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

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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