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725-02-02 PW1000 4.5-10 kVA User Manual UK.book

1. 3 Installation and Set up A KOHLER COMPANY 3 4 Rack configuration set up BI 1 x Adjustable mounting rail Left B2 1 x Adjustable mounting rail Right B3 2 x Adapter plate BA 2x Rack mounting handle B5 12 x Captive nuts B6 8x Dome head bolts B7 4x Countersunk bolts Figure 3 5 UPS Rack mounting kit The PowerWave 1000 UPS and battery enclosure s can be installed in a standard 19 inch rack and can be either shelf mounted or installed on adjustable mounting rails that are provided as part of the rack installation kit If the batteries are housed in a separate enclosure it should be mounted on an adjacent shelf in the same rack using same procedure as mounting the UPS The two enclosures are then later connected together using the supplied interconnecting cable CAUTION When rack mounting the equipment always install it at the bottom of the cabinet with the battery enclosure installed below the UPS enclosure or e Shelf mounting Adjustable mounting rails Figure 3 6 Rack mounting options 3 4 1 Installing the adjustable mounting rails The adjustable mounting rail kit contains a pair of mounting rails left and right handed that are fitted to each side of the cabinet and secured by two screws front and back The rails can be extended to any length between 543 mm and 925 mm and are compatible with most standard 19 inch rack assemblies of 600 mm to 900 mm depth 22 UPS725 02 02 PowerWave 1000 4 5 10 kVA User
2. UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 33 Uninterruptible Power Supplies Ltd 3 Installation and Set up A KOHLER company 3 Leave the modules in this state for at least 4 hours to fully charge the batteries then turn on each module in turn following the instructions given in paragraph 5 1 Troubleshooting other fault codes that might appear Er I amp Output parameters setting error Cause One or more parameter settings conflict between each module Solution Check the parameter settings are identical in each module as per paragraph 3 7 1 Er 17 Conflicting ID Number Cause parallel system Two or more modules have the same parallel ID number Solution single module Change the modules ID settings so that they are not duplicated paragraph 3 7 3 Cause single module Parallel function is deselected but module ID number is not d0 Solution single module Change the module ID number to db I see page 29 E dl Incorrect operating mode selected Cause UPS module is selected to ECO or frequency changer mode Solution Set the UPS operating mode to nor normal E 08 DC Bus high level abnormal Cause UPS output voltages not within 1V of each other when run individually Solution Recalibrate UPS output voltages paragraph 3 7 2 Cause Improper installation or parallel communications failure Solution Check parallel settings paragraph 3 7 3 and cable c
3. In built computer interfaces 1 x RS 232 1 x USB Optional plug in interface cards SNMP Card Modbus Card Relay Card Compatible operating systems Windows Unix and derivatives OS 2 Novell AppleOS 58 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 9 Specification Accessories External bypass External battery module Output distribution 19 in rack mounting rails Temperature C Operating 0 40 Storage 0 45 Maximum altitude above sea level 0 2000m up to 40 C 3000m up to 35 C Humidity 0 90 non condensing Sound level 50 dBA 1m Heat dissipation approx 450W 500W 600W 700 Dimensions WxHxD mm 440x88x680 440x132x680 19 rack mounting space 2U 3U x680 3U 3U x680 Weight net 24 kg 26 kg Input output power connections Hard wired to terminal block Other connectors 1 x USB 1 x RS232 1 x 2 pole EPO Connector 1 x Interface Slot CE a a A Safety EN 62040 1 1 IEC 60950 1 EMV Compatibility EN 62040 2 EN 61000 3 2 EN61000 3 3 FCC A Performance features IEC EN 62040 3 Product certification CE FCC additional versions on request Protection class IP 20 Manufacturing standards ISO 9001 2000 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 59
4. Alpha numeric display Figure 2 5 LCD Display Four digit alpha numeric display The four digit alpha numeric display provides a metering facility which can be selected to show the input voltage frequency output voltage frequency load together with battery voltage and the internal enclosure temperature Details of the meter facilities are shown on page 40 A variety of operating status and fault codes are also shown on the display as described throughout this manual 12 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER COMPANY Warning symbols o 2 INN deh Overload This symbol indicates a UPS overload Low battery This warning symbol appears if the battery voltage is low Battery fault This symbol indicates that there is a battery fault Supply fault This symbol indicates an input supply problem such as reversed Line Neutral Service mode This symbol indicated that the UPS is operating in Service mode Load transfer Load transferred to bypass due to loss of UPS inverter output Bypass defective Load unable to transfer to bypass in ECO mode due to defective bypass Utility supply defective Utility supply defective at the UPS input terminals Mimic diagram LCD Mimic diagram The LCD Mimic indicates the existing power flow through the UPS The LINE UPS LOAD and BATTERY symbols are permanently shown
5. RS 232 Interface port Figure 2 7 item 2 The RS 232 port also allows the UPS to be connected to a PC It can be used with the UPS external monitoring and shutdown software WAVEMON and with the supplied UPS Configuration Software Pin 5 Ground The RS 232 interface should be set as follows Pin 3 RS232 Rx Baud Rate 2400 bps Pin 2 RS232 Tx Data Length 8 bits Stop bit 1 bit SC Figure 2 8 RS232 arity None Emergency power off EPO Figure 2 7 item 4 If an external emergency power off EPO facility is required a normally open circuit must be connected to the two pin plug located on the UPS enclosure rear panel When the external emergency power off circuit is operated it connects a short circuit across these terminals and effects a total UPS shutdown A plug in connector with screwed terminals is supplied ready fitted to the EPO socket to simplify the connection of the external cable if the UPS is located in a confined space such as when it is rack mounted Optional interface card slot Figure 2 7 item 6 Four optional interface cards are available to meet various communication needs DCE dry contact relay card R2E USE and SNMP Web These cards can be fitted into the options slot located behind a blanking plate on the UPS back panel as shown Full installation and set up procedures are provided in chapter 8 The software bundled with the UPS is compatible with most operating systems including Windows 98 2000 ME NT and XT
6. Over temperature AC mode Switch to bypass Over temperature Bypass mode Immediate UPS shutdown Battery Battery type VRLA leak proof lead acid Battery quantity 12V 20 x 7 0 Ah 20 x 9 0 Ah Autonomy time full load gt 7 min gt 4 min gt 4 min gt 2 min Charging time to 90 load 4 hours 6 hours External battery connection Plug amp play cable provided Life cycle typical Up to 5 years at max 20 C ambient temperature Display Panel Status on LED and LCD On line mode On battery mode ECO mode Input supply Bypass supply Battery low Battery bad disconnect Overload Transfer with interruption UPS fault LCD Metering display Input voltage Input frequency Output voltage Output frequency Load percentage Battery voltage Internal temperature LCD Status display Module mimic showing operating status fault and diagnostic indications Software configuration menu indications Self diagnosis Upon power on Front panel setting and software control 24 hour routing checking Operator buttons keys UPS ON OFF Alarm test silence Meter selection Software menu selection Audible Alarms Line failure on battery mode Audible beep every 1 5 seconds Battery low Audible beep every 0 2 seconds Overload Audible beep every 3 0 seconds Fault transfer to bypass Will sound permanently or every 3 seconds System fault condition Will sound permanently or every 3 seconds Communications Options
7. Single Module System UPS Module 3 UPS Module 4 Multi Module System or Parallel System UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 3 Uninterruptible Power Supplies Ltd 2 General Description A KOHLER Company 2 General Description 2 1 Introduction Congratulations on your purchase of the PowerWave 1000 UPS High reliability low operating cost and excellent electrical performance are just some of the highlights of this innovative UPS solution By employing the latest technological developments in power engineering the PowerWave 1000 represents a new generation of transformerless UPS System Its advanced double conversion Voltage and Frequency Independent VFI topology responds fully to both the highest availability and environmentally friendly requirements compliant with IEC 62040 3 VFI SS 111 standards A full UPS specification is shown in chapter 9 of this manual 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 to come The PowerWave 1000 key features include e High frequency transformerless technology with a rack tower compatible enclosure which permits the integration of the UPS even under the most challenging space constrain
8. as required by some manufacturers systems and so avoids a potential single point of failure In a multi module parallel system the topology and internal operation of each UPS module is identical to that described previously for a stand alone system However when operating as part of a parallel system it is critical that UPS control functions such as load sharing frequency synchronisation and load transfer between UPS and bypass are observed by all the connected modules In the PowerWave 1000 UPS system the inter module control functions are achieved using a parallel control bus which takes the form of a ring network connected to all the modules in the system that allows the modules to communicated with each other to properly share their control operation When a parallel system is installed each module is assigned a numerical position within the parallel ring and the first module is deemed to be the master from which the other modules take their lead If the master module undergoes a problem or is shut down the next highest available module in the ring will take over the master role This avoids a potential single point of failure in the parallel chain and ensures the highest level of power availability Parallel system capacity expansion Some applications present a low initial power demand which increases over time as the application grows and it is essential that the installed system can be expanded to meet
9. 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 47 Uninterruptible Supplies Ltd Se 6 Maintenance A KOHLER Company 6 Maintenance 6 1 Battery replacement The UPS batteries are fitted in plastic covered packs which are accessible from the front of the enclosure and can be replaced without shutting down the UPS A CAUTION If battery replacement is necessary it should undertaken by a trained engineer 1 Using a small screwdriver as a lever carefully remove the two press fit plastic covers from the left hand end of the UPS front panel This will expose two front panel securing screws Press fit covers Remove the two front panel securing screws using a Phillips screwdriver Carefully pull the fascia away from the front panel to expose the battery packs Cut any cable ties that are holding the battery cables in place Disconnect the battery connector s and carefully withdraw the battery pack s ak oh Figure 6 1 Use the above procedure in reverse order to fit the battery pack s 48 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER company T Troubleshooting d Troubleshooting 7 1 Introduction If a fault occurs due to either a UPS internal malfunction or severe overload 0 0 e age R och cd condition the UPS will shut down and lock out and must be reset by the pal Tg GE gt operator by turning th
10. 2 After a few seconds the UPS will completely shut down and all led and display indications will extinguish 42 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 4 Single Module Operating Procedures 4 4 Manual load transfer between inverter and bypass Some installations might include an external maintenance bypass circuit connected in parallel with the UPS to provide an alternative power source for the load supply Such installations are designed to enable the UPS to be totally removed or powered down for troubleshooting without disrupting the load When an external bypass facility is installed the circuit design does not include a safety interlock to prevent the external bypass circuit from being closed if the UPS is operating on line i e to prevent the external bypass from back feeding the UPS inverter and causing it damage This means that the transfer between the UPS and external bypass is only permitted when the UPS is itself operating on its internal bypass The PowerWave 1000 allows the operator to manually switch the load between inverter and bypass so that it can be used within an external bypass environment In practice a variety of external bypass designs are used so explicit external bypass operating instructions are not provided here The following instructions refer only to the UPS internal inverter bypass transfer operation 4
11. 3 8 3 Setting up the basic UPS operating parameters 36 3 8 4 Output voltage calibration 36 3 8 5 Managing the UPS data file 37 4 Single Module Operating Procedures 4 1 Single module start up procedures 38 4 1 1 Normal start up utility available 38 4 1 2 Start up on battery mode cold start 39 4 2 Operator control functions 40 4 2 1 Using the LCD metering function 40 4 2 2 Enable disable the audible alarm 41 4 2 3 Battery test 41 4 3 Shutdown procedures 42 4 3 1 Normal shutdown with mains available 42 4 3 2 UPS shutdown when on battery 42 4 4 Manual load transfer between inverter and bypass 43 4 4 1 Transferring the load from the UPS inverter to the internal bypass 43 4 4 2 Transferring the load from the static bypass back to the UPS inverter 43 5 Parallel UPS System Operating Procedures 5 1 System start up procedure 44 5 2 Shutdown procedure 46 5 3 Manual load transfer between inverter and bypass 46 5 3 1 Transferring the load from the UPS inverter to the internal bypass 46 5 3 2 Transferring the load from the static bypass back to the UPS inverter 47 6 Maintenance 6 1 Battery replacement 48 7 Troubleshooting 7 1 Introduction 49 7 2 Error codes 49 7 2 1 Audible alarm interpretation aids 50 7 3 Troubleshooting a fault condition 50 7 4 Troubleshooting an operational problem 51 7 5 UPS Fault handling 51 7 5 1 UPS Overload 51 7 5 2 Output short circuit 51 7 5 3 Inverter internal over temperature 52 7 5 4 Inverter over cu
12. 4 1 Transferring the load from the UPS inverter to the internal bypass 1 Press the OFF button for approximately 3 5 seconds until you hear a double beep then release it dy Sr d The LCD mimic will show the load connected to the input LINE via the internal bypass e The batteries are shown still connected to the input LINE and charging a if the charger is still operative f The audible alarm will sound but can be silenced by pressing the ON button g All metered parameters can be monitored as per normal Note If the UPS input mains supply is disconnected when it is operating on e Se bypass the UPS will not revert to battery power but will instead shut down with a FAI L status indication The UPS internal electronics will remain powered from the battery and all leds will extinguish apart from the red FAULT led which will be permanently lit and the audible alarm will sound continuously 4 4 2 Transferring the load from the static bypass back to the UPS inverter 1 Press the ON button for approximately 3 5 seconds until you hear a double beep then release it 0 a TheLCD mimic will show the load connected to the UPS b The audible alarm will sound but can be silenced by pressing the ON button c TheLCD display will revert to normal on line mode indications BA O gt Sr Ww UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 43 5 P
13. As the modules are turned off the load will be transferred to the internal static bypass line on bypass mode in ALL modules when the number modules remaining on line defeats the system s redundancy depending on load On ALL modules a The input mains and bypass supply leds will remain illuminated but the N 1 led will extinguish b The LCD screen will show the UPS status as oF F c On the LCD mimic the load will be shown disconnected from the UPS but the battery still connected to the input LINE and on charge d All metered parameters can be monitored as per normal 46 UPS725 02 02 PowerWave 1000 4 5 10 KVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 5 Parallel UPS System Operating Procedures Note If the UPS bypass mains supply is disconnected when it is operating on bypass the UPS will not revert to battery power but will instead shut down with a FAI L status indication The UPS internal electronics will remain powered from the battery and all leds will extinguish apart from the red FAULT led which will be permanently lit and the audible alarm will sound continuously 5 3 2 Transferring the load from the static bypass back to the UPS inverter To transfer the load from the internal static bypass supply On bypass mode to normal operation On line mode follow the normal start up procedure in paragraph 5 1 beginning at step 8 UPS725
14. Loador Battery Input line voltage Input line frequency Load voltage Load frequency Scroll DOWN Scroll UP 005000 Load percentage Battery voltage 68 6 6 Internal temperature 40 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 4 Single Module Operating Procedures 4 2 2 Enable disable the audible alarm You can use the following procedure to enable or disable the audible alarm operation This will not affect the audible beeps associated with pressing the control buttons which will remain active even if the audible alarm is turned off Note If the UPS is powered down and disconnected from its input supply the audible alarm status will revert to 0N b on default when the UPS is next started 1 With the UPS on line press the FUNCTION button O A O Ki Us Sr a The LCD will display either b_ oo or b ob This indicates that the UPS Se ae is now in its operator set up mode and shows the current operational status of the audible alarm b_on audible alarm enabled b_ of audible alarm disabled 2 Press the UP button to select the wanted audible alarm status 3 Press the FUNCTION button to activate the selected status and return to the normal LCD Display Note If you do not press the FUNCTION button the LCD will revert to its normal display automatically after approximately 10 seconds and the
15. Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER ComPANy 3 Installation and Set up 1 Remove five screws from the front of both sides of the UPS 2 Attach a mounting handle assembly B4 to both sides of the UPS enclosure using the holes vacated in the previous step to secure the handles in place 3 Extend the adjustable mounting rail and hold in place see Figure 3 6 Align the two holes in the back of the adjustable mounting rail with the holes in the cabinet s vertical fixing rail 5 Identify and mark the two vertical fixing rail holes to which the adjustable mounting rail is to be fixed Clip captive nuts B5 to the two vertical fixing rails holes identified above 7 Secure the rear of the adjustable mounting rail to the vertical fixing rail using two dome headed bolts B6 8 With the rear of the adjustable mounting rail secured in place and the adjustable mounting rail extended identify the four fixing points that will align with the equipment mounting handles and clip four captive nuts to the required fixing points Note The fixing points will vary according to the equipment height 2U 3U 4U as shown in Figure 3 8 9 Secure the adjustable mounting rail to the rack s front vertical fixing rail using two countersunk bolts B7 and adapter plate B3 see Figure 3 8 10 Repeat the steps 1 to 9 above to fit the second adjustable mounting rail WARNING The UP
16. OFF ON Figure 2 4 Operator control panel 2 4 1 LED Indicators a Input mains supply status CI This led indicates that the utility mains voltage applied to the UPS input terminals is within the specified operating range 168 288 VAC and is therefore normally illuminated The led flashes if the supply falls to within 120 168 VAC and extinguishes altogether in the event of a total utility supply failure O 2 Bypass mains supply status CI This indicates the state of the bypass mains supply This supply is internally linked to the UPS input supply terminals in the 4 5 kVA 6 kVA and 8 kVA models and this indicator will therefore reflect the utility supply status indication above however in the 10 kVA the UPS bypass terminals are optional connected to a dedicated bypass supply N 1 Redundancy status aa Used in a parallel system only This led is fully illuminated when the number of on line UPS modules exceeds the number required to power the existing load by at least one module i e the system can afford to lose one module without having to transfer the load to the bypass supply due to an overload The led brightness will dim if the load increases or the number of on line modules decreases to the point where system redundancy no longer exists O o ECO Mode Be This led illuminates when the UPS is set to operate in the ECO mode which is available on a single module installation only O UPS fault indication gt This LED illumi
17. UPS module paragraph 3 7 1 e Configuring each UPS module for parallel operation paragraph 3 7 3 e Parallel system start up and testing paragraph 3 7 4 3 7 1 Independent set up of each UPS module Key Point The selected operating parameters of all the UPS modules must be identical P Key Point The output voltage of all modules should be within 1V of each other when operating individually If a module s voltage is greater than 1V compared with the others you should calibrate its output as described in 3 7 2 before configuring the parallel system functions Use the following procedure to set up each UPS module in turn 1 Check that the utility supply voltage matches the input voltage range specified on the UPS data plate 2 Connect the UPS output cables but ensure the load is isolated from the UPS output load distribution isolator must be open 3 Connect the battery cable supplied between the UPS enclosure and battery enclosure see Figure 2 7 Note that the connector should be secured in place using the supplied metal bracket 4 Connect the UPS input power cables to the utility supply and bypass supply cables to the bypass mains supply if using a split bypass input on the 8 kVA and 10 kVA models as shown in paragraph 3 5 1 5 Turn ON the utility oypass supply close the input circuit breaker and the battery circuit breaker located on the rear of the enclosures a TheLCD display will turn on and all of its symbols will illuminat
18. be connected to independent sources Input Earth Ground G1 Input Neutral N1 Input Line L12 Bypass Line L11 DUAL INPUT MODEL SYSTEM UPS BATTERY RATING Max Current Conductor Torque Max Current Conductor 8 0 kVA 43 4A 10 mm 2 Nm 33A 6mm 10 0 kVA 54 3A 16 mm 2 Nm 41A 10 mm Figure 3 10 8 0 kVA and 10 kVA single phase power connections 26 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 3 Installation and Set up 10 0 KVA three phase input UPS Output Live L21 The 10 0 kVA UPS model is available as a three phase input uput ivea single phase output version and connected as shown Output Neutral N22 O P Earth Ground G2 O P Earth Ground G1 10 kVA 3 Phase input UPS Input lines max current 54 3 A Input lines conductor 16 mm or 25 mm Input Neutral 16 mm or 25 mm Output max current 54 3A Input Neutral N1 Output conductor 16 mm or 25 mm Input Line T L3 Battery max current 41A Input Line S L2 Battery conductor 10 mm Input Line R L1 Figure 3 11 10 Kva three phase input version power connections 3 5 2 Parallel control cables In a parallel module system a control bus formed by RJ45 terminated cables is connected between all the UPS enclosures in a ring configuration The cables are held in situ by a metal cla
19. bypass mode It also applies if the UPS locks out due to a fault Static Bypass Line Utility Mains Input e If the utility supply is still available the battery charger will be live and maintain the battery charging e UPS output has raw mains available AC DC PFC CONVERTER DC AC INVERTER STATIC SWITCH BATTERY DC DC BOOST CHARGER CONVERTER BATTERY Static Bypass Line AC DC PFC CONVERTER DC AC INVERTER d UPS AC Ins O Q Output Input STATIC SWITCH BATTERY DC DC BOOST CHARGER CONVERTER BATTERY UPS ON BATTERY Mode Static Bypass Line UPS ON LINE Mode This is the UPS normal mode of operation The battery charger charges the battery The AC DC converter processes the utility mains input and turns it into controlled DC power for the inverter input The inverter converts the DC supplied by the AC DC converter back into AC suitable for connecting to the load The static switch connects the inverter output to the UPS output load terminals This is the UPS mode of operation if the utility input fails during normal ON LINE operation Utility Mains Input The battery discharges through the DC DC boost converter which provides the DC power for the inverter input The Inverter convert the DC supplied by the DC DC boost converter back into AC suitable for connecting to the load The static switch connects the inverter output to the
20. if a parallel system is operating with module redundancy it is possible to isolate a module from the system for service or repair without affecting the remaining modules or load But in order to do this safely each module should by connected to the utility mains through a dedicated input supply circuit breaker and each UPS output should be similarly connected to the load via a dedicated output circuit breaker as illustrated in Figure 2 3 Once a module s output circuit breaker is open there is no load power being drawn from its inverter and it can be shut down in the normal way without affecting the remain on line modules 10 UPS725 02 02 PowerWave 1000 4 5 10 KVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 2 General Description 2 4 Operator control panel The UPS is fully controlled from the operator control panel located on the front of the unit The user friendly UPS control panel comprises three areas Led indicators A row of leds indicate the UPS input and output power status together with a general fault warning Alpha numeric LCD Display Provides indication of the UPS operating mode together with the input output and battery supply parameters It also displays error messages and UPS set up data via a system of configuration menus Operator Keypad The keypad contains 6 keys that are used to navigate through the UPS control menu system and turn the UPS
21. it from its mounting rotate it to the correct angle then relocate it and press it back into place 24 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER Company 3 Installation and Set up 3 5 Electrical Wiring In addition to the UPS input and output power cables the UPS requires the following cables to be connected prior to commissioning depending on the installed options and UPS system configuration e Battery connection cable required for all modules e Parallel control bus cables required for parallel system only e Emergency power off EPO optional for all systems see page 15 e Communications options optional for all systems see Chapter 8 General cabling notes In order to minimise any problems due to noise interference always use separate cable runs for the various power cables and control cables In particular if the control cables have to run parallel to the power cables keep a separation distance of 20 cm if possible Do not attach the control cables to the power cable looms using cable ties spiral wrap or any other means Where the control cables have to cross the power cables make best effort to ensure they do so at an angle of 90 3 5 1 Power cables Depending on the model variant the UPS input and output power cables can be connected either by means of a plug socket connector or hard wired to a terminal block If a
22. modules 2 Select correct operating mode then turn OFF the UPS to reset it Parallel communication error 1 Check that all RJ 45 cables are connected properly 2 Check that only one module is assigned an ID 1 3 If occurs during system start up check that it resets when module 1 is powered up last Site wiring earth fault 1 Check that the utility AC source L amp N have been wired correctly 2 Check that the earth neutral voltage has exceeded the limits specified in chapter 9 3 Contact your local dealer right away if you can find no problem with the above For all other error codes contact your local dealer for technical assistance UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 7 Troubleshooting 7 4 Troubleshooting an operational problem Symptom Possible Solution UPS fails to provide battery back up or its back up time is 1 Ensure that the circuit breaker on the back of the battery enclosure shorter than its specified performance is closed 2 Charge the battery for eight hours 3 Recheck and if the back up time remains unsatisfactory after 8 hours of charging please contact your local dealer for battery replacement UPS operation appears to be normal but there is no output to 1 Check that all output power cables are connected correctly and all load output isolators are closed 2 Ifthe problem
23. on screen and their interconnecting lines appear depending on the UPS mode of operation see below LINE UPS LOAD l Note the arrowheads shown in Figure 2 6 are used in conjunction with the LCD meter display to gt identify the source of the meter indication SE LOAD 5 LINE UPS TELOAD Cc LINE EE 5 LINE UPS LOAD c5 Figure 2 6 LCD Mimic diagram UPS OFF This mimic is displayed when the utility power is first applied to the UPS or if the UPS is turned OFF due to a fault It shows that the battery is being charged from the utility LINE but the LOAD is isolated from the UPS and is therefore unpowered UPS ON This mimic is displayed during normal UPS operation It shows the battery being charged from the utility LINE and the LOAD connected to the UPS output and therefore being supplied with processed backed up power ON BATTERY MODE This mimic is displayed if the utility supply fails It shows the battery now providing the UPS and LOAD power The battery will sustain the UPS output until it is discharged whereupon the UPS will shutdown LOAD ON BYPASS MODE This mimic is displayed if the UPS develops a fault or is overloaded whereupon the load is transferred to the bypass line and therefore connected directly to the unprotected utility supply LINE The battery will remain on charge if the UPS charger is healthy The load can be manually switched from the UPS to Bypass by pressing the OFF button
24. selected audible alarm setting will be activated 4 2 3 Battery test You can carry out a periodic battery test using the following procedure This test effectively places the UPS in its On Battery mode for approximately 10 seconds during which time the control electronics monitors the battery performance 1 With the UPS turned ON press the FUNCTION button a The LCD will display b_ on or b_ oF pI ped 2 Press the DOWN button a TheLCD will display Enon gt O Y gt De Vv gt Y gt at Vv 3 Press the UP button Ze ps w a The LCD will momentarily display Erun followed by EESE which will remain on the display while the battery test takes place Ge e d a ai y 4 When the test is completed the LCD will display this OK screen if the battery test was successful otherwise it will show FAI L Note If the UPS fails the battery test contact your supplier for technical assistance UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 41 Uninterruptible Supplies Ltd Se 4 Single Module Operating Procedures A KOHLER company 4 3 Shutdown procedures 4 3 1 Normal shutdown with mains available This procedure describe the shutdown sequence when turning OFF the UPS when it is operating in its normal On Line mode Before you shut down the UPS make sure it is safe to disconnect
25. the battery cable supplied between the UPS enclosure and battery enclosure see Figure 2 7 Note that the connector should be secured in place using the supplied metal bracket 4 Connect the UPS input power cables to the utility supply and bypass supply cables to the bypass mains supply if using a split bypass input option on the 8 kVA and 10 kVA models as described in paragraph 3 5 1 5 Turn ON the utility bypass supply close the input circuit breaker and the battery circuit breaker located on the rear of the enclosures a TheLCD Display will turn on and all of its symbols will illuminate for approximately 3 seconds b The status leds will all turn on for approximately 3 seconds and then extinguish except for the utility input supply and bypass supply green leds which will remain lit c The LCD panel will indicate that the battery is on charge and the UPS is of F 6 Simultaneously press and hold the ON and DOWN buttons for 3 5 seconds until a beep is heard and then release them a The LCD will display b_on This indicates that the UPS is now in its set up mode Bypass voltage window 7 Press the DOWN button twice a The LCD indication will scroll through Enon and end up showing either 5 Lo or 5 H I This indicates the applied bypass voltage window S_Lo sets the bypass window to 184 260 VAC and 5 H I sets it to 195 260 Vac 8 Press the UP button to select the wanted bypass voltage window either _Lo or 5_H is displayed Inverter f
26. the load supply 7 5 4 Inverter over current and output voltage out of tolerance If the UPS develops a fault and its inverter delivers an over current and out of tolerance voltage a The UPS will transfer the load to the bypass line as long as the utility supply is normal b The UTILITY led BYPASS led and FAULT led will illuminate If these fault conditions occur when the utility supply is abnormal a The UPS will cut off the supply to its outlets and shut down b The FAULT led will illuminate 52 UPS725 02 02 PowerWave 1000 4 5 10 KVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 8 Options 8 Options 8 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 1000 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
27. will simultaneously switch to the On bypass mode and the LCD will be as shown in the lower illustration 3 To completely shut down the UPS a Turn OFF the UPS utility supply and bypass supply if separate b Open the input circuit breaker s located on the back of the UPS c Open the battery isolator on the back of the battery enclosure 4 The UPS fans and control panel will remain operative for a few seconds before the unit completely shuts down 5 3 Manual load transfer between inverter and bypass Some installations might include an external maintenance bypass circuit connected in parallel with the UPS to provide an alternative power source for the load supply Such installations are designed to enable the UPS system to be totally powered down without disrupting the load for example for troubleshooting or repair To prevent the external bypass from back feeding the UPS inverter and causing it damage the transfer between the UPS and external bypass is only permitted if the UPS is itself operating on its internal static bypass Note In practice a variety of external bypass designs are used so explicit external bypass operating instructions are not provided here The following instructions refer only to the UPS internal inverter bypass transfer operation 5 3 1 Transferring the load from the UPS inverter to the internal bypass 1 Turn OFF ALL the UPS modules in turn by pressing their OFF button 2
28. with the UPS To connect the power Remove the cover from the socket on the back of the UPS Fit the cabled plug into the socket and lock it in place using the clamp bar located on the socket housing OUTPUT INPUT l l l G2 N22 L22 Gi M L12 Klak Output Live Input Live Output Neutral Input Neutral Output Earth Input Earth Ground Ground All cables must be supplied by the customer To connect the power Open the terminal block on the back of the UPS Connect the individual input output power cables and secure them in place using the two clamps fitted to the inside of the terminal block cover SYSTEM UPS BATTERY RATING Max Current Conductor Torque Max Current Conductor 4 5 kVA 25A 6 mm 2Nm 19A 6 mm 6 0 kVA 33A 10 mm 2Nm 25A 6 mm Figure 3 9 4 5 kVA amp 6 0 kVA power connections 8 0 kVA and 10 0 kVA single phase input UPS Output Line L21 Output Line L21 Input Line L12 Output Neutral N22 Output Neutral N22 Input Neutral N1 O P Earth Ground G2 Output Earth G2 Input Earth G1 Not used Ground Ground SINGLE INPUT MODEL The cabling methods for the 8 0 kVA and 10 0 kVA are similar to those described above for the smaller models The major difference is that the terminal block version can have an optional split bypass facility whereby the utility input and bypass input supplies can
29. with the remaining modules in an ON BYPASS mode as such a situation would certainly damage the UPS modules Note If any module in the system generates a LOAD ON BYPASS or LOAD ON INVERTER command it is signalled to all the connected modules via the parallel control bus so they will all simultaneously switch to the ON BYPASS mode or the ON LINE mode provided a sufficient number of modules are available accordingly UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 9 2 General Description Uninterruptible Power Supplies Ltd A KOHLER COMPANY Module 1 Output Dustribution Panel Static Bypass Line Utility Mains Supply Parallel control bus cables AC DC CONVERTER UPS1 STATIC O P SWITCH DC AC INVERTER BATTERY Z Module 2 Static Bypass Line AC DC CONVERTER UPS2 STATIC O P SWITCH DC AC INVERTER BATTERY Static Bypass Line AC DC CONVERTER UPS3 O P DC AC STATIC INVERTER SWITCH BATTERY _ Figure 2 3 PowerWave 1000 UPS Parallel system Inter module frequency synchronisation and load sharing Using sensing signals passed over the parallel control bus each UPS is able to compare its own frequency and output current with that of its neighbouring modules and carry out fine adjustments to achieve balanced conditions Isolating a module from the system As explained immediately above
30. 2 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 31 Uninterruptible Power Supplies Ltd 3 Installation and Set up A KOHLER COMPANY b The utility input led should extinguish on the operator control panel c The LCD mimic should indicate On Battery mode of operation d The LCD metering facility should indicate nominal UPS output voltage 4 Restore the UPS utility input supply and check that the operator control panel a The utility input led should illuminate on the operator control panel b The LCD mimic should indicate On Line mode of operation 5 Turn off the UPS and isolate its input bypass supply This completes the individual module configuration and functional check Repeat the above procedure on ALL modules before going to 3 7 3 3 7 2 Output voltage calibration Before you connect the UPS modules together to form a parallel system it is important that you check the output voltage from each module in turn If a module s output voltage is more than 1V higher lower than the other modules then its output should be calibrated using the UPS Setting Tool software as described in paragraph 3 8 4 3 7 3 Configuring each UPS module for parallel operation Once the modules have been individually set up and functionally checked they must be configured for parallel operation The position of each module within the parallel system is numerically identified during this set up with module 7 serving
31. 250 125 50 20 5 2 1 0 32 0 16 7 5 2 Output short circuit Output load short circuit when the output supply is via inverter If output load is short circuited while it is being supplied via the inverter a The inverter is shutdown immediately and stop the supply to the load b The FAULT led will illuminate up and the audible alarm will beep continuously c The UPS will not switch on automatically after the short circuit condition is eliminated It has to be re started manually see paragraph 4 1 1 Output short circuit when the output supply via the bypass line If the output load is short circuited in bypass mode a The utility fuse breaker will be activated open circuited to prevent the output load from damage b You must replace the fuse with a fuse of the same rating after the cause of the short circuit condition has been rectified UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 51 7 Troubleshooting Uninterruptible Power Supplies Ltd A KOHLER COMPANY 7 5 3 Inverter internal over temperature If the UPS experiences an internal over temperature when the utility supply is normal it will transfer the load to the bypass line and switch back to inverter mode when the over temperature situation has been eliminated If over temperature occurs when the utility supply is abnormal a The audible alarm will beep continuously b The FAULT led will illuminate c The UPS will cut off
32. 4 seconds to check the battery operation a Ifthe UPS does not complete its self test successfully the LCD will show a FAIL status and the FAULT led will illuminate b If the self test is successful the LCD will show an OK status for about 5 seconds then change over to display the normal on line indications CI Gi ow c The utility input and bypass input power leds green remain illuminated gt Y gt Bi Vv 4 You can now check all the metered input output and battery parameters to ascertain that the UPS is working correctly see page 40 KI a o If the machine is set to operate in the ECO mode the ECO led will be illuminated throughout this procedure If the machine is set to operate in the ECO mode the ECO the screen will continue to indicate the on bypass mode i Y CAUTION When turning on the UPS for the first time or following a long shut down period leave the unit running for at least eight hours to fully charge the batteries before connecting any critical load otherwise you may not obtain the specified battery autonomy time if the utility input supply fails 38 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 4 Single Module Operating Procedures 4 1 2 Start up on battery mode cold start output power for a short time depending on load unless the UPS util
33. 6 On the UPS Setting Tool click the Read button then click on OK in the confirmation popup 7 Inthe Calibration 1 area of the UPS Setting Tool click Calibration Skip Step 1 Without Transformer With Transformer No zl 8 Inthe Calibration 2 area ensure that the YP Voltage 208 Syster With Transformer field is set to No Load Votage 220 O P Voltage 208 Syster Load No Load Output Voltage i 9 Enter the measured voltage in the No Load Output Was EE Voltage field 221 5V in the example shown E 10 Click the Calibration2 button a The UPS will beep twice to confirm that it has received the data b The N 1 light will extinguish Qy c The ECO light will illuminate to confirm that the data has been updated 11 Turn off the UPS battery isolators to recycle the UPS 12 Start the UPS using the normal start procedure and check that the output voltage is now adjusted 13 Quit the UPS Setting Tool software 14 Turn OFF the utility input power then turn it back ON 15 Start the UPS following the normal start procedure and check that the UPS output voltage is correct Qo gr 3 8 5 Managing the UPS data file You can open the UPS configuration data file stored on your computer at any time using File gt Open from the menu bar as described in paragraph 3 8 2 When the file is open you can select a record by clicking anywhere in the record line a selected record is highlighted blue
34. 8 Introduction PowerWave 1000 Model range Functional description of operation 2 3 1 UPS Internal operation 2 3 2 UPS Module operating modes 2 3 3 Parallel system operation Operator control panel 2 4 1 LED Indicators 2 4 2 Operator keypad 2 4 3 LCD Display UPS Enclosure rear panel 2 5 1 Communication options Battery enclosure rear panel Warranty 2 7 1 Extended warranty 2 7 2 Additional service maintenance support Extended Service enquiry form 3 Installation and Set up 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 Unpacking the UPS equipment Selecting a suitable installation location 3 2 1 Clearances Tower hardware configuration set up Rack configuration set up 3 4 1 Installing the adjustable mounting rails Electrical Wiring 3 5 1 Power cables 3 5 2 Parallel control cables Commissioning procedure single module system 3 6 1 Initial UPS power up Commissioning procedure parallel module system 3 7 1 Independent set up of each UPS module 3 7 2 Output voltage calibration 3 7 3 Configuring each UPS module for parallel operation 3 7 4 Parallel system testing UPS Setting Tool 3 8 1 Establishing communication UNN NOON E 11 12 12 14 15 15 16 16 16 17 18 18 19 20 22 22 25 25 27 28 29 30 30 32 32 33 34 35 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 8 2 Generating a UPS profile and data file 35
35. Adding a new record to the UPS data file 1 As described above to add the current configuration to the UPS data file select Record gt Add New on the UPS Setting Tool menu bar a The new record will be added to the bottom of the data file Updating an existing UPS data file record To update an existing data file record with configuration data displayed in the UPS Setting Tool 1 Open the UPS data file Select the particular record that you want to update Click the Unlock button that appears between the Read and Wr ite buttons on the UPS Setting Tool Ensure that the UPS Setting Tool contains the required update data Select Record gt Update from the UPS Setting Tool menu bar a Click the Yes button in the Update confirmation dialog b The UPS data file record will now be updated ak oh Applying configuration data from an existing record Use this procedure to set up the UPS using data obtained from an existing data file record 1 Open the UPS data file Select the data record that you want to apply to the UPS Click the Unlock button that appears between the Read and Write buttons on the UPS Setting Tool The UPS Setting Tool data fields will now be populated with data retrieved from the selected data record Click the Write button to send the data to the UPS a Click the Yes button in the Writing confirmation dialog b The UPS will beep twice to confirm that it has received the data c Click OK to clear the Transm
36. For other applications such as Novell Netware Unix or Linux please contact your local dealer for suitable products All of the fitted communication ports including the optional cards can be active and used simultaneously to monitor the UPS status However only one communication the one with the highest priority has the ability to command and control the UPS at any given time The priority of the communication interfaces are 1 EPO input port 2 Optional slot mounted interface card 3 RS 232 2 6 Battery enclosure rear panel SN lui 1 Battery cable connection from UPS enclosure DC Breaker 30A 250Vdc 2 Battery circuit breaker 3 Battery cable connection to Extended Battery enclosure option Figure 2 9 Battery enclosure rear panel detail UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 1 5 Uninterruptible Power Supplies Ltd 2 General Description A KOHLER Company 2 7 Warranty The PowerWave 1000 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 authoris
37. MP functionality for NetWare OS 2 all Windows NT systems on INTEL and ALPHA network platforms The main features of WAVEMON are e On screen autonomy time battery time countdown e On screen server log off and shutdown procedure e Time and date stamp event log e Extensive logging of all UPS activity and power quality data e Permits alarm warnings to be monitored remotely via email e Scheduled UPS service mode and other systems status e Graphical user interface for Windows compatible platforms e Automatic unattended local shutdown e Special modules for MS Office software to close and save open documents e Compatible with all optional modules like UPSDIALER SNMP adaptors temperature sensors etc 8 2 1 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
38. PowerWAVE 1000 4 5 KVA to 10 kVA Single Phase Models User Manual JP Le Yd Mii ys Uninterruptible Supplies Ltd A KOHLER company Uninterruptible Power Supplies Ltd A KOHLER COMPANY Document Control ISSUE DATE REVISION SUMMARY 725 02 00 05 08 14 Manual revised and issued as 725 02 00 725 02 01 03 11 14 Updated rack mounting procedure 725 02 02 13 03 15 Updated front cover to show Single Phase Output UPS UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 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 mis interpretation of or accidental mistakes in this manual 2015 Uninterruptible Power Supplies Ltd This manual may not be copied nor reproduced without written permission of Uninterruptible Power Supplies Ltd UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Table of Contents 1 Safety 1 1 1 2 1 3 1 4 1 5 Description of the safety symbols used in this manual User precautions Important safety notes Storage instructions Terminology 2 General Description 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2
39. S Battery enclosure is heavy When lifting the equipment ensure that adequate A manpower is available and any mechanical lifting aids are suitable for the weights involved WARNING When inserting the enclosure into the rack ensure that it is held level If it is inserted at an angle it could pivot about the back of the mounting rail runners if the front of the enclosure is tilted upwards 11 When both mounting rails are fitted carefully insert the UPS Battery enclosure into the rack so that it rests correctly on the rails Then secure it in place using the four dome head bolts B6 as shown in Figure 3 8 12 The UPS should now be commissioned as detailed in paragraph 3 6 before it is put into service Figure 3 7 Adjustable mounting rail installation UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 23 Uninterruptible Supplies Ltd 3 Installation and Set up A KOHLER company D D Ip 2U Fixing Rack fixing rail Adjustable rail Adapter plate G p ip ls Rack fixing rail igl g Adjustable rail i h f G A ip Bi Adapter plate Ig 3U Fixing g SG gi 4U Fixing Rack fixing rail Adjustable rail Adapter plate 4 ig m al Figure 3 8 Fixing points for captive nuts Once the UPS has been installed if necessary rotate the UPS control panel so that it is correctly orientated To achieve this carefully pull the control panel forward to unclip
40. S mode Output Volte Bypass Volt Syn Freque Funt Fun2 Tt Fund To add a record for the current configuration data select Record gt Add New from the menu bar The new record will now be shown in the data file The Name of Company and UPS type details are shown in the first two fields to identify the UPS machine In order to associate the data file with the UPS you must once again turn OFF the UPS input supply then turn it back ON again This will store a reference to the data filename in the UPS memory and enable quick access when you want to open the file in the future To close the data file click the standard Windows Close button X in the top right of the window UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 35 Uninterruptible Supplies Ltd Se 3 Installation and Set up A KOHLER COMPANY 3 8 3 Setting up the basic UPS operating parameters The UPS Setting Tool allows you to set up several basic UPS operating parameters 1 Select the required parameters using the drop down selector boxes default Display System 220y X a Display System voltage selection 220V 110V Volaw gt b Vo Output voltage selection 200V 208V 220V 230V 240V UPS mode Nomalmode v c UPS Mode Normal moder 50Hz input output CF50 50Hz 60Hz Number of battery 20 e input output CF60 60HZ 50Hz input output Note that in a parallel ID of PS t gt system Nor
41. T 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 54 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 8 Options 8 3 SNMP adapters External SNMP card Internal SNMP card fitted in expansion slot Figure 8 2 SNMP Adapters 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 a browser based application The UPS management software can make your UPS data available in this SNMP format thanks to the software agent built in to the SNMP adapter Uninterruptible Power Supplies Ltd offer software with SNMP functionality for Novell OS 2 and Windows that run both on INTEL and on ALPHA DEC VMS and Apple Two models of SNMP adapters are available for use with the PowerWave 1000 both of which share the same functionality An internal SNMP card can be fitted into the communications card expansion slot located on the UPS enclosure rear panel and communicates with the UPS via a serial interface An optional external SNMP adapter can be used located remotely and connected to the UPS via its RS232 port The SNMP adapt
42. UPS output load terminals BATTERY CHARGER Static Bypass Line AC DC PFC CONVERTER DC AC INVERTER Utility Mains Input UPS AC O Output STATIC SWITCH BATTERY DC DC BOOST CHARGER CONVERTER BATTERY AC DC PFC CONVERTER DC AC INVERTER UPS AC O Output STATIC SWITCH DC DC BOOST CONVERTER BATTERY UPS ON BYPASS Mode This is the normal mode of operation if the UPS is used in its ECO mode otherwise this mode is usually entered if the UPS has a fault or overload The battery is permanently charged as long as the battery charger is still serviceable and able to operate If the bypass transfer was due to a UPS fault the battery charger might also have shut down The static switch connects the UPS output load terminals directly to the raw utility mains via the static bypass line Figure 2 2 Summary of UPS module operating modes UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd 2 General Description A KOHLER Company Paragraph 2 3 1 described the internal operation of an individual UPS module However as an operational unit the UPS can be described as being in one of four modes UPS OFF ON LINE ON BATTERY and ON BYPASS as illustrated in Figure 2 2 UPS systems are generally categorised as being either On line or Off line systems and you can configure
43. allel function must be set to P D default If this is set incorrectly the UPS LCD will display error message Ere when it is started Confirm amp Save 18 Press the DOWN button a The LCD indication will now show DE b If you want to double check all the selected values you can scroll through the above list of parameters by repeatedly pressing the DOWN button and make any necessary further changes c Once you are satisfied that all the selected values are correct with SAuE shown on the LCD display press the ENTER button to store the selected values in the UPS memory d The LCD panel will revert to indicate the battery is on charge and UPS is of F Note Once the configuration has been saved you must turn OFF the UPS and temporarily turn off the input utility supply before you can access the setup mode again using the ON and DOWN buttons This is a safety measure designed to prevent the UPS operating parameters being changed while it is on line UPS Module functional check 1 Turn ON the UPS module as described in paragraph 4 1 1 2 Check all metered parameters to ascertain that the indications are correct see page 40 and make a note of the UPS output voltage 3 Leave the UPS running for at least 10 minutes to ensure there is some charge in the battery then isolate the UPS input supply The UPS should automatically switch to battery operation a The audible alarm should beep cancel by pressing the ON button UPS725 02 0
44. allel system communications error Er I0 Inverter overload Ere Low input voltage lt 85 170V or disconnected battery Er lI UPS Over temperature Erg Parallel system not set to NORMAL mode Er lg UPS output overload Ereb Bypass overload Er 14 Fan failure IER Incorrect EEPROM jumper setting Er IS Incorrect mode entry UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 49 7 Troubleshooting Uninterruptible Power Supplies Ltd A KOHLER COMPANY 7 2 1 Audible alarm interpretation aids Continuous beep Audible Alarm beeps Interpretation Single beep every 2 secs Single beep every sec Quick and short successive beeps Two quick and short beeps One quick and short beep Two quick and short beeps repeating every two secs UPS Faulty Inverter shutdown All functions inhibited UPS Faulty load is still supplied via inverter or bypass UPS On Battery mode Battery low Confirm RS232 port receiving Service Mode UPS Initial start up with self test 7 3 Troubleshooting a fault condition If the UPS develops a fault during operation FAULT led illuminated you should check the error codes listed below for appropriate solutions Should the problem persist please contact your local dealer for assistance Cay E 0S Erey ZO E 06 Er I0 Er Ile Ereb Er II Er 14 Er 15 Ere Er 16 Erel Ere Other error codes LCD Error Code Possible Solution Battery p
45. any electromagnetic noise generated by the UPS i e reduces external radio interference Battery charger A multi stage battery charger is powered from the utility mains input supply and charges the battery whenever the input supply is available The charger uses an intelligent charging profile to obtain the best battery charge discharge performance and thereby optimise the battery life AC DC Converter As its name suggests the AC DC Converter converts the utility mains input into a controlled DC power supply that is suitable for use by the inverter The converter uses leading edge switched mode techniques which produces an input power factor of almost unity over its operating range 0 99 at full rated linear load and thereby maximises the UPS input efficiency The converter can satisfy the inverter DC power demands over a utility input voltage range of between 160V 288V which means that the battery is not called upon even during substantial power dips brownouts once again maximising battery life and availability DC DC Boost converter In times of utility mains failure the AC DC converter shuts down and it is no longer able to power the inverter Under these circumstances the inverter input power is provided by the battery via the DC DC boost converter which now turns on to increase the battery voltage to the level that required by the inverter to continue its normal operation The DC DC converter provides a regulated DC output as the
46. arallel UPS System Operating Procedures Uninterruptible Supplies Ltd Se A KOHLER COMPANY 5 1 Parallel UPS System Operating Procedures System start up procedure This procedure assumes that the UPS system is being started from a fully shutdown condition and no external maintenance bypass facility is connected 1 Ensure that all the UPS input circuit breakers located on the rear of the UPS are open for both utility and bypass supplies where separate Ensure that all load distribution isolators are open or the individual load items are turned OFF Ensure that you can identify module 1 in the parallel system the module set as d I This should be the bottom most or left most module See paragraph 3 7 3 A CAUTION The system may malfunction if Module 1 is not the last to be started 4 On each UPS module in turn EXCLUDING MODULE 1 Turn ON the UPS utility input supply and bypass supply if separate then close the input circuit breaker s and battery circuit breaker located on the rear of the enclosures a The UPS fans will start b The control system will boot up and initially turn on all the leds and LCD symbols for a few seconds c Once the control system has booted the ECO and N 1 leds will extinguish d The UPS will then carry out some internal self tests e When the self tests are completed the LCD screen will display an Ere I error code ON MODULE 1 Turn ON the UPS uti
47. as the master module Before you commence this procedure you should either sketch out or label the modules with their intended identification number as an aide memoir Key Point The modules should be numbered sequentially from 1 to 4 max In rack installed systems set the P lowest UPS module in the rack to be the master Module 1 in a tower installation number the modules from left to right with the master module Module 1 on the left It is important that the operator knows which is the master module in order to start up the system correctly Carry out the follow procedure on each module in turn beginning with module 1 Setting the terminal resistors 1 Ensure that the parallel bus cables are connected in a ring network between the parallel UPS modules 2 On the UPS modules at either end of the parallel system i e bottom most top most or left most right most turn ON switch 1 on the rear of the UPS adjacent to the parallel bus control cables Terminal Resistor Switch S1 Status UPS 1 UPS2 UPS3 UPS4 2 Modules ON ON 3 Modules ON OFF ON 4 Modules On OFF OFF ON Figure 3 13 Terminal resistor termination Setting the module system parameters 3 Turn ON the utility and bypass supply and close the UPS input and battery circuit breakers a TheLCD Display will turn on and all of its symbols will illuminate for approximately 3 seconds b The status leds will all turn on for approximately 3 seconds and then extinguish exce
48. ay from direct sunlight The operating temperature should be between 0 40 C with relative humidity of 30 90 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 e Accidental damage to the UPS e Ingress of liquids or foreign bodies e Damage or malfunction due to installing the UPS in an environment that fail to meet the conditions specified in this manual e 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 3 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 A CAUTION Always switch off the UPS before moving it 2 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 1 Safety 1 5 Terminology The following terms are used in this manual to described the UPS system components UPS Enclosure UPS Module or Battery Enclosure o E
49. backed up power running for at least eight hours to fully charge the batteries before connecting any mission critical load i CAUTION When turning on the UPS for the first time or following a long shut down period leave the unit otherwise you may not obtain the specified battery autonomy time if the utility input supply fails UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 45 5 Parallel UPS System Operating Procedures Uninterruptible Supplies Ltd Se A KOHLER COMPANY 5 2 Shutdown procedure This procedure assumes that the UPS system is to be totally shut down from a fully On line condition and no external maintenance bypass facility is connected CAUTION Before you shut down the UPS system you should first check with the load user that it is operationally safe to disconnect the critical low power 1 Turn off the load by opening the external load isolators or switching off the individual load items 2 On each UPS module in turn press the OFF button for approximately 3 5 seconds until you hear two beeps then release it a The input mains and bypass supply leds will remain lit b The LCD screen will show the UPS status as oF F c On the LCD mimic the load will be shown disconnected from the UPS but the battery still connected to the input LINE and on charge top illustration d Continue switching OFF the other modules e When ALL the modules have been turned OFF they
50. battery voltage decays during battery discharge and includes voltage and current monitoring and overload protection DC AC Inverter The inverter converts the DC input voltage connected to its input from either the utility mains supply via the AC DC converter or from the battery via the DC DC converter into a regulated AC output voltage suitable to power the connected load equipment The control logic associated with this power block is substantial and in addition to the output voltage regulation it 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 load supply to either the inverter or to a static bypass line which is connected directly to the raw utility mains supply The control logic within this power block will transfer the load to the bypass supply in the event of overload or UPS inverter malfunction Note that a controlled no break transfer can take place only if the inverter output frequency and the static bypass line frequency are fully synchronised 6 UPS725 02 02 PowerWave 1000 4 5 10 KVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 2 General Description 2 3 2 UPS Module operating modes UPS OFF This is the state of the UPS when it is turned off from the operator control panel it is effectively running in
51. ding energy efficiency e Operation over a wide range of input voltages The UPS will operate normally with a utility supply of 160V 288V without draining the battery which extends the battery service life e ADC start function permits the UPS to be started during a utility power failure if required e A revolutionary battery management circuit continuously analyses the battery status during discharge and adjusts the battery cut off point accordingly which once again maximises the battery service life e A selectable bypass voltage tolerance low high sensitivity can be used to restrict the range of voltages that can be applied to the load when the UPS operates on bypass The selectable voltage ranges are 184V 260V low sensitivity and 194V 260V high sensitivity 4 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description e A range of UPS output voltages 200 208 220 230 240V can be selected to suit the local supply or specific load voltage requirements e An overload detection system automatically switches the UPS output from its inverter to an internal bypass in the event of an overload that exceeds the rated inverter capacity and automatically switches back to the inverter mode once the overload condition clears e An output short circuit detection circuit turns off the UPS and disconnects its output supply until the cause of t
52. e even very brief supply interruption Off line operation single module installation only When the PowerWave 1000 is used as an off line UPS it is normally operated in its ON BYPASS mode Figure 2 2 with the load supplied via the static bypass line However the AC DC 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 static bypass supply error the inverter is immediately brought on line and the load is transferred from the static bypass to the inverter by the static switch within 3 to 5 milliseconds so the UPS is now operating in its ON LINE mode If the utility mains supply is unavailable when the transfer takes place the UPS inverter will support the load operating from its battery power i e ON BATTERY mode When the static bypass supply returns to normal the load is re transferred back to the static bypass line and the inverter returns to its standby operation Operating in this mode is slightly more energy efficient than operating in the on line mode due to the reduced AC DC converter 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 pr
53. e for approximately 3 seconds b The status leds will all turn on for approximately 3 seconds and then extinguish except for the utility input supply and bypass supply green leds which will remain lit c The LCD panel will indicate that the battery is on charge and the UPS is of F 6 Simultaneously press and hold the ON and DOWN buttons for 3 5 seconds until a beep is heard and then release them a TheLCD will display b_on This indicates that the UPS is now in its set up mode Bypass voltage window 7 Press the DOWN button twice a The LCD indication will scroll through Enon and end up showing either 5 Lo or 5 H I This indicates the applied bypass voltage window S_Lo sets the bypass window to 184 260 VAC and 5 H I sets it to 195 260 Vac 8 Press the UP button to select the wanted bypass voltage window either 5_Lo or 5_H I is displayed Inverter frequency sync window 9 Press the DOWN button a The LCD indication will now show either DEU Hz or SEG3 Hz This indicates the permitted bypass frequency window to which the UPS inverter will synchronise SED I Hz sets the frequency window to 1 Hz and GEI Hz sets it to 3 Hz 10 Press the UP button to select the wanted bypass frequency sync window 30 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 Installation and Set up Inverter output voltage 11 Press the DOWN button a The LCD indication wi
54. e input power off and on in order to bring it back into operation The red FAULT led will illuminate on the control panel and the LCD will indicate an error code see below Depending on the cause of the fault the UPS may either shut down entirely top illustration or transfer the load to the internal bypass line lower illustration In a parallel system if one module shuts down due to a fault condition the remaining modules will continue to operate and maintain the supply to the load if the system redundancy permits If the system redundancy is exceeded then ALL the remaining modules will transfer to on bypass operation lower illustration Figure 7 1 UPS Fault screens In a single module installation if the UPS shuts down due to a fault condition and is able to transfer the load to the static bypass then it will do so to maintain the load supply lower illustration 7 2 Error codes In general under fault conditions the red FAULT led will illuminate and an audible warning will be given Many faults can be identified by briefly pressing the OFF button which then displays a fault code on the LCD message area P Key Point If you press the OFF button for longer than five seconds the UPS will shut down Error Codes Er0S Weak or faulty battery Er 16 Parallel system setup error E 06 Output short circuited Er il Module ID number error Erg EPO Operated Er 18 EEPROM Data error E ag DC bus voltage high Erel Par
55. e rear of the UPS must not be obstructed The UPS equipment must be installed with the clearances illustrated in Figure 3 1 as a minimum 18 UPS725 02 02 PowerWave 1000 4 5 10 KVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 3 Installation and Set up 3 2 1 Clearances N Rack mounting 800 mm When rack mounting the UPS in a standard 19 in cabinet a minimum cabinet depth of 900 mm is required in order to provide an adequate exhaust airflow from the cooling fans on the rear of the UPS enclosure An adjustable rack mounting kit that can be extended to fit a 900 mm cabinet is available A clearance of 800 mm 31 in is required at the rear of the rack to permit pedestrian access to cable up the UPS and 800 mm is also required at the front of the rack to allow sufficient room to lift and install the enclosures onto the rack mounting rails or shelf Due to weight distribution considerations the UPS and Battery enclosures must be kept level while they are inserted into the rack to prevent them from tilting backwards Front H 680 mm 800 mm Tower mounting ww l With regards to a Tower installation there are two sets of clearance criteria to consider the first is to satisfy the ventilation requirements and the other concerns the installation cabling access 300 mm 7a o Minimum For ventilation purposes a minimum of 300 mm 12 in free space fro
56. early stage In spite of extensive system monitoring if an administrator fails to intervene in a timely manner serious 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 8 2 WAVEMON shutdown and management software Uninterruptible Eventlist 24 09 2003 12 45 System Serial communication restored Supplies Ltd 24 09 2003 12 39 System Serial communication lost KOHLER con 24 09 2003 12 35 System Connected to UPS System 5 Available UPS AA Figure 8 1 WAVEMON Monitoring screen UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 53 8 Options Uninterruptible Power Supplies Ltd A KOHLER COMPANY 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 Uninterruptible Power Supplies Ltd offer suitable monitoring software with SN
57. ed 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 e life support applications 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 e the risks of injury or damage have been minimized e the customer assumes all such risks e 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 three months to prevent deep discharging Batteries that have been deep discharged for whatever reason are not cov
58. er can be configured via Telnet http browser or serial connection For normal operation at least one Ethernet network connection is necessary Further details are provided in the manual that is supplied on the WAVEMON installation CD RCCMD RCCMD Remote Console Command Module for multi server shutdown is an independent software module intended for transmitting and receiving remote commands The new version RCCMD2 is similar to WAVEMON available for the most widespread operating systems Using the RCCMD send function the SNMP adapter can send status messages to connected users or initiate automatic shutdown throughout the whole network Our SNMP adapters are fully compatible with RCCMD 8 4 AS400 dry contact card The DCE dry contact card provides volt free outputs that can be used for the automatic and orderly shutdown of servers AS400 or used as control inputs to building management systems The signal descriptions of the 10 pins of the dry contact card are shown below Note that all pins except Pins 9 and 10 which are isolated are link selectable to be either short circuited or open circuited to the common Pin 8 when the monitored parameter is active Figure 8 3 DCE Dry contact card The pin assignment of the 10 pin terminals are 1 UPS on bypass mode Battery weak or faulty 2 Utility input abnormal UPS fault Alarm 3 Utility input normal Common 4 Inverter On 5 Battery Low Shutdown UPS po
59. ered by this warranty 2 7 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 e 24 hour telephone support e fully comprehensive cover excluding batteries and capacitors Contact the Service Support Hotline on 0800 731 3269 for further details 2 7 2 Additional service maintenance support In addition to providing support for the PowerWave 1000 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 1000 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 1 6 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description 2 8 Extended Service enquiry form Fax to 01256 386701 www upspower co uk Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Busine
60. ery enclosure an external maintenance bypass enclosure and an isolation transformer The PowerWave 1000 UPS module can be operated as a stand alone UPS or up to four modules can be connected in parallel and configured to operate as a multi module UPS system A multi module configuration is generally chosen either to increase a system s total output power capacity or to increase the system s overall reliability by providing module redundancy In this manual the terms multi module system and parallel system are synonymous P Key Point All the UPS modules connected to a parallel system must be of the same model type and power rating 2 3 Functional description of operation This section describes The internal operation of an individual UPS module see paragraph 2 3 1 e The UPS operational modes see paragraph 2 3 2 e Multi module system operation and paralleling considerations see paragraph 2 3 3 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 5 Uninterruptible Power Supplies Ltd 2 General Description A KOHLER COMPANY 2 3 1 UPS Internal operation Static Bypass Line DC AC INVERTER AC DC PFC CONVERTER Utility Mains Input UPS AC O Output STATIC SWITCH BATTERY CHARGER DC DC BOOST CONVERTER BATTERY Figure 2 1 UPS Functional block diagram EMI Filters The UPS has an input and output EMI filter to reduce the effects of
61. few seconds and will then run a self test routine for several seconds during which time the LCD screen will show the input voltage r V b The audible alarm will sound intermittently but may be silenced by pressing the alarm silence ON button c Ifthe UPS passes its self test routine it will turn on the inverter and begin to provide output power The LCD mimic display will show that the UPS e 0 0 IN is operating on battery mode CSI eh Ve 2 Check all metered parameters to ascertain that the battery voltage and UPS output indications are correct see page 40 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 39 Uninterruptible 4 Single Module Operating Procedures SE A KOHLER COMPANY 4 2 Operator control functions At any time during normal operation of the UPS the operator can Monitor the UPS input supply output supply battery and internal temperature using the LCD display e Enable or disable the audible alarm e Functionally test the battery 4 2 1 Using the LCD metering function The LCD metering function can display the input voltage input frequency load voltage load frequency percentage load battery voltage and internal temperature When the UPS is operating you can scroll through these parameters using the DOWN or UP button Note that the three arrowheads on the LCD mimic diagram identify the source of the meter indication as being either Input
62. for approximately 5 seconds or from the Bypass to UPS by pressing the ON button UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 2 General Description 2 General Description Uninterruptible Supplies Ltd Se A KOHLER COMPANY 2 5 UPS Enclosure rear panel 4 5 kVA 6 0 kVA Models socket 4 5 kVA 6 0 kVA Models terminals 8 0 kVA 10 kVA Models socket P e LS 6N 1N _ 8 0 kVA ee ee eil ei 10 kVA o E oe Kstsetzsts Models Ss Ss terminals nF J SSA4 SS d e Kg e SZ e 1 RS232 Port 6 Communication options slot SNMOP etc 2 Parallel termination resistor selection 7 Input supply circuit breaker 3 Parallel control CAN bus RJ45 ports 8 Bypass supply circuit breaker 10 kVA only 4 Emergency Power Off terminal block 9 Input Output power connection socket TB 5 Cooling fans 10 Battery connection socket Figure 2 7 UPS Enclosure rear panel detail 14 UPS725 02 02 PowerWave 1000 4 5 10 KVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER company 2 General Description 2 5 1 Communication options Several communication options can connected to the PowerWave 1000 rear panel These are described briefly below with further details provided in chapter 8 Options
63. he short circuit is manually remedied 2 2 PowerWave 1000 Model range PW1000 4 5 PW1000 6 0 PW1000 8 0 PW1000 10 0 Maximum output power kVA 4 5 6 0 8 0 10 0 kW 4 05 5 4 7 2 9 0 Dimensions with batteries WxHxD mm 222 x 445 x 680 222 x 445 x 680 267 x 445 x 680 267 x 445 x 680 19 rack mounting space 2U 3U x 680 2U 3U x 680 3U 3U x 680 3U 3U x 680 Weight with standard batteries kg 85 85 92 92 Sound level dBA 50 50 50 50 The PowerWave 1000 UPS range compromises 4 5 kVA 6 kVA 8kVA and 10 kVA models each of which comprises two matching enclosures The main UPS enclosure contains the major UPS power components including a rectifier battery charger inverter and static switch and the second enclosure contains the UPS battery pack The enclosures can be configured as a floor standing tower unit or installed in a standard 19 rack An accessory pack containing all the parts necessary to prepare the enclosures for either type of installation is supplied with the UPS When installed as a tower system the UPS and battery enclosures are mechanically attached together to form a single unit For 19 rack mounting it is usual to fit the UPS system near the bottom of a rack with the UPS enclosure mounted immediately above the battery enclosure see chapter 3 Installation for mechanical configuration details Optional equipment designed to enhance the overall UPS installation include a matching extended batt
64. ility 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 1000 is a Class A UPS product according to EN 62040 3 additional measures UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 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 Although the PowerWave 1000 UPS was designed for simple installation it 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 The UPS is equipped with an electromagnetic interference filter EMI It must be properly earthed at all times in order to prevent excessive leakage currents To prevent the UPS from overheating the UPS ventilation louvres on the UPS front panel must be kept free of obstructions at all times A space of at least 30 cm 12 in should be provided at the back of the UPS to allow adequate airflow from the ventilation fans The UPS is must be installed in a sheltered and controlled environment aw
65. it OK dialog oP N 6 To apply the changes you have made you must now turn OFF the UPS input supply then turn it back ON again UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 37 4 Single Module Operating Procedures Uninterruptible Supplies Ltd Se A KOHLER COMPANY Single Module Operating Procedures 4 1 Single module start up procedures 4 1 1 Normal start up utility available 1 Turn ON the UPS utility input supply and bypass supply if separate then close the input circuit breaker s and battery circuit breaker located on the back of the enclosures a The UPS fans will start b The UPS control system will boot up and initially turn on all the leds and LCD symbols for a few seconds K er K l c Once the control system has booted the ECO N 1 and FAULT leds will extinguish leaving only the utility input and bypass input power leds green illuminated d The LCD mimic will show the load on bypass the battery being charged and the UPS output status will be shown as oF F 0 0 0 Bi Ki lt 0 L Ki 2 Press and hold the UPS ON button for approximately 3 5 seconds until you hear two beeps then release it a The UPS will indicate the bypass voltage b The audible alarm will sound intermittently but can be silenced by pressing the alarm silence ON button 0 0 L L 3 The UPS will run another self EESE for about
66. ity input supply is restored This facility is CAUTION If you start the UPS using battery power the battery will begin to discharge and will only provide primarily intended to be used when testing the UPS In the absence of the utility power supply the UPS can be started from its internal batteries sometimes referred to as a cold start This is only possible if the batteries are well charged Read through this procedure before you attempt to carry it out In a part of this procedure you have to press the ON button twice within a 15 second period If you take longer than this the UPS will not start and you will have to turn it OFF by pressing the OFF button before you can make another attempt to start it 1 Hold the ON button for approximately 5 seconds until a double beep is heard then momentarily within 15 seconds release the button and press it again CI PI os for approximately 3 seconds until a further beep is heard During the first button press a The UPS fans will start b The UPS control system will boot up and initially turn on all the leds and LCD symbols for a few seconds VI wl c When control system boot up has completed all the leds will turn off the LCD mimic will display the UPS connected to the battery and the UPS status will be shown as oF F Following the second button press a The LCD display will initially keep the UPS oF F screen displayed for a S Or Qo Gr
67. l port you will require a readily available USB to RS232 serial adapter cable BS Port eae 1 Zi tandard v Serial port open Connected 4 Figure 3 14 UPS Setting tool 34 UPS725 02 02 PowerWave 1000 4 5 10 KVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 3 Installation and Set up 3 8 1 Establishing communication 1 2 3 8 2 Connect the RS232 serial cable between the computer and UPS Turn ON the UPS input supply but DO NOT press the UPS control panel ON button a The UPS will run through its start up self tests and then adopt its oF F status b Run the UPS Setting Tool application on the computer Select the appropriate Com Port in the UPS Setting Tool a A communication link should establish automatically but press the Connect button if necessary to force the connection b The Serial port open and Connected status messages should appear Generating a UPS profile and data file yeh GA Los Ads Ts Com Port 10 7 2400 Standard Serial port open Connected The UPS settings you apply through this tool can be saved to a data file on your computer for later recall This allows you to observe the changes you ve made over time and provides an easy way to restore a previous configuration profile if required This procedure shows you how to set up a data file for the specific UPS machine generate a config
68. l you hear two beeps then release it a The UPS will indicate the bypass voltage b The audible alarm will sound intermittently but can be silenced by pressing the alarm silence ON button c The UPS will run another EESE for about 4 seconds to check the battery 0 0 0 na Oo operation Zi o A gt d If the UPS does not complete its battery test successfully the LCD will show a FAI L status and the FAULT led will illuminate If the self test is pA a e e successful the LCD will show an OK status for about 5 seconds 10 When the ON button has been pressed on all module and they have successfully passed their battery checks they will carry out some further parallel operation checks and once these final tests are passed typically 5 10 seconds the modules will then simultaneously transfer their output from the static bypass to the inverter a TheLCD mimic will now show the on line status with the battery being 0 0 GQ ge charged PA i b The LCD meter will indicate the utility input voltage c The utility input and bypass input power leds will remain illuminated green and the N 1 led will be fully illuminated if there is system redundancy 11 You can now check all the metered input output and battery parameters to ascertain that the UPS system is working correctly see page 40 A CAUTION Congratulations Your load is now being provided with consistent and
69. lity input supply and bypass supply if separate then close the input circuit breaker s and battery circuit breaker located on the rear of the enclosures Module 1 will boot up in exactly the same manner as described above for the other models but at the end of its self checks a It will turn on its static bypass supply and the LCD mimic will indicate the on bypass status and the battery being charged b The UPS output status will be shown as of F Qo 44 UPS725 02 02 PowerWave 1000 4 5 10 KVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 5 Parallel UPS System Operating Procedures 7 On ALL modules check that the Erd I error has disappeared from the LCD screen and they now indicate the on bypass status cI fy e a If any module still shows Ere I it indicates that it has a problem concerning the parallel communication bus which must be rectified before the UPS system can be turned on 8 If ALL the modules are energised and operating in the on bypass mode you can now turn on the load by closing the external load isolators or switching on the individual load items Note The load will not be receiving protected power until the UPS system has been fully turned on 9 On each UPS module in turn LEAVE MODULE 1 UNTIL LAST n 0 wl Press and hold the UPS ON button for approximately 3 5 seconds unti
70. ll now show either od V 0208 V 0228 V o02I0 Vor od V 12 Press the UP button to select the required output voltage Input Output frequency changer mode The UPS cannot be configured to operate as either a 50 60 Hz or 60 50 Hz frequency changer in a parallel system 13 Press the DOWN button a The LCD indication will now show either norl Eco c50 Hz or c60 Hz 14 Press the UP button if necessary to ensure the frequency is set to nor default Inverter output fine adjustment 15 Press the DOWN button a By default the LCD indication will now show off O b If you want to trim the output voltage press the UP button to cycle through the available options and select the required value of of 2 of 3 of of oA JF Parallel ID Number Note This is a temporary setting necessary to run the UPS as a single module for functional test purposes before configuring it as part of a parallel system This setting will be changed later 16 Press the DOWN button a Fora single module operation the parallel ID number must be set to d default If this is set incorrectly the UPS LCD will display error message Er 7 when it is started Parallel Function Note This is a temporary setting necessary to run the UPS as a single module for functional test purposes before configuring it as part of a parallel system This setting will be changed later 17 Press the DOWN button a Fora single module operation the par
71. mal mode is the only permitted selection Parallel Non Perallel t gt d Number of battery number of battery block fitted If it important Fine Tuningfax that this is set correctly as it affects the battery charging parameters Bypass Window Sensiiviy Low e I D of UPS Set to 01 in a single module installation In a Synchronization 3Hz parallel system this sets the module identity within the parallel chain The module set at 01 is the master module and the remaining modules must be set to 02 03 or 04 respectively f Parallel Non Parallel Set to 01 in a single module installation and 02 in a parallel module system g Fine Tuning Output Voltage 3 2 1 0 1 2 3 h Bypass Voltage Window Sensitivity Low Sensitivity High i Syn Frequency Window 3Hz 1Hz 2 Once all the parameters have been selected click the Write button to send the data to the UPS a Click the Yes button in the Writing confirmation dialog b The UPS will beep twice to confirm that it has received the data c Click OK to clear the Transmit OK dialog 3 To apply the changes you must now turn OFF the UPS input supply then turn it back ON again 3 8 4 Output voltage calibration This procedure can be used to calibrate the UPS output voltage and requires access to the UPS output terminals to enable the output voltage to be measured It can be used to accurately trim the output voltage in a single module installation or to ma
72. mp which is secured by two screws as illustrated Note that although in practice the UPS modules are usually positioned close to each other the maximum parallel bus cable length is 7m Figure 3 12 Parallel control bus cable connection Key Point For a parallel system it is necessary to utilise a bespoke distribution panel for the UPS input and output connections Contact UPS Limited for details UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 27 Uninterruptible Power Supplies Ltd 3 Installation and Set up A KOHLER COMPANY 3 6 Commissioning procedure single module system Use this procedure to commission a single stand alone UPS system Before the UPS is put into service it should be configured to suit the local electrical supply and load application This can be considered a once only commissioning procedure and once completed will only need to be repeated if the application requirements change CAUTION Before you carry out this procedure you must be familiar with the Operator Control Panel functions and the rear panel connections see paragraph 2 4 and paragraph 2 5 You should also be familiar with the safety information contained in Chapter 1 1 Check that the utility supply voltage matches the input voltage range specified on the UPS data plate 2 Connect the UPS output cables but ensure the load is isolated from the UPS output load distribution isolator s open 3 Connect
73. nates to indicate a fault condition within the UPS that needs attention UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 1 1 Uninterruptible Supplies Ltd Se 2 General Description A KOHLER COMPANY 2 4 2 Operator keypad D sg le 0 je e v i e A ON Button This button is used to turn ON the UPS silence the audible alarm and activate certain other functions when used in conjunction with other buttons as described later in this chapter To turn ON the UPS the button must be held down for approximately five seconds until two audible beeps are heard OFF Button To turn OFF the UPS this button must be held down for approximately five seconds until two audible beeps are heard ENTER Button The ENTER button is used to select a parameter from the UPS configuration setup menus UP BACK Button This button is used to navigate UP through the UPS menus DOWN NEXT Button During normal operation this button is used to scroll through the metered parameters shown on the LCD display It is also used two navigate forward through the UPS configuration setup menus FUNCTION Button This button is used to access the UPS configurations setup menus 2 4 3 LCD Display The LCD has three functional areas that can be broadly described as Warning Symbols Mimic Diagram and a four digit Alpha numeric Display Each of these areas are described individually below Warning Symbols Mimic Diagram
74. nt back must be provided at the front and rear of the UPS to permit adequate ventilation cooling air flow however a rear clearance of 500 mm 20 in and side for cooling clearance of 300 mm 12 in is necessary to gain cabling access to the rear of the UPS beo a 300 mm r Depending on the installed location a compromise can sometimes be achieved by installing the enclosure with a sufficient cable length to enable it to be pulled forward sufficiently for rear access If the UPS is installed in a location which is subject to regular E Safe pedestrian passage it is recommended that the front clearance is e pedestrian increased to at least 1000 mm 40 in S passage 4 5 kVA 6 kVA 8 kVA 10 kVA 220 x 680 mm 264 x 680 mm UPS Enclosure tower footprint Figure 3 1 UPS Location clearances UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 19 3 Installation and Set up Uninterruptible Supplies Ltd Se A KOHLER COMPANY Tower hardware configuration set up Using the components shown in Figure 3 2 which are supplied as standard for both the UPS and battery enclosures the UPS can be configured as a floor standing Tower unit as follows All necessary screws and hardware included DI gt First assemble two tower feet A1 by attaching the foot to the sole plate see Figure 3 2 Turn the UPS enclosure on its side and attach the two assembled tower feet to the enclosu
75. ntrol panel forward to unclip it from its mounting rotate it to the correct angle then relocate it and press it back into place 7 Remove three screws from the top of the each enclosure two from the front and one from the back as identified in the top diagram of Figure 3 4 8 Remove two screws from the top of each enclosure as identified in the bottom diagram of Figure 3 4 9 Fit two tie bars A3 between the enclosures using screws S1 to secure them together Figure 3 4 bottom diagram 10 Attach the angle brackets A2 to the top front of the UPS enclosure using two screws such that the lip of the bracket faces the front of the enclosure Figure 3 4 top diagram 11 Locate the new UPS enclosure top panel A3 into the bracket A2 and secure it in place by screwing it to the top rear of the enclosure using a single screw 12 Repeat the above two steps to fit the new top cover to the battery enclosure 13 Move the completed UPS tower assembly to its final location then connect the battery cable between the UPS and battery enclosures The battery cable must be secured in place using the clamp attached 14 This completes the tower hardware configuration The UPS should now be commissioned as detailed in paragraph 3 6 before it is put into service Figure 3 4 Tower configuration UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 21 Uninterruptible Supplies Ltd Se
76. on to cycle through the available options and select the required value of e oh of 3 of oA 2 oA J Parallel ID Number 15 Press the DOWN button a Fora single module operation the parallel ID number must be set to d default If this is set incorrectly the UPS LCD will display error message Er 7 when it is started Parallel Function 16 Press the DOWN button a Fora single module operation the parallel function must be set to P DI default If this is set incorrectly the UPS LCD will display error message Ere I when it is started Confirm amp Save 17 Press the DOWN button a The LCD indication will now show SAuE b If you want to double check all the selected values you can scroll through the above list of parameters by repeatedly pressing the DOWN button and make any necessary further changes c Once you are satisfied that all the selected values are correct with SAuE shown on the LCD display press the ENTER button to store the selected values in the UPS memory d The LCD panel will revert to indicate the battery is on charge and UPS is of F Note Once the configuration has been saved you must turn OFF the UPS and temporarily turn off the input utility supply before you can access the setup mode again using the ON and DOWN buttons This is a safety measure designed to prevent the UPS operating parameters from being changed while it is on line 3 6 1 Initial UPS power up 1 The optional UPS comm
77. onnections Then reapply Ere I check to the system 3 8 UPS Setting Tool UPS Setting Tool Ven WO0 The UPS Setting Tool is a software application that is rei Di supplied with the PowerWave 1000 It enables you to select UPS Ver M5341111 Display System 220 certain basic UPS basic operating functions calibrate the Vo loan i Name of Company Ablerex UPS output voltage and set up the module s single parallel UPS mode Normal mode UPS ype ASTET operating parameters to make it suitable for either mode of Number of battery 20 kwalo operation LD of UPS fy Parallel Non Parallel 4 Special Function The operating parameters can also be set up from the UPS control panel as described in paragraph 3 6 for a single module installation or paragraph 3 7 1 for a parallel module system ss ee ey E p 8 WS WWW IW Read Write Fine Tuning 0 Bypass Window Sensitivity Low falla lal lalla lal la Synchronization 3 Hz In order to use the UPS Setting Tool you must connect an calibration RS232 serial cable between the UPS COM port and the EH EC computer on which the application is installed with the AP ae Seer 8 Load Voltage 220 O P Voltage 208 Sy computer COM port configured as described in paragraph Load No Load Output Vottage STE 2 5 1 Calibration Skip Step Note If you are using the application on a laptop that does not have a seria
78. otection Frequency changer operation single module installation only In addition to the more normal on line and off line system operation the PowerWave 1000 can also be used ina frequency changer mode where the inverter output is produced at a different frequency to that of the utility supply for example 50 Hz utility mains input with 60 Hz UPS output or vice versa When operating in this mode it is clearly not possible to switch the load between the inverter and bypass so the bypass side of the static switch is electronically disabled by the UPS control logic which means that the static bypass line is not available to assist clearing an overload For this reason it is recommended that the UPS is operated to a maximum 75 load capacity if the input voltage is 176 280 VAC and 50 if the input voltage range is set to 160 280 Vac 8 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER company 2 General Description 2 3 3 Parallel system operation Up to four PowerWave 1000 UPS modules can be connected in parallel for increased power capacity or redundancy operation A functional block diagram of a three module parallel system is shown in Figure 2 3 A PowerWave 1000 UPS parallel system has a decentralised bypass architecture in that each UPS module contains its own static switch and static bypass line This eliminates the need for a separate bypass cabinet
79. persists consult your local dealer for technical assistance The UPS switches to battery mode then back to on line mode 1 Check for a faulty UPS input cable or utility supply wall receptacle when the connected device is turned on and replace repair any faulty item found 2 Ifthe problem persists consult your local dealer for technical Or the UPS switches back and forth between battery and on line assistance mode Strange noise and or odour emitted by UPS Immediately shut down the UPS System 2 Disconnect the UPS input power and call for service 7 5 UPS Fault handling 7 5 1 UPS Overload Items of electronics and IT equipment can generate an inrush current when they switch on To prevent severe inverter damage caused by inrush currents the UPS is equipped with an electronic overload protection feature which switches the load to the bypass line within 1 minute if the UPS load rises to between 105 120 of its rated capacity As inrush currents are normally short lived once the current being drawn from the bypass falls below lt 105 the UPS will switch back to inverter mode automatically Note that if the UPS is overloaded by gt 150 its inverter will shut down immediately The bypass line is also equipped with overload protection Its overload capacity time characteristics are illustrated in the table below Load 110 120 121 130 131 135 136 145 146 148 149 157 158 176 177 187 188 lt Delay Time sec
80. plug socket arrangement is used then a ready cabled plug will be supplied with the UPS equipment If a terminal block connection is used then the provision of all external cables and fuses or circuit breakers used to connect the UPS input and output terminals to their respective distribution panels is the responsibility of the customer All cables and fuses should be rated according to the maximum UPS system rating in accordance with local regulations For guidance e Fuse and cable recommendations must be to IEC 60950 1 2001 e 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 Parallel system power cable considerations In order to obtain the optimum balanced conditions when cabling a parallel module system you should ensure that the input cables to each module are of equal length and not longer than 25m The output cables from all modules to the load distribution panel should similarly be of equal lengths and a maximum of 25m UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 25 3 Installation and Set up Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 5 kVA and 6 0 kVA UPS OUTPUT OUTPUT INPUT L L N N 3 Output Live 4 Output Neutral 5 Earth Ground 1 Input Live 2 Input Neutral A plug complete with pre wired power cables is supplied
81. pt for the utility input supply and bypass supply green leds which will remain lit c The LCD panel will indicate that the battery is on charge and the UPS is of F 4 Simultaneously press and hold the ON and DOWN buttons for 3 5 seconds until you hear a beep and then release a The LCD will display b on This indicates that the UPS is now in its set up mode 32 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 3 Installation and Set up Parallel ID Number 5 Press the DOWN button seven times to access the Parallel ID number configuration menu indicates dQ by default a Press the UP button to select the ID number according to the module s assigned position in the parallel system Parallel Function 6 Press the DOWN button a Press the UP button to select P Oe parallel operation in now enabled Confirm amp Save 7 Press the DOWN button a The LCD indication will now show SAE b If you want to double check all the selected values you can scroll through the above list of parameters by repeatedly pressing the DOWN button and make any necessary further changes c Once you are satisfied that all the selected values are correct with SAuE shown on the LCD display press the ENTER button to store the selected values in the UPS memory d The LCD panel will revert to indicate the battery is on charge and UPS is of F Note Once the configuration ha
82. re s left hand base as shown in Figure 3 3 top diagram Attach two tower feet sole plates without feet to the enclosure s right hand base so that they do not protrude from the side of the enclosure as shown in Figure 3 3 top diagram This is necessary to ensure the UPS enclosure stands level when it is turned back onto its feet Repeat steps 1 to 3 on the base of the battery enclosure but in this case ensure that the protruding feet are fitted to the battery enclosure s right hand side Note that Figure 3 3 lower diagram is provided to illustrate the positional relationship between the UPS and battery enclosure feet only In practice the UPS enclosure would not normally be laying on top of the battery enclosure while fitting the battery enclosure feet Carefully lift both assemblies and stand them on their feet adjacent to each other with the battery enclosure to the right of the UPS enclosure see Figure 3 4 Figure 3 2 Tower configuration kit A1 A2 A3 A4 Figure 3 3 Attaching the enclosures feet Foot Sole plate 4 x Tower feet 1 x Tower top panel bracket 1 x Tower top panel 1 x Tower battery cabinet tie bar 20 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER COMPANY 3 Installation and Set up 6 If necessary rotate the UPS control panel so that it is correctly orientated To achieve this carefully pull the co
83. requency sync window 9 Press the DOWN button a The LCD indication will now show either 54 Hz or S93 Hz This indicates the permitted bypass frequency window to which the UPS inverter will synchronise SED I Hz sets the frequency window to 1 Hz and GEI Hz sets it to 3 Hz 10 Press the UP button to select the wanted bypass frequency sync window Inverter output voltage 11 Press the DOWN button a The LCD indication will now show either od V 0208 V od V 0230 Vor od V b Press the UP button to select the required output voltage Input Output frequency changer mode The UPS can be configured to operate as either a 50 60 Hz or 60 50 Hz frequency changer Note When operating in a frequency changer mode the bypass supply is disabled 12 Press the DOWN button 28 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER Company 3 Installation and Set up a The LCD indication will now show either norl Eco c50 Hz or cb0 Hz norl normal operation with 50 Hz input and output default Eco Economy mode On bypass for normal operation c50 Hz 60 50 Hz frequency changer and c60 Hz 50 60 Hz frequency changer 13 Press the UP button to select one of the frequency changer modes if required Inverter output fine adjustment 14 Press the DOWN button a By default the LCD indication will now show of J b If you want to trim the output voltage press the UP butt
84. roblem 1 Check that the battery connections have been made correctly 2 Measure the battery voltage to ensure it is charged and in good condition Recharge battery for 8 hours if necessary 3 Simulate a utility supply outage to establish that UPS is able to provide DC back up 4 Contact your local dealer right away if you can find no problem with the above Overload 1 Disconnect any non critical loads from the UPS output until the overload ceases 2 Check the condition of the output cables and connectors to determine that they are undamaged and the insulation is sound Replace the output cables if necessary 3 Contact your local dealer right away if you can find no problem with the above UPS Over temperature 1 Remove any objects obstructing the ventilation louvers 2 Check to ensure that the cooling fans are working properly see also Er 4 and contact your local dealer to replace the fans if necessary 3 Contact your local dealer right away if you can find no problem with the above Fan error 1 Verify if the ventilating fans are functioning properly Do not attempt to replace the fans by yourself 2 Contact your local dealer for fan replacement Incorrect mode selected 1 UPS must be selected to operate in NORMAL mode 2 Select correct operating mode then turn OFF the UPS to reset it Parallel module set up error 1 Check that all set up parameters apart from the module ID number are identical in all parallel
85. routines are a part of the management software and can be configured in accordance with local application requirements The software of your PowerWave 1000 UPS unit can be integrated into a network in two ways 1 By the 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 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 8 2 2 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 N
86. rrent and output voltage out of tolerance 52 8 Options 8 1 The importance of UPS management 53 8 2 WAVEMON shutdown and management software 53 8 2 1 Functional description 54 8 2 2 Licensing 54 8 3 SNMP adapters 55 8 4 AS400 dry contact card 55 8 5 USE USB card 56 8 6 R2E second RS 232 card 56 9 Specification UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Supplies Ltd Se A KOHLER company 1 Safety 1 1 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 procedures 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 responsib
87. s been saved you must turn OFF the UPS and temporarily turn off the input utility supply before you can access the setup mode again using the ON and DOWN buttons This is a safety measure designed to prevent the UPS operating parameters being changed while it is on line Repeat the above procedure on ALL modules 3 7 4 Parallel system testing Parallel communications test 1 Turn on the utility input supply to all the modules except module 1 the module set as d9 I and check that the module indications are as shown in the top row of the table below Begin with the 2nd 3rd then 4th module if present a The LCD on the powered modules should indicate Ere l b The LCD status diagram will show the On Bypass mode 2 Turn on the utility input supply to module 1 a The LCD indications for all modules should change to the standard UPS OFF status as shown in the bottom row of the table below b This indicates that the modules parallel bus is operating normally Note If Er21 remains on any module there is a problem with the parallel communication of that module and you should check the parallel bus cable connections WARNING Do not turn ON any UPS before all modules clear the Er21 test as it could cause unpredictable UPS failure or damage UPS 1 UPS2 UPS3 UPS4 TEST UTILITY OFF D7 Or Ao a ga Ep Or Qo Oy ga D7 Or Qe Oy TEST OK Op D7 On Oo Oy aa KR L D O17 On Oo ge D GA On Oo Oy
88. sitive signal 0 Shutdown UPS negative signal gt N OJ To shut down the UPS you must connect a DC voltage of 5 5V 25V between pin 9 and pin 10 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 55 Uninterruptible Supplies Ltd Se 8 Options A KOHLER COMPANY 8 5 USE USB card This card can be installed in the Option Slot located on the rear of the UPS to facilitate an alternative USB interface The USB configuration detail is described in paragraph 2 5 Figure 8 4 USB Option card 8 6 R2E second RS 232 card This card can be installed in the Option Slot located on the rear of the UPS to facilitate an alternative RS 232 interface The RS 232 configuration detail is described in paragraph 2 5 Figure 8 5 RS232 Option card 56 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 9 Specification D Specification Input Nominal voltage Single phase 160 VAC 288 VAC 1 160 288VAC 39 277 485VAC Frequency 50 65 Hz 5 Hz auto sensing Phase Single Single or three Power factor Up to 0 99 at full rated linear load Input current total harmonic distortion THDi lt 6 at 100 linear load Output Voltage 200 208 220 230 240 VAC selectable 208 120V optional Voltage adjustment 40 1 2 3 selected by software Voltage reg
89. ss Park Hook Hampshire RG27 9XA Tel 01256 386700 Names deta Seciednoden fe e ase edge dodebencsstndee tt Sscieecencs iecdeedvesiealsieesatenbates JOD IC VG clulsCle GEET elei EEEEE Post Gode ederem reder aar dar En EEn EES edocs Ana E n ETERS ENRERE Tek Ee ee eege CZE Emal eege ee EE Please contact me to discuss C Extended Warranty options for my PowerWave 1000 UPS C Extended warranty options for my UPS System as below Man tact re r rirci aiena raies Mod l Ne E Rating KVA KE C Replacement Batterie C Other dey Aiea Va ea a aa aaa a aE ENEE 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 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 1 T Uninterruptible Power Supplies Ltd 3 Installation and Set up A KOHLER COMPANY Installation and Set up A CAUTION Read the safety information contained in chapter 1 before installing the UPS 3 1 Unpacking the UPS equipment The manufacturer has designed robust packaging for your product to help ensure it reaches you in good order however accidents and damage may sometimes occur during shipment You should inspect the UPS carefully upon receipt and if there are signs of damage you must inform the carrier and dealer immediately WARNING Under no circum
90. stances should you connect electrical power to a damaged unit or attempt to start it using its batteries The packaging is recyclable save it for re use or dispose of it appropriately and correctly 1 Remove the UPS from the packing carton 2 Check the package contents The standard unit includes a User Manual b A set of UPS communication software complete with RS232 cable c Amounting accessories kit which allows the UPS Battery cabinets to be configured for Tower or Rack installation d Battery connecting cable 3 Before proceeding with the installation check that the voltage and power ratings on the data plate located on the rear of the UPS matches the equipment order details Contact your dealer if this is incorrect 3 2 Selecting a suitable installation location As the UPS weighs several kilograms the intended location must e able to safely support its weight To ensure correct operation and a long service life the site where the UPS is to be installed must satisfy the following environmental condition s The UPS must be installed in a sheltered location It is not designed for outdoor use e The installed location must be dry and free of excessive dust e The UPS must not be installed in a corrosive environment or in the vicinity of flammable items The ambient temperature and humidity must be within the limits specified in chapter 9 of this manual The ventilation grills at the front of the UPS and extractor fans at th
91. tch the output of all the modules connected to a parallel system Note In a parallel system this should be carried out on the individual modules before they are connected together Calibration is carried out at 220V irrespective of the desired UPS output voltage 1 Turn ON the utility supply and close the UPS input circuit breaker and battery circuit breaker located on the rear of the UPS battery enclosures a The LCD Display will turn on and all of its symbols will illuminate for approximately 3 seconds 4 K Sr b The status leds will all turn on for approximately 3 seconds and then extinguish except for the utility input supply and bypass supply green leds which will remain lit c TheLCD panel will indicate that the battery is on charge and the UPS is oF F 2 Ensure there is no load connected to the module output 0 0 och cd 3 Simultaneously press and hold the ON and ENTER buttons for 3 5 Ge S 7 seconds until a beep is heard and then release them a The N 1 led will illuminate to show that you are in the calibration mode 4 Measure the output voltage using an accurate DVM and note the result if the indication is anything other than 220V it represents an error 5 Connect the UPS Setting Tool Software application as described in paragraph 3 8 1 36 UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 Uninterruptible Power Supplies Ltd A KOHLER Company 3 Installation and Set up
92. the PowerWave 1000 to operate in either one The difference between the two types of system are described below On line UPS system operation When used as an on line UPS the PowerWave 1000 is configured to normally operate in the ON LINE mode as shown in Figure 2 2 In the event of a utility supply failure the UPS changes to its ON BATTERY mode without affecting the UPS output supply i e the changeover 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 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 During ON LINE operation if the UPS experiences an inverter fault or overload condition the static switch transfers the load to the static bypass line ON BYPASS mode automatically and without interruption transfer time 0 provided the inverter and bypass supplies are synchronised If the transfer is due to a UPS overload the static switch will transfer the load back to the inverter if the overload clears and the UPS will return to its normal ON LINE mode of operation This system provides the highest degree of load protection especially in the event of a utility mains disturbance or complete failure and we always recommended its use if the critical load e g computer system will not tolerat
93. the critical load SESCH power 1 Press the OFF button for approximately 3 5 seconds until you hear two beeps then release it a The inverter switches OFF b The input mains and bypass supply leds will remain lit GN Sr c The LCD screen will show the UPS status as oF F d On the LCD mimic the load will be shown On Bypass and the battery still connected to the input LINE and on charge 2 To completely shut down the UPS disconnect the UPS utility mains supply a The UPS fans and control panel will remain operative for a few seconds before the unit completely shuts down b The UPS output will turn OFF and the load will no longer be supplied 4 3 2 UPS shutdown when on battery This procedure describe the shutdown sequence when turning OFF the UPS C e GN A kco when it is operating in its standby On Battery mode You would typically use this procedure during a prolonged utility mains failure if you chose to shutdown the critical load followed by the UPS in a controlled manner before the battery reaches the end of its autonomy time 1 Turn OFF the UPS by pressing the OFF button for approximately 3 5 seconds until you hear two beeps then release it 0 0 a The two programmable UPS outlet leds will extinguish to indicate the removal of UPS output power b The LCD screen will show the UPS status as oF F c On the LCD mimic the load will be shown disconnected from the UPS
94. the growing needs without compromising the existing load This situation is easily managed in a PowerWave 1000 parallel system installation which allows an additional module to be connected to an existing parallel system up to a maximum of four modules P Key Point All the UPS modules connected to a parallel system must be of the same model type and power rating Module redundancy If a system is designed with module redundancy it contains at least one UPS module over and above that necessary to power the system s connected load For example if the system shown in Figure 2 3 comprises 3x10 kVA modules it could be employed as a redundant module system for a load of up to 20 kVA This means that under normal circumstances each module shares the load equally and supplies up to 6 6 kVA but if one module fails or is taken off line the remaining two modules can sustain the full rated load by each serving 10 kVA The ability to lose one module yet still provided the rated load with processed backed up power significantly increases the overall system reliability Note If a parallel system is operating with a redundant module the N 1 led will be fully illuminated on the all the module control panels System wide load transfer operation All the UPS modules that are connected to the load in a parallel system must be in the same internal mode of operation at all times i e it is not permissible for one module to be operating in an ON LINE mode
95. ts e Up to four PowerWave 1000 UPS modules can be configured to operate as a parallel system with designed module redundancy to further enhance the overall system reliability e OFF LINE ECO operating mode is available to reduce running costs of suitable applications e User friendly design that permits simple and trouble free installation e The use of maintenance free batteries reduces the need for after sales service e True on line technology continuously supplies your critical applications with stable regulated transient free pure sine wave AC power e Highly efficient PWM sine wave technology yields excellent UPS efficiency The high crest factor of the inverter means that it can handle loads with peak inrush current characteristics and so avoids a need to upgrade to a UPS with a higher power rating e Compliance with stringent international standards for electromagnetic interference amp protection e Inbuilt frequency changer capabilities that can be selected for 50 60 Hz or 60 50 Hz input output frequency operation single module installation only e Fully digitized control logic for better functionality and high quality output power supply Digital signal processing DSP also provides an efficient communication capability that facilitates flexible remote control and monitoring options e An active input power factor correction PFC control function that produces in an input power factor PF of 0 99 resulting in outstan
96. ulation 2 Capacity 4500VA 4050W 6000VA 5400W 8000VA 7200W 10000VA 9000W Power factor 0 9 Lagging Wave form Sine wave THD lt 3 linear load Frequency stability 0 2 unless synchronised to line Synchronisation window 1 Hz 3Hz selectable via software Transfer time Inverter Bypass typical 0 ms Crest factor 3 1 DC Start Yes Efficiency Efficiency AC to AC Normal 91 Efficiency AC to AC ECO mode Up to 92 Up to 93 Up to 96 Protection Overload capability AC mode amp Backup mode Up to 105 load normal operation from 106 120 load switching to bypass after 1 min from 121 150 load switching to bypass after 10 Sec from 151 load switching to bypass immediately UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 57 Uninterruptible EE S lies Ltd Se 9 Specification SER pene Overload capability bypass operation lt 105 load continuously gt 106 120 load for 250sec shut down gt 121 130 load for 125sec shut down gt 131 135 load for 50sec shut down gt 136 145 load for 20sec shut down gt 146 148 load for 5sec shut down gt 149 157 load for 2sec shut down gt 158 176 load for 1sec shut down gt 177 187 load for 0 32sec shut down gt 188 load for 0 16sec shut down Short circuit handling In normal mode output breaker electronic fuse In battery mode output breaker electronic fuse In bypass mode input fuse
97. unications cards can be fitted at this point or installed later as required see Chapter 8 for option card details 2 Turn ON the UPS as described in paragraph 4 1 1 3 Check all metered parameters to ascertain that the indications are correct see page 40 4 Leave the battery on charge for 4 hours Note You can charge the batteries with the UPS output turned OFF as long as its utility input supply is connected and turned ON 5 Carry out a battery test as described in paragraph 4 2 3 6 If the battery test is successful the UPS can now be put into service CAUTION It is recommended that the battery is charged for further 4 hours before connecting any critical load This is to ensure that the battery is charged to a level that enables the UPS to perform to full specification UPS725 02 02 PowerWave 1000 4 5 10 kVA User Manual UK Dated 13 03 15 29 Uninterruptible Power Supplies Ltd 3 Installation and Set up A KOHLER company 3 7 Commissioning procedure parallel module system Use this procedure to commission a parallel module redundant or capacity UPS system CAUTION Before you carry out this procedure you must be familiar with the Operator Control Panel functions and the rear panel connections see paragraph 2 4 and paragraph 2 5 You should also be familiar with the safety information contained in Chapter 1 Commissioning a parallel UPS system comprises the following steps e Independent commissioning of each
98. uration data record and then access the file to observe the configuration history 1 10 11 12 In the top right hand corner of the UPS Setting Tool enter some unique details to identify the connected UPS Click the Write button to send the identification data to the UPS where it will be stored in memory a Click the Yes button in the Writing confirmation dialog b The UPS will beep twice to confirm that it has received the data c Click OK to clear the Transmit OK dialog To save the machine profile data to the UPS memory you must reset the UPS by turning OFF its input supply then turning it back ON again At any time when the UPS is re started you can download the data held in the UPS memory by clicking the Read button This will then populate the UPS Setting Tool fields with the stored values To set up a new data file click Fi Le gt New from the menu bar Using standard Windows file navigation methods select the directory in which you want to save the file enter a filename and click the Open button to save the file The file will be save with a ret filetype If you open the file using Fi le gt Open from the menu bar you will see an empty data file similar to that shown below UPS Ver M5341111 Name of Company Ablerex UPS type MSIITOKAT KYA 10 0 Special Function T23 E i rf a WWW WW Ja a Read Write UPS Setting Tool Ver XX3011B1 File Record Quit UP

725-02-02 PW1000 4.5-10 kVA User Manual UK.book

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