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471-02-00 PW9000DPA User Manual UK.book

Contents

1. lo JE A le P UPS Power Module SS Saaaa d w S F2 Module bypass supply fuse E als mJ lg c c Ru EINE CH SEI J8t BC TET IE JSt JSt Battery trays I BCS SC I iw LUC sim zc LLLA LEAL F4 Battery fuse Le UPS Customer Interface connections IA2 Parallel Isolator described in the Options chapter IA1 Maintenance Bypass Isolator Figure 2 10 DPA 50 Cabinet details UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 1 1 Uninterruptible Powerm Supplies Ltd 2 General Description KOHLER COMPANY DPA 150 Component identification The DPA 150 can be fitted with up to three UPS power modules with the uppermost module identified as module 1 The battery fuses F4 are identified with their associated power module on the panel silk screen e g F4 2 is the battery fuse associated with module 2 The module parallel isolator switches IA2 are similarly identified e g 1A2 2 pertains to power module 2 Note that the module input mains fuses F1 are located within the modules and are not accessible with the module in
2. CLASSIC TRIPLE UPGRADE DPA 50 DPA 150 DPA 250 T E n E jJ Power module capacity Max 1 module 30 50kVA 3 modules 30 50kVA 5 modules 30 50kVA 280 x 7 9Ah batteries 240x 7 9Ah batteries External batteries Maximum power connection kVA 50 150 250 Dimensions WxHxD mm 730x1650x800 730x1975x800 730x1975x800 Weight of empty frame kg 262 239 205 Weight of frame with modules fitted kg 305 309 368 379 420 439 but without batteries with 1 Module with 3 Modules with 5 Modules Colours Front RAL 9007 black inlets Sidewalls Graphite grey Figure 2 1 PowerWave 9000 Cabinets frames DPA 30 Module DPA 40 Module DPA 50 Module Output Apparent Power KVA 30 40 50 Output Active Power KW 24 32 40 Output Power PF 1 KVA KW 24124 32132 40 40 Number of 12V Battery Blocks No 40 50 40 50 40 50 Dimensions WxHxD mm 663 x 225 x 720 Weight UPS Module kg 43 1 45 3 46 8 Colours Front Graphite grey On Inverter mode 50 KVA 40kW on Bypass mode 45 KVA 40kW Figure 2 2 PowerWave 9000 UPS Power Modules UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd 2 General Description A KOHLER COMPANY 2 2 4 Advanced design features Hot swappable modules In a redundant module system the unique hot swappable feature enables a UPS power module to be inserted or removed from its cabinet whilst it is still powered hot without having to shut dow
3. JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter JD5 Parallel BUS Input Connector JD6 Parallel BUS Output Connector JD11 RS232 Sub D9 female PC interface JD12 RS232 Sub D9 male for Multidrop ONLY USB PC Interface SNMP Slot for optional SNMP card ONLY Slot for optional Modem Ethernet card ONLY 9 Battery terminal N for 16 25 mm 10 Input Bypass terminals 16 25mm 11 Input Bypass terminals 16 25mm 13 Output Load terminal 16 25mm 13 IA1 Maintenance Bypass 14 1A2 1 Parallel Isolator UPS Module 1 15 F4 Battery Fuse Holder Module 1 16 F2 Bypass Line Fuse on each module Module DPA 30 22x58 50A Pronorm Module DPA 40 22x58 63A Pronorm Module DPA 50 22x58 63APronorm 17 JD1 Smart Port RS232 Sub D9P 18 JD7 Connector for Control Panel gt id RK Figure 3 14 DPA 50 Input output terminal block front view UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 37 3 Installation Uninterruptible Powerm Supplies Ltd KOHLER COMPANY IN 21 22 20 9 10 ONDA k 17 18 19 141516 EJ I E I IF I fe le fe A 713 9 10 11 12 ey a ed VR Le X1 X4 Customer interface on Phoenix Terminals X1 Customer Inputs X2 X4 Potential free contacts SW1 9 Multi Cabinet Configuration Switch JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter JD5 Parallel BUS Input Connector
4. Power Supplies Ltd A KOHLER COMPANY Operation Maintenance 4 1 4 2 4 3 4 4 4 5 5 1 5 2 5 3 5 4 5 5 5 6 5 7 Troubleshooting Options 6 1 6 2 6 3 6 4 7 1 7 2 7 3 7 4 7 5 7 6 Introduction 4 1 1 Operating procedure summary Operating Instructions 4 2 1 Starting the UPS system from the maintenance bypass 4 2 2 Individual module start stop procedure in a parallel system 4 2 3 Transfer the load from UPS to maintenance bypass mode 4 2 4 Complete system shutdown Replacement of the UPS module in a single module system 4 3 1 Removing a UPS Module in a single module system e g DPA 50 4 3 2 Refitting the UPS module Replacing a module in a REDUNDANT multi module system 4 4 1 Removing the UPS module 4 4 2 Inserting a UPS module Replacing a module in a CAPACITY multi module system 4 5 1 Removing a module 4 5 2 Refitting a module in a capacity multi module system Introduction System calibration User responsibilities Routine maintenance Battery testing Battery maintenance Battery disposal and recycling Alarms Menu Commands Event Log Measurements Fault Identification and Rectification Messages and Alarms Contacting Service Introduction Dry port volt free contacts 7 2 1 Input interfaces terminal block X1 7 2 2 Output interfaces terminal blocks X2 X3 X4 RS232 Computer serial interface USB amp JD11 RS232 Interface for multidrop JD12 SNMP Modem slots for remote moni
5. 3x380 400 415 UPS MAINS SUPPLY INPUT BYPASS LINKS FITTED 1L1 2L1 1L2 2L2 1L3 2L3 1N 2N d Rectifier Inverter Static Bypass Line Static Bypass Line Static Bypass Line Cabinet Power Single Input 3 x 400V Output 3x400V 0 8 pf Frame kVA FuseA A Gable A mm2 Max Input with batt Gable D mm Nominal Current charging A A DPA 50 50 3x100 5x25 67 5x25 72 DPA 150 450 3x250 5x120 or 5x 2x50 202 5x120 or 5x 2x50 218 DPA 250 250 3x400 5x 2x95 337 5x 2x95 362 Notes 1 Fuse and Cable recommendations to IEC 60950 1 2001 2 The fuse and cable rating details in the above tables are a recommendation only 3 The UPS must be installed to prescribed IEC or local regulations e g BS7671 2008 4 DC Cables and Battery fuses are bespoke to the installation 72 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 8 Specifications 8 8 Cable and fuse sizing Dual feed input _ MAINS DISTRIBUTION BOARD Mains Supply 3x380 400 415 Mains Supply 3x380 400 415 UPS MAINS SUPPLY UPS BYPASS SUPPLY ral Rectifier Rectifier Inverter Inverter Static Bypass Line Static Bypass Line Static Bypass Line Static Switch Static Switch Cabinet Powe Dual Input 3 x 400V Output 3x400V 0 8 pf usu p Fuse B C C
6. 5x28Ah 5x28Ah 4 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 3 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 2 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 1 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 3x40 x28Ah 4x50 x28Ah Figure 3 13 External battery cabinet configurations 34 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 3 Installation 3 7 UPS Cabling procedure WARNING Opening or removing the UPS covers will create a risk of exposure to dangerous voltages if power is connected to the UPS Safety notes Please ensure you read and understand the following safety notes before you begin the UPS electrical installation 1 Do not commence this procedure until the UPS mechanical installation is completed 2 Allthe cable installation procedures detailed below must be supervised by a qualified electrician 3 Do not connect or operate the UPS if there is water or moisture present 4 When carrying out any work on the UPS power cables or terminals you must ensure that the UPS input and load supplies are isolated and locked out at their respective distribution boards Warning notices should be posted to prevent any inadvertent operation of the UPS mains supply isolators 5 Before you connect the UPS input cables ensure that the customer provided
7. LINE 1 INVERTER T mmi LINE 2 Green BY PASS Off ENSE BATTERY INVERTER Green BATTERY Green 11 The UPS is now operating in On Line mode The load is protected and supplied by inverter power 4 2 2 Individual module start stop procedure in a parallel system If a multi module system is designed with redundancy it is possible to stop and start one module without affecting the operational status of the remainder of the system e g one module can be taken off line for servicing whilst the remaining modules maintain a protected load supply A WARNING All the operations in this section must be performed by authorised and trained personnel UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 45 4 Operation Uninterruptible Powerm Supplies Ltd KOHLER COMPANY Module start up Use this procedure to start a module and connect it to a multi module system This procedure assumes the following initial conditions The fused battery isolator s are open in the UPS cabinet or external battery cabinet n the UPS cabinet the modules bypass isolator F2 and the parallel isolator IA2 are open 1 Inthe UPS cabinet close the modules bypass isolator F2 and the parallel isolator IA2 2 Close the UPS input supply isolator at the LV switchboard if open a The LINE 1 indicator will illuminate green b The LCD display will indicate LOAD OFF SUPPLY FAILURE If necessary press the RESET button to obtain t
8. i e when using an independent battery configuration only one power module will be affected in the event of a battery failure Remove links for dual feed input External Mains Bypass Mains Input UPS Output Battery Input Dual feed only Figure 3 5 DPA 50 Terminal connections 28 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COVPANY 3 Installation Bypass Mains Input Dual feed only Remove links for dual feed input Protective e3 K K Mains UPS Output Earth Common battery links Input External Battery Figure 3 6 DPA 150 Terminal connections Bypass Mains Input Dual feed only Remove links for dual feed input UPS Output Common battery links Mains Input External Battery Figure 3 7 DPA 250 Terminal connections UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 29 Uninterruptible Supplies Ltd Se 3 Installation KOHLER COMPANY 3 6 5 Power cabling in a multi cabinet installation In order to achieve equal load sharing between the UPS cabinets in a multi cabinet installation the input cables from the input distribution board to each cabinet should be of equal length as should the UPS output cables to the output distribution board See Figure 3 8 Recommended cable configurations Rectifier Feed Bypass Feed UPS 1 UPS2 UPS 3 UPS 4 To Load The ca
9. is automatically processed and UPSL s Service Centre personnel are alerted UPSL s Service Centre personnel are then able to liaise with the company s field service team and will remotely diagnose the UPS incident before reaching the facility with appropriate spare parts within the contracted service agreement time frame 66 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se 7 Options KOHLER COMPANY UPS with Power REPORTER UPS Batteries Email Battery Care Site manager System Servers with Power REPORTER mi software Alarm Event Data amp monthly report UPS Email server Analyst Consultant specialists UPS Service Engineer Figure 7 9 PowerREPORTER operation UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 67 Uninterruptible Supplies Ltd uw 8 Specifications KOHLER COMPANY 8 Specifications 8 4 Mechanical Characteristics Capacity Max 1 module 30 45kVA 3 modules 30 45kVA 5 modules 30 45kVA 280 x 7 9Ah batteries 240x 7 9Ah batteries no batteries Max Power connection kVA 50 150 250 Dimensions WxHxD mm 730x1650x800 730x1975x800 730x1975x800 Weight of Empty Cabinet kg 250 270 190 Weight of Cabinet with kg 300 310 420 450 440 490 modules and no batteries with 1 Module with 3 Modules with 5 Modules Colours Front RAL 9007 black inlets
10. suitable LV Distribution board containing a circuit breaker or fused isolator to provide both overload protection and a means of isolating the UPS from the mains supply when required Similarly the UPS output supply terminals should be connected to the load equipment via a suitably fused load distribution board Input neutral grounding A permanently connected input neutral is required to enable the rectifier to operate UPS correctly and allow the UPS to function properly when operating on battery The input neutral must also be grounded to permit correct operation when the UPS is running on battery Key Point As the input neutral must ap DE IG NND OV X 230V P be unswitched and connected to the UPS at all times DO NOT use a 4 E e Figure 3 2 Permanent grounded input neutral pole input switch or isolator at the LV Distribution board on a TN S system 3 6 2 UPS Cable and fuse sizing Single feed dual feed inputs The UPS can be wired for a single feed input standard whereby the UPS input supply terminals and bypass supply terminals are internally linked or it can be wired for a dual feed input where the bypass links are removed and the UPS bypass terminals are connected to a dedicated bypass supply Both configurations are shown in Figure 3 3 single feed and Figure 3 4 dual feed together with details of the recommended fuse and cable ratings Fuse and
11. JD6 Parallel BUS Output Connector JD11 RS232 Sub D9 female PC interface JD12 RS232 Sub D9 male for Multidrop ONLY USB PC Interface SNMP Slot for optional SNMP card ONLY Slot for optional Modem Ethernet card ONLY Battery terminal N for 16 25 mm Input Bypass terminal for Dual Input feed 3xM10 11 Input Rectifier terminal for Single feed 4xM10 12 Output Load terminal 4xM10 13 IA1 Maintenance Bypass 14 1A2 1 Parallel Isolator UPS Module 1 15 1A2 2 Parallel Isolator UPS Module 2 16 1A2 3 Parallel Isolator UPS Module 3 17 F4 Battery Fuse Holder Module 1 18 F4 Battery Fuse Holder Module 2 19 F4 Battery Fuse Holder Module 3 20 F2 Bypass Line Fuse on each module Module DPA 30 22x58 50A Pronorm Module DPA 40 22x58 63A Pronorm Module DPA 50 22x58 63APronorm 21 JD1 Smart Port RS232 Sub D9P 22 JD7 Connector for Control Panel Figure 3 15 DPA 150 Input output terminal block front view 38 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 3 Installation Figure 3 16 14 15 E gt ol Me st 10 1 12 og L Sie 3 1 X1 X4 Customer interface on Phoenix Terminals X1 Customer Inputs X2 X4 Potential free contacts 2 SW1 9 Multi Cabinet Configuration Switch 3 JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter JD5 Parallel B
12. LED indicator will illuminate on the operator control panel and the audible alarm will sound In this case proceed as follows 1 Silence the audible alarm by pressing the RESET button 2 Identify the cause of the alarm condition by means of the events register in the main menu see paragraph 2 5 3 3 In case of doubt please contact your nearest service agent or call Uninterruptible Power Supplies Ltd on 0800 731 3269 Fault identification and rectification information is given on the following pages 6 2 Menu Commands Event Log Measurements A detailed description of the Menu Commands Event Log and Measurements that can be operated and displayed on the LCD can be found on page 15 Event Log Screen DESCRIPTION LCD DISPLAY 1 Logging Control B is aun 14 35 76 LOAD TO IM 2 Alog of the last 64 events is stored in the Power Management Display 83 16 88 LOAD TOBY 3 All events and alarms are indicated with their date and time of occurrence e The full list of Alarms and Messages are shown in paragraph 6 3 As you step through the event memory make a separate note of each alarm condition as this will assist in the identification of any problems UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 57 6 Troubleshooting Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 6 3 Fault Identification and Rectification Messages and Alarms Messages will not appear automatically on the LCD as the
13. SNMP Internal and external SNMP adapters 7 6 UPS Monitoring and automated control software 7 6 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 9000 UPS system in conjunction with purpose designed network management tools a systems administrator can take measures to back up data and prevent system errors or data loss even in the event of a relatively long utility supply outage In the case of an abnormal utility supply suitable UPS management software will also enable a system administrator to monitor all concerned networks from a central point and identify bottlenecks at an early stage In spite of extensive system monitoring if an administrator fails to intervene in a timely manner 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 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 63
14. Sidewalls Graffito grey PowerWAVE DPA MODULES Output Apparent Power KVA 30 40 45 Output Active Power KW 24 32 40 Output Power PF 1 KVA 24124 32132 40 40 KW Number of 12V Battery Blocks No 40 50 40 50 40 50 Dimensions WxHxD mm 663 x 225 x 720 Weight UPS Module kg 50 57 60 Colours Front RAL 9007 On Inverter mode 50 KVA 40kW on Bypass mode 45 KVA 40kW 68 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 8 Specifications 8 2 Input Characteristics Module Type DPA 30 DPA 40 DPA 50 Output Rated Power per Module cos 0 8 kVA 30 40 451 Output Rated Power per Module cos 1 0 KW 24 32 40 Nominal Input Voltage V 3x380 220V N 3x400V 230V N 3x415 240V N Input Voltage Tolerance V 23 15 3x308 177 V to 3x460 264 V for 100 load ref to 3x400 230V for Loads in 30 15 3x280 161 V to 3x460 264 V for lt 80 load 40 15 3x240 138 V to 3x460 264 V for lt 60 load Input Frequency Hz 35 70 Input Power Factor PF 0 99 100 load Inrush Current A limited by soft start max In Input Distortion THDI Sine wave THDi 2 96 100 load Max Input Power with rated output power and charged kW 254 33 9 42 9 battery per Module output Cos 1 0 Max Input Current with rated output power and charged A 36 8 49 1 62 1 battery per Module output Cos 1 0 Max Input Power
15. The requirement to press both buttons is to help avoid accidental UPS start up or shutdown operation During normal operation pressing the two ON OFF buttons simultaneously will immediately shutdown the UPS module n a single module system e g DPA 50 this will disconnect the UPS from the load unless the load is first transferred to the maintenance bypass Ina parallel module system the power module will shutdown and be disconnected from the load bus However the load may or may not transfer to the static bypass depending on whether or not the number of remaining live modules satisfies the system s redundancy i e if there are a sufficient number of modules remaining to support the system s load then the load will not be transferred Note To shut down all the modules in a parallel system you must press both ON OFF buttons on every module 14 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description 2 5 2 Module mimic leds The mimic diagram leds indicate the status of the general UPS power flow and change colour between Green and Red and OFF to indicate the present UPS operating conditions LED Indication summary Indicator Indicator Status Interpretation LINE 1 GREEN Input mains available RED Input mains not available LINE 2 GREEN Bypass mains bypass OK RED Bypass mains bypass not OK or not present ALARM OFF No alarm condition F
16. UK Dated 06 08 14 5 Uninterruptible Power Supplies Ltd 2 General Description KOHLER COMPANY UPS Output load supply Figure 2 3 shows that the UPS output Load Supply can be provided through one of three power paths depending on the UPS operating mode From the inverter 4 via the static switch and isolator IA2 From the static bypass line 5 via the static switch and isolator IA From the maintenance bypass line 6 via the maintenance bypass isolator IA1 The criteria for operating under each of these UPS modes is described below 2 3 2 UPS Module operating modes The diagrams in this section illustrate cabinet fitted with a single power module Where two or more power modules are fitted they will always adopt the same operating mode due to the parallel control logic signals Load on Inverter MAINTENANCE BYPASS LINE Bypass ee STATIC BYPASS LINE LINE 2 BY PASS LOAD LINE 1 INVERTER T PS BATTERY i BATTERY PW9000 DPA Cabinet Figure 2 4 Load on inverter This is the normal operating mode and the only one that provides the load with continuously processed and backed up power In this mode the mains supply is converted to DC by the rectifier which then charges the battery and provides operating power for the inverter which converts the rectifier output back to AC suitable for powering the load The inverter output frequency is synchronised to the bypass su
17. Uninterruptible Supplies Ltd Se T Options KOHLER COMPANY Two monitoring system options are available for use with the PowerWave 9000 UPS system SNMP monitoring software The SNMP adapter described above requires a PC with terminal connections and for normal operation at least one Ethernet network connection It also requires that the network operating system in use is SNMP compatible Uninterruptible Power Supplies Ltd offer suitable monitoring software with SNMP functionality for NetWare OS 2 all Windows NT systems on INTEL and ALPHA network platforms WAVEMON UPS monitoring and control software WAVEMON is designed to operate in conjunction with many of the systems supplied by Uninterruptible Power Supplies Ltd and features both UPS monitoring and automatic UPS server shutdown facilities The system comprises a bespoke software package which is installed on a local PC and communicates with the UPS over a standard RS232 cable of up to 15m in length 7 6 2 WAVEMON Shutdown and Management Software Eventlist 24 09 2003 12 45 System Serial communication restored Supplies Ltd 24 09 2003 12 39 System Serial communication lost MONUIR Co 24 09 2003 12 35 System Connected to UPS Uninterruptible System S d Available UPS Figure 7 8 Monitoring screen image WAVEMON is a software application designed to operate with many of the systems supplied by Uninterruptible Power Supplies Ltd and features both
18. X1 7 4 L 3 3Vdc Customer IN 2 X1 8 x SNB X1 9 3 3Vdc Temperature Battery X1 10 X ene Figure 7 2 Dry Port X1 Connections Remote emergency shutdown customer input Emergency Stop Switch N C Normally Closed Z X a Link Facility UPS Emergency Stop X1 x11 3 x12 e 08 Terminal Block Figure 7 3 Remote Emergency OFF Switch Cabling The remote emergency stop input uses a normally closed contact which opens to trigger the emergency stop sequence In order to allow maintenance or testing of the remote emergency stop circuit without disturbing the normal UPS operation it is recommended that a terminal block with linking facilities is installed between the UPS and the remote emergency stop button as shown 1 Usea screened cable with 1 pair section of wires 0 6 mm and maximum length of 100 m 2 Connectthe cable as shown in Figure 7 3 60 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY T Options Generator ON customer input The Generator ON input uses a normally open contact which closes to indicate that the standby generator is running and supplying input power to the UPS When used this facility enables an option to inhibit the operation of the battery charger and or static bypass see Set up User menu screen on page 18 U
19. a CAPACITY multi module system WARNING All the operations in this section must be performed by authorised and trained personnel By opening or removing the UPS modules and module covers you run risk of exposure to dangerous voltages WARNING When removing a UPS module wait for at least 2 minutes after it has been disconnected in order to allow the DC Capacitors to fully discharge WARNING When the UPS module is removed from the cabinet always fit an appropriate blanking cover WARNING Two persons are needed to pull out the module from the UPS Frame The weight of a DPA 50 40kW module is 60kg Employ suitable lifting aids and safety platforms where possible SEPP If a UPS module fails and there is not enough capacity left to protect the load by the remaining operating UPS modules the load will automatically transfer to the static bypass and continue to be supplied from the mains supply 52 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 4 Operation 4 5 4 Removing a module 1 Verify that the load is on BYPASS and is supplied by the mains power on ALL UPS modules a In the majority of the events the LED indicators on control panel of a faulty module will show BY PASS LED Colour LINE 1 Green LINE 1 INVERTER mm LINE 2 Green BY PASS Green P BATTERY INVERTER RED BATTERY Green b Whereas the LED indicators on the control panels of
20. above before continuing with this procedure 44 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 Operation Transferring the load to the UPS from the maintenance bypass 6 Ensure that the BYPASS LED is green on all modules 7 Open the maintenance bypass switch IA1 on all cabinets in a multi cabinet system a TheLCD panels will display MANUAL BYPASS OPEN b The INVERTER LED will be extinguished c An audible alarm will sound BY PASS LED Colour LINE 1 Green LINE 2 Green BY PASS Green INVERTER RED BATTERY Green INVERTER PS BATTERY 8 Press the RESET button to cancel the audible alarm on all modules a TheLCD display s will now indicate LOAD NOT PROTECTED Transferring the load to the inverter 9 Onthe control panel of any one module in a parallel module system a Press the UP key once to access the menu system b Use the UP DOWN keys to move the cursor so that it is adjacent to COMMANDS then press the ENTER key c Use the UP DOWN keys move the cursor so that it is adjacent to LOAD TO INVERTER then press the ENTER key 10 The UPS system will now transfer the load to inverter on all modules in a parallel module system a The LCD display s will now indicate LOAD PROTECTED b Check and confirm that the LED display s are as shown below BY PASS LED Colour LINE 1 Green
21. after it has been disconnected in order to allow the DC Capacitors to fully discharge WARNING When the UPS module is removed from the cabinet always fit an appropriate blanking cover WARNING Two persons are needed to pull out the module from the UPS Frame The weight of a DPA 50 40kW module is 60kg Employ suitable lifting aids and safety platforms where possible SEPP If a UPS module goes faulty in a single module system e g DPA 50 the load will automatically transfer to the UPS bypass supply BYPASS mode and the load is unprotected against a mains supply failure 4 3 4 Removing a UPS Module in a single module system e g DPA 50 If your PowerWave 9000 consists of a single UPS power module then perform the following steps to shutdown and extract the module Transfer the load to the maintenance bypass see paragraph 4 2 1 a The load is now directly supplied by mains and is not protected N Simultaneously press the two ON OFF buttons on the UPS control panel a The LED display will give the following indications BY PASS LED LINE 1 LINE 2 BY PASS EHE BATTERY INVERTER BATTERY 3 Open the fused battery isolator s associated with the module a The UPS module is now totally shut down 4 Disconnect cables from connectors JD7 and remove the four screws on the front of the UPS module that secure it to the cabinet frame 5 Pull the UPS power module forward
22. connected by the commissioning engineer External battery cabinet mounted batteries The batteries within the external battery cabinet will be connected by the commissioning engineer The only wiring that can be carried out by the installation engineer is the cabling between the external battery cabinet and the UPS battery terminal blocks as detailed below 1 Familiarise yourself with the wiring diagrams in Figure 3 10 and determine whether the installation is designed to use a common battery or individual battery 2 Ensure that the fused battery isolator s in the external battery cabinet are open WARNING Do not re close the fused battery isolators in the battery cabinet before the UPS system is commissioned 3 Connectthe protective earth cable PE between the UPS and external battery cabinet 4 Connect the battery cables from the UPS battery terminal blocks to the corresponding battery terminal blocks in the external cabinet ensuring that the cables are connected to the corresponding N terminals as illustrated in Figure 3 10 40 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 3 Installation 3 9 Multi cabinet configuration and paralleling cables Key Point This section is required only if two or more cabinets are to be connected in a multi cabinet parallel configuration as described paragraph 2 3 3 In a multi cabinet system a series of communica
23. mentioned in the delivery note The rating specifications can be found on a nameplate located inside the UPS door 8 Open the cabinet door and ensure that all the UPS power modules are correctly and securely fitted in their compartments Ensure that a protection cover is fitted to the front of any empty compartments Doc fF WON 3 4 Storage UPS Cabinet If you plan to store the UPS cabinet prior to use it should be held it in a clean dry environment with a temperature between 5 C to 40 C and RH lt 90 The UPS should preferably be stored in the original packing and shipping carton but if the packing container is removed you must take measures to protect the UPS from dust Battery The UPS uses sealed maintenance free batteries whose storage capacity depends on the ambient temperature It is important not to store the batteries for longer than 6 months at 20 C 3 months at 30 C or 2 months at 35 C storage temperature without recharging them For longer term storage the batteries should be fully recharged every 6 months 20 C temperature under charge overcharge or over discharge will destroy batteries Charge the battery both before and after storing Always store the batteries in a dry clean cool environment in their original packaging Ifthe packaging is removed protect the batteries from dust and humidity i CAUTION Sealed batteries must never be stored in a fully or partially discharged state Extreme UPS47
24. situ UPS Power Module 1 SS F2 1 Module 1 bypass supply fuse ES El UPS Power Module 2 sz F2 2 Module 2 bypass supply fuse el UPS Power Module 3 F2 3 Module 3 bypass supply fuse B d EI ofa Battery trays Parallel Isolator 1 per power module IA2 1 IA2 2 IA2 3 Tt CES zer Battery fuse 1 per power module F4 1 F4 2 F4 3 cHEcHEEH UPS Customer Interface connections IA Maintenance Bypass Isolator described in the Options chapter iem en Figure 2 11 DPA 150 Cabinet details 12 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description DPA 250 Component identification The DPA 250 contains no batteries and can be fitted with up to five UPS power modules with the uppermost module
25. the UPS via an RS232 USB interface Running as a background application UPSMAN collects and interprets the messages received from the UPS and places them at the disposal of the client module UPSMON as well as any connected SNMP based instrumentation and control system If UPSMAN detects voltage variations or a power failure it can execute various system event routines by means of which for example the server is switched off or a warning is sent to the connected users These system event routines are a part of the management software and can be configured in accordance with local application requirements The software of your PowerWave 9000 UPS unit can be integrated into a network in two ways 1 Bythe server which is supplied by the UPS itself and has been integrated into the network In most cases this server is used as a sub agent and you only need the WAVEMON software without an SNMP adapter You will also need to establish an RS232 USB connection between the 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 Licensing A licence is issued with every software serial number for use of what
26. the remaining healthy modules will show LINE 2 BY PASS Colour LINE 1 INVERTER LNE Green LINE 2 Green BY PASS Green INVERTER RED BATTERY Green P BATTERY Close maintenance bypass switch IA1 in all cabinets in a multi cabinet system 3 Onall modules check and confirm that a The INVERTER LED has turned to red b The BYPASS LED is green c TheLCD displays MANUAL BYP IS CLOSED BY PASS Sa LED Colour LINE 1 Green LINE 1 INVERTER FS mm LINE 2 Green BY PASS Green P BATTERY INVERTER RED BATTERY Green Open the parallel isolator switch IA2 of the UPS module to be replaced Open the fused battery isolator s associated with the module The UPS module is now totally shut down Disconnect the control panel cable to connector JD7 Remove the four screws on the front of the UPS module that are fixing it to the cabinet frame Pull the UPS module forwards until the rear connectors are disconnected DO NOT FULLY EXTRACT THE UNIT ooudoosfbn A WARNING Wait at least 2 minutes to allow the module s electrolytic capacitors time to discharge UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 53 4 Operation Uninterruptible Power Supplies Ltd A KOHLER COMPANY 10 After waiting two minutes fully withdraw the UPS power module from the cabinet by pulling it forward horizontally 11 If you are not intending to replace the UPS module immediately cov
27. 00 for battery configurations for 24Ah or 28Ah blocks max 200 Blocks S type For Separate Battery C type For Common Battery CBAT DPA 120 S type item no 00 7912 C type item no 00 7964 CBAT DPA 200 S type item no 00 7913 C type item no 00 7965 BATTERY FRAMES Configuration accommodates Max 120 Batt block x 24Ah 28Ah 200 Batt blocks x 24Ah 28Ah on 8 shelves on 7 shelves 3x5 15 blocks shelf 6x5 30 blocks shelf Battery fuses Max Batt Strings S type 3 3 Terminal 9 x 16 25mm 5 5 Terminal 15 x 16 25mm Terminals Battery fuses Max Batt Strings C type 3 3 Com Connection Bar 5 5 Com Connection Bar Terminals 3 x 2xM8 PE 2xM8 3 x 2xM10 PE 2xM10 Fuse Type Very Fast acting A 3x100 A 5x100A Dimensions WxHxD mm 730x1975x800 1200x1975x800 Weight w o trays and w o batteries kg 150 250 Note Battery fuses and cables are bespoke to the installation The above are recommendations only all fuses and cables must comply with prescribed IEC standards or local regulations CBAT DPA 120 CBAT DPA 200 A B C A B C D E F 8 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 7 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 6 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah 5x28Ah
28. 0x7Ah 10x7Ah 10x7Ah 4 10x7Ah 2x5x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 3 2x5x7Ah 2x5x7Ah 2x5x7Ah 2x5x7Ah 2x5x7Ah 2x5x7Ah 2x5x7Ah 2x5x7Ah 10x7Ah 10x7Ah 10x7Ah 2 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 1 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 5x50 x7Ah 4x50 x7Ah 3x40 x7Ah Figure 3 11 DPA 50 Battery configurations DPA 150 A DPA 150 cabinet can contain up to three UPS power modules and has space for up to 240 x 7Ah internal batteries Figure 3 12 shows the full battery configuration Each vertical block of batteries can be wired as an individual string for each power module or connected as three parallel strings to provide a common battery for all three modules A B 03 UPS Module 3 UPS Module 2 UPS Module 1 6 10x7Ah 10x7Ah 10x7Ah 5 10x7Ah 10x7Ah 10x7Ah 4 10x7Ah 10x7Ah 10x7Ah 3 10x7Ah 10x7Ah 10x7Ah 2 10x7Ah 10x7Ah 10x7Ah 1 10x7Ah 10x7Ah 10x7Ah 3x 2x40 x7Ah Figure 3 12 DPA 150 Battery configurations UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 33 Uninterruptible Powerm Supplies Ltd 3 Installation KOHLER COMPANY External battery installations Two matching external battery cabinets are available CBAT DPA 120 for battery configurations of 24Ah or 28Ah blocks max 120 Blocks CBAT DPA 2
29. 1 02 00 PW9000DPA User Manual UK Dated 06 08 14 23 3 Uninterruptible Supplies Ltd Se Installation KOHLER COMPANY 3 5 Planning the installation site considerations A certain amount of pre planning will help ensure a smooth and trouble free installation of the UPS system The following guidelines should be taken into account when planning a suitable UPS location and operating environment 1 2 The route to the installation location must allow the equipment to be transported in an upright position The floor at the proposed installation site and en route from the off loading point must be able to safely take the weight of the UPS and battery equipment plus fork lift during transit Locations with high ambient temperature moisture or humidity must be avoided a b c d The installation site humidity should be lt 90 non condensing The prescribed ambient temperature is 15 C to 25 C An ambient temperature of 20 C is recommended to achieve a long battery life Any requested cooling air flow must be available The air entering the UPS must not exceed 40 C The air conditioning system must be able to provide a sufficient amount of cooling air to keep the room within the prescribed temperature range The following environmental conditions should also be considered a b c d e 3 5 1 Fire protection standards must be respected The floor material should be non flammable The location mus
30. 3 6 3 UPS Power cable termination sizes The table below gives details of the cable termination sizes applicable to the various models across the PowerWave 9000 range Cabinet Battery Input Output Frame INI 4PE Bypass 3 N Rectifier 3 N PE 3 N PE DPA 50 DC Fuses and cables 4 x 16 25mm T 5 x 16 25mm T 5 x 16 25mm T are bespoke to the DPA 150 installation 3x M10 B APE 1xM10 B 4x M10 B PE 1xM10 B 4 x M10 B PE 1xM10 B DPA 250 3x M12 B PE 1xM12 B 4x M12 B PE 1xM12 B 4 x M12 B PE 1xM12 B T signifies Terminal block B signifies Busbar 3 6 4 UPS Power connection details Figures 3 5 to 3 7 illustrate the power terminal connections for the DPA 50 DPA 150 and DPA 250 UPS cabinets respectively In each case the diagrams depict a single feed input supply with links fitted between the Mains and Bypass input supply terminals This is the standard configuration and the identified links must be removed for dual feed operation is required The diagrams for the DPA 150 and DPA 250 models also show optional links adjacent to the external battery terminal connections If a common battery is used these links must be fitted to the terminals shown so that the external battery is connected to all the fitted power modules Note Best UPS system reliability is achieved when using an independent battery bank for each power module as this extends the module redundancy to include the battery
31. Cable recommendations are to IEC 60950 1 2001 All external fuses isolators and power cables must be rated and installed in accordance with the prescribed IEC standards or local regulation e g BS7671 2008 e External DC Cables and battery fuses are bespoke to the installation P Key Point The information in figures 3 3 and 3 4 is given for guidance only Note All cabinets must be cabled according to their full rated output even if the cabinet is not fully populated with power modules at the time of installation This allows for future expansion to be carries out safely UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 25 Uninterruptible Supplies Ltd Se KOHLER COMPANY 3 Installation Mains Supply 3x380 400 415 UPS MAINS SUPPLY INPUT BYPASS LINKS FITTED 1L1 2L1 112 2L2 113 213 1N 2N Fil F2 Rectifier Inverter Static Bypass Line Static Bypass Line Static Bypass Line Static Switch Cabinet Power Single Input 3 x 400V Output 3x400V 0 8 pf Frame kVA Fuse A A CRISAN Max Input with batt Cable D mm Nominal Current charging A A DPA 50 50 3x100 5x25 67 5x25 72 DPA 150 150 3x250 5x120 or 5x 2x50 202 5x120 or 5x 2x50 218 DPA 250 250 3x400 5x 2x95 337 5x 2x95 362 Note This illustration shows connections to an external battery cabinet The DPA 50 and DPA 150 model
32. Common Figure 7 5 Dry port X2 X4 connections 7 3 RS232 Computer serial interface USB amp JD11 A serial RS 232 interface is available through a standard 9 pin D Type female socket JD1 or USB port to provide an intelligent RS 232 serial port which allows the UPS to be connected to a computer When used in conjunction with the optional WAVEMON software this port allows the connected computer to continuously monitor the input mains voltage and UPS status and display a message in the event of any UPS system changes Figure 7 6 shows the cable wiring suitable for PC s with a 9 pin or 25 pin serial port respectively Note that the maximum length for the interconnecting RS232 cable is 15m Interface Cable Interface Cable UPS end Computer end 9 Pin D Type 9 Pin D Type Male Female 9 Pin D Type 25 Pin D Type Male Female Figure 7 6 PC Serial port connector cable 7 4 RS232 Interface for multidrop JD12 The Computer Interface JD12 5 is an intelligent RS232 serial port that monitors signals from several UPS cabinets connected in parallel The connector JD12 is a standard D Type 9 pin male 62 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd KOHLER company 7 Options 7 5 SNMP Modem slots for remote monitoring control Simple Network Management Protocol SNMP is a world wide standardised communication protocol that can be used to monitor any n
33. ES ES NS Ki KS TTT TTTS NN RENS NAY cE AMMAN SN TATA A Laas De en al ERA ER ERE Ee H SS SITET ee ues SaaS SRS SSE zi d Le QE e eege Keesen bumn x Bernas SHIVA AEA RTT nanm iech Gemma SEIT SE 7 SEE EA ALA GBYRSNESEGAN BUA Re eee AA TERT TS TR mx zd m xd zi 2 Ra Sat Saas kamarna ERAN CERGUDSGUNGCURSS ao muna eA aaa SSSA DN eel el eS aunan SSS SEN LE Ce Se TLLA See GEN PowerWAVE 9000DPA Uninterruptible Powerm Supplies Ltd E Uninterruptible Supplies Ltd KOHLER COMPANY Document Control 471 02 00 06 08 2014 Manual revised and published as 471 02 00 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY Uninterruptible Power Supplies Ltd has taken every precaution to produce an accurate complete and easy to understand manual and will therefore assume no responsibility nor liability for direct indirect or accidental personal or material damage due to any misinterpretation of or accidental mistakes in this manual 2005 Uninterruptible Power Supplies Ltd This manual may not be copied nor reproduced without written permission of Uninterruptible Power Supplies Ltd UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Table of Contents Safety 1 1 Description of symbols used in this manual 1 2 User precautions General Description 2 1 Introducti
34. F Le xe x 2 SW1 9 Multi Cabinet Configuration Switch 2z o l3 3 3 JD8 Parallel BUS connector WS de Only for paralleling cabinets use optional adapter ba 4 JD5 Parallel BUS Input Connector CR 5 JD6 Parallel BUS Output Connector ne 2 Elsa 6 4 JD11 RS232 Sub D9 female PC interface e d as 7 5 JD12 RS232 Sub D9 male for Multidrop ONLY e e o 6 USB PC Interface o ei d Ji 2 7 SNMP Slot for optional SNMP card ONLY i E 8 Slot for optional Modem Ethernet card ONLY Figure 7 1 UPS Interface board DPA 50 details shown Each UPS cabinet is fitted with an interface board as shown in Figure 7 1 which enables various external monitoring and control applications to be connected to the UPS system to satisfy particular site requirements The interface board s input and output connections are shown above in Figure 7 1 The interface board has two LEDs The green LED indicates the status of the interface and blinks twice per second when the board is fitted to the master UPS 1st cabinet in the parallel system and once per second when the board is fitted to a slave UPS The red LED is an alarm indication and illuminates to indicate a possible faulty board The following ports are active on the interface board when fitted to the master UPS cabinet The Input ports X1 The Output port X2 X3 X4 The following ports are active on the Interface Board when fitted to a Slave cab
35. HE UPS SYSTEM MAY CONTAIN BATTERIES WHICH MUST BE RE CHARGED FOR A MINIMUM OF 24 HOURS EVERY SIX MONTHS TO PREVENT DEEP DISCHARGING BATTERIES THAT HAVE BEEN FOR WHATEVER REASON DEEP DISCHARGED ARE NOT COVERED BY THE WARRANTY 2 7 Extended Warranty The Standard Warranty may be enhanced by protecting the UPS with an Extended Warranty Agreement maintenance contract An Extended Warranty Agreement enhances the standard warranty by providing the following Regular preventative maintenance inspections Guaranteed speed of response to operational problems 24 hour telephone support Fully comprehensive excluding batteries cover Contact the Service Support Hotline on 0800 731 3269 for further details 2 8 Additional Service Maintenance Support In addition to providing support for the PowerWave 9000 Uninterruptible Power Supplies Ltd can provide maintenance and support of a wide range of different UPS products If you are interested in an extended warranty for your PowerWave 9000 or any other UPS you may have please complete the enquiry form shown opposite and return or FAX to Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Business Park Hook Hampshire RG27 9XA Tel 01256 386700 0800 731 3269 24 Hr Fax 01256 386701 Email service upspower co uk 20 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 2 General Description F
36. HLER COMPANY 8 Specifications Efficiency AC AC up to pf 1 0 Load 100 75 50 25 depending on Module power Efficiency 94 5 94 5 94 93 Efficiency Linear Load at pf 0 8ind Typically up to 1 higher of above values Efficiency Non linear Load EN 62040 1 1 2003 Typically up to 1 lower of above values Eco Mode efficiency at 100 load 96 98 Heat Dissipation with 10096 Non linear Load per Module EN Ww 1670 2225 2780 62040 1 1 2003 Heat Dissipation with 100 Non linear Load per Module EN BTU 5698 7592 9485 62040 1 1 2003 Airflow 25 30 C with Non linear Load per Module EN m3 h 380 380 380 62040 1 1 2003 8 6 Packed weights DPA 50 1 360 367 370 880x1825x915 300 307 310 730x1650x800 DPA 150 1 TBA TBA TBA 880x2150x915 TBA TBA TBA 730x1975x800 2 TBA TBA TBA 880x2150x915 TBA TBA TBA 730x1975x800 3 TBA TBA TBA 880x2150x915 TBA TBA TBA 730x1975x800 DPA 250 1 300 307 310 880x2150x915 240 247 250 730x1975x800 2 350 364 370 880x2150x915 290 304 310 730x1975x800 3 400 421 430 880x2150x915 340 361 370 730x1975x800 4 450 478 490 880x2150x915 390 418 430 730x1975x800 5 500 535 550 880x2150x915 440 475 490 730x1975x800 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 71 Uninterruptible Supplies Ltd Se 8 Specifications KOHLER COMPANY 8 7 Cable and fuse sizing Single feed input _ MAINS DISTRIBUTION BOARD Mains Supply
37. In the case of a single feed input the bypass supply will fail at the same time as the mains supply and the LINE 2 led will extinguish along with the LINE 1 led Under these circumstances inverter frequency will revert to a free running oscillator that will produce a constant 50 60Hz UPS output Battery discharge operation Various alarms are generated at preset levels as the battery discharges This allows the operator observe the remaining autonomy and if required shut down the load in an orderly manner e g to save data before the battery reaches its final end of discharge voltage Various options are available to automate the load shut down process as described in Chapter 8 of this manual Options When the battery is initially put on load the BATTERY led will flash green as shown in Figure 2 5 This will continue until the remaining autonomy time falls to 3 minutes whereupon the led will begin flashing red and if a data protection application such as WAVEMON is installed it will begin its automatic PC shutdown routine at this point When the battery reaches its fully discharged voltage the BATTERY led will change to solid red and the UPS will attempt to transfer the load to the bypass supply if it is present Load on Bypass MAINTENANCE BYPASS LINE Bypass Supply STATIC BYPASS LINE LINE 2 BY PASS NE TA Load l LOAD Supply LINE 1 INVERTER EE BATTERY gt INVERTER i BATTERY PW9000 DPA Cabinet Figur
38. ON OFF ON ON SW 1b 2 OFF OFF ON ON SW 1c 3 ON OFF OFF ON SW 1d4 ON OFF ON ON SW 1e 5 ON OFF ON ON SW 1f 6 ON OFF ON ON SW 19 7 ON OFF ON ON SW 1h 8 ON OFF ON ON SW 1i 9 ON OFF ON ON UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 41 Uninterruptible Power Supplies Ltd 3 Installation A KOHLER COMPANY Connecting the parallel cabinet control cables 2 Fita parallel adaptor board over the connector JD8 on the interface board Figure 3 17 in every UPS cabinet Note The parallel adapter contains two port connectors JD5 and JD6 and a configuration DIP Switch SW2 see Figure 3 18 3 Connect JD6 of the parallel adapter in UPS Cabinet 1 to JD5 of the parallel adapter in Cabinet 2 using the corresponding bus cable supplied Similarly connect JD6 of the parallel adaptor in UPS Cabinet 2 to JD5 in Cabinet 3 5 Continue in the same manner for the remaining UPS Cabinets as illustrated in Figure 3 18 UPS Cabinet 1 UPS Cabinet 2 UPS Cabinet n 1 UPS Cabinet n Parallel Adaptor Parallel Adaptor Parallel Adaptor Parallel Adaptor Master Slave Master Slave Master Slave Master Slave Master Slave Master Slave Master Slave Master Slave utput Input Output Input Output Input Output Input te Jbs SW 2 2 JD6 JD5 SW 2 2 JD6 JD5 SW 2 2 JD6 JD5 SW2 2 TT T I TT TT T I TI L JL T T TL I L TL A J L JL J Parallel adapter board fitted to JD8 on UP
39. PS Generator Generator Alarm Port X1 Panel x1 3 X1 4 e Figure 7 4 Generator ON Connection 1 Usea screened cable with 1 pair section of wires 0 6 mm and maximum length of 100 m 2 Connectthe cable as shown in Figure 7 3 7 2 2 Output interfaces terminal blocks X2 X3 X4 These volt free changeover outputs provide signals that can be used for the automatic and orderly shutdown of servers AS400 or used as control inputs to building management systems Term Contact Signal Display Function X2 1 8 ALARM MAINS OK Mains Present X2 2 Mains Failure X2 3 W Common X2 4 e Message LOAD ON INV Load on Inverter X215 Load on Bypass X2 6 pa Common X2 7 e ALARM BATT LOW Battery Low X2 8 Battery OK X2 9 e Common X2 10 e Message LOAD ON MAINS Load on Bypass X3 1 Load on Inverter X3 2 23 Common X3 3 2 ALARM COMMON ALARM Common Alarm X3 4 No Alarm X3 5 B Common X3l6 e ALARM MODUL ALARM1 Module 1 Alarm X3 7 No Alarm X3 8 W Common X3 9 ALARM MODUL ALARM2 Module 2 Alarm X3 10 No Alarm X4 1 e Common X4 2 e ALARM MODUL ALARM3 Module 3 Alarm X4 3 No Alarm X4 4 e Common UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 61 Uninterruptible Power Supplies Ltd 7 Options KOHLER COMPANY Term Contact Signal Display Function X4 5 e ALARM MODUL ALARMA Module 4 Alarm X4 6 No Alarm X4 7 E Common X4 8 a ALARM MODUL_ALARM5 Module 5 Alarm X4 9 No Alarm X4 10 W
40. PS system status The load is supplied via the maintenance bypass switch closed in all modules The UPS module s are powered down Powering up the UPS module s In a multi module system perform each of the steps in turn on every module 1 Onthe UPS power module close the bypass line fuse holder F2 if open 2 Close the battery fuses breaker in external battery cabinet if fitted a The UPS mimic panel LINE 1 LED will be permanent green b The BATTERY LED will be flashing green c TheLCD display will indicate LOAD OFF SUPPLY FAILURE BY PASS E BATTERY Colour LINE 1 LINE 2 BY PASS INVERTER BATTERY Green Off Off Off Green Flashing 3 Close the parallel isolator switch IA2 and check that the PARALLEL SW CLOSED message is shown on the LCD display 4 Onthe UPS mimic panel press and release both ON OFF buttons simultaneously and wait approximately 60 seconds a The UPS module will begin to power up b Initially LINE 2 LED will be red then change to green c Atthis stage the LCD display will indicate LOAD NOT PROTECTED and the module mimic LED indications should be as follows BY PASS Sa LINE 1 INVERTER a Pa ENSE BATTERY LED Colour LINE 1 LINE 2 BY PASS INVERTER BATTERY Green Green Green RED Green 5 When powering up a multi module system ensure that ALL the modules are in the state shown
41. S communications Master Slave Master Slave interface board Output Input SW2 2 T e JD6 JD5 SW2 2 Configuration Switch Parallel Adaptor JD6 JD5 Figure 3 18 Connection of the Bus lines when paralleling UPS Cabinet Parallel Adaptors Setting the configuration DIP Switch SW2 2 6 Set the configuration DIP Switch SW2 2 on each parallel adapter according to the position of the particular UPS Cabinet in the parallel system as previously set by SW1 9 above P Adepter Single First Middle Last Unit Unit Unit Unit Swi ON OFF OFF ON Sw2 ON ON OFF OFF Figure 3 19 Configuration DIP Switch SW2 2 3 10 Optional remote monitoring and control facilities In addition to the paralleling facilities described above the interface board also contains various input output connections that can be used with a number of optional external monitoring and control devices These are described in Chapter 7 42 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 4 Operation 4 Operation 4 1 Introduction The PowerWave 9000 UPS system must be commissioned by a fully trained field service engineer authorised by Uninterruptible Power Supplies Ltd before it is put into use The commissioning engineer will Connect the UPS batteries Check the UPS electrical installation and operating environment Check the UPS cabinet paralleling configur
42. UP GEN SET OPER DAY OF MONTH C1l 31 gt HOUF OF DAY 5 233 REPETITIVE Ch BEE gt SET UP GEH SET OPER EEATT CHARGE LOCK CWA BYPASS LOCK WAH 18 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 2 General Description Set Up Service menu screen DESCRIPTION LCD DISPLAY 1 This Menu is reserved for authorized service engineers It is not to be used by End gt SET UP SERVICE Users PRSSH RTI 2 Type in password gt FASSHORDE P Key Point It is essential to enter the password From within the Set up Service menu a service engineer can adjust the UPS voltages frequencies currents power and autonomies together with setting up UPS Rated Power Module configuration and position in the system Single standard or Dual input feed Frequency converter 50 60Hz and 60 50Hz Synchronisation window 2 494 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 1 9 Uninterruptible Power Supplies Ltd 2 General Description A KOHLER COMPANY 2 6 Warranty The PowerWave 9000 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 original commissioning or fifteen months from the date of original delivery whichever is the sooner This warranty is the only warranty given and no other wa
43. UPS monitoring and automatic UPS server shutdown facilities It comprises a bespoke software package which is installed on a local PC and communicates with the UPS via USB or a standard RS232 serial cable of up to 15m in length It is only required when an SNMP card or adapter box is not purchased Uninterruptible Power Supplies Ltd offer suitable monitoring software with SNMP functionality for NetWare OS 2 all Windows NT systems on INTEL and ALPHA network platforms The main features of WAVEMON are On screen autonomy time battery time countdown On screen server log off and shutdown procedure Time and date stamp event log Extensive logging of all UPS activity and power quality data Permits alarm warnings to be monitored remotely via email 64 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY T Options Scheduled UPS service mode and other systems status Graphical user interface for Windows compatible platforms Automatic unattended local shutdown Special modules for MS Office software to close and save open documents Compatible with all optional modules like UPSDIALER SNMP adaptors temperature sensors etc 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
44. US Input Connector JD6 Parallel BUS Output Connector JD11 RS232 Sub D9 female PC interface JD12 RS232 Sub D9 male for Multidrop ONLY USB PC Interface SNMP Slot for optional SNMP card ONLY Slot for optional Modem Ethernet card ONLY 9 Battery terminal N for 16 25 mm 10 Input Bypass terminal for Dual Input feed 3XM10 11 Input Rectifier terminal for Single feed 4xM10 12 Output Load terminal 4xM10 13 IA1 Maintenance Bypass 14 IA2 1 Parallel Isolator UPS Module 1 15 1A2 2 Parallel Isolator UPS Module 2 16 1A2 3 Parallel Isolator UPS Module 3 17 1A2 4 Parallel Isolator UPS Module 4 18 1A2 5 Parallel Isolator UPS Module 5 19 F2 Bypass Line Fuse on each module Module DPA 30 22x58 50A Pronorm Module DPA 40 22x58 63A Pronorm Module DPA 50 22x58 63APronorm 20 JD1 Smart Port RS232 Sub D9P 21 JD7 Connector for Control Panel oe JO Om P DPA 250 Input output terminal block front view UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 39 Uninterruptible Powerm Supplies Ltd 3 Installation KOHLER COMPANY 3 8 Battery cabling procedure Safety Notes WARNING Opening or removing the UPS Battery enclosure covers will create the risk of exposure to A dangerous voltages if power is connected to the UPS If the UPS is delivered without batteries Uninterruptible Power Supplies Ltd is not responsible for any damage or malfunction caused to the UPS by the incorrect storage installa
45. Unitreded OFF buttons SUPPLY FAILURE LOAD OLSCOMMEC TED Unitreied 4 UPS module is not supplying load The output switch is open FARALLEL SH ITCH OPEN Note The Unit number on the right hand side of the LCD indicates the cabinet number in a multi cabinet system together with the UPS power module slot number within the cabinet The maximum number of Module units is 10 and the module slot number can vary from 1 to 5 The definition of a Module s position is achieved in the menu Service Set Up For example Unit 05 3 indicates power module number 3 in system Cabinet number 5 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 1 5 Uninterruptible Power Supplies Ltd 2 General Description KOHLER COMPANy DESCRIPTION LCD DISPLAY 1 Single Systems SYSTEM CONFIGURATION Un its Diet SINGLE 2 Parallel System e g First Cabinet Master Modules no 2 in slot 2 SYSTEM CONFIGURATION Unitismez PARALLEL 3 Parallel System e g Second Cabinet Slave Modules no 5 in slot 3 LOAD OFF Unit SUPPLY FAILURE 4 Parallel System e g Second Cabinet Slave Modules no 6 in slot 2 LOAD DISCONNECTED Unit GA PARALLEL SHITCH OPEN Main menu screen DESCRIPTION LCD DISPLAY 1 Alog of the last 64 events is stored in the Power Management Display gt EVENT LOG MEASUREMENTS 2 Allows monitoring of voltages power frequencies currents autonomy etc gt MEASUREMENTS COMMANDS 3 Enables the commands Load to inverter Load to bypas
46. able B Cable C Max Input A With Cable D mm Nominal kVA A mm mm battery charging Current A DPA 50 80 3x100 5x25 4x25 67 5x25 72 DPA 150 450 3x250 5x120 or 4x120 or 202 5x120 or 218 5x 2x50 4x 2x50 5x 2x50 DPA 250 250 200 5x 2x95 4x 2x95 337 5x 2x95 362 Notes 1 Fuse and Cable recommendations to IEC 60950 1 2001 2 The fuse and cable rating details in the above tables are a recommendation only 3 The UPS must be installed to prescribed IEC or local regulations e g BS7671 2008 4 DC Cables and Battery fuses are bespoke to the installation UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 73
47. an also be used to configure and test a module s operating parameters during troubleshooting and commissioning and monitor the module s input output battery values during normal operation UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 1 3 Uninterruptible Powerm 2 General Description KOHLER COMPANY Mimic LED Indicators Power Management Display PMD Powers powerWA E 9000 Supplies Ltd www upspower co uk Module ON OFF control keys ALARM Alarm amp Reset Menu navigation amp selection keys Figure 2 13 UPS Module control panel 2 5 4 UPS Module control panel keys The keys on the operator control panel allow the user to Make settings and adjustments via a menu driven LCD display Start up and shut down the UPS and transfer the load between inverter and bypass Monitor and display the UPS operating voltages currents frequencies and other values on the LCD display Reset cancel an alarm Key function summary KEYS FUNCTION ON OFF Used to switch on or switch off the UPS ON OFF UP A Scroll upwards through a displayed menu DOWN W Scroll downwards through a displayed menu ENTER Confirms selects a chosen menu item RESET Cancels an audible alarm If the alarm condition was transient the ALARM LED will also extinguish otherwise it will remain ON red ON OFF Keys The UPS can be switched ON or OFF by simultaneously pressing both ON OFF keys on the control panel
48. ation settings Checkthe installation of any optional equipment Perform a controlled UPS start up and functionally test the system for correct operation and configuration Carry out customer operator training and equipment handover WARNING Uninterruptible Power Supplies Ltd accepts no responsibility for the equipment or the safety of any A personnel when operating this equipment before it has been properly commissioned The manufacturer s warranty is immediately invalidated if power is applied to any part of the UPS system before it has been fully commissioned and handed over to the customer 4 1 4 Operating procedure summary Under normal circumstances all the UPS modules in a multi module system are running and operating in their on line on inverter mode If a module fails in a redundant module system the faulty module will shut down but will not affect the remaining on line modules which will continue to supply the load with processed power The failed module can then be replaced or tested off line without affecting the remaining working modules If a UPS module fails in a capacity or single module system the faulty module is shut down and the load is immediately transferred to the static bypass supply in all modules from where it is supplied with unprotected mains power The UPS cabinet contains a maintenance bypass switch which when closed completely bypasses the UPS modules and connects the cabinet output terminals dir
49. ax to 01256 386701 WWW upspower co uk Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Business Park Hook Hampshire RG27 9XA Tel 01256 386700 Name Nc JOD Titles tuse tte tierno bina Sx Io ERE AUI SERE Len fk eese aa PNE R MER ABER Eas es COMPANY coc Address assai einer Lese eit Fate A de o Tego Ole ues bxc poda cds PostCode EE UD EE P HE E mail uuu eege EEN ee sd PEE Oe edo Der e Please contact me to discuss IT Extended Warranty options for my PowerWave 9000 UPS C Extended warranty options for my UPS System as below Mani facturef sirier aeeai Model m dee Rating KVA sean a IT Replacement Batterie C Eer tege ege aina ii please specify Thank you for your enquiry which will receive our prompt attention If you need to contact us immediately call free on Freephone 0800 731 3269 or E mail us on service upspower co uk WWW Upspower co uk UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 21 3 Installation Uninterruptible Supplies Ltd Se KOHLER COMPANY Installation 3 14 Introduction This chapter contains essential information concerning the unpacking positioning installing and cabling of the PowerWave 9000 UPS WARNING All cabling operations must be supervised by an authorised electrician or other suitably qualified person All installation and operating procedures must be carried out in strict accordan
50. ble configuration below is not recommended Bypass Feed Rectifier Feed UPS 1 UPS 2 UPS 3 UPS 4 To Load Figure 3 8 Cable lengths for multi cabinet installation dual feed input supply shown 30 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 3 Installation 3 6 6 Battery cabling considerations The PowerWave 9000 UPS battery comprises a number of 30 50 sealed maintenance free batteries that are mounted either within the UPS cabinet DPA 50 amp DPA 150 or in an external battery cabinet s DPA 250 An external battery cabinet can also be used in conjunction with the DPA 50 or DPA 150 to increase the available battery autonomy time if required A number of battery blocks are connected in series to form a battery string of the required voltage and capacity and connected to three power terminals annotated and N The plus and minus connections are taken from the battery string positive and negative extremities and the N terminal is connected to a point exactly mid way in the battery string For this reason the string must comprise an even number of battery blocks Battery configuration Two battery configurations are possible Common battery where all the power modules are connected to the same battery source although that source may itself comprise several battery strings connected in parallel This
51. cal equipment with a steady and reliable power supply for many years Key features The highlights of this innovative UPS solution include its high reliability upgrade ability low operating costs and excellent electrical performance Decentralised Parallel Architecture DPA Highest availability with near zero down time Each UPS module contains its own bypass circuit which greatly improves the overall system reliability by removing a common point of failure that is often present in more traditional UPS systems Truly modular design The PowerWave 9000 is designed around multiple 3OKVA 40kVA or 50kVA UPS modules Hot swappable modules Enables system expansion and module replacement to be carried out without disturbing the connected load Compact size small foot print Up to 342kW m saving on expensive floor space Flexible battery management Advanced management of battery charging and preventive failure diagnostics avoids premature deterioration of battery life High ac ac efficiency up to 95 7 even with partial loads Results in energy and operational cost savings TCO Full power available from 0 9 lead to 0 8 lag Blade server friendly power No de rating required with leading power factor loads Very low input current distortion THDi lt 3 496 100 2596 load leads to savings in generator set power and installation costs 2 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Unin
52. ce with the instructions contained in this manual Uninterruptible Power Supplies Ltd will take no responsibility for any personal injury or material damage caused by the incorrect installation cabling or operation of this product WARNING Once the UPS equipment is installed it must be commissioned by an engineer approved by Uninterruptible Power Supplies Ltd before it is powered up Uninterruptible Power Supplies Ltd will take no responsibility for any personal injury or material damage caused by the application of electrical power to this equipment before it has been fully commissioned 3 2 Taking receipt of the UPS The UPS cabinet and accessories are delivered on purpose designed pallets that are easy to off load and move using a forklift or suitable pallet jack CAUTION Observe the following precautions when off loading and moving the UPS e Always keep the packages in an upright position e Do not drop the equipment Due to the high energy batteries involved and heavy weight do not stack the pallets The packing container protects the UPS from mechanical and environmental damage during transit This protection is further increased by wrapping the PowerWave 9000 UPS with a plastic sheet Upon receiving the UPS you should carefully examine the packing container for any sign of physical damage The external Tip amp Tel FRAGILE and ARROW indicator should be intact if the equipment has been correctly transported in an upright positi
53. d independently Phase Angle Tolerance With 100 Unbalanced load Overload Capability on Inverter Output short capability RMS Crest Factor 1 On Inverter mode 50 KVA 40kW on Bypass mode 45 KVA 40kW lt 4 Free running 0 1 96 At Nominal Input voltage of 3x400 V 15 or 190 V to 264 V ph N 100 Deg 0 deg 125 load 10 min 150 load 60 sec A Inverter 2 x In during 250 ms Bypass 10 x In during 10 ms 3 1 8 5 Environmental Module Type Audible Noise with 10096 5096 Load Operation temperature Ambient Temperature for Batteries Storage Temperature Battery Storage Time at Ambient Temperature Max altitude above sea level De rating factor for use at altitudes greater than 1000m above sea level IEC 62040 3 Relative Air humidity Accessibility Positioning Input and Output Power Cabling DPA 30 DPA 40 DPA 50 dBA 59 51 65 55 65 55 C 0 40 C 20 25 recommended C 25 70 Max 6 months m 1000m 3300ft without de rating 0 9 1500m 4850ft asl 0 91 2000m 6600ft asl 0 86 2500m 8250ft asl 0 82 3000m 9900ft asl Max 95 non condensing Totally front accessibility for service and maintenance no need for side top or rear access Min 20 cm rear space required for fan From the bottom on the front 70 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se TE KO
54. d to inverter 2 Transfer Load to bypass 3 Battery Test BATT RUM TIME ch IM Bah Beat OUTPUT FREQUENCY Hz GD AE BATTER VOLTAGE v 65 6 6 8 BATT CHARGE CUR Fa 8 8 8 8 DISCHARGE CURRENT A3 RECTIFIER VOLTAGE Cv Be Ae Be Be Be DD OUTPUT CURRENT A06 ACTIVE POHER Kh REACTIVE POHER kVAr gt Be Be Ae DI BE dd APPARENT POHER KEVAD Be DD Be Be Be DD BATT CAPACITY CHO gt LOAD TO INVERTER LOAD TO BYPASS gt LOAD TO BYPASS PERFORM BATT TEST gt PERFORM BATT TEST UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 17 2 General Description Uninterruptible Supplies Ltd Se KOHLER COMPANY UPS Data menu screen 1 These general UPS Data are installed at the manufacturing plant 2 Manufacturing date 3 EPROM Version 4 Actual Date and Time Set up User menu screen LIPS SER TAL NUMBER nim nnnnn DATE OF MANUFACTURE 13 83 89 EPROM VERS TOM Y K DATE TIME ddl hih ans mm 1 Set up language 2 Set up Date and Time 3 Set up battery test 4 Set up operation with Gen Set gt SET LANGUAGE SET DATE AND TIME EMGL ISH FRANCAIS DEUTCH DUTCH SPAM ISH FOL ISH FOR TOGUESE gt SET UP DATETIME SET UP BATT TEST Dn MrF HH MM SS gt SET UP BATT TEST SET
55. e 2 6 Load on bypass In the load on bypass mode the load supply is connected to the unprocessed static bypass line via the static switch Depending on the reason for switching to bypass operation i e manually transferred or transferred due to a fault when operating in this mode the rectifier charger section can be turned off entirely or remain running and continue to provide battery charging as shown above Similarly the inverter may have been manually turned OFF or shutdown due to a fault and the INVERTER led may be OFF or solid RED Static switch operation The static switch is a solid state switch contained in each power module and operated by the module s microprocessor control logic which ensures that the static switch of all the power modules connected to the load through IA2 are always in the same operational state It is not permissible for one module to be operating with load on inverter while the remaining modules are in the load on bypass mode as such a situation would cause damage to the modules During normal operation the load is transferred from the inverter to the static bypass line in the event of an overload or loss of system redundancy due to a failed power module Load transfer can also be initiated manually via the UPS operator control panel located on the front cabinet door see paragraph 2 3 3 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 7 Uninterruptible Powerm Supplies Ltd 2 General De
56. e front of the UPS module that are fixing it to the cabinet UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 51 Uninterruptible Supplies Ltd Se 4 Operation KOHLER COMPANY T Pullthe UPS module forwards until the rear connectors are disconnected DO NOT FULLY EXTRACT THE UNIT A WARNING Wait at least 2 minutes to allow the module s electrolytic capacitors time to discharge 8 After waiting two minutes fully withdraw the UPS Module from the cabinet by pulling it horizontally 9 If you are not intending to replace the UPS module immediately cover the UPS compartment opening with an appropriate protection cover and secure with four screws 4 4 2 Inserting a UPS module Key Point The replacement module must be preset according to system personalization Please make sure with your nearest service centre for correct settings Remove the UPS module compartment protection cover if fitted by unscrewing four screws on the front Using two persons to lift the UPS module slide two thirds of the module into the UPS compartment make sure not to plug the UPS Module into the rear connector Push UPS module firmly into its final position to assure good contact on the rear plugs N Tighten the four screws on the front of module to secure it to the UPS cabinet frame Connect the control panel cable to connector JD7 Start the UPS module and bring it on line see paragraph 4 2 2 pgs 45 Replacing a module in
57. e must be unswitched and ALWAYS connected 5 Secure the cables to the fixing rail under the connection terminals Dual input feed 6 Refer to the schematic drawing and connection table in Figure 3 4 7 The UPS is supplied for single feed input as standard For a dual feed configuration remove the links between the UPS power terminals 1L1 2L1 1L2 2L2 1L3 2L3 and 1N 2N UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 35 3 Installation Uninterruptible Power Supplies Ltd A KOHLER COMPANY 8 Connect the UPS input supply cables to the UPS power terminals 1L1 1L2 1L3 and 1N Ensure correct clockwise phase rotation A CAUTION The input Neutral cable must ALWAYS be connected 9 Connect the earth cable from the bypass mains distribution board to the UPS cabinet s protective earth PE terminal 10 Connect the UPS bypass mains supply cables to the UPS bypass power terminals 2L1 2L2 2L3 and 2N Ensure correct clockwise phase rotation A CAUTION The bypass Neutral cable must ALWAYS be connected 11 Secure the cables to the fixing rail under the connection terminals Note The UPS commissioning engineer will re configure the UPS electronics to operated with a dual feed input at the time of commissioning 3 7 2 Connecting the UPS output cables It is recommended that a separate load distribution board is provided for the load Before you begin connecting the UPS output cables to the load distribution boa
58. e they become a crisis Acquires key performance parameters and productivity information in real time to enable you to better understand machine performance and faster troubleshoot downtime events Gives total transparent information concerning all actions performed on the system such as all critical status changes coordination of equipment service reporting of all alarms with priorities UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 65 Uninterruptible Power Supplies Ltd T Options A KOHLER COMPANY Key features Redundant and secure communication Alarm acknowledgment Priority driven Management with escalation Comprehensive management system Reception and management of alarm calls from Uninterruptible Power Supplies Ltd Storage of UPS data in a database exportable in a CSV format for easy handling in Excel Unlimited number of UPS that can be managed User administration with passwords and permission level Administration of Log file Data logging with statistical analysis and diagnostics report Visualization of the UPS data Current status Measured values for single or three phase Recording function including graphs with zooming capabilities for selected measured values Display of event log file Display of UPS parameters Web server functionality for data access from any web browser PowerREPORTER management software PowerREPORTER is a remote monitoring and managemen
59. ectly to its bypass mains input When operating via the maintenance bypass switch the UPS modules can be replaced or tested off line as required In the case of a single module installation the load must be transferred to the maintenance bypass to maintain the load power while the UPS module is replaced Note All the switches and control panel operations mentioned in this chapter are identified and described in chapter 2 4 2 Operating Instructions A WARNING The procedures given below must be performed only by a trained operator The following procedures are provided in this section Starting the UPS system from the maintenance bypass see paragraph 4 2 1 Individual module start stop procedure in a parallel system see paragraph 4 2 2 Transfer the load from UPS to maintenance bypass mode see paragraph 4 2 3 Complete system shutdown see paragraph 4 2 4 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 43 4 Operation Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 4 2 1 Starting the UPS system from the maintenance bypass This procedure describes the sequence of operations necessary to power up the UPS module s whilst the load is connected to the maintenance bypass supply and then transfer the load to the UPS inverter s On Line mode A WARNING All the operations in this section must be performed by authorised and trained personnel Prior to powering up the system check and confirm the U
60. ed to the output of the UPS system by opening the fused isolators or circuit breakers in the load distribution board A WARNING Perform the following steps only after the load has been fully isolated 2 Verify that the loads are powered down Then carry out the following actions on every module in a multi module system On the UPS control panel simultaneously press both ON OFF buttons a TheLCD panel will indicate LOAD OFF SUPPLY FAILURE Ve Open the fused battery isolator s associated with the module 5 Open the modules parallel isolator switch IA2 BY PASS LED LINE 1 LINE 2 BY PASS E BATTERY INVERTER BATTERY Off Off Off Green Flashing Open the module s bypass line fuse holder F2 7 Isolate the UPS input bypass supplies at the input distribution board The UPS is now voltage free WARNING Allow 2 minutes for the internal DC capacitors to discharge before touching the UPS internal components UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 49 Uninterruptible Supplies Ltd Se 4 Operation KOHLER COMPANY 4 3 Replacement of the UPS module in a single module system WARNING All the operations in this section must be performed by authorised and trained personnel By opening or removing the UPS modules and module covers you run risk of exposure to dangerous voltages WARNING When removing a UPS module wait for at least 10 minutes
61. ed via a fused isolator F2 to the static switch within each power module It is also to the cabinet s maintenance bypass switch IA1 In a standard installation the bypass supply terminals 2 are usually linked to the mains supply terminals 1 within the cabinet so only one mains supply feed is required See paragraph 3 6 3 for details concerning Single Feed amp Dual Feed input supply configurations MAINTENANCE BYPASS LINE Bypass Suppl SPP A FB STATIC BYPASS LINE KZ F2 1 STATIC Mains SWITCH IA2 1 Supply EL RECTIFIER INVERTER 5 Booster E Charger STATIC BYPASS LINE STATIC SWITCH F1 RECTIFIER INVERTER e SO EB Booster 4 2 Charger Figure 2 3 PowerWave 9000 UPS block diagram 2 modules fitted IA2 2 Each power module is wired to individual battery connections on the cabinet s main terminal block 3 This terminal block is then connected to internal batteries in the case of the DPA 50 and DPA 150 cabinets or to an external battery cabinet in the case of the DPA 250 If required two or more power modules can be connected to a common battery by linking together the modules battery terminal block connections 3 as described in paragraph 3 8 However by employing a separate battery bank for each module it again avoids a potential single point of failure and effectively extends the system redundancy to include the batteries which is highly recommended UPS471 02 00 PW9000DPA User Manual
62. edicated dc dc charger independent from the rectifier and inverter Wide range of number of battery blocks 30 50 x 12V blocks depending autonomy times Wide UPS input voltage operating window extends the battery life due to fewer discharge cycles Battery discharge protection caused by load jumps Proactive battery protection from false manipulations and inadequate charging voltages Proactive battery failure detection thanks to the Advanced Battery Diagnosis ABD algorithm User selectable battery tests to ascertain the battery state Optional temperature compensated charging regime to enhance battery life Decentralised Parallel Architecture DPA In a redundant parallel UPS system the power modules outputs are connected in parallel so that if one module fails the remaining modules can sustain the load supply Such operation requires a certain amount of inter module communication to control frequency synchronisation load sharing load transfer etc This is achieved by having a master slave relationship among the power modules whereby the master logic gives out individual commands to all the s ave units to keep them in step In some designs this can unfortunately lead to a single point of failure for the entire system if the master logic or communication with the slaves fails however the PowerWave 9000 technology uses multi master logic with separated independent regulation and control logic busses which enables any of the c
63. er the UPS compartment opening with an appropriate protection cover and secure with four screws event of a mains failure the load supply will be interrupted CAUTION While the UPS is operating in the maintenance bypass mode the load is not protected and in the 4 5 2 Refitting a module in a capacity multi module system 1 2 oa kw Remove the UPS module compartment protection cover if fitted by unscrewing four screws on the front Using two persons to lift the UPS module slide two thirds of the module into the UPS compartment make sure not to plug the UPS Module into the rear connector Push UPS module firmly into its final position to assure good contact on the rear plugs Tighten the four screws on the front of module to secure it to the UPS cabinet frame Connect the control panel cable to connector JD7 Start the UPS module and transfer the load from the maintenance bypass back to the UPS system see paragraph 4 2 1 54 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 5 Maintenance 5 Maintenance 5 1 Introduction WARNING All the operations described in this chapter must be performed by an authorised electrician or manufacturer trained personnel 5 2 System calibration To ensure optimum UPS operation and continuous efficient protection of the connected load it is recommended that the system s operating parameters are checked every s
64. etwork connected device via a simple control language and display the results in an application running within a standard web browser The PowerWave 9000 contains two SNMP slots one is designed to house a Modem Ethernet SNMP adapter card and the other a Modem GSM adapter see Figure 7 1 Alternatively SNMP connectivity can also be implemented using an external SNMP adapter connected to the UPS RS232 output JD11 An SNMP Ethernet adapter contains an RJ 45 connector which allows it to be connected to the network using a standard network cable Once connected the UPS Management software agent which is already installed in the SNMP adapter then monitors the UPS operating parameters and outputs its data in SNMP format to the connected network In a multi module UPS system the SNMP interface can communicate system wide data or data for an individual UPS module The SNMP adaptor requires a PC with terminal connections and for normal operation at least one network connection Ethernet is also required External SNMP Adapter Soe Sa s ess Sess p oS ee entente NE SNMP MONITOR T i JD11 Internal SNMP Card D al J Slot 2 mm m E S a x Figure 7 7
65. fers back to the static bypass load on bypass mode and the inverter returns to its standby function An off line line interactive system is a slightly more efficient than an on line system due to the reduced rectifier inverter losses during normal operation and it is sometimes referred to as the ECO mode However this mode is recommended only if the connected load equipment can tolerate power interruptions of up to 3 to 5 ms during the transfer period 8 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 2 General Description A WARNING The on line mode must always be used for critical load protection 2 3 4 Multi module parallel system operation As described above the PowerWave 9000 cabinets are designed to Operator Control Panel for each Module accommodate between one and five UPS power modules Each module has an individual output power isolator IA2 which connects the module s GSH ze output to the cabinet s output power terminals This enables an individual module to be disconnected from the load supply for maintenance or repair purposes Fully populated cabinet with 5 parallel power modules connected to a parallel control bus Under normal conditions all the modules within the cabinet are turned on and operating in parallel to provide the cabinet s rated output Capacity versus redundant module sy
66. fuses and cables are suitably rated in accordance with the prescribed IEC standards or local regulations for example BS7671 2008 see figures 3 3 and 3 4 for guidance 6 Once the electrical installation is completed the UPS must be commissioned by an engineer authorised by the manufacturer before it is brought into use A WARNING Do not apply electrical power to the UPS before it has been commissioned 7 When installing the UPS cables ensure that the connection procedures are performed under the following conditions a No mains voltage is present at the UPS mains or bypass distribution board terminals b All loads are disconnected at the load distribution board c The UPS is fully shut down and voltage free d The UPS Maintenance Bypass Isolator IA1 is open OFF bat The UPS Parallel Isolator IA2 is open OFF for all fitted modules 3 7 1 Connecting the input cables Refer to figures 3 5 to 3 7 also figures 3 14 to 3 16 1 Gain full access to the UPS power terminals by removing the aluminium panel at the bottom of the UPS below the Switch gear 2 Connectthe earth cable from the mains distribution board to the UPS protective earth terminal PE Single input feed standard 3 Referto the schematic drawing and connection table in Figure 3 3 4 Connect the UPS input supply cables to the UPS input power terminals 1L1 1L2 1L3 and 1N Ensure correct clockwise phase rotation A CAUTION The input Neutral cabl
67. his display 3 Close the fused battery isolator s associated with the module Simultaneously press the two ON OFF push buttons on the UPS control panel a The UPS will run through an automated start up sequence accompanied by the following indications LINE 2LED lights red then changes to green INVERTER LED lights green BATTERY LED lights green constant b LCD displays the LOAD PROTECTED message BY PASS LED Colour LINE 1 Green LINE 1 INVERTER pm ENG BY PASS off ENSE BATTERY INVERTER Off BATTERY Green LINE 2 Green 5 The UPS module is now On Line and connected to the parallel system Module shut down Use this procedure to power down a single UPS power module in a redundant module system 1 Simultaneously press the two ON OFF buttons on the UPS module s control panel a The LED display will give the following indications BY PASS LED LINE 1 LINE 2 BY PASS EHE BATTERY INVERTER BATTERY Open the parallel isolator switch IA2 In the UPS cabinet open the module s bypass supply fused isolators F2 Open the fused battery isolator s associated with the module af oh The UPS module is now shut down 46 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd KOHLER company 4 Operation 4 2 3 Transfer the load from UPS to maintenance bypass mode If needed to perform
68. identified as module 1 The module parallel isolator switches IA2 are identified with their associated power module on the panel silk screen e g IA2 2 pertains to power module 2 Note that the module input mains fuses F1 are located within the modules and are not accessible with the module in situ UPS Power Module 1 F2 Module 1 bypass supply fuse UPS Power Module 2 F2 Module 2 bypass supply fuse UPS Power Module 3 F2 Module 3 bypass supply fuse UPS Power Module4 F2 Module 4 bypass supply fuse UPS Power Module 5 F2 Module 5 bypass supply fuse Parallel Isolator 1 per power module IA2 1 IA2 2 IA2 3 IA2 4 IA2 5 UPS Customer Interface connections described in the Options chapter IA1 Maintenance Bypass Isolator Figure 2 12 DPA 250 Cabinet details 2 5 UPS Module control panel The UPS module control panel is used to start stop an individual module as part of the UPS system operating procedures It c
69. inet The Output ports X3 6 X3 10 The Output ports X4 1 X4 10 Means Alarm Module 1 2 3 4 5 All other input or output ports on the Slave boards are not activated These interfaces are described below Dry port customer interface X1 customer inputs X2 X4 customer outputs see paragraph 7 2 RS232 Computer serial interface USB amp JD11 see paragraph 7 3 RS232 Interface for multidrop JD12 see paragraph 7 4 SNMP Modem slots for remote monitoring control see paragraph 7 5 Cabinet paralleling connection and configuration see paragraph 3 9 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 59 Uninterruptible Powerm Supplies Ltd K Options A KOHLER COMPANY 7 2 Dry port volt free contacts Customer I O interface facilities are made to Phoenix spring terminal blocks cable 0 2mm to 1 5mm annotated X1 X2 and X3 All voltage free contacts are rated at 250Vac 8A 30Vdc 8A 110Vdc 0 3A 220Vdc 0 12A 7 2 1 Input interfaces terminal block X1 The customer inputs normally connected to the input interface terminal block X1 are Remote emergency shutdown Generator ON Customers specials functions Term Contact Signal Display Function X1 1 3 3Vdc Remote Shutdown Do not remove the factory mounted bridge until X4 2 x GND external Remote Shut down is connected X1 3 at 3 3Vdc Generator Operation X1 4 x GND X1 5 a 3 3Vde Customer IN 1 X1 6 x GNP
70. is known as the UPS service on a single server in connection with one UPS and an unlimited number of connected WINDOWS workstations For operation with two or more servers a further licence is required for each additional server In this case it is of no importance whether the UPS service on these servers is active or whether the server was stopped by a remote UPS service The same applies to the use of RCCMD with the remote send receive modules for multi server shutdown under NT UNIX and other operating systems The service programs are generally supplied as single licences In order to use a single CD ROM for several multi server shut down units you must acquire additional licence codes RCCMD Server shutdown In order that remote shutdown of servers can take place initiated by the SNMP card or WAVEMON software further licenses must be purchased The license s for the RCCMD client or listening software that resides in each target server Note Virtual servers may not need a license per virtual server client Please contact Technical Support to discuss you requirements 7 6 3 PowerREPORTER management software PowerREPORTER is a remote monitoring and management service which is a part of the premium power protection concept ThePowerREPORTER application Provides affordable continuous monitoring over mission critical facilities and offers peace of mind by detecting and warning of any potential system problems befor
71. ix months and recalibrated where necessary The batteries should also be checked every six months depending on the ambient temperature 5 3 User responsibilities There are no user serviceable parts contained within the UPS so the maintenance requirements of the user are minimal To maximise the useful working life and reliability of the UPS and its batteries the environment in which the UPS operates should be kept cool and dust free 5 4 Routine maintenance It is essential that the UPS system and batteries receive regular preventative maintenance inspection to maximise both the useful working life and the reliability of the UPS system When the UPS is commissioned the commissioning field service engineer will attach a service record book to the front of the UPS which will be used to log the full service history of the UPS Preventative maintenance inspections involve working inside the UPS which contains hazardous AC and DC voltages WARNING Only Uninterruptible Power Supplies Ltd trained and authorised field service engineers are fully aware of all of the hazardous areas within the UPS During a preventative maintenance inspection the field service engineer will check Site environment conditions Integrity of electrical installation Cooling airflow Rectifier operation and calibration Inverter operation and calibration Static switch operation Battery status Load characteristics Integrity of alarm and monito
72. kk e Rsislssiieieeieie Lu lu zZ z ca ea lt lt O O Wn LO a a 2 gt For reasons of clarity the wiring for modules 1 3 5 only is shown in detail lo ojojo OOJO JOJO OO op SSdN 104 aen Kieneg SSdN 104 aen Kuayeg KN EAR iva va ra YSdN 104 asny Aiaugg vSdn 404 asny Auaqjeg ESdN 104 aen Auayeg ESdN 404 aen Jjexeg T z ea on ion ER ooo oclo olo CSdN 10 aen Auayieg TSdN 404 asny Auayjeg EXTERNAL BATTERY CABINET EXTERNAL BATTERY CABINET LSdN 104 aen Aiaugg LSdf 104 aen Auayjeg ool log olo lol ojo OO lolo olo oloo olo OC OO OO IOC Go SES opp eee OO opp ololo UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Figure 3 10 External battery cabinet wiring 5 module UPS cabinet shown 32 Uninterruptible Powerm Supplies Ltd KOHLER company 3 Installation Internal battery installations DPA 50 A DPA 50 cabinet contains a single UPS power module and can accommodate up to 280 x 7Ah internal batteries Figure 3 11 shows the different battery configurations A B C D A B C D A B C D UPS Module UPS Module UPS Module 7 10x7Ah 10x7Ah 6 10x7Ah 2x5x7Ah 10x7Ah 5 10x7Ah 10x7Ah 10x7Ah 10x7Ah 10x7Ah 1
73. lashing RED buzzer Alarm condition RED Alarm condition present audio has been reset INVERTER GREEN Load on inverter RED Inverter fault OFF Inverter not operating BY PASS GREEN Load on bypass OFF Bypass not operating BATTERY GREEN Battery OK RED Battery faulty or discharged Flashing RED Battery fuses blown Flashing GREEN On Battery The ALARM LED is a visual indication of an internal or external alarm condition When activated it is accompanied by an audible alarm which can be cancelled by pressing the RESET key 2 5 3 Power Management Display PMD The 2 x 20 character LCD Power Management Display PMD simplifies communication with the UPS power module and also provides monitoring information The menu driven LCD enables the access to Access the Event register Monitoring the input and output voltage current frequency amp power Monitoring battery run time Perform commands such as module START and STOP Load transfer between INVERTER to BYPASS Access the module s Diagnostics service mode Carry out module adjustments and testing service mode Status screens DESCRIPTION LCD DISPLAY 1 Load is protected by UPS power Load is supplied by inverter Normal LOAD Unit idciz l Operation PROTECTED 2 Load is not protected by UPS LOAD Lmit tiszi Load is supplied by mains power load on bypass HOT PROTECTED 3 Load supply completely interrupted UPS has been switched off by ON LOAD OFF
74. le of master and the former master module will turn off Multi cabinet parallel system To further expand the overall UPS system capacity several up to ten PowerWave 9000 cabinets can be connected together to operate as a multi cabinet parallel system This is achieved by connecting each cabinet s output power terminals in parallel at an external load distribution panel and linking together the parallel control bus in each cabinet to effectively provide a single parallel control bus that is connected to every power module in the system see Figure 2 9 Taken to its limit a system comprising ten fully populated DPA 250 cabinets would result in a UPS system rating of 2500kW however such large systems are rare and a typical multi cabinet installation will contain far fewer than the maximum ten cabinets It is essential that any installed UPS power protection system can be expanded to meet a growing load demand without compromising the existing load supply This condition is easily managed by a PowerWave 9000 system which due to its hot swappable design makes it possible to fit an additional power module to a DPA 150 or DPA 250 cabinet if it is not already fully populated or add a further cabinet to an existing UPS system without disrupting the load supply Note Every standard PowerWave 9000 cabinet is supplied with all the features required for parallel operation to eliminate any need for time consuming or expensive upgrading
75. n the load or transfer it to the bypass supply Note In a non redundant system the load will unavoidably have to be transferred to the bypass supply while a module is shut down or removed from the system Advanced booster technology The UPS power module s inbuilt advanced booster technology results in a perfect sinusoidal input power quality at 0 99 input power factor with a harmonic content of less than 3 THD i This leads to a more reliable system operation together with savings in generator and transformer sizing due to reduced winding losses and also means that traditional input harmonic filters still used by some systems are not required The high power factor presented by the UPS on the incoming mains supply minimises cabling and fusing costs due to the reduced reactive power consumption which together with the accompanying low harmonic currents provides the following benefits No additional losses in wires and cables No extra heating of transformers and generators Noover sizing of generators No false circuit breaker tripping and malfunction Noerratic operation of computers telecommunications monitors electronic test equipment etc Noresonance with power factor correction capacitors Flexible battery management FBM Premature battery deterioration is avoided by the advanced management of battery charging and preventive failure diagnostics The major benefits are AC ripple free battery charging due to a d
76. on 2 2 PowerWave 9000 Model range 2 2 1 Advanced design features 2 3 Functional description of operation 2 3 1 PowerWave 9000 Module block diagram 2 3 2 UPS Module operating modes 2 3 3 UPS System operating modes 2 3 4 Multi module parallel system operation 2 4 PowerWave 9000 User controls 2 5 UPS Module control panel 2 5 1 UPS Module control panel keys 2 5 2 Module mimic leds 2 5 3 Power Management Display PMD 2 6 Warranty 2 7 Extended Warranty 2 8 Additional Service Maintenance Support Installation 3 1 Introduction 3 2 Taking receipt of the UPS 3 2 1 Site transportation 3 3 Unpacking 3 4 Storage 3 5 Planning the installation site considerations 3 5 1 Clearances 3 6 Planning the installation cabling considerations 3 6 1 General requirements 3 6 2 UPS Cable and fuse sizing 3 6 3 UPS Power cable termination sizes 3 6 4 UPS Power connection details 3 6 5 Power cabling in a multi cabinet installation 3 6 6 Battery cabling considerations 3 7 UPS Cabling procedure 3 7 1 Connecting the input cables 3 7 2 Connecting the UPS output cables 3 8 Battery cabling procedure 3 8 4 Connecting the battery cables 3 9 Multi cabinet configuration and paralleling cables 3 10 Optional remote monitoring and control facilities ak oo o oo boah N MMM A A A A A OO OO Om Om P Go 22 22 22 22 23 23 24 24 25 25 25 28 28 30 31 35 35 36 40 40 41 42 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible
77. on If the packaging has been ruptured in transit or if the Tip amp Tel indicator is suspect inform both the carrier and Uninterruptible Power Supplies Ltd immediately shipping damage claims must be filed immediately when found and the carrier must be informed within a maximum of 7 days following receipt of the equipment If shipping damage is discovered store all packing materials for further investigation i CAUTION Claims for visible shipping damage must be notified to the carrier immediately on receipt Other Ensure that the received UPS equipment corresponds to the description indicated in the delivery note 3 2 1 Site transportation Please observe the following precautions when you transport the UPS equipment from the off loading site and its intended installation or storage location CAUTION Transportation e When transporting the equipment use the front and rear shipping brackets to secure the cabinet to help prevent the UPS from toppling over e Do not at any time tilt the cabinet by more than 10 from vertical 22 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 3 Installation CAUTION Potential dangers e fthe UPS battery cabinet is tilted by more than 10 it could cause internal damage If tilting occurs do not connect the UPS to the mains electrical supply e The weight of the UPS battery equipment can cause serious personal injury and or str
78. on site UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 9 2 General Description Uninterruptible Supplies Ltd Se KOHLER COMPANY Parallel Control Bus Parallel Control Bus Three cabinet parallel system with interconnected Parallel Control Bus 5x Power Modules in each cabinet Inter cabinet Parallel Control Bus Cabinet 1 Cabinet 2 CABINET 1 MAINTENANCE BYPASS LINE Bypass STATIC BYPASS LINE Figure 2 9 PowerWave 9000 UPS Parallel cabinet system Cabinet n Load Dist Panel 10 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 2 General Description 2 4 PowerWave 9000 User controls The following illustrations show the location of the PowerWave 9000 power switches and fused isolators that are used when operating the equipment Note that the input mains fuse F1 is located within the module and is not accessible with the module in situ The Operator Control Panel one per UPS module is described in paragraph 2 5 DPA 50 Component identification MAINTENANCE BYPASS LINE STATIC BYPASS LINE Mains Supply
79. onnected power modules to adopt the master role if called upon This control philosophy maintains the highest possible system availability This unique decentralized design Enables a parallel redundant system providing 10096 conditioned power at all time Eliminates the system level single point of failure inherent in traditional parallel UPS systems Exponentially increases the reliability of the overall system 4 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description 2 3 Functional description of operation This section describes The internal operation of an individual UPS power module at block diagram level see paragraph 2 3 1 The various operational modes of an individual UPS power module see paragraph 2 3 2 UPS system operational modes On line versus Off line system operation see paragraph 2 3 3 e Multi module system operation and paralleling considerations see paragraph 2 3 4 2 3 4 PowerWave 9000 Module block diagram Figure 2 3 shows a functional block diagram of a PowerWave 9000 cabinet containing two power modules UPS Input supplies The mains supply 1 is a standard 3ph N supply which is connected to the rectifier section of each power module During normal operation this supply is rectified to provide a DC input to the inverter and also powers the battery charger A 3ph N bypass supply 2 is shown connect
80. or removing the UPS modules and module covers you run risk of exposure to dangerous voltages WARNING When removing a UPS module wait for at least 2 minutes after it has been disconnected in order to allow the DC capacitors to fully discharge WARNING When the UPS module is removed from the cabinet always fit an appropriate blanking cover WARNING Two persons are needed to pull out the module from the UPS Frame The weight of a DPA 50 40kW module is 60kg the weight of DPA 10 8kW60 module is 24kg Employ suitable lifting aids and safety platforms where possible SEPP If a UPS module goes faulty in a REDUNDANT parallel system the load will continue to be protected by the remaining modules which will remain operating in the ON LINE mode INVERTER mode Under these circumstances the faulty UPS module can be replaced without having to transfer the load to bypass 4 4 1 Removing the UPS module 1 Onthe UPS module to be replaced simultaneously press the two ON OFF buttons on the UPS control panel a The LED display will give the following indications BY PASS LED Colour LINE 1 Green LINE 2 Off BY PASS Off ENSE BATTERY INVERTER Off BATTERY Open the UPS module s parallel isolator IA2 Open the fused battery isolator s associated with the module The UPS module is now totally shut down Disconnect the control panel cable to connector JD7 moto Remove the four screws on th
81. pply provided it remains within preset limits If these limits are exceeded or if the bypass supply fails altogether the inverter frequency control reverts to a free running oscillator that will produce a constant 50 60Hz UPS output Load on Battery MAINTENANCE BYPASS LINE STATIC BYPASS LINE LINE 2 BY PASS Load Supply LOAD LINE 1 INVERTER Ex md BATTERY P RECTIFIER Jr i BATTERY PW9000 DPA Cabinet Figure 2 5 Load on battery 6 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description If the mains supply fails the LINE 1 led will extinguish and the rectifier will shut down The battery now provides an alternative DC power source for the inverter via the charger booster and the BATTERY led will flash green to indicate that itis on load Larger installations often include a standby generator which is designed to start up and connect to the UPS automatically within a short period of time following a mains failure Once the UPS input power is restored from the standby source the rectifier and charger will resume normal operation which results in very short battery discharge periods In the case of a dual feed input if the bypass supply remains live the LINE 2 led will stay illuminated and the inverter frequency will remain synchronised to the bypass provided it stays within its preset limits
82. rd Check that the potential full load does not exceed the UPS output power rating OUTPUT POWER on the nameplate Ensure the load circuit breakers on the load distribution board are correctly sized with respect to the load rating and associated cabling Ensure that the maximum total load rating and maximum load rating of each individual load socket is indicated on the load distribution board The circuit breakers must comply with the prescribed IEC Standards e g BS7671 2008 1 Gain full access to the UPS power terminals by removing the aluminium panel at the bottom of the UPS below the switch gear 2 Connect the protective earth cable from the load distribution board to the UPS cabinet s protective earth PE terminal 3 Connect the UPS output supply cables to the UPS output power terminals 3L1 3L2 3L3 and 3N Ensure correct clockwise phase rotation A CAUTION The output Neutral cable must ALWAYS be connected 4 Secure the cables to the fixing rail located under the UPS connection terminals 5 Ensure the output cables are connected to the correct power terminals on the load distribution board 36 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 3 Installation n N 9 10 11 12 X1 X4 Customer interface on Phoenix Terminals X1 Customer Inputs X2 X4 Potential free contacts SW1 9 Multi Cabinet Configuration Switch
83. requires common battery links to be fitted to the UPS battery power terminals as shown below Individual battery where each module is connected to an individual battery string These configurations are illustrated in Figure 3 9 which shows the alternative connections for internal batteries in a DPA 150 cabinet fitted with three power modules Figure 3 10 shows an example of the alternative connections when using an external battery cabinet shown connected to a DPA 250 5 module cabinet 4 222 Vu 222 DECRE vi Cl oO si Co vi CN oO ANM si CN C vi CN oO LO LO LO GO LO GO LO LO L I LO LOGO LO OO LO LO GO D D D D D O AAA D OD OD D AAA 222 DDD DDD 2232025025202 DDD ololo ololo ololo C doco C dodo Ololo OOJO OIOJO COOC 222 Vu 00 222 TOS vi Cl om ei Co ANM ANM ANM ANM 60 60 00 Dp OD OO OO OO ON 60 60 OO 60 o0 OO O0 OO o0 ccc c c c ccc o rl c cC cC C ccc CCC Ek ccu KE E Ek EEE 429 42 429 42 42 Ai 42 42 42 429 429 429 A 42 Ai 42 42 42 LO LO LO NNN unu LO LO LO LO LO LO LO LO LO COMMON BATTERY INDIVUAL BATTERY Figure 3 9 Internal battery connections 3 module UPS cabinet shown UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 31 KOHLER COMPANY Uninterruptible Supplies Ltd Installation 3 TO UPS Modules TO UPS Modules o CCCA CCAA AAAA
84. ring systems Operation of all installed options Preventative maintenance inspections form an integral part of all Extended Warranty Agreements maintenance contracts offered by Uninterruptible Power Supplies Ltd For further details on Extended Warranty Agreements see paragraph 2 7 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 55 Uninterruptible Power Supplies Ltd 5 Maintenance A KOHLER COMPANY 5 5 Battery testing The battery test takes approximately 3 minutes and should be performed only if There are no alarm conditions The battery is fully charged The input mains supply is present Battery testing can be carried out independently of the operating mode Off line or On line and whether or not the load is connected The battery test procedure can be performed from the UPS front panel See paragraph 4 3 5 5 6 Battery maintenance The battery maintenance shall be done by an authorized Uninterruptible Power Supplies Ltd Service Partner 5 7 Battery disposal and recycling Batteries contain dangerous substances that will harm the environment if thrown away If you change the batteries yourself call qualified organizations for battery disposal and recycling ay eo 56 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 6 Troubleshooting 6 Troubleshooting 6 1 Alarms In the event of an alarm condition the red ALARM
85. rranty express or implied is provided This warranty is invalidated if the UPS is put into use without having been commissioned by a fully trained and authorised person This warranty does not apply to any losses or damages caused by misuse abuse negligence neglect unauthorised repair or modification incorrect installation inappropriate 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 repaired or 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 any of its products in 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 Uninterruptible Power Supplies Ltd does not recommend the use of any of its products in 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 the risks of injury or damage have been minimized the customer assumes all such risks and the liability of Uninterruptible Power Supplies Ltd is adequately protected under the circumstances T
86. rvice centre for assistance Call an authorised service centre for assistance Call an authorised service centre for assistance The frequency of the UPS input supply is outside preset operational limits and the UPS static bypass has been temporarily disabled Shutdown the load connected to UPS before the UPS switches itself off to protect its batteries This alarm is only displayed if the UPS is on Maintenance Bypass 6 4 Contacting Service Uninterruptible Power Supplies Limited has a service department dedicated to providing routine maintenance and emergency service cover for your UPS If you have any queries regarding your UPS please contact us Hook Hampshire RG27 9XA Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Business Park Tel 01256 386700 0800 731 3269 24 Hr Fax 01256 386701 Email service Qupspower co uk We recommend that your UPS is protected by an Extended Warranty Agreement see Section 2 for details These agreements assist us in caring for your UPS correctly ensuring that it is well maintained and attended to promptly should any problems occur 58 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY T Options Options 7 1 Introduction 1 X1 X4 Customer interface on Phoenix Terminals j 1 X1 Customer Inputs ELCO E e X2 X4 Potential free contacts I CA ks ue 2 e
87. s On line operation When used as an on line UPS system the PowerWave 9000 UPS modules normally operate in their load on inverter mode and will switch over to load on bypass in the event of an inverter fault or overload which exceeds the system redundancy This will transfer the load to the static bypass without interruption transfer time 0 If the transfer is due to an overload the UPS modules will switch back to the load on inverter mode if the overload clears and the inverter returns to normal operation An on line system therefore provides the highest degree of load protection and is always recommended if the critical load will not tolerate even a very brief supply interruption Off line line interactive operation When the PowerWave 9000 is used as an off line or line interactive UPS system it normally operates in its load on bypass mode with the load being supplied through the static bypass supply however the rectifier and battery charger are still powered up to maintain battery charging and the inverter section is enabled and operating on standby In the bypass supply fails the static switch will automatically transfer the load to the inverter within 3 5ms and if the rectifier input mains supply is missing when the transfer takes place the inverter will operate from battery power If the bypass supply returns to normal when operating with the load on inverter the load automatically trans
88. s and battery test to be gt COMMANDS executed SET LIF DATA 4 Allows the UPS personalized information such as serial number to be entered gt SET UP DATA SET UP USER 5 Allows user to set up Date Time automatic battery test etc gt SET UP USER SET UP SERVICE 6 Password protected area for service engineer use only gt SET UP SERVICE Event log menu screen DESCRIPTION LCD DISPLAY 1 Logging Control a log of the last 64 events is stored in the Power Management Display 1 65 16 93 14 38 56 LOAD TO IHN 2 Every stored event is identified with a sequential number and time stamp G2 63 16 08 14 28 59 LOAD TO EYF 3 By pressing ENTER the code of the event will be displayed 03 95 16 608 14 39 14 LOAD OFF 1 6 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 2 General Description Measurements menu screen 1 Battery Runtime 2 UPS Output Frequency 3 Bypass Frequency 4 Battery Voltage 5 Battery Charger Current 6 Battery Discharge Current 7 Rectifier Input Voltage all three phases 8 Bypass Input Voltage all three phases 9 Output Voltage all three phases 10 Output Current all three phases 11 Active Output Power all three phases 12 Reactive Output Power all three phases 13 Apparent Output Power all three phases 14 Output Power all three phases 15 Battery capacity Commands menu screen 1 Transfer Loa
89. s also contain an internal battery complete with a fused isolator F4 for each fitted power module Figure 3 3 Single input block diagram with recommended cable and fuse sizing 26 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 3 Installation Mains Supply 3x380 400 415 Mains Supply 3x380 400 415 UPS MAINS SUPPLY UPS BYPASS SUPPLY ral Rectifier ral Rectifier Static Switch Inverter Inverter Static Bypass Line Static Bypass Line Static Bypass Line Static Switch Static Switch Cabinet Power Dual Input 3 x 400V Output 3x400V 0 8 pf Frame kVA Fuse B C Cable B Cable C Max Input with Cable D Nominal Current A mm mm battery charging mm A A DPA 0 80 3x100 5x25 4x25 67 5x25 72 DPA 150 150 3x250 5x120 or 4x120 or 202 5x120 or 218 5x 2x50 4x 2x50 5x 2x50 DPA 250 250 3x400 5x 2x95 4x 2x95 337 5x 2x95 362 Note This illustration shows connections to an external battery cabinet The DPA 50 and DPA 150 models also contain an internal battery complete with a fused isolator F4 for each fitted power module Figure 3 4 Dual input block diagram with recommended cable and fuse sizing UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 27 3 Installation Uninterruptible Supplies Ltd Se KOHLER COMPANY
90. s until the rear connectors are disconnected DO NOT FULLY EXTRACT THE UNIT A WARNING Wait at least 2 minutes to allow the module s electrolytic capacitors time to discharge 6 Wait two minutes then fully withdraw the UPS power module from the cabinet by pulling it forwards horizontally 7 f you are not intending to replace the UPS module immediately cover the UPS compartment opening with an appropriate protection cover and secure with the four screws removed earlier 50 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 4 Operation 4 3 2 Refitting the UPS module Remove the UPS module compartment protection cover if fitted by unscrewing four screws on the front 2 Using two persons to lift the UPS module slide two thirds of the module into the UPS compartment make sure not to plug the UPS Module into the rear connector 3 When you are certain the module is located correctly on its guide rails push it firmly into its final position to assure good contact on the rear plugs 4 Tighten the four screws on the front of module to secure the module to the cabinet frame 5 Connect the control panel cable to connector JD7 6 Start the UPS module and bring it on line see paragraph 4 2 1 4 4 Replacing a module in a REDUNDANT multi module system WARNING All the operations in this section must be performed by authorised and trained personnel By opening
91. scription KOHLER COMPANY Load on Maintenance Bypass MAINTENANCE BYPASS LINE Bypass Supply gt STATIC TE SWITCH Supply RECTIFIER INVERTER Eet BATTERY STATIC BYPASS LINE Pw9000 DPA Cabinet Figure 2 7 Load on maintenance bypass In this mode of operation the manually closed maintenance bypass switch IA1 connects the load supply directly to the unprocessed bypass supply This is used to keep the load supplied albeit without any power protection whilst allowing the remainder of the UPS system to be shut down for service repair To prevent possible inverter damage it is important that the inverter output and maintenance bypass lines are never connected in parallel Therefore when transferring from the load on inverter mode to the load on maintenance bypass mode it is important that the load is first transferred to the static bypass load on bypass mode before the maintenance bypass switch is closed A WARNING always follow the operating instructions in this manual when starting or shutting down the UPS 2 3 3 UPS System operating modes The previous section described the operating modes of the UPS power module but UPS systems are also categorised according to the way in which they are used at a system level and are typically described as being an on line off line or line interactive UPS system The PowerWave 9000 can be operated in all three of the above categorie
92. service or maintenance it is possible to transfer the load to maintenance bypass and power down the UPS module s whilst leaving the load connected to the raw bypass mains supply operating in the static bypass mode WARNING Before you close the maintenance bypass isolator ensure that the UPS is A All the operations in this section must be performed by authorised and trained personnel This procedure describes the sequence of operations to transfer the load to the maintenance bypass supply and then shut down and isolate the UPS module s Prior to commencing this procedure check and confirm the following UPS system status on all modules in a parallel system The mimic panel LED indications should be as per the following table on all modules in a multi module system BY PASS LED Colour LINE 1 Green LINE 1 INVERTER Ee LINE 2 Green BY PASS OFF PS BATTERY INVERTER Green BATTERY Green The LCD panel should display LOAD PROTECTED If anything other than LOAD PROTECTED is displayed then press the RESET button and if LOAD PROTECTED is still not displayed there is a problem with the UPS seek assistance Transferring the UPS to static bypass mode 1 Onany one of the UPS module s mimic panel press the ENTER key once to access the menu system 2 Using the UP DOWN keys move the cursor so that it is adjacent to COMMANDS and then press the ENTER key 3 Using the UP DOWN keys mo
93. stem The paralleled UPS modules can be operated as either a capacity or redundant module system Parallel Control Bus The difference between the two is that a capacity system is rated such that ALL the power modules are required to furnish the specified full load power whereas a redundant module system is designed with one or more modules over and above that required to supply the full load In a redundant module system it is therefore possible to lose one or more power module without disrupting the load whereas this is not the case in a capacity system where the loss of one power module would Figure 2 8 Single cabinet with five automatically transfer the load to the bypass supply parallel power modules Parallel control bus All the UPS power modules within a cabinet are connected to a parallel control bus which carries various inter module control signals used for frequency synchronisation load sharing etc By using sensing signals passed over the parallel control bus each power module can electronically compare its own frequency and output current with that of its neighbouring module and carry out fine adjustments to achieve balanced conditions The module control logic always observes one of the power modules as being the master and the others as slaves However if the master module goes faulty at any time the next module in the chain a former slave will immediately take over the ro
94. t be free of dust and corrosive explosive gases The location must be vibration free If the UPS is located in bayed enclosures partition walls must be installed The available space must permit the minimum cabinet clearances shown below Clearances Battery Cabinet Front Front Z Z E ALD loi UE Qe Cdp rip Minimum 200 200 1000 Figure 3 1 UPS amp Battery cabinet clearance requirements The UPS cabinet requires space to bottom front and back to enable cooling airflow Suitable ventilation airflow must be provided See Figure 3 1 All parts of the UPS required for maintenance servicing and user operation are can be accessed from the front of the cabinet a clearance of 1000mm space should be provided at the front of the UPS cabinet to enable component removal Cabling is also carried out from the front of the cabinet 24 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 Installation 3 6 Planning the installation cabling considerations 3 6 1 General requirements The information in this section should help with the preparation and planning of the UPS power cabling It is the customer s responsibility to provide all external fuses isolators and cables that are used to connect the UPS input and output power supplies The UPS input and bypass terminals should be connected to the utility mains supply through a
95. t service which provides peace of mind protection by offering a continuous 24 7 365 watch over mission critical facilities Continuous monitoring is an affordable insurance policy to detect issues and provide an early warning before they develop into a crisis The main features and benefits offered by PowerREPORTER are Real time email notification sent directly to UPSL Service Centre in response to alarm critical events Acquisition of key performance data and productivity information Empowers you with the details needed to better understand machine performance and quickly troubleshoot downtime events Combined with a service contract PowerREPORTER improves service levels The engineer can determine if site attendance is necessary and bring relevant spare parts Monthly Status Report detailing trends and alarms Optional battery analysis and care service PowerNSURE measures battery voltage temperature impedance and prolongs battery service life through the application of battery charge equalization Functional description PowerREPORTER communicates constantly with your UPS system in order to automatically detect any error or alarm messages In the event of an incident being detected PowerREPORTER automatically connects with UPSL s Service Centre via an email transmitting a status message The email which provides details relating to the fault a snapshot of the UPS performance parameters and a device identification string
96. terruptible Supplies Ltd Se KOHLER COMPANY 2 2 PowerWave 9000 Model range The PowerWave 9000 UPS is based on a range of 30kVA to 50kVA plug in power modules fitted into one of three purpose designed cabinets Each power module is a self contained UPS comprising a rectifier battery charger inverter and static switch and when two or more modules are fitted into a cabinet they effectively operate as a parallel UPS System The available cabinets can contain up to one three or five power modules as shown below in Figure 2 1 Key Point All the modules fitted within a cabinet must be of the same rating for example it is not possible to mix 30kVA and 50kVA modules in the same cabinet The PowerWave 9000 cabinets are identified as CLASSIC DPA 50 TRIPLE DPA 150 and UPGRADE DPA 250 where the model number represents the maximum kVA output available when the cabinet is fully populated with 50 kVA power modules Figure 2 1 shows that the DPA 50 and DPA 150 cabinets include shelves for housing the UPS batteries however the DPA 250 cabinet has no internal battery mounting facilities and requires an external battery cabinet A range of matching battery cabinets is available which are installed adjacent to the UPS cabinet in the majority of installations An additional external battery cabinet can also be connected to the DPA 50 and DPA 150 models to extended the overall system autonomy time if desired 2 General Description
97. tion bus cables must be connected between each cabinet to enable various parallel control functions to operate Each module must also be configured to identify its position within the parallel system e g first middle or last module The module set up to be the first module in the chain acts as the master module in relation to the inter module parallel control logic Te SW1 9 Multi Cabinet Configuration Switch e eI n Te oe de ofa JD8 Parallel BUS connector e M e For paralleling cabinets fit optional adapter el JD5 Parallel BUS Input Connector e k o JD6 Parallel BUS Output Connector en o B ele Je 9 eli o o olf Figure 3 17 Cabinet interface board WARNING Before making the following connections ensure that all the UPS cabinets are powered down and all parallel isolators IA2 are open Setting the configuration DIP Switch SW1 9 DIP Switch SW1 9 located on the UPS interface board see Figure 3 17 is used to configure the position of the cabinet in the parallel UPS chain Using this switch you can define the cabinet s position as the first master cabinet in the chain e g cabinet 1 in Figure 3 18 the middle cabinet in the chain there may be more than one middle cabinet the last cabinet in the chain e g cabinet n in Figure 3 18 1 Set DIP Switch SW1 9 of each cabinet according to the table below First UPS Middle UPS Last UPS Single UPS SW 1a 1
98. tion or connection of batteries by third parties The final assembly and battery connection must be supervised by the commissioning engineer Do not attempt to complete the battery wiring or close the battery isolators before the system has been commissioned Please ensure you read and understand the following safety notes before you begin the battery installation 1 All the cable installation procedures detailed below must be supervised by the commissioning engineer 2 Ensure that the UPS input and output supplies are isolated and locked out at their respective distribution boards Warning notices should be posted to prevent any inadvertent operation of the UPS mains supply isolators 3 External battery cables and fuses are bespoke to the installation Before you connect the battery cables ensure that the customer provided fuses and cables are suitably rated in accordance with the prescribed IEC standards or local regulations for example BS767 1 2008 Ensure that the UPS maintenance bypass switch IA1 5 Ensure that the UPS fused battery isolator s F4 is open DPA 50 amp DPA 150 and the battery isolators are open in the external battery cabinet DPA 250 or where used the terminals to which the battery cables are to be fitted must be electrically isolated 3 8 4 Connecting the battery cables Note The battery cables and fuses are bespoke to the installation UPS Cabinet mounted batteries Internally mounted batteries will be
99. toring control UPS Monitoring and automated control software 7 6 1 The importance of UPS management 7 6 2 WAVEMON Shutdown and Management Software 7 6 3 PowerREPORTER management software 43 43 43 43 44 45 47 49 50 50 51 51 51 52 52 53 54 55 55 55 55 55 56 56 56 57 57 57 58 58 59 59 60 60 61 62 62 63 63 63 64 65 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY Specifications 8 1 Mechanical Characteristics 8 2 Input Characteristics 8 3 Battery 8 4 Output 8 5 Environmental 8 6 Packed weights 8 7 Cable and fuse sizing Single feed input 8 8 Cable and fuse sizing Dual feed input 68 68 69 69 70 70 71 72 73 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 1 Safety 1 Safety 1 Description of 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 gt gt 2 User precautions WARNING Keep this manual with the UPS for future reference WARNING The UPS and peripheral equipment m
100. uctural damage to the surrounding area if dropped in transit Always take extreme care when moving the equipment CAUTION Storage A e The UPS should be stored in the original packing and shipping carton e The recommended storing temperature for the UPS system and batteries is between 5 and 40 C e The UPS system and the battery sets must be protected from high humidity which should not exceed 90 RH non condensing 3 3 Unpacking WARNING The UPS system the battery cabinet option and the batteries are heavy and may tip during transportation causing serious injury if these unpacking instructions are not followed closely If the packages are received in good order i e the tip amp tell FRAGILE and ARROW indications on the packing container are intact then unpack the UPS and any accessory equipment as follows 1 If the cabinet is shipped inside a wooden case remove the screws at the base and sides of the case then carefully remove the case from the equipment Cut the wrappers and remove the packing container by pulling it upwards Remove the plastic sheeting covering the UPS Remove any anchor bolts securing the cabinet to the pallet then remove the UPS from the pallet Retain the packaging materials for future shipment of the UPS Examine the UPS for any sign of damage and notify your supplier immediately if damage is found Check that the details on the UPS nameplate corresponds to the purchased material
101. usly press both ON OFF buttons a TheLCD panel will indicate LOAD OFF SUPPLY FAILURE 8 Open the fused battery isolator s associated with the module 9 Open the module s parallel isolator IA2 10 Open the bypass line fuse holder F2 A p BY PASS BATTERY LED Colour LINE 1 LINE 2 BY PASS INVERTER BATTERY Green Off Off Off Green Flashing WARNING The UPS cabinet is still live at its input and output power terminals due to the closure of maintenance bypass isolator WARNING Allow 10 minutes for the internal DC capacitors to discharge before touching any UPS internal components WARNING The load is now supplied from the bypass mains and is not protected against power failure 48 UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 Uninterruptible Supplies Ltd Se KOHLER COMPANY 4 Operation 4 2 4 Complete system shutdown The UPS system may be shutdown completely if the load does not require power for an extended period of time Use this procedure to turn off the load power and shutdown the entire UPS system gt gt WARNING All the operations in this section must be performed by authorised and trained personnel CAUTION This procedure will totally disconnect load power Ensure that it is safe to lose power to all the loads connected to the UPS system before you begin this process 1 Isolate all load equipment connect
102. ust be installed and commissioned by suitably qualified and trained personnel who are aware of the potential shock hazards WARNING Do not attempt to install this UPS system until you are satisfied that ALL the safety instructions and hazard warnings contained in this manual are read and fully understood WARNING High leakage current Ensure that the UPS has been correctly earthed before you connect the mains power supply WARNING This UPS must not be started up or put into use without having first been commissioned by a fully trained engineer authorised by the manufacturer WARNING This UPS must be serviced by qualified personnel You run risk of exposure to dangerous voltages by opening or removing the UPS covers Uninterruptible Power Supplies Ltd will assume no responsibility nor liability due to incorrect operation or manipulation of the UPS WARNING The PowerWave 9000 is a Class A UPS product according to EN 62040 3 In a domestic environment the UPS may cause radio interference In such an environment the user may be required to undertake additional measures AAAA AAA UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 1 Uninterruptible Powerm Supplies Ltd 2 General Description KOHLER COMPANY 2 General Description 2 1 Introduction Congratulations on your purchase of the PowerWave 9000 UPS Continuous power availability is essential in today s dynamic IT and process related work environments It is equall
103. ve the cursor so that it is adjacent to LOAD TO BYPASS and then press the ENTER key a The UPS system will transfer the load to static bypass on all connected modules 4 On all modules check and confirm that a The INVERTER LED has extinguished b The BYPASS LED is green c TheLCD displays LOAD NOT PROTECTED BY PASS 1 LED Colour LINE 1 Green LINE 2 Green BY PASS Green ww BATTERY INVERTER OFF BATTERY Green INVERTER UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 47 4 Operation Uninterruptible Supplies Ltd Se KOHLER COMPANY Closing the maintenance bypass switch 5 Close the maintenance bypass switch IA1 in all cabinets in a multi cabinet system 6 Onall UPS modules check and confirm that a The INVERTER LED has turned to red b The BYPASS LED is green c TheLCD displays MANUAL BYP IS CLOSED LINE 2 LINE 1 BY PASS D ono INVERTER PS BATTERY Powering down a UPS module LED Colour LINE 1 LINE 2 BY PASS INVERTER BATTERY Green Green Green RED Green When the load is connected to the maintenance bypass supply as described above the UPS module s can be powered down for example if required for maintenance testing using the following procedure Note Carry out the following procedure on each module in a parallel system to totally shut down the system 7 Onthe UPS control panel simultaneo
104. with rated output power and discharged kw 27 8 37 1 46 9 battery per Module output Cos 1 0 Max Input Current with rated output power and A 40 3 53 7 68 0 discharged battery per Module output Cos 1 0 1 On Inverter mode 50 KVA 40kW on Bypass mode 45 KVA 40kW 8 3 Battery ModueTye 1 DPA30 X DPA40 DPASO Variable Number of 12V Battery Blocks No 40 50 40 50 40 50 Maximum Battery Charger Current A 10A Standard 15 A optional Battery Charging Curve Ripple free IU DIN 41773 Temperature compensation Standard temp sensor optional Battery Test Automatic and periodically adjustable Battery Type Maintenance free VRLA or NiCd UPS471 02 00 PW9000DPA User Manual UK Dated 06 08 14 69 8 Specifications Uninterruptible Powerm Supplies Ltd KOHLER COMPANY 8 4 Output Module Type DPA 30 DPA 40 DPA 50 Output Rated Power per Module kVA 30 40 45 1 Output Rated Power per Module KW 24 32 40 Output Current In cos 1 0 400 V A 35 46 5 58 Output Rated Voltage V 3x380 220V or 3x400 230V or 3x415 240V Output Voltage Stability 96 Static lt 1 Dynamic Step load 0 100 or 100 0 lt 4 Output Voltage Distortion With Linear Load lt 2 With Non linear Load EN62040 3 2001 lt 4 Output Frequency Hz 50 Hz or 60 Hz Output Frequency Tolerance Synchronized with mains lt 2 selectable or Bypass operation Permissible Unbalanced Load All 3 phases regulate
105. y important that any installed power protection system is sufficiently resilient and adaptable to handle any changes brought about by the introduction of new server technologies migration and centralization Such demands are well met by the PowerWave 9000 UPS system which provides the foundation for continuous power availability of network critical infrastructures both in enterprise data centres where business continuity has paramount importance and in process control environments where manufacturing continuity is essential Reliability and quality standards By using a unique modular construction and incorporating the latest technological developments in power engineering the PowerWave 9000 represents a completely new generation of transformerless 3 phase UPS System Its advanced double conversion VFI Voltage and Frequency Independent topology responds fully to both the highest availability and environmentally friendly requirements compliant with IEC 62040 3 VFI SS 111 standards A full UPS Specification is given in Chapter 8 of this manual High reliability upgrade ability low operating cost and excellent electrical performance are just some of the highlights of this innovative UPS solution 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 criti
106. y occur but will be recorded in the Event Log with the time and date of their occurrence Alarm Condition Interpretation Suggested Solution UPS FAULT bo INS BVPVRECT FAULT tolerance OUTPUT SHORT OVERLOAD OVER TEMPERA TURE BATTER CHARGER OFF INVERTER FAULT SY NCHROM FAULT BATTERY IM DISCHARGE MANHJAL EYF ISCLOSED Inverter is faulty There is a fault in the UPS and therefore normal operation cannot be guaranteed Mains power supply is outside prescribed There is a short circuit at the output of UPS on load side Load exceeds the UPS rated power The UPS temperature has exceeded the maximum permitted value Either the attached battery and the battery charger set up do not correspond or there is a battery charger fault The inverter and mains are not synchronised Battery is near end of autonomy Maintenance Bypass closed Load supplied by mains Call an authorised service centre for assistance The UPS input supply is too low or missing If site power appears to be OK check the external input supply circuit breakers etc Check all output connections and repair as required Identify which piece of equipment is causing the overload and remove it from the UPS Do not connect laser printers photocopiers electric heaters kettles etc to the UPS Check that the UPS ambient temperature is less than 30 C If the ambient temperature is normal call the authorised se

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