 10 those in the third cabinet are given 11 to 15 and so on The following table shows the static parameters for each configuration 1 Module 2 Module 3 Module 4 Module 5 Module System power rating per cabinet KVA KW 100 200 300 400 500 Cabinet weight including modules kg 539 648 757 866 975 Cabinet weight without fitted modules
72. ive input supply from a standby generator which starts automatically following a mains supply failure Where this is implemented the batteries discharge for a short period only until the generator comes on line which not only avoids the UPS shutting down due to discharged batteries but also increases the battery life cycle During ON LINE operation if the UPS experiences an internal fault the inverter is turned off and the static switch transfers the load to the bypass line Figure 2 6 automatically and without interruption transfer time 0 provided the inverter and bypass supplies are synchronised In the event of an output overload the inverter can still supply the load for a limited time depending on the severity of the overload and if the permitted time is exceeded the UPS will then switch to bypass If the output overload condition clears while running on bypass the static switch will re transfer the load back to the inverter and the UPS will return to its normal ON LINE mode of operation Off line On stand by UPS system operation When the PowerWave 9500 is used as an off line UPS it is normally operated in its ON BYPASS mode Figure 2 6 with the load supplied via the bypass line However the rectifier DC boost converter and battery charger are still powered up and maintain battery charging and the inverter section is turned on and operating on standby In the event of a bypass supply failure the inverter is immediately brought
73. kg 430 Cabinet dimensions w x h x d mm 1580 x 1975 x 940 Heat dissipation 100 linear load W 4500 9000 13500 18000 22500 Heat dissipation 10096 linear load BTU 15395 30717 46076 61434 76793 Heat dissipation 10096 non linear load W 5710 11420 17130 22840 28550 Heat dissipation 10096 non linear load BTU 19488 38976 58465 77953 97441 Heat dissipation no load W 660 1320 1980 2640 3300 Acoustic noise 1m TBA Cooling airflow 25 C 30 C at full load m s 1200 2400 3600 4800 6000 Installation clearances mm Front 1500 Side 100 Rear 200 Top 400 UPS Module weight Active sub module 55 kg Passive sub module 54 kg UPS Module dimensions w x h x d mm Active amp Passive modules 710 x 178 x 750 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 5 Uninterruptible Power Supplies Ltd 2 General Description KOHLER COMPANY 2 3 Functional description of operation This section describes A block diagram level description of the individual UPS module internal operation see paragraph 2 3 1 The various UPS module operational states see paragraph 2 3 2 UPS system operation On line versus Off line system operation see paragraph 2 3 3 Multi module system operation and paralleling considerations see paragraph 2 3 4 2 3 1 UPS Module internal operation Bypass Line AC DC PFC RECTIFIER DC BOOST CONVERTER DC AC
74. le s operating parameters during troubleshooting and commissioning and monitor the module s input output battery supply values during normal operation Power Management Display PMD Module ON OFF control keys Menu navigation amp selection keys Mimic LED indicators Alarm amp Reset Figure 2 11 UPS Module control panel 2 7 4 Operator keys FUNCTION Used to switch on or switch off the UPS module Both keys must be pressed simultaneously Scroll upwards through a displayed menu Scroll downwards through a displayed menu Cancels the audible alarm If the alarm condition was transient the ALARM LED will also extinguish otherwise it will remain ON red Confirms selects a chosen menu item ON OFF Start up and shutdown buttons The UPS module can be switched ON or OFF by simultaneously pressing both ON OFF keys on the control panel This is to prevent accidental UPS start up or shutdown 2 7 2 Module mimic leds Mimic LED indicators The mimic diagram indicates the status of the module s power flow and changes colour between Green and Red and OFF to indicate the UPS operating conditions The UPS operating modes are described in paragraph 2 3 2 14 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description LED Indication summary Indicator Indicator Status Interpretation LINE 1
75. ly cables to busbars 1L1 1L2 1L3 and 1N on the UPS terminal block Ensure correct clockwise phase rotation A CAUTION The input Neutral cable must be unswitched and permanently connected 5 Secure the cables to the fixing rail located beneath the connection busbars Dual Input Feed 6 Referto the schematic drawing and connection table in Figure 3 10 common battery system or Figure 3 11 separate battery system 7 Connect the UPS mains input rectifier supply cables to busbars 1 L1 1 L2 1 L3 and N Ensure correct clockwise phase rotation 8 Connectthe UPS bypass input supply cables to terminals 2 L1 2 L2 2 L3 and N Ensure correct clockwise phase rotation 40 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 3 Installation and Set up A CAUTION The input and bypass Neutral cables must be unswitched and permanently connected 9 Connect the earth cable from the bypass mains distribution board to the protective earth PE busbar 10 Connect the earth cable from the bypass mains distribution board to the protective earth PE busbar 11 Secure the cables to the fixing rail located beneath the connection busbars 3 7 2 Connecting the UPS output cables It is recommended that a separate load distribution board is provided for the load Before you begin connecting the UPS output cables to the load distribution board Check that the po
76. ly functional and operating in its On Line mode and supplying protected load power 60 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 5 Maintenance 5 Maintenance 5 1 Introduction WARNING The procedures described in this chapter must be performed by an authorised electrician who has received the appropriate level of training on this UPS system As there are no user serviceable parts contained within the UPS the maintenance requirements are minimal 5 2 User responsibilities In order to obtain the best performance and reliability from the UPS system daily checks should be carried out to ensure that the environment in which the UPS operates is kept cool dry and dust free at all times Any active alarm or status indication that indicates that the UPS is not functioning correctly should be dealt with immediately when found by referring to the troubleshooting chapter of this manual or contacting the manufacture s service desk 5 3 Routine maintenance When the UPS is commissioned the commissioning field service engineer will attach a service record book to the front of the UPS which will be used to log the full service history of the UPS To ensure optimum UPS operation and continuous efficient protection of the connected load we recommend that the system s operating parameters are checked every six months and recalibrated where ne
77. mains are not The UPS input supply frequency is outside operational limits synchronised and the UPS static bypass has been temporarily disabled BATTERY IM DISCHARGE Battery is near end of autonomy Shutdown the load connected to UPS before the UPS Switches itself off to protect its batteries MANUAL BYP IS CLOSED WMaintenance bypass closed This alarm is only displayed if the UPS is on maintenance Load is being supplied by raw mains bypass 6 3 Contacting service Uninterruptible Power Supplies Limited has a service department dedicated to providing routine maintenance and emergency service cover for your UPS If you have any queries regarding your UPS please contact us Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Business Park Hook Hampshire RG27 9XA Tel 01256 386700 0800 731 3269 24 Hr Fax 01256 386701 Email service upspower co uk For peace of mind we recommend that you protect your UPS with an extended warranty agreement which will ensure that your UPS system and batteries are well maintained and running at their optimum efficiency and attended to promptly should any problems occur see page 27 for details 64 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 7 Options Options 7 14 Customer interface options e 9 1 a e 9 2 e o o Aa o
78. minology The following terms are used in this manual to described various UPS system configurations Active sub module UPS Module or Passive sub module Single Module System UPS Module 05 UPS Module 04 Parallel UPS System or Multi module System UPS Module 03 UPS Module 02 Fully populated PW9500 cabinet containing UPS Module 01 5 x UPS Modules operating in parallel Cabinet 1 Cabinet 2 Cabinet 3 4 5 Cabinet 6 Multi cabinet System Up to six PW9500 cabinets can be connected in or parallel to effectively offer a multi module system Parallel Cabinet System containing up to 30 6x5 parallel UPS Modules UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 3 Uninterruptible Powerm Supplies Ltd 2 General Description KOHLER COMPANY 2 General Description 2 4 Introduction Congratulations on your purchase of the PowerWave 9500 UPS Continuous power availability is essential in today s dynamic IT and process related work environments It is equally important that any installed power protection system is sufficiently resilient and adaptable to handle inevitable changes brought about by the introduction of new server technologies migration and centralization Such demands are well met by the PowerWave 9500 UPS system which provides the foundation for continuous power availability of network critical infrastructures both in enterprise data centres where business contin
79. n 46 4 1 1 Operating procedure summary 46 4 1 2 This chapter contains the following operating procedures 46 4 2 Initial system power up and functional testing 47 4 3 Total system shutdown 50 4 4 Load transfer from inverter to maintenance bypass 51 4 5 Load transfer from maintenance bypass to inverter 52 4 6 UPS module replacement 53 4 6 1 General information 53 4 6 2 Replacing a module in a single module UPS system 53 4 6 3 Replacing a module in a redundant parallel module system 55 4 6 4 Replacing a module in a capacity parallel module system 57 Maintenance 61 5 1 Introduction 61 5 2 User responsibilities 61 5 3 Routine maintenance 61 5 4 Battery maintenance 62 5 5 Battery testing 62 5 5 1 Battery test procedure 62 Troubleshooting 63 6 1 Fault and alarm indications 63 6 2 Fault identification and rectification 64 6 3 Contacting service 64 Options 65 7 1 Customer interface options 65 7 1 1 Introduction 66 7 1 2 Serial RS 232 USB Computer interface JD1 amp USB Smart Port 66 7 1 3 Dry ports customer interface X2 X3 66 7 1 4 RS485 Interface for multidrop JR2 68 7 1 5 RS485 Interface for remote panel JR3 68 7 1 6 SNMP Card slots 69 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 7 2 UPS Monitoring and automated control software 7 2 1 7 2 2 7 2 3 7 2 4 7 2 5 Specification The importance of UPS management WAV
80. ns both at system level and by selecting an individual module from it s module selection screen and obtaining the module s operating parameters a O0 Oc Note This completes the initial system start up and functional check procedure The UPS is now operating on line and providing processed and backed up power to the load UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 49 4 Operating Procedures Uninterruptible Supplies Ltd ta KOHLER COMPANY 4 3 Total system shutdown This procedure can be used to completely shut down the UPS system and remove load power if it is not required for a significant period data has been backed up and the load equipment has been shut down in a controlled manner prior to losing its WARNING This procedure will totally disconnect load power Before you continue ensure that any critical A operating power Verify that the loads are shut down 2 Open the UPS cabinet s output supply fuses breakers at the load distribution panel 3 Turn OFF each UPS module in sequence by pressing both ON OFF buttons LINE 2 BY PASS simultaneously then releasing them a The module control panel will display LOAD OFF and SUPPLY LOAD FAILURE LINE 1 INVERTER b The module control panel mimic indications should be as shown here ENE BATTERY 4 Open the battery fuses breaker in the battery cabinet rack Tem ane 5 a The BATTERY led on the m
81. o complete and can be carried out independently of the operation mode OFF LINE or ON LINE and whether or not the load is connected P Key Point The load is always protected during the battery test procedure The battery test should be performed only if there are no alarm conditions the battery is fully charged UPS utility mains supply is present 5 5 1 Battery test procedure 1 Before initiating the battery test ensure that a There are no alarm conditions present b The battery is fully charged c The UPS utility mains supply is present On the system control panel a Press the HOME icon to access the HOME screen b From the HOME screen press the Commands icon to access the Commands screen c From the Commands screen select Battery test Refer to Set up User menu screen on page 19 for battery test set up details 62 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 6 Troubleshooting 6 Troubleshooting 6 4 Fault and alarm indications At the system control panel If a system fault occurs the audible alarm will sound and the Warning symbol will appear in the system control panel header bar as shown in Figure 2 15 Pressing the warning symbol will silence the audible warning and present the detected problem on the Events screen If the fault relates to a particular UPS module the faulty module will be id
82. ocedures contained in Chapter 3 WARNING This UPS does not contain any user serviceable parts If the UPS develops a fault it must be repaired by a trained engineer You run risk of exposure to dangerous voltages if you open UPS covers Uninterruptible Power Supplies Ltd will assume no responsibility or liability for accidents or injuries due to incorrect operation or manipulation of the UPS or peripheral equipment WARNING The UPS and peripheral equipment must be installed by a suitably qualified engineer who is aware In a domestic environment the UPS may cause radio interference and the user may be required to undertake CAUTION The PowerWave 9500 is a Class A UPS product according to EN 62040 3 additional measures UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 1 Uninterruptible Power Supplies Ltd q1 Safety A KOHLER COMPANY 1 3 Important safety notes A CAUTION Please read the following notes carefully prior to installation The PowerWave 9500 UPS contains components that carry high current and voltages and must be installed by a suitably qualified service specialist The UPS does not contain any user serviceable parts so if it malfunctions it must be serviced or repaired by a trained engineer To prevent the UPS from overheating the UPS ventilation grills must be kept free of obstructions at all times A space of at least 200 mm 8 in should be provided at the back of the UPS an
83. odule control panel mimic should change LOAD from permanent to flashing green paa INVERTER b The module control panel mimic indications should be as shown here BATTERY Open the UPS cabinet s input bypass supply fuses breakers at the input distribution board 7 Inthe UPS cabinet s open the bypass isolator F2 and parallel isolator IA2 for every module Note This completes the procedure The UPS is now powered down and its input and output terminals are volt free WARNING If you intend to work inside the UPS cabinet wait for 5 minutes to allow the internal capacitors to discharge before you remove any internal panel 50 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 4 Operating Procedures 4 4 Load transfer from inverter to maintenance bypass It may be necessary to transfer the load to the maintenance bypass supply to perform certain service or maintenance operations for example when replacing a module in a single module system CAUTION Warn the critical load user that the load will not be supplied with processed backed up power when the UPS is operating on maintenance bypass 1 Transfer the load to bypass using the commands function on the system LINE 2 BY PASS control panel on the UPS cabinet door RR nn ERR a Access the HOME screen LOAD b Press the COMMANDS icon quus INVERTER
84. on line and the load is transferred from the bypass line to the inverter by the static switch within 3 to 5 milliseconds If the UPS bypass and mains inputs are connected to separate switchboards and the mains supply is still live when the transfer takes place then the UPS will operate in its ON LINE mode Figure 2 4 However these supplies are connected to a common source the UPS will immediately revert to its ON BATTERY mode Figure 2 5 When the bypass supply returns to normal the load is re transferred back to the bypass line and the inverter returns to its standby operation UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 2 General Description Operating in this mode is slightly more energy efficient than operating in the on line mode due to the reduced rectifier and inverter losses during normal system operation and it is sometimes referred to as the ECO economy mode However this mode is recommended only if the connected load equipment can tolerate power interruptions of up to 3 5 ms during the transfer period A WARNING The ON LINE mode should always be used for critical load protection 2 3 4 Parallel system operation Inter module parallel control The power outputs from all the modules in a UPS cabinet are connected in parallel at the cabinet s output terminals furthermore the outputs from up to six cabinets can themselves be conne
85. ons LOAD OFF put SLIPPL FAILURE 4 The UPS module is not supplying load LORD DISCONNECTED FS PARALLEL SHITCH OPEN Note On the right hand side of the LCD there is a 2 digit indicator defining the module s position in a multi module system The maximum number of modules in a parallel system is five Main menu screen DESCRIPTION LCD DISPLAY 1 Alog of the last 64 events is stored in the Power Management Display gt EVENT LOG see page 17 MEASUREMENTS 2 Allows monitoring of voltages power frequencies currents autonomy etc gt MEASUREMENTS see page 17 COMMANDS 3 Enables the commands Load to inverter Load to bypass and battery test gt COMMANDS to be executed see page 18 UPS DATA 4 Allows the UPS personalized information such as serial number to be OPRANA NR entered see page 18 SETUP USER 5 Allows user to set up Date Time automatic battery test etc see page 19 r uc E 6 Password protected area for service engineer use only see page 19 gt SET UP SERVICE 1 6 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description Event log menu screen DESCRIPTION Logging Control a log of the last 64 events is stored in the power management display Every stored event is identified with a sequential number and time stamp All events
86. or so that it is adjacent to LOAD TO INVERTER and then press the ENTER key d The module control panel will display LOAD PROTECTED e The module control panel mimic indications should be as shown here Turn OFF the UPS module by pressing both ON OFF buttons simultaneously LINE 2 then releasing them a The module control panel will display LOAD OFF and SUPPLY FAILURE LINE 1 b The module control panel mimic indications should be as shown here Close the module s parallel switch A2 and check that PARALLEL SW CLOSED status appears on the module control panel BY PASS LOAD INVERTER ES BATTERY BY PASS LOAD INVERTER EEE BATTERY Turn ON the UPS module by pressing both ON OFF buttons simultaneously then releasing them a The module will restart automatically and run in parallel with other on line modules b The module control panel should indicate LOAD PROTECTED Note This completes the procedure The UPS system is now fully functional and operating in its On Line mode and supplying protected load power 4 6 4 Replacing a module in a capacity parallel module system If a UPS module fails in a capacity parallel system there will be insufficient capacity in the remaining modules to supply the load and they will all transfer to bypass mode and continue to supply the load via their raw static bypass mains supply For the majority of detected failures the faulty module will shut down in a
87. ous damage can still occur It is important therefore that the installed UPS software will react automatically in such a case and shut down the supplied system in a safe and controlled manner Uninterruptible Power Supplies Ltd considers it important to have a complete solution for its UPS systems and offers its customers a number of remote control and monitoring tools to provide optimum protection Two monitoring system options are available for use with the PowerWave 9500 UPS system SNMP monitoring software The SNMP adapter described above requires a PC with terminal connections and for normal operation at least one Ethernet network connection It also requires that the network operating system in use is SNMP compatible Uninterruptible Power Supplies Ltd offer suitable monitoring software with SNMP functionality for NetWare OS 2 all Windows NT systems on INTEL and ALPHA network platforms UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 69 Uninterruptible Supplies Ltd ta T Options KOHLER COMPANY WAVEMON UPS monitoring and control software WAVEMON is designed to operate in conjunction with many of the systems supplied by Uninterruptible Power Supplies Ltd and features both UPS monitoring and automatic UPS server shutdown facilities The system comprises a bespoke software package which is installed on a local PC and communicates with the UPS over a standard RS232 cable of up to 15m in length
88. put with a common battery Common input with individual batteries Dual input with a common battery Dual input with individual batteries See page 37 for a more detailed description and wiring details for each cabinet configuration UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 11 Uninterruptible Supplies Ltd La 2 General Description KOHLER company UPS AC Output Y 1A1 F2 Utility Mains Input Pd F3 Battery d UPS CABINET UPS AC Output BYPASS Input RECTIFIER Input i Load 2 Battery is UPS CABINET Figure 2 9 Common and Dual input supply configurations 1 2 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description 2 6 Customer interface board A customer interface board fitted in the right hand side of each UPS cabinet provides a means of connecting the cabinet to a range of external monitoring and control facilities It also allows the connection of the communications bus between the individual UPS cabinets in a multi cabinet installation which is required to effect its parallel control operation The external monitoring and control facilities available for use in conjunction with the interface board are described in the Options chapter of this manual oo
89. rWave 9500 is available in two input power configurations as illustrated in Figure 2 9 The top diagram shows a common input configuration where the UPS mains input is internally connected to both the rectifier input and the bypass line the lower diagram shows a dual input configuration where separate supplies are connected to the rectifier and bypass circuits Note that in both configurations the fused isolator F2 is connected to the UPS module s bypass line only The parallel switch IA2 is connected between the UPS module output and the UPS cabinet output In a parallel system this switch can be used to isolate a UPS module from the remaining the working modules for testing or during module replacement IA2 is also used as part of the module s start up procedure The maintenance bypass isolator IA1 can provide an alternative load power source if it is necessary to power down the UPS cabinet An interlock on this isolator sends all connected modules to static bypass when it is switched ON 10 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 2 General Description For Module 5 E Module Control Panel 1 per UPS Module System Control Panel located on front of door Only fitted to one cabinet in a parallel cabinet system oc IA1 Maintenance B
90. rallel switch is closed and connecting the UPS output to the bypass supply unprotected raw mains PUN Module System ON MAINTENANCE BYPASS This mimic indicates that the maintenance bypass isolator is closed and the UPS output is connected to the bypass supply through both the maintenance and static bypass lines in parallel The rectifier is working normally The battery is charging The Inverter is turned OFF The parallel switch is shown closed At the module level if the module s output isolator is now opened the UPS module is totally isolated from the UPS output and can be replaced or serviced without affecting the rest of the UPS system BONA Figure 2 18 Operational status mimic display UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 23 2 General Description Uninterruptible Supplies Ltd ta KOHLER COMPANY 2 8 4 Home screen The home screen which is accessed by pressing the HOME icon on the display header bar on any screen item A in Figure 2 15 contains six icons that provide access to various control and set up function screen A Events B Measures dd mm yy hh mm ss ae Load protected P 01 Nees Evonts Measures Commands Ups Data Service Displays a list of recently occurred events with date time event name description and sequential ID number It is possible to order the events and as default the most recent appe
91. rs A control panel cable is connected to JD7 on the back of the passive sub module This connector is most easily accessed when the passive sub module is inserted into the UPS cabinet by about 6096 and the active sub module is totally withdrawn A CAUTION Do not attempt to fully withdraw the passive sub module without first disconnecting JD7 4 6 2 Replacing a module in a single module UPS system Removing the module 1 Transfer the load to bypass using the commands function on the system control panel on the UPS cabinet door Note If the UPS is operating in ECO mode or shut down due to a fault it will already be on bypass and you can skip this step a Access the HOME screen LINE 2 BY PASS b Press the COMMANDS icon RR N c Selectthe Load to bypass command LOAD d The system control panel mimic indicates the load on bypass see pasi INVERTER Figure 2 18 e The module control panel display will indicate LOAD NOT PROTECTED f The module control panel mimic indications should be as shown here BATTERY UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 53 Uninterruptible Powerm Supplies Ltd 4 Operating Procedures KOHLER COMPANY 2 Close the maintenance bypass switch IA1 LINE 2 BY PASS a The LCD display will now indicate MANUAL BYP IS CLOSED R b The system control panel mimic
92. s are open OFF Check that the parallel configuration DIP switches are set correctly in all cabinets see paragraph 3 8 Starting the UPS modules 1 Close the UPS cabinet s input bypass supply fuses or breakers at the distribution board and the module s fused bypass isolator F2 ON UPS module 1 Close the module s fused bypass isolator F2 a The UPS mimic panel LINE 1 LED will be permanent green b The BATTERY LED will be flashing green LOAD c The LCD display will indicate LOAD OFF SUPPLY FAILURE NE INVERTER LINE 2 BY PASS E BATTERY this point e g Set Time Date Module ID etc This requires access to a password protected menu area and must be carried out only by an approved engineer P Key Point During commissioning the commissioning engineer can set up the module s configuration data at Turn ON the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them a The UPS module will power up over approximately 60 seconds LOAD b Initially LINE 2 LED will be red then change to green puce INVERTER c The module control panel will display LOAD DISCONNECTED and PARALLEL SW OPEN d The module control panel mimic indications should be as shown here BATTERY On the module control panel LINE 2 BY PASS a Press the UP key once to access the menu system b Use the UP DOWN keys to move the cursor so
93. should change to flashing green CO LOAD b The module control panel mimic indications should be as shown here LINE 1 INVERTER 35 Open the module s fused bypass isolator F2 a The faulty module is now fully powered down E BATTERY 36 Remove the UPS sub modules from the cabinet in accordance with the guidance in paragraph 4 6 1 Fitting the module 37 Fitthe UPS sub modules into the cabinet in accordance with the guidance in paragraph 4 6 1 38 In the UPS cabinet close the module s fused bypass isolator F2 a The UPS mimic panel LINE 1 LED will be permanent green b The BATTERY LED will be flashing green LOAD c The LCD display will indicate LOAD OFF SUPPLY FAILURE LINE T TENEN LINE 2 BY PASS E BATTERY 39 In the UPS cabinet close the module s bypass isolator F3 LINE 2 BY PASS a The module control panel display will indicate LOAD OFF SUPPLY FAILURE LOAD b The BATTERY led on the module mimic should change to permanent gn INVERTER green c The module control panel mimic indications should be as shown here EE BATTERY Time Date Module ID etc P Key Point If this is a new modules the module s configuration data can be entered at this point e g Set This requires access to a password protected menu area and must be carried out only by an approved engineer 58 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01
94. sometimes known as an N 1 system System wide load transfer operation In a parallel system all the UPS modules must be in the same output state at all times i e it is not permissible for one module to be operating in the ON LINE mode with the remaining modules in ON BYPASS In the PowerWave 9500 system the load transfer between inverter and bypass supplies is manually controlled from the System Control Panel mounted on the UPS cabinet door which sends a load transfer request to every UPS module in all cabinets simultaneously via the parallel communications bus shown above Note If a UPS module internally generates a load transfer command for example due to an overload the command is similarly sent to all the modules via the parallel control bus to ensure that they ALL transfer their outputs together 2 4 PowerWave 9500 User controls This section describes the switches and control panels illustrated in Figure 2 8 that are used to operate and monitor the PowerWave 9500 UPS system 2 5 Powerisolators Each UPS module has three associated power isolators located in the right hand cabinet In order to make system expansion straightforward all the isolators shown are fitted to the cabinet as standard even if the cabinet is not initially fully populated This allows additional modules to be inserted into a vacant cabinet slot without needing to shut down the system to carry out additional mechanical or cabling work The Powe
95. ss Maintenance bypass opened Parallel switch is closed Position ON Default condition with single UPS Parallel switch is opened Position OFF Figure 2 16 System level mimic display screen Three meters are included on the mimic display screen to indicate the rectifier inverter bypass and load voltage frequency and current The displayed battery parameters include the battery temperature and remaining autonomy time The meter display sources are selected by pressing lightly on the associated interactive block on the mimic display UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 21 Uninterruptible Supplies Ltd uw 2 General Description KOHLER COMPANY 2 8 3 Module selection screen The module selection screen is accessed by pressing the MODULE SELECTION icon on the display header bar item F in Figure 2 15 On opening the screen displays an icon for every UPS module connected to the system in all cabinets and indicates their operating status through the colour coding shown in Figure 2 17 Touching a module icon provides access the status and measurements navigation screen for the selected module dd mm yy hh mm ss A Black Module in normal operation B White Module inactive switched OFF C Red Module has a general alarm The UPS modules which are identified numerically by the ID number entered into the module s configuration set up during commissionin
96. stallation and Set up 3 8 3 Module customer interface facilities Each UPS cabinet is fitted with a customer interface board which enables various external monitoring and control applications to be connected to the system to satisfy particular site requirements Details of the interface facilities and available options are provided in Chapter 7 P Key Point All used options should be installed and connected prior to commissioning the UPS so that they can be functionally checked as part of the commissioning procedure Slot for optional Modem Ethernet card ONLY Slot for optional SNMP card ONLY Sub D9 female connector RS232 User interface UPS system to computer Standard USB interface UPS system to computer 2 LEDs that indicate the interface board status RJ45 Port RS485 communication for remote panel Module selection used by multidrop configuration RJ45 Port RS485 communication for multidrop cable connected between all the UPS cabinets Used with RJ45 splitter adapter to enable module daisy chaining Terminal block used for external customer inputs Terminal block with volt free outputs for use with customer remote indications panel Castell interlock function 9 pole configuration DIP switch used to configure module for parallel operation Parallel comm
97. t to fit the batteries complete the battery wiring or close the battery A commissioning engineer To protect personnel during the battery installation ensure that the connections are performed under the following conditions a No mains voltage is present at the UPS mains bypass distribution board terminals b All loads are shut down and disconnected at the load distribution board c The UPS is fully shut down and voltage free d The UPS and battery cabinet power connection terminals are voltage free e The UPS maintenance bypass isolator IA1 is open OFF f The UPS modules parallel switches IA2 are open OFF Check that the battery fuses and cables are suitably rated Battery fuse and cable ratings are bespoke to the installation Figure 3 4 to Figure 3 7 show recommended values only Q UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 41 Uninterruptible Supplies Ltd ta 3 Installation and Set up KOHLER COMPANY Note there are two methods of battery connection within the UPS cabinet depending on whether the UPS cabinet is configured to be used with a common or separate battery installation Both forms of connection are shown in Figure 3 8 to Figure 3 11 2 Ensure that the fused isolators and or circuit breakers in the external battery cabinet or racks are open 3 Connectthe protective earth cable PE between the UPS cabinet and external battery cabinet 4
98. tential full load does not exceed the UPS output power rating OUTPUT POWER on the UPS nameplate Ensure the circuit breakers on the load distribution board are correctly sized with respect to the load rating and associated cabling Ensure that the maximum total load rating and maximum load rating of each individual load socket is indicated on the load distribution board The circuit breakers must comply with the prescribed IEC Standards e g BS7671 2008 1 Gain access to the UPS power connection busbars by removing the covers in the right hand UPS Cabinet if fitted 2 Connectthe protective earth cable from the load distribution board to the protective earth PE busbar in the UPS 3 Connect the UPS output supply cables to busbars 3 L1 3 L2 3 L3 and N Ensure correct clockwise phase rotation A CAUTION The output Neutral cable must ALWAYS be connected 4 Secure the cables to the fixing rail located beneath the connection busbars 5 Ensure the output cables are securely connected to the correct power terminals on the load distribution board 3 7 8 Connecting the battery cables Battery installation must be carried out by competent personnel isolators before the system has been commissioned WARNING This procedure must be carried out by or under the supervision of an approved UPS WARNING The final assembly and connection of the battery installation must be carried out by the A commissioning engineer Do not attemp
99. ter then monitors the UPS operating parameters and outputs its data in SNMP format to the connected network In a multi module UPS system the SNMP interface can communicate system wide data or data for an individual UPS module The SNMP adaptor requires a PC with terminal connections and for normal operation at least one network connection Ethernet is also required Internal SNMP Card JL EM BEE S SNMP MONITOR Figure 7 6 SNMP Internal and external adapters 7 2 UPS Monitoring and automated control software 7 2 1 The importance of UPS management The utility supply is inevitably unreliable every now and then and assuring continuous power to all the facilities connected to it can be a difficult task The situation is further complicated if worldwide systems are managed via a Local Area Network LAN or Wide Area Network WAN However by using the PowerWave 9500 UPS system in conjunction with purpose designed network management tools a systems administrator can take measures to back up data and prevent system errors or data loss even in the event of a relatively long utility supply outage In the case of an abnormal utility supply suitable UPS management software will also enable a system administrator to monitor all concerned networks from a central point and identify bottlenecks at an early stage In spite of extensive system monitoring if an administrator fails to intervene in a timely manner seri
100. th common battery UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 33 Uninterruptible Supplies Ltd ta 3 Installation and Set up KOHLER COMPANY Cable C UPS AC Fuse C Output BYPASS Input Cable D Cable B T use RECTIFIER Input i Load ut Cable E Fuse E Common Battery Cabinet UPS CABINET 1 500 kW Ratings for fully populated cabinet 500 kW Fuse B Cable B Max Rect Fuse C Cable C MaxBypass CableD Nom output Fuse E Cable E Agl CB mm current Agl CB mm input current mm current Agl CB mm 3x800A 5x 2x240 835A 3x800A 4x 2x240 732A 5x 2x240 725A Bespoke Bespoke or or or 5x 3x120 4x 3x120 5x 3x120 Recommended values only Battery fuses and cabling are bespoke to the installation Figure 3 5 Dual input supply with common battery 34 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd Ea 3 Installation and Set up A KOHLER COMPANY UPS AC Output IA1 Cable D Common Fuse B Mains Input Cable B Cable F Battery Cabinet Cle Fuse F Cable F Battery Cabinet Ces Fuse F Cable F Battery Cabinet Clee Fuse F Cable F Battery Cabinet E Fuse F Ca
101. that it is adjacent to LOAD COMMANDS and then press the ENTER key puit Mission c Usethe UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key d The UPS module output should transfer to inverter and the module control panel mimic indications should be as shown here E BATTERY UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 47 Uninterruptible Power Supplies Ltd 4 Operating Procedures KOHLER company 5 Scroll through the measurements menu and check that the module s input and output supply indications are correct Repeat steps 2 to 5 for all the other modules in the system in ALL UPS cabinets and ensure that every module is in the state shown above before continuing with this procedure 7 Check the battery voltage and polarity at the live side of the battery fuses breaker located in the external battery cabinet or adjacent to the battery rack with the fuses breaker still open 8 Check the cabling between the UPS cabinet and battery cabinet or rack to determine that it is safe to connect the battery 9 Close the battery fuses breaker in the battery cabinet rack 10 In the UPS cabinet s close the battery isolator F3 for every module a The BATTERY led on the module control panel mimic should change from flashing to permanent green Testing the parallel function 11 Check that the UPS output fuses breakers are open OFF
102. tible with all optional modules like UPSDIALER SNMP adaptors temperature sensors etc 70 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY T Options 7 2 3 Functional description WAVEMON is a client server software application for networks and local workstations In general it consists of two parts the server module of the UPS management software is UPSMAN which communicates with the UPS via an RS232 USB interface Running as a background application UPSMAN collects and interprets the messages received from the UPS and places them at the disposal of the client module UPSMON as well as any connected SNMP based instrumentation and control system If UPSMAN detects voltage variations or a power failure it can execute various system event routines by means of which for example the server is switched off or a warning is sent to the connected users These system event routines are a part of the management software and can be configured in accordance with local application requirements The software of your PowerWave 9500 UPS unit can be integrated into a network in two ways 1 Bythe server which is supplied by the UPS itself and has been integrated into the network In most cases this server is used as a sub agent and you only need the WAVEMON software without an SNMP adapter You will also need to establish an RS232 USB connection between the
103. tions where failure or malfunction of the product can be reasonably expected to cause failure of the life support device or to significantly affect it s safety or effectiveness applications concerned with direct patient care Uninterruptible Power Supplies Ltd will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to Uninterruptible Power Supplies Ltd that therisks of injury or damage have been minimized the customer assumes all such risks the liability of Uninterruptible Power Supplies Ltd is adequately protected under the circumstances CAUTION The UPS contains batteries that must be re charged for a minimum of 12 hours every six months at 20 to prevent deep discharging Batteries that have been deep discharged for whatever reason are not covered by this warranty 2 9 1 Extended warranty The standard warranty may be enhanced by protecting the UPS with an extended warranty agreement maintenance contract An extended warranty agreement enhances the standard warranty by providing the following regular preventative maintenance inspections guaranteed speed of response to operational problems 24 hour telephone support fully comprehensive cover excluding batteries and capacitors Contact the Service Support Hotline on 0800 731 3269 for further details 2 9 2 Additional service maintenance support In addition to providing support for the
104. to shut down or disturb the load in any way modules before installing the next cabinet For example if it is known at the outset that the eventual load is likely to exceed 500 KW it makes sense to install and cable up two UPS cabinets and distribute the initially required number of modules between the two P Key Point When planning a multi cabinet system it is not necessary to fully populate one cabinet with UPS Capacity system When a system is described as a Capacity system it implies that the potential full load requires ALL the paralleled UPS modules to be operational i e if one UPS module trips off line due to a fault the remaining modules will transfer the load to the bypass supply Redundant system If a system is designed with module redundancy it must contain at least one UPS module over and above that necessary to power the applied load For example a PowerWave 9500 cabinet containing three 100 kW modules could be employed as a redundant system for a load of up to 200 kW Under normal circumstances all three module share the load equally with each one supplying up to 67 kW but if one module fails or is taken off line the remaining two modules can sustain the full rated load by each providing 100 kW The ability to lose one module yet still supply the rated load with processed backed up power significantly increases the overall system reliability Note A parallel system operating with a redundant module is
105. uity has paramount importance and in process control environments where manufacturing continuity is essential Reliability and quality standards The PowerWave 9500 UPS incorporates the latest technological developments in power engineering Representing a completely new generation of high power three phase UPS systems its advanced double conversion VFI Voltage and Frequency Independent topology responds fully to both the highest availability and environmentally friendly requirements compliant with IEC 62040 3 VFI SS 111 standards Uninterruptible Power Supplies Ltd specialises in the installation and maintenance of Uninterruptible Power Systems and this powerful UPS is just one example of our wide range of state of the art power protection devices that will provide your critical equipment with a steady and reliable power supply for many years Key features High reliability upgrade ability low operating costs and excellent electrical performance are just some of the highlights of this advanced UPS system Other key features include Decentralised Parallel Architecture DPA Each UPS module contains its own bypass circuit which greatly improves the overall system reliability by removing a common point of failure that is often present in more traditional UPS systems Truly modular design The PowerWave 9500 is designed around 100 kW rated UPS modules e System expandability Each PowerWave 9500 cabinet can contain up to five
106. unication bus connector Used in parallel cabinet system only and fitted with parallel adapter board to enable module daisy chaining 9 1 e cl Q D 1 MODEM 2 2 SNMP e 3 JD1 LS 3 4 USB T 4 5 LEDs 6 6 JR3 j 8 7 DIPSW 8 JR2 H9 9 x3 10 10 X2 11 X1 12 SW1 9 i 11 13 JD8 12 6 9 Figure 3 15 UPS Customer interface board connectors UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 45 4 Operating Procedures Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 4 Operating Procedures 4 4 Introduction The PowerWave 9500 UPS system must be commissioned by a fully trained field service engineer authorised by Uninterruptible Power Supplies Ltd before it is put into use The commissioning engineer will Connect the UPS batteries Check the UPS electrical installation and operating environment Check the UPS cabinet paralleling configuration settings e Check the installation of any optional equipment Perform a controlled UPS start up and functionally test the system for correct operation and configuration Carry out customer operator training and equipment handover WARNING Uninterruptible Power Supplies Ltd accepts no responsibility for the equipment or the safety of any A personnel when operating this equipment before it has been properly commissioned The manufacturer s warranty is immediately invalidated if power
107. values only Battery fuses and cabling are bespoke to the installation Figure 3 7 Dual input supply with separate batteries 36 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 3 Installation and Set up 3 6 3 Power cable terminations All input output battery electrical power connections are made to busbars located in the UPS cabinet right hand side Cables should be fitted with M12 ring terminations and tightened to 84 8 Nm M8 for separate battery cables 3D View 000000000 r2 000000000 Top View PE 1 L1 1 L2 1 L3 Mains Connect UPS Connect Input To Output To 3 L1 Phase L1 1 L1 Phase L1 3 L1 3 L2 Phase L2 1 L2 Phase L2 3 L2 3 L3 5 Y TPP Phase L3 1 L3 Phase L3 3 L3 Batt F F F 9 3 g 9 7 9 Neutral N Neutral N Batt Earth PE Earth PE TTTTTTTTT Figure 3 8 Single input with common battery 000000000 3D View Front View gt 999690909 000000000 e n e ji Top View PE 1 L1 1 L2 1 L3 3 L1 3 L2 3 L3 FETE Battery connected to each module s battery circuit breaker Figure 3 9 Single input with separate batteries UPS740 01 00 PowerWave PW9500DPA User
108. vel Figure 2 15 Navigation and status header bar 20 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd ta KOHLER COVPANY 2 General Description 2 8 2 Mimic Diagram system level The system level mimic diagram is the default screen and shows the power flow through the UPS system and indications of its operating status in either single cabinet or multi cabinet configuration This screen can be accessed from any other screen by pressing the MIMIC icon in the display header The functional status of each block is identified by its line colour as shown below in Figure 2 16 and the green connecting lines indicate the power flow in the system A Rectifier Green Red B Inverter Green Red C Bypass Green Red D Battery Green Yellow Red E Maintenance Yellow Bypass Isolator IA1 White F parallel switch IA2 Green White dd mm yy hh mm ss System Status A rectifier inverter Ubatt 528 0 V Temp 20 0 C Time 15 min Rectifier is on Rectifier is switched off Load is on inverter Inverter is switched off Load is on bypass or the system is operating in eco mode Bypass is switched off Battery is charging or discharging the direction of flow is indicated by the adjacent green arrowheads Battery is not charging nor discharging Battery is in fault condition or is discharged Load is on maintenance bypa
109. xceed 90 RH non condensing 3 3 Unpacking the equipment Unpacking the UPS cabinet Figure 3 1 UPS Cabinet packaging If the cabinet is shipped inside a wooden case remove the screws at the base and sides of the case then carefully remove the case from the equipment pallet Cut away and remove any outer cardboard wrapper to expose the polythene wrapped UPS cabinet as shown above Carefully remove the plastic sheeting covering the UPS together with the cardboard edge protector strips Remove the anchor bolts securing the cabinet to the pallet then remove the UPS from the pallet Retain the packaging materials for possible future shipment of the UPS Further examine the UPS for signs of damage and notify your supplier immediately if any damage is found NOAN Check that the details on the UPS nameplate corresponds to the purchased material mentioned in the delivery note The rating specifications can be found on a nameplate located inside the UPS door UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 29 Uninterruptible Powerm Supplies Ltd 3 Installation and Set up A KOHLER COMPANY 3 4 Storage UPS Cabinet If you plan to store the UPS cabinet prior to use it should be stored in the original packing and shipping carton in a clean dry environment with a temperature between 5 C to 40 C and RH lt 90 If the packing container is removed you must take measures to protect the UPS from dust
110. y see Figure 3 5 Single input supply with separate batteries see Figure 3 6 Dual input supply with separate batteries see Figure 3 7 The following diagrams provide information concerning the UPS external fuse and cable size requirements Key Point The information in figures 3 4 to 3 7 is given for guidance only P Fuse and cable size recommendations are to IEC 60950 1 2001 All external fuses isolators and power cables must be rated and installed in accordance with the prescribed IEC standards or local regulation e g BS7671 2008 External DC cables and battery fuses are bespoke to the installation 32 UPS740 01 00 PowerWave PW9500DPA User Manual Issue 1 0 Dated 01 05 14 Uninterruptible Supplies Ltd Ea A KOHLER COMPANY 3 Installation and Set up Ratings for fully populated cabinet 500 kW Common Fuse A UPS AC Output Mains Input Cable E Cable A Fuse E Common Battery Cabinet UPS CABINET 1 500 kW Cable D I Load Fuse A Agl CB Cable A mm Max Input current Cable D mm Nom output current Fuse E Agl CB Cable E mm 3 x 800A 5x 2x240 or 5x 3x120 835A 5x 2x240 or 5x 3x120 725A Bespoke Bespoke Recommended values only Battery fuses and cabling are bespoke to the installation Figure 3 4 Common input supply wi
111. you have any doubts as to how to safely carry out the instructions given then please contact Uninterruptible Power Supplies Ltd on 0800 731 3269 ALARM CONDITION MEANING SUGGESTED SOLUTION UPS FAULT There is a fault in the UPS and therefore Call an authorised service centre for assistance normal operation cannot be guaranteed MAINS BYPRECT FAULT Mains power supply is outside The UPS input power is low or missing prescribed tolerance If site power appears to be OK check the UPS input supply fuses breaker at the distribution board OUTPUT SHORT There is a short circuit at the output of Check all output connections and repair as required UPS on the load side OVERLOAD Load exceeds the UPS rated power Identify which load item is causing the overload and disconnect repair it Do not connect extraneous laser printers photocopiers electric heaters kettles etc to the UPS if near capacity OVER TEMPERA TURE UPS temperature has exceeded the Check the UPS ambient temperature is less than 30 C allowed value If the ambient temperature is normal call an authorised service centre for assistance BATTERY CHARGER OFF The attached battery and the battery Call an authorised service centre for assistance charger set up do not correspond or there is a battery charger fault INVERTER FAULT Inverter is faulty Call an authorised service centre for assistance SYNCHRON FAUL T The inverter and
112. ypass Isolator Interface board For Module3 m Lie For Module 2 IA2 Parallel switch F3 Fused battery isolator F2 Fused bypass isolator For Module 1 Figure 2 8 Power fuses and isolators F3 is a fused isolator connected in the battery power line This line must also be fused externally normally within the external battery cabinet The PowerWave 9500 can be supplied ready cabled for one of two battery configurations In the case of a common battery configuration all the battery isolators shown are connected to a common battery busbar which is then connected externally to a single battery supply Alternatively the cabinet can be supplied with an individual battery configuration whereby each battery isolator is connected externally to a separate dedicated battery As a common battery system exhibits a point of common failure that is avoided in an individual battery system a UPS system configured with individual batteries is always recommended for critical load applications 2 5 1 PowerWave 9500 cabinet power configurations The UPS cabinet s input supply and battery connection configurations are fixed at the time of manufacture and cannot be changed on site When ordering a UPS it is important that the configuration is stipulated as either Common in

740-01-00 PW9500DPA User Manual Issue 1.0.book

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