Kohler PW 9000DPA User manual

Kohler
PW 9000DPA
User Manual
Pioneering solutions for
total power protection
Document Control
ISSUE
1.0
DATE
01-06-10
REVISION SUMMARY
Initial issue.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
Kohler Uninterruptible Power 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.
© 2010 Kohler Uninterruptible Power
This manual may not be copied nor reproduced without written
permission of Kohler Uninterruptible Power.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
Table of Contents
1
Safety
1.1 Description of symbols used in this manual
1.2 User precautions
2
Description
2.1 Reliability and Quality Standards
2.2 PowerWAVE 9000 DPA System
2.3 System Configuration
2.3.1 Single/Parallel module configurations
2.3.2 Single/Multi cabinet configurations
2.3.3 ‘Redundant-module’ versus ‘Capacity’ system
2.3.4 PowerWAVE 9000DPA MD Frames
2.3.5 PowerWAVE 9000DPA MX Frames
2.4 Advanced Design Features
2.4.1 Hot-swappable modules
2.4.2 Advanced booster technology
2.4.3 Flexible battery management (FBM)
2.4.4 Decentralized Parallel Architecture (DPA)
2.5 Warranty
2.6 Extended Warranty
2.7 Additional Service/Maintenance Support
3
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2-2
2-3
2-4
2-4
2-4
2-4
2-5
2-5
2-6
2-6
2-6
Installation
3.1 Introduction
3.2 Receipt of the UPS
3.2.1 Site transportation
3.3 Unpacking
3.3.1 Nameplate
3.4 Batteries
3.5 Storage
3.5.1 UPS
3.5.2 Battery
3.6 Positioning
3.6.1 Planning the installation
3.7 UPS Power Cabling (preparation and planning)
3.7.1 General requirements
3.7.2 Multi-cabinet installation cabling considerations
3.8 Connecting the UPS input supply
3.8.1 Safety notes
3.8.2 Preparing the input cabling
3.8.3 Connecting the UPS input power cables
3.9 Connecting the UPS output
3.9.1 Safety notes
3.9.2 Preparation for the output cabling
3.9.3 Connecting the UPS output cables
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
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3.9.4 Connection Terminal Details
3.10 Connecting the batteries
3.10.1 Safety Notes
3.10.2 Battery cabling
3.10.3 Connecting the battery cables
3.11 Internal Battery Systems
3.11.1 DPA-25
3.11.2 DPA-75
3.11.3 DPA-50
3.11.4 DPA-150
3.12 External Battery Cabinets and Battery Connections
3.13 Multi-cabinet Parallel Communication Cables (Bus-lines)
3.14 Interfacing Facilities
3.14.1 Interface Board
3.14.2 Smart Port (Serial RS 232)
3.14.3 Dry Port (volt-free contacts)
3.14.4 JD11/RS232 Computer Interface
3.14.5 JD12/RS232 Interface for Multidrop
3.14.6 USB/2 Computer Interface
4
Operation
4.1 Commissioning
4.2 Control Panel
4.2.1 Power Management Display (PMD)
4.2.2 Mimic LED indicators
4.2.3 Operator keys
4.3 Description of the LCD
4.3.1 Status screens
4.3.2 Main menu screen
4.3.3 Event log menu screen
4.3.4 Measurements menu screen
4.3.5 Commands menu screen
4.3.6 UPS Data menu screen
4.3.7 Set-up User menu screen
4.3.8 Set-Up Service menu screen
4.4 Operating Modes
4.4.1 On-Line (Inverter) mode
4.4.2 OFF-Line (also known as ECO or Bypass) mode
4.4.3 Maintenance Bypass mode
4.4.4 Parallel Isolator switch(IA2)
4.5 Operating Instructions
4.5.1 Transfer to Maintenance Bypass Mode
4.5.2 Starting the UPS system from the Maintenance Bypass
4.5.3 Complete system shutdown
4.5.4 Individual module start/stop procedure
4.6 Replacement of the UPS Module in a Single Module System
4.6.1 Removing a UPS Module
4.6.2 Refitting the UPS Module
4.7 Replacing a UPS Module in a REDUNDANT Multi-Module System
4.7.1 Removing the UPS Module
4.7.2 Inserting a UPS Module
4.8 Replacing a Module In a CAPACITY Multi-Module System
4.8.1 Removing a Module
4.8.2 Refitting a Module in a Capacity Multi-Module System
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UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
5
Maintenance
5.1
5.2
5.3
5.4
5.5
5.6
5.7
6
Alarms
Menu, Commands, Event Log, Measurements,
Fault Identification and Rectification Messages and Alarms
Contacting Service
6-1
6-1
6-2
6-2
Options
7.1
7.2
7.3
7.4
Introduction.
Remote Emergency Stop Facilities
Generator ON Facilities
WAVEMON Shutdown and Management Software
7.4.1 Why is UPS Management important?
7.4.2 Wavemon Shutdown and Monitoring Software
7.5 SNMP CARD/ADAPTER For Network Management /Remote Monitoring
8
5-1
5-1
5-1
5-1
5-2
5-2
5-2
Troubleshooting
6.1
6.2
6.3
6.4
7
Introduction
System calibration
User responsibilities
Routine maintenance
Battery Testing
Battery Maintenance
Battery Disposal and Recycling
7-1
7-1
7-2
7-2
7-2
7-3
7-4
Specifications
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
Mechanical Characteristics
Input Characteristics
Battery
Output
Environmental
Packed weights
Cable and fuse sizing (Single feed input)
Cable and fuse sizing (Dual feed input)
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UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
1
1.1
Safety
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.
1.2
User precautions
WARNING: Keep this manual with the UPS for future reference.
WARNING: The UPS and peripheral equipment must 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: All servicing must be performed by qualified personnel. Do not attempt to service
the UPS yourself.
You run risk of exposure to dangerous voltages by opening or removing the UPS-covers!
Kohler Uninterruptible Power will assume no responsibility nor liability due to incorrect
operation or manipulation of the UPS.
WARNING: The PowerWAVE 9000 DPA is a Class A UPS product (according to EN 500912). In a domestic environment the UPS may cause radio interference. In such an environment
the user may be required to undertake additional measures.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
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1: Safety
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UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
2
2.1
Description
Reliability and Quality Standards
Congratulations on your purchase of the PowerWAVE 9000 DPA UPS.
By using a unique modular construction and incorporating the latest technological developments in power
engineering, the PowerWAVE 9000 DPA represents a completely new generation of transformer-less 3
phase UPS-System. High reliability, upgrade ability, low operating cost and excellent electrical performance
are just some of the highlights of this innovative UPS solution.
Kohler Uninterruptible Power specialises in the design, building, installation and maintenance of
Uninterruptible Power Systems. This compact and powerful UPS is just one example of our wide range of
state of the art power protection devices and will provide your critical equipment with a steady and reliable
power supply for many years.
The criteria and methods which are used in the design, manufacture, and maintenance of Uninterruptible
Power Supply systems are certified to International Standard ISO 9001/EN 29001. A full UPS Specification is
given in Chapter 8 of this manual.
2.2
PowerWAVE 9000 DPA System
PowerWAVE 9000 DPA is a truly modular system based on a range of 10kVA to 45kVA UPS power modules
that can be connected in parallel to form a redundant-module system. The UPS modules are housed in freestanding cabinets which are purpose designed to contain up to one, three or five modules. Two cabinet
ranges are available as standard – the ‘MD’ cabinet range is designed for use with 10kVA-25kVA modules
(see Figure 2.2), whereas ‘MX’ cabinets are used with modules from 30kVA to 45kVA (see Figure 2.3).
Key Point: All the modules fitted within a cabinet must be of the same rating – i.e. it is not possible
to mix 10kVA and 20kVA modules in the same parallel system.
Cabinets designed for three (or fewer) modules also contain the UPS batteries; however an additional,
external battery cabinet can be used to extended the battery autonomy time if required. An external battery
cabinet is always required for cabinets designed for 5 UPS modules. A range of battery cabinets of matching
style and colour is available to sit alongside the UPS cabinets to provide a matching suite.
2.3
System Configuration
The PowerWAVE 9000 DPA system configurations are described below.
2.3.1 Single/Parallel module configurations
Within the UPS cabinet, the power modules can be configured in one of two ways:
Single-module system
As its name suggests, a ‘single-module’ system comprises a cabinet fitted with just one UPS module, even if
the cabinet is designed to house several modules – for example a TRIPLE DPA-75 or -150, UPGRADE DPA125 or -250 fitted with a single module is still considered as a ‘single’ module system.
Parallel-module system
A ‘parallel-module’ system employs several modules (of the same rating) operating in parallel within the
same cabinet (e.g. TRIPLE DPA-75) using the DPA technology (see paragraph 2.4.4).
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
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2: Description
2.3.2 Single/Multi cabinet configurations
Single cabinet system
A single-cabinet system comprises a stand-alone cabinet containing one or more UPS power module(s)
operating as a single-module or module-module system (as defined in paragraph 2.3.1).
Multi-cabinet system
To further increase the overall system capacity it is possible to connect up to 10 standard cabinets in parallel.
Depending on the model type, each cabinet can contain up to 5 UPS power modules, thereby potentially
resulting in a system comprising up to 50 parallel modules if 10x UPGRADE DPA-125 or 10x UPGRADE
DPA-250 cabinets are employed. Although, in practice, a typical multi-cabinet system will be made up of
fewer than 10 cabinets.
Every standard PowerWAVE 9000 DPA cabinet is provided with the parallel option, eliminating any need for
time-consuming or expensive upgrading on site.
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PowerWAVE 9000 DPA UPS Multi-Cabinet Chain.
The multi-cabinet configuration is based on a Decentralised Bypass Architecture (DPA) – i.e. every UPS is
provided with its own static bypass. In a parallel system there is always one master module and the other
modules are slaves. If at any time the master goes faulty the next UPS (former slave) will immediately take
over the master function and the former master will switch off.
2.3.3 ‘Redundant-module’ versus ‘Capacity’ system
The difference between a ‘redundant-module’ system and a ‘capacity’ system is that a ‘capacity’ system is
rated such that ALL the UPS power modules are required to provide the necessary output load power. This is
not the case for a ‘redundant-module’ system, whereby the overall 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) UPS module without affecting the load supply.
Every UPS power module in a parallel configuration is provided with an output parallel Isolator (IA2) which,
when opened, isolates the corresponding module from the parallel system and the module no longer
contributes to the system’s power output. In a ‘capacity’ system opening this isolator this will cause the load
to transfer to the (unprotected) bypass supply. but in a ‘redundant-module’ system the load will continue to
receive protected power until the number of off-line modules exceeds the inbuilt system redundancy.
2-2
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
2: Description
2.3.4 PowerWAVE 9000DPA MD Frames
CLASSIC
DPA-25
TRIPLE
DPA-75
UPGRADE
DPA-125
1 module (10-25kVA)
200 x 7/9Ah batteries
3 modules (10-25kVA)
180 x 7/9Ah batteries
5 modules (10-25kVA)
External batteries
PowerWAVE DPA
MD Frames
Capacity
Max.
Max. Power connection
kVA
25
75
125
Dimensions (WxHxD)
mm
550x1650x780
550x1975x780
550x1975x780
Weight of Empty Frame
kg
200
220
160
Weight of Frame with modules and
no batteries
kg
224 - 233
(with 1 Module)
292 - 319
(with 3 Modules)
280 - 325
(with 5 Modules)
Colours
Front: RAL 9007 + black (inlets). Side walls: Graffito grey
DPA 10
DPA 15
DPA 20
DPA 25
PowerWAVE DPA
Modules
Output Apparent Power
KVA
10
15
20
25
Output Active Power
KW
8
12
16
20
Output Power (PF=1)
KVA/KW
8/8
12 / 12
16 /16
20 /20
Variable Number of 12V Battery
Blocks
No.
30 – 50
30 – 50
30 – 50
40-50
Dimensions (WxHxD)
mm
Weight UPS Module
kg
483 x 225 x 700
24
Colours
33
Front: RAL 9007
Figure 2.2 PowerWAVE 9000DPA MD Frames
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
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2: Description
2.3.5 PowerWAVE 9000DPA MX Frames
CLASSIC
DPA-50
TRIPLE
DPA-150
UPGRADE
DPA-250
1 module (30-45kVA)
280 x 7/9Ah batteries
3 modules (30-45kVA)
240x 7/9Ah batteries
5 modules (30-45kVA)
External batteries
PowerWAVE DPA
MX Frames
Capacity
Max.
Max. Power connection
kVA
50
150
250
Dimensions (WxHxD)
mm
730x1650x800
730x1975x800
730x1975x800
Weight of Empty Frame
kg
250
270
190
Weight of Frame with modules and
no batteries
kg
300 - 310
(with 1 Module)
420 - 450
(with 3 Modules)
440 - 490
(with 5 Modules)
Colours
Front: RAL 9007 + black (inlets). Sidewalls: Graffito grey
DPA 30
DPA 40
DPA 50
45*
PowerWAVE DPA
MODULES
Output Apparent Power
KVA
30
40
Output Active Power
KW
24
32
40
Output Power (PF=1)
KVA / KW
24 / 24
32 / 32
40 /40
Number of 12V Battery Blocks
No.
40-50
40-50
40-50
Dimensions (WxHxD)
mm
Weight UPS Module
kg
Colours
663 x 225 x 720
50
57
60
Front: RAL 9007
* On Inverter mode 50 KVA/40kW on Bypass mode 45 KVA/40kW
Figure 2.3 PowerWAVE 9000DPA MX Frames
2.4
Advanced Design Features
2.4.1 Hot-swappable modules
In a redundant module system (see paragraph 2.4.4) the unique Hot-Swappable feature enables a UPS
module to be inserted or removed from the larger cabinet assembly whilst it is still powered (hot) without
affecting the supply to the load, and without having to transfer to bypass.
Note: In a non-redundant configuration the load will unavoidable have to be transferred to bypass while a
module is removed from the system.
2.4.2 Advanced booster technology
The UPS 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 total
system operation and savings in generator and transformer sizing as winding losses are minimised. It also
means that traditional harmonic filters are no longer required.
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UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
2: Description
The high power factor presented by the UPS on the incoming mains supply minimises cabling and fusing
costs due to the resulting lack of reactive power consumption. This, together with the accompanying low
harmonic currents, provide the following benefits:
•
•
•
•
•
•
No additional losses in wires and cables.
No extra heating of transformers and generators.
No over sizing of generators.
No false circuit breaker tripping and malfunction.
No erratic operation of computers, telecommunication, monitors, electronic test equipment etc.
No resonance with power factor correction capacitors.
2.4.3 Flexible battery management (FBM)
This equipment employs a flexible battery management which avoids premature deterioration of battery life
by advanced management of battery charging and preventive failure diagnostics.
The major benefits are:
•
•
•
•
•
•
•
•
AC-ripple free battery charging due to a dc-dc charger separated from the rectifier and inverter.
Wide range of number of battery blocks (30-50 blocks of 12V; depending autonomy times).
UPS's wide 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 Advanced Battery Diagnosis (ABD) - Algorithm.
User selectable battery tests.
Optional temperature compensated charging to enhance battery life.
2.4.4 Decentralized Parallel Architecture (DPA)
In a ‘redundant’ parallel UPS system the UPS modules are linked together in parallel so that in the event that
one module fails the others can automatically sustain the load supply.
A ‘parallel redundancy’ configuration is achieved by having a random or fixed master-slave relationship
among the UPS modules whereby the master logic gives out individual commands to all the slave units.
Unfortunately, in some designs this can lead to a single-point-of-failure for the entire system if the master
logic or communication to the slaves fails.
The PowerWAVE 9000 DPA system features DPA paralleling technology that provides n+x redundancy
without introducing a single-point-of-failure. The modules utilizing the DPA technology are completely
autonomous by means of individual power units, bypasses, CPUs, control panels and separate battery
configuration.
DPA technology uses multi-master logic with separated independent regulation and logic buses to maintain
the highest system availability.
This unique decentralized design:
•
•
•
•
enables a parallel redundant system providing 100% conditioned power at all times.
eliminates the system-level single point of failure inherent in traditional parallel UPS
exponentially increases the reliability of the overall system.
allows up to ten UPS cabinets to supply the same load in parallel and redundant configuration.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
2-5
2: Description
2.5
Warranty
The PowerWAVE 9000 DPA 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 warranty, 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 Kohler Uninterruptible Power will, at
its sole option, repair or replace the UPS. All repaired or replaced parts will remain the property of Kohler
Uninterruptible Power.
As a general policy, Kohler Uninterruptible Power 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. Kohler Uninterruptible Power
does not recommend the use of any of its products in direct patient care. Kohler Uninterruptible Power will not
knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to
Kohler Uninterruptible Power that the risks of injury or damage have been minimized, the customer assumes
all such risks and the liability of Kohler Uninterruptible Power is adequately protected under the
circumstances
THE 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.
2.6
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:•
•
•
•
•
2.7
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 +65 6302 0708 for further details.
Additional Service/Maintenance Support
In addition to providing support for the PowerWAVE 9000 DPA, Kohler Uninterruptible Power 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 DPA, or any other UPS you may
have, please complete the enquiry form shown opposite and return or FAX to:
Kohler Uninterruptible Power.
7 Jurong Pier
Singapore 619159
2-6
Tel:
+65 6302 0708
Fax:
+65 6302 0717
Email:
[email protected]
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
2: Description
www.kohlerupu.sg
Fax to: +65 6302 0717
Kohler Uninterruptible Power
7 Jurong Pier
Singapore 619159
Tel:
+65 6264 6422
Name:
............................................................................................
Job Title:
............................................................................................
Company:
............................................................................................
Address:
............................................................................................
............................................................................................
............................................................................................
............................................................................................
Post Code
............................................................................................
Tel.
............................................................................................
Fax.
............................................................................................
E-mail
............................................................................................
Please contact me to discuss:
Extended Warranty options for my PowerWAVE 9000 DPA UPS
Extended warranty options for my UPS System as below:
Manufacturer:...................................................................
Model Nº:..........................................................................
Rating kVA:.......................................................................
Replacement Batteries......................................................................
Other
..................................................................(please specify)
Thank you for your enquiry, which will receive our prompt attention.
If you need to contact us immediately on +65 6264 6422 ,
or E-mail us on [email protected]
www.kohlerups.sg
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
2-7
2: Description
2-8
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3
3.1
Installation
Introduction
This chapter contains all the information necessary for the correct unpacking, positioning, cabling and
installation of the PowerWAVE 9000 DPA.
WARNING: All the operations described in this section must be performed by authorised
electricians or suitably qualified personnel.
Kohler Uninterruptible Power will take no responsibility for any personal or material damage
caused by incorrect cabling or operations, or activities which are not carried out in strict
accordance with the instructions contained in this manual.
3.2
Receipt of the UPS
The UPS and accessories are delivered on a specifically designed pallet that is easy to move with a forklift or
a pallet jack.
CAUTION: When off loading the UPS always keep it in an upright position.
Do not drop the equipment.
Do not stack the pallets due to the high-energy batteries involved and the heavy weight.
The packing container protects the UPS from mechanical and environmental damage. This protection is
further increased by wrapping the PowerWAVE 9000 DPA UPS with a plastic sheet.
Upon receiving the UPS, carefully examine the packing container and the UPS for any sign of physical
damage. The outside 'Tip&Tel' (“FRAGILE” and “ARROW”) indicator should be intact if the equipment has
been transported in an upright position. In case of rupture (or if they are suspect) inform the carrier and
Kohler Uninterruptible Power immediately.
CAUTION: Visible transport damages must be claimed to the carrier immediately after receipt!
Other claims for shipping damage must also be filed immediately and the carrier must be
informed within 7 days of receipt of the equipment.
Packing materials should be stored for further investigation.
Ensure that the received UPS corresponds to the description indicated in the delivery note.
3.2.1 Site transportation
If you transport the UPS equipment after it has been off-loaded (for example, for storage or moving to a
different installation location) please observe the following precautions.
CAUTION: Transportation:
To avoid the UPS cabinets and/or battery cabinet falling over, use the shipping brackets on the
rear and front to secure the cabinets.
– Do not tilt the cabinets more than 10° from vertical.
CAUTION: Potential dangers:
– If the cabinet has been tilted it might damage the equipment and it should not therefore be
connected to the mains electricity supply.
– The weight of the UPS system could cause serious injuries to persons or anything in the
surrounding area.
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3: Installation
CAUTION: Storage:
– The UPS should be stored in the original packing and shipping carton.
– The recommended storing temperature for the UPS system and batteries is between +5 °C
and +40°C.
– The UPS system and the battery sets must be protected from humidity
< 90% RF (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 the unpacking instructions are not
followed closely.
If the packages are received in good order (i.e. the ‘tip & tell’ “FRAGILE” and “ARROW” indications on the
packing container are intact) then perform the following steps to unpack the UPS:
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.
2.
Cut the wrappers and remove the packing container by pulling it upwards.
3.
Remove the plastic sheeting covering the UPS.
4.
Remove the UPS from the pallet.
5.
Retain the packaging materials for future shipment of the UPS.
6.
Examine the UPS for any sign of damage.
Notify your supplier immediately if damage is apparent.
7.
Open the cabinet door and ensure that all the UPS modules are correctly and securely fitted in their
compartments. Ensure that a protection cover is fitted to the front of any empty UPS compartments.
3.3.1 Nameplate
The technical specifications of the PowerWAVE 9000 DPA are provided on the nameplate which is situated
at the front (internal door) of the UPS.
Check that the details on the nameplate corresponds to the purchased material detailed on the delivery note.
3.4
Batteries
The standard batteries connected to the UPS are sealed, maintenance-free batteries which will be mounted
either within the UPS cabinet or an external battery cabinet. The battery will usually be connected when the
UPS is commissioned.
Battery life depends very much on the ambient temperature, and optimum battery life will be obtained if the
batteries are operated at a temperature of 20°C.
If the UPS is delivered without batteries, Kohler Uninterruptible Power is not responsible for any damage or
malfunctioning caused to the UPS by the incorrect storage, installation or connection of batteries by third
parties.
3-2
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3: Installation
3.5
Storage
3.5.1 UPS
If you plan to store the UPS prior to use, store it in a clean dry environment with a temperature between 5°C
to +40°C and RH of less than 90%. If the packing container is removed, you must protect the UPS from dust.
3.5.2 Battery
The UPS utilizes sealed, maintenance-free batteries, whose storage capability depends on ambient
temperature. It is therefore important not to store the UPS for longer than 6 months at 20°C, 3 months at
30°C or 2 months at 35°C storage temperature without recharging the batteries. For longer term storage the
battery should be fully recharged every 6 months @20°C.
CAUTION: Sealed batteries must never be stored in a discharged or partially discharged state.
Extreme temperature, under-charge, overcharge or over-discharge will destroy batteries!
Key Point: Note the following:
•
•
•
3.6
Charge the battery both before and after storing.
Always store the batteries in a dry, clean, cool environment in their original packaging.
If the packaging is removed protect the batteries from dust and humidity.
Positioning
3.6.1 Planning the installation
A certain amount of pre-planning will help ensure smooth, trouble-free equipment installation. The following
guidelines should be taken into account when planning a suitable UPS location and environment.
1.
The equipment must be installed and transported in a upright position.
2.
The floor at the installed location 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.
3.
The UPS cabinet requires space to bottom/front and back to enable cooling airflow. Suitable ventilation
airflow must also be provided (See Figure 3.1). Allow a 200mm minimum clearance at the back of the
cabinet.
4.
All parts of the UPS required for maintenance, servicing and user operation are accessible from the front.
Reserve a minimum of 1000mm space at the front of the UPS cabinet.
5.
An ambient temperature of 20°C is recommended to achieve a long battery life. The cooling air entering
the UPS must not exceed +40°C.
6.
Avoid high ambient temperature, moisture and humidity. The floor material should be non-flammable and
strong enough to support the heavy load.
7.
In summary, the UPS should be located where:
a) Humidity (< 90% non-condensing) and temperature (+15°C to 25°C) are within prescribed limits.
b) Fire protection standards are respected.
c) Cabling can be performed easily.
d) A minimum 900mm front accessibility is available for service or periodic maintenance.
e) Requested air cooling flow is available.
f) The air conditioning system can provide a sufficient amount of air cooling to keep the room at, or
below, the maximum desired temperature.
g) No dust or corrosive/explosive gases are present.
h) The location is vibration free.
i) If the UPS will be installed in bayed enclosures, partition walls have to be installed.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-3
3: Installation
X
X
Battery
Cabinet
UPS
Y
Front
UPS
Y
Front
Z
Z
Clearance (mm)
Minimum
X
Y
Z
200*
200
1000
*Rear access is essential for maintenance.
Figure 3.1 UPS & Battery Cabinet Space Requirements
3.7
UPS Power Cabling (preparation and planning)
3.7.1 General requirements
It is the customer’s responsibility to provide all external fuses, isolators and cables used to connect the UPS
input and output power supplies. The information in this section should assist in the planning and preparation
of the UPS power cabling.
The UPS input supply and bypass supply should be connected to the utility mains through a LV-Distribution
board and protected by a circuit breaker or fuse. This provides overload protection and also a means of
isolating the UPS from the mains supply when required. Similarly, the UPS output supply should be
connected to the load equipment via a suitably fused output distribution panel.
The UPS can be wired with a ‘single feed’ input (standard), whereby the UPS input supply is connected
internally to the UPS bypass circuit (see Figure 3.5); or it can be wired with a ‘dual feed’ input, whereby the
UPS bypass circuit is connected to a dedicated ‘bypass’ supply (see Figure 3.6). These diagrams identify the
UPS input/output cabling requirements and provides information regarding fuse ratings, cable ratings and
cable sizing.
Key Point: This information is given for guidance only. All fuses, isolators and power cables must
be rated and installed in accordance with the prescribed IEC standards or local regulation.
Figure 3.4 outlines of the power terminal connections withing the various UPS cabinets including connection
sizes. Detailed connection diagrams can be found in:
•
•
•
•
•
•
3-4
Figure 3.7 (DPA-25 Input/Output Terminal Block, Front View)
Figure 3.8 (DPA-75 Input/Output Terminal Block, Front View)
Figure 3.9 (DPA-125 Input/Output Terminal Block, Front View)
Figure 3.10 (DPA-50 Input/Output Terminal Block, Front View)
Figure 3.11 (DPA-150 Input/Output Terminal Block, Front View)
Figure 3.12 (DPA-250 Input/Output Terminal Block, Front View)
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
These illustrations show that the UPS cabinet requires the following power cables:
Rectifier (In):
• three-phase (1L1, 1L2, 1L3)
• neutral (1N)
• protective earth (PE) connection for the rectifier input
Bypass (In):
• three-phase (2L1, 2L2, 2L3)
• neutral (2N)
• protective earth (PE) connection for the bypass if used as ‘Dual Feed’ input
Load (Out):
• three-phase (3L1, 3L2, 3L3)
• neutral (3N)
• protective earth (PE) connection for the load output
(External) Battery:
• Plus (+)
• Common (N)
• Minus (-)
• protective earth (PE) connection for the external batteries
Input neutral grounding
Key Point: Input neutral is required to operate the rectifier.
In TN-S systems, no 4-pole input switches or circuit breakers should be used.
During battery operation the neutral must always be grounded.
UPS
0V
230V
Figure 3.2 Input neutral grounding
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-5
3: Installation
3.7.2 Multi-cabinet installation cabling considerations
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 UPS cabinet should be of equal length. Similarly the UPS
output cables to the output distribution board should be of equal length (See Figure 3.3).
.
Recommended cable configurations
Bypass Feed
Rectifier Feed
UPS 1
UPS 2
UPS 3
UPS 4
To Load
The cable configuration below is not recommended
Bypass Feed
Rectifier Feed
UPS 1
UPS 2
UPS 3
UPS 4
To Load
Figure 3.3 Cable Lengths for Multi Cabinet Configurations (assuming a 2 cable input)
3-6
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3: Installation
3.8
Connecting the UPS input supply
WARNING: Opening or removing the UPS enclosure covers will create the risk of exposure to
dangerous voltages if power is connected to the UPS.
3.8.1 Safety notes
Please ensure you read and understand the following safety notes before you begin the UPS electrical
installation.
1.
All operations detailed in this section must be performed by an authorised electrician or qualified/
approved personnel.
2.
Once the electrical installation is completed the initial UPS start-up and commissioning must be
performed by qualified personnel authorised by the manufacturer.
3.
Do not operate the UPS if there is water or moisture present.
4.
When carrying out any work on the UPS input power cables you must ensure that the UPS supplies are
isolated at the supply distribution panel and, where possible, locked out. Warning notices should be
posted where applicable to prevent inadvertent operation of the input supply isolators.
3.8.2 Preparing the input cabling
Before you start connecting the UPS input cables:
• Ensure that the provided fuses and cables satisfy the ratings shown in Figures 3.5 and 3.6, and are in
accordance with the prescribed IEC Standards or local regulations.
• Do not commence this procedure until the UPS is properly installed at its intended final location.
3.8.3 Connecting the UPS input power cables
1.
To protect personnel during the UPS installation ensure that the connections are performed under the
following conditions:
a)
b)
c)
d)
No mains voltage is present.
Loads are shut down and disconnected.
The UPS is shut down and voltage-free.
The UPS Maintenance Bypass Isolator IA1 is OFF.
2.
Gain internal access to the UPS cabinet and remove the UPS power terminal cover.
3.
Connect the earth cable from the LV-Distribution Board to the protective earth (PE) terminal in the UPS.
4.
The PowerWAVE 9000 DPA input supply can be wired for ‘single feed’ (standard) or ‘dual feed’
operation. Connect the input power cable coming from the LV-Distribution Board to the UPS input
terminals following the appropriate instructions (single feed) or (dual feed) below.
Single Input Feed
Refer to the schematic drawing and connection table shown in Figure 3.5.
1.
Connect the UPS input supply cables to terminals 1L1, 1L2, 1L3 and 1N on the UPS main terminal block
(See Figure 3.4). Ensure correct (clockwise) phase rotation.
CAUTION: The input Neutral cable must ALWAYS be connected.
2.
Secure the cables to the fixing rail located under the UPS connection terminals.
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3: Installation
Dual Input Feed
Refer to the schematic drawing and connection table in Figure 3.6.
1.
The UPS is supplied (as standard) with facilities for a single cable feed for the rectifier and bypass
supplies. For a dual feed configuration remove the links between 1L1 - 2L1; 1L2 - 2L2; 1L3 - 2L3 and 1N
- 2N, on the input terminal block.
2.
Connect the UPS input supply cables to terminals 1L1, 1L2, 1L3 and 1N on the UPS main terminal block.
Ensure correct (clockwise) phase rotation.
CAUTION: The input Neutral cable must ALWAYS be connected.
3.
Connect the UPS bypass supply cables to terminals 2L1, 2L2, 2L3 and 2N on the UPS main terminal
block. Ensure correct (clockwise) phase rotation.
CAUTION: The bypass Neutral cable must ALWAYS be connected.
4.
Secure the cables to the fixing rail located under the UPS connection terminals.
Note: The UPS commissioning engineer will configure the UPS system for a dual input operation at the time
of commissioning.
3.9
Connecting the UPS output
WARNING: Opening or removing the UPS enclosure covers will create the risk of exposure to
dangerous voltages if power is connected to the UPS.
3.9.1 Safety notes
Ensure you read and understand the following safety notes before you begin the UPS electrical installation.
1.
All operations detailed in this section must be performed by an authorised electrician or qualified/
approved personnel.
2.
Once the electrical installation is completed the initial UPS start-up and commissioning must be
performed by qualified personnel authorised by the manufacturer.
3.
Do not operate the UPS if there is water or moisture present.
4.
When carrying out any work on the UPS output power cables you must ensure that the UPS supplies are
isolated at the supply distribution panel and, where possible, locked out. Warning notices should be
posted where applicable to prevent inadvertent operation of the input supply isolators.
3.9.2 Preparation for the output cabling
Circuit breakers (or equivalent protection) must be fitted between the UPS output and load equipment to
provide additional protection to the UPS in the event of an overload or short circuit, and also provide a means
of isolating individual loads if required.
Before you start connecting the UPS output cables to the load distribution panel:
• Ensure that the potential load does not exceed the UPS model output power rating (OUTPUT
POWER) on the nameplate.
• Ensure the output circuit breakers are correctly sized with respect to the load rating and associated
cabling.
• The maximum total load rating and maximum load rating of the individual load sockets should be
indicated on the output distribution board.
• The circuit breakers must comply with the prescribed IEC Standards. It is recommended that a
separate output distribution board is provided for the load.
3-8
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3: Installation
3.9.3 Connecting the UPS output cables
1.
To protect personnel during the UPS installation ensure that the connections are performed under the
following conditions:
a)
b)
c)
d)
No mains voltage is present.
Loads are shut down and disconnected.
The UPS is shut down and voltage-free.
The UPS Maintenance Bypass Isolator IA1 is OFF.
2.
Gain internal access to the UPS and remove the UPS terminal cover (if fitted).
3.
Connect the protective earth cable from the Load Distribution Board to the output protective earth (PE)
terminals, as shown in Figure 3.4.
4.
Connect the UPS output supply cables to terminals 3L1, 3L2, 3L3 and 3N on the UPS main terminal
block. Ensure correct (clockwise) phase rotation.
CAUTION: The output Neutral cable must ALWAYS be connected.
5.
Secure the cables to the fixing rail located under the UPS connection terminals.
6.
Ensure the output cables are connected to the correct power terminals on the output (load) distribution
panel.
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3: Installation
3.9.4 Connection Terminal Details
DPA-25
DPA-50
DPA-75
DPA-150
DPA-125
DPA-250
Single Input
Dual Input
PE
B+
E
BN
B-
1L1
2L1
1L2
Batts
2L2
1L3
2L3
1N
2N
DPA-25
DPA-75
3L1
3L2
3L3
3N
Input*
Output*
Separate
(+ / N / -) +PE
Bypass
3+N
Rectifier
3+N+PE
3+N+PE
DC Fuses and cables
are bespoke to the
installation.
4 x 10/16mm2(T)
5 x 10/16mm2(T)
5 x 10/16mm2(T)
4 x 35/50mm2(T)
4 x 35/50mm2(T) +PE
4 x 35/50mm2(T) +PE
2
DPA-125
PE
Output
Battery
FRAME
PE
Input / Bypass
4 x 70/95mm2(T)
50mm (T)
50mm2(T)
4 x 70/95mm2(T) + PE
4 x 70/95mm2(T) + PE
2
50mm (T)
50mm2(T)
DPA-50
4 x 16/25mm2(T)
5 x 16/25mm2(T)
5 x 16/25mm2(T)
DPA-150
3 x M10(B) +PE 1xM10 (B)
4 x M10 (B) +PE 1xM10 (B)
4 x M10 (B) +PE 1xM10 (B)
DPA-250
3 x M12 (B) +PE 1xM12 (B)
4 x M12 (B) +PE 1xM12 (B)
4 x M12 (B) +PE 1xM12 (B)
(T) signifies Terminals. (B) signifies Bar (See Figure 3.4)
Fuse and Cable recommendations to IEC 60950-1:2001 or locally recoginsed standards.
The fuse and cable rating details in the above tables are a recommendation only.
The UPS must be installed to prescribed IEC or local regulations.
Figure 3.4 Terminal Layouts
3-10
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3: Installation
SINGLE INPUT FEED
Mains (3x400/230V)
Fuse A
Cable A
Inverter
Rectifier
Inverter
F2
Rectifier
Inverter
Static Switch
Static Switch
Static Switch
IA2-1
IA2-2
IA2-3
Upgrade
Frame
BATTERY
CABINET
UPS Modules 2
Rectifier
F1
F2
UPS Module 3
F1
F2
UPS Module 1
F1
Maintenance Bypass IA1
Cable D
Load
Power
(kVA)
FRAME
Single Input
(3 x 400V)
Output
(3x400V, 0.8 pf)
Fuse A
(A)
Cable A
Max Input with batt
charging (A)
Cable D
(mm2)
(mm2)
Nominal Current
(A)
DPA-25
25
3x63
5x10
34
5x10
36
DPA-75
75
3x125
5x50
101
5x50
108
DPA-125
125
3x225
5x95
169
5x95
181
DPA-50
80
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
Notes:
1.
Fuse and Cable recommendations to IEC 60950-1:2001 or locally recoginsed standards.
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.
4.
DC Cables and Battery fuses are bespoke to the installation.
Figure 3.5 Single input block diagram with cable and fuse sizing
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3: Installation
BYPASS FEED
INPUT FEED
Mains (3x400/230V)
Mains (3x400/230V)
Fuse B
Fuse C
F2
F1
Inverter
F2
F1
Rectifier
UPS Module 1
Rectifier
F2
UPS Modules 2
F1
Cable C
Inverter
Rectifier
UPS Module 3
Cable B
Inverter
Static Switch
Static Switch
Static Switch
IA2-1
IA2-2
IA2-3
BATTERY
CABINET
Maintenance Bypass IA1
Cable D
Load
Frame
Power
(kVA)
Dual Input
(3 x 400V)
Fuse B/C
(A)
Cable B
2)
(mm
Output
(3x400V, 0.8 pf)
Cable C
2)
(mm
Max Input with
battery charging (A)
Cable D
2)
(mm
Nominal
Current (A)
DPA-25
25
3x63
5x10
4x10
34
5x10
36
DPA-75
75
3x125
5x50
4x50
101
5x50
108
DPA-125
125
3x225
5x95
4x95
169
5x95
181
DPA-50
80
3x100
5x25
4x25
67
5x25
72
DPA-150
150
3x250
5x120 or
5x(2x50)
4x120 or
4x(2x50)
202
5x120 or
5x(2x50)
218
DPA-250
250
3x400
5x(2x95)
4x(2x95)
337
5x(2x95)
362
Notes:
1.
Fuse and Cable recommendations to IEC 60950-1:2001 or locally recoginsed standards.
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.
4.
DC Cables and Battery fuses are bespoke to the installation.
Figure 3.6 Dual input block diagram with cable and fuse sizing
3-12
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
15
23
14
13
1
2
24
3
22
4
5
6
9 10 11 12
7
8
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 BUS - Input Connector
JD6 Parallel BUS - Output Connector
4
JD11 RS232 / Sub D9/ female, PC interface
5
JD12 RS232/ Sub D9 / male for Multidrop ONLY
6
USB PC Interface
7
SNMP Slot for optional SNMP card ONLY
8
Slot for optional Modem/Ethernet card ONLY
9
Battery terminal + / N / - for 16/25 mm2
10
Input Bypass terminal for Dual Input feed 10/16 mm2
11
Input Rectifier terminal for Single feed 10/16 mm2
12
Output Load terminal 10/16 mm2
13
IA1 Maintenance Bypass
14
IA2-1 Parallel Isolator
15
F4 Battery Fuse Holder
22
F2 Bypass Line Fuse
Module DPA 10 14x41 / 25A Pronorm
Module DPA 15 14x41 / 32A Pronorm
Module DPA 20 14x41 / 32A Pronorm
Module DPA 25 14x41 / 40A Pronorm
23
JD1 Smart Port- RS232 (Sub-D9P)
24
JD7 Connector for Control Panel
Figure 3.7 DPA-25 Input/Output Terminal Block, Front View
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-13
3: Installation
23
14
15
1
16
2
24
3
22
4
19
20
21
13
5
6
7
9/9*
10
11
12
8
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 BUS - Input Connector
JD6 Parallel BUS - Output Connector
4
JD11 RS232 / Sub D9/ female, PC interface
5
JD12 RS232/ Sub D9 / male for Multidrop ONLY
6
USB PC Interface
7
SNMP Slot for optional SNMP card ONLY
8
Slot for optional Modem/Ethernet card ONLY
9
Battery terminal + / N / - for 16/25 mm2
9*
3 Battery terminal for common battery for M6 + PE 1x 16mm2
10
Input Bypass terminal for Dual Input feed 35/50mm2
11
Input Rectifier terminal for Single feed 35/50mm2
12
Output Load terminal 35/50mm2
13
IA1 Maintenance Bypass
14
IA2-1 Parallel Isolator UPS-Module 1
15
IA2-2 Parallel Isolator UPS-Module 2
16
IA2-3 Parallel Isolator UPS-Module 3
19
F4 Battery Fuse Holder Module 1
22
F2 Bypass Line Fuse on each module
Module DPA 10 14x41 / 25A Pronorm
Module DPA 15 14x41 / 32A Pronorm
Module DPA 20 14x41 / 32A Pronorm
Module DPA 25 14x41 / 40A Pronorm
23
JD1 Smart Port- RS232 (Sub-D9P)
24
JD7 Connector for Control Panel
Figure 3.8 DPA-75 Input/Output Terminal Block, Front View
3-14
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
23
1
14 15 16 17 18 13
24
2
3
22
4
5
6
7
8
9/9*
10
11
12
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 BUS - Input Connector
JD6 Parallel BUS - Output Connector
4
JD11 RS232 / Sub D9/ female, PC interface
5
JD12 RS232/ Sub D9 / male for Multidrop ONLY
6
USB PC Interface
7
SNMP Slot for optional SNMP card ONLY
8
Slot for optional Modem/Ethernet card ONLY
9
Battery terminal + / N / - for 16/25 mm2
9*
3 Battery terminal for common battery for M10 + PE 1x 50mm2
10
Input Bypass terminal for Dual Input feed 70/95mm2
11
Input Rectifier terminal for Single feed 70/95mm2
12
Output Load terminal 70/95mm2
13
IA1 Maintenance Bypass
14
IA2-1 Parallel Isolator UPS-Module 1
15
IA2-2 Parallel Isolator UPS-Module 2
16
IA2-3 Parallel Isolator UPS-Module 3
17
IA2-4 Parallel Isolator UPS-Module 4
18
IA2-5 Parallel Isolator UPS-Module 5
22
F2 Bypass Line Fuse on each module
Module DPA 10 14x41 / 25A Pronorm
Module DPA 15 14x41 / 32A Pronorm
Module DPA 20 14x41 / 32A Pronorm
Module DPA 25 14x41 / 40A Pronorm
23
JD1 Smart Port- RS232 (Sub-D9P)
24
JD7 Connector for Control Panel
Figure 3.9 DPA-125 Input/Output Terminal Block, Front View
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-15
3: Installation
23
1
2
24
3
19
14
13
22
4
5
6
7
8
9 10 11 12
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 BUS - Input Connector
JD6 Parallel BUS - Output Connector
4
JD11 RS232 / Sub D9/ female, PC interface
5
JD12 RS232/ Sub D9 / male for Multidrop ONLY
6
USB PC Interface
7
SNMP Slot for optional SNMP card ONLY
8
Slot for optional Modem/Ethernet card ONLY
9
Battery terminal + / N / - for 16/25 mm2
10
Input Bypass terminal for Dual Input feed 16/25mm2
11
Input Rectifier terminal for Single feed 16/25mm2
12
Output Load terminal 16/25mm2
13
IA1 Maintenance Bypass
14
IA2-1 Parallel Isolator UPS-Module 1
19
F4 Battery Fuse Holder Module 1
22
F2 Bypass Line Fuse on each module
Module DPA 30 22x58 / 50A Pronorm
Module DPA 40 22x58 / 63A Pronorm
Module DPA 50 22x58 / 63APronorm
23
JD1 Smart Port- RS232 (Sub-D9P)
24
JD7 Connector for Control Panel
Figure 3.10 DPA-50 Input/Output Terminal Block, Front View
3-16
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
23
19
20
21 14 15 16
1
2
24
13
3
4
22
5
6
7
8
9
10 11
12
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 BUS - Input Connector
JD6 Parallel BUS - Output Connector
4
JD11 RS232 / Sub D9/ female, PC interface
5
JD12 RS232/ Sub D9 / male for Multidrop ONLY
6
USB PC Interface
7
SNMP Slot for optional SNMP card ONLY
8
Slot for optional Modem/Ethernet card ONLY
9
Battery terminal + / N / - for 16/25 mm2
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
IA2-2 Parallel Isolator UPS-Module 2
16
IA2-3 Parallel Isolator UPS-Module 3
19
F4 Battery Fuse Holder Module 1
20. F4 Battery Fuse Holder Module 2
21. F4 Battery Fuse Holder Module 3
22. F2 Bypass Line Fuse on each module
Module DPA 30 22x58 / 50A Pronorm
Module DPA 40 22x58 / 63A Pronorm
Module DPA 50 22x58 / 63APronorm
23
JD1 Smart Port- RS232 (Sub-D9P)
24
JD7 Connector for Control Panel
Figure 3.11 DPA-150 Input/Output Terminal Block, Front View
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-17
3: Installation
23
1
2
14
24
15
16
17
18
3
4
13
22
5
6
7
8
10/11
12
9/9*
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 BUS - Input Connector
JD6 Parallel BUS - Output Connector
4
5
JD11 RS232 / Sub D9/ female, PC interface
JD12 RS232/ Sub D9 / male for Multidrop ONLY
6
USB PC Interface
7
SNMP Slot for optional SNMP card ONLY
8
Slot for optional Modem/Ethernet card ONLY
9
Battery terminal + / N / - for 16/25 mm2
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
IA2-2 Parallel Isolator UPS-Module 2
16
IA2-3 Parallel Isolator UPS-Module 3
17
IA2-4 Parallel Isolator UPS-Module 4
18
IA2-5 Parallel Isolator UPS-Module 5
22
F2 Bypass Line Fuse on each module
Module DPA 30 22x58 / 50A Pronorm
Module DPA 40 22x58 / 63A Pronorm
Module DPA 50 22x58 / 63APronorm
23
JD1 Smart Port- RS232 (Sub-D9P)
24
JD7 Connector for Control Panel
Figure 3.12 DPA-250 Input/Output Terminal Block, Front View
3-18
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
3.10 Connecting the batteries
3.10.1 Safety Notes
WARNING: Opening or removing the UPS enclosure covers will create the risk of exposure to
dangerous voltages if power is connected to the UPS.
The final assembly and connection of the battery units must be carried out by (or under the
supervision of) the commissioning engineer. Do not attempt to complete the battery wiring or
close the battery isolators before system commissioning.
1.
For personal protection, ensure that the battery cables are connected under the following conditions:
a)
b)
c)
No mains voltage is present in the UPS.
All the loads are disconnected.
The UPS battery isolators are open and the external battery isolators are open in the external battery
cabinet (where used) – i.e. the terminals to which the battery cables are to be fitted are electrically
isolated.
3.10.2 Battery cabling
The UPS battery comprises a number of battery blocks (30-50) connected in series to form a battery string of
the required voltage and capacity; and connected to the UPS module by three connections 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 mid-way in the battery string (hence the reason why the string
must comprise an even number of battery blocks.
There are two basic battery supply configurations:
• Common battery – where several battery strings are connected in parallel to each UPS module.
• Individual battery – where each module is connected to individual battery string.
These configurations are depicted in Figure 3.13, which shows the alternative connections for internal
batteries in a 3-module cabinet. Figure 3.14 shows an example of the alternative connections when using an
external battery cabinet (shown connected to a 5-module UPS cabinet).
UPS1 +
UPS2 +
UPS3 +
UPS1 N
UPS2 N
UPS3 N
UPS1
UPS2
UPS3
UPS1 +
UPS2 +
UPS3 +
UPS1 N
UPS2 N
UPS3 N
UPS1
UPS2
UPS3
The available battery configurations within the standard internal and external battery cabinets are described
in paragraph 3.11 (Internal Battery Systems) and paragraph 3.12 (External Battery Cabinets and Battery
Connections).
1L1
1L1
PE
2L1
COMMON BATTERY
String 1 +
String 2 +
String 3 +
String 1 N
String 2 N
String 3 N
String 1
String 2
String 3
String 1 +
String 2 +
String 3 +
String 1 N
String 2 N
String 3 N
String 1
String 2
String 3
PE
2L1
INDIVIDUAL BATTERIES
Figure 3.13 Internal battery connections (3-module UPS cabinet shown)
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-19
3-20
Battery fuse
for UPS5
5+
5N
5-
UPS1 +
UPS2 +
UPS3 +
UPS4 +
UPS5 +
UPS1 N
UPS2 N
UPS3 N
UPS4 N
UPS5 N
UPS1
UPS2
UPS3
UPS4
UPS5
Battery fuse
for UPS4
4+
4N
4-
Battery fuse
for UPS3
Battery fuse
for UPS2
2+
2N
23+
3N
3-
Battery fuse
for UPS1
1+
1N
1-
Battery fuse
for UPS5
5+
5N
5-
UPS1 +
UPS2 +
UPS3 +
UPS4 +
UPS5 +
UPS1 N
UPS2 N
UPS3 N
UPS4 N
UPS5 N
UPS1
UPS2
UPS3
UPS4
UPS5
Battery fuse
for UPS4
4+
4N
4-
Battery fuse
for UPS3
Battery fuse
for UPS2
2+
2N
23+
3N
3-
Battery fuse
for UPS1
1+
1N
1-
3: Installation
EXTERNAL BATTERY CABINET
UPS CABINET
TO UPS Modules
PE
EXTERNAL BATTERY CABINET
PE
PE
For reasons of clarity, the wiring for modules 1,3,5 only is shown in detail
UPS CABINET
TO UPS Modules
PE
Figure 3.14 External battery cabinet wiring (5-module UPS cabinet shown)
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
3.10.3 Connecting the battery cables
WARNING: This procedure must be carried out by (or under the supervision of) the system
commissioning engineer.
1.
Ensure that the UPS input/bypass supply isolators/fuses are open on the input distribution board and
verify that no power is being fed to the UPS.
2.
Ensure that the MAINTENANCE BYPASS isolator (IA1) is open (OFF).
3.
Ensure that the battery isolators within the UPS cabinet are open.
4.
If connecting wiring to an external battery cabinet (or racks):
a) Ensure that the fused battery isolators in the external battery cabinet (or racks) are open.
b) Connect the protective earth cable (PE) between the UPS and external battery cabinet.
c) Connect the battery cables, ensuring the cables are connected to the corresponding + / N /terminals.
5.
If connecting the internal batteries:
a)
Connect the batteries to the battery connection terminal blocks ensuring the cables are connected to
the corresponding + / N /- terminals.
Note: DC and battery fuses are bespoke to the installation.
3.11 Internal Battery Systems
CAUTION: In DPA 10kVA, DPA 15kVA, DPA 20kVA, 30-50 12V-battery blocks are permitted
(even numbers only).
In DPA 25kVA, DPA 30kVA and DPA 50kVA, 40-50 12V-battery blocks are permitted (even
numbers only). The correct number of battery blocks is set up on the Control Panel Menu:
Service-Set-Up).
3.11.1 DPA-25
In a DPA-25 FRAME there is space for up to 200 x 9Ah internal batteries. Figure 3.15 shows the different
battery and system configurations.
A
B
C
A
B
UPS Module
C
A
B
UPS Module
7
10x7Ah
2x5x7Ah
10x7Ah
6
10x7Ah
2x5x7Ah
10x7Ah
5
10x7Ah
10x7Ah
10x7Ah
4
10x7Ah
2x5x7Ah
10x7Ah
3 2x5x7Ah 2x5x7Ah 2x5x7Ah
C
UPS Module
A
B
10x7Ah
10x7Ah
10x7Ah
10x7Ah
2x5x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
2x5x7Ah 2x5x7Ah 2x5x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
2
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
2x5x7Ah
1
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
(4x50)x7Ah
C
UPS Module
(3x50)x7Ah
(3x40)x7Ah
(2x30)x7Ah
Figure 3.15 DPA-25 Battery Configurations
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-21
3: Installation
3.11.2 DPA-75
In a DPA-75 FRAME there is space for up to 180 x 9Ah internal batteries. Figure 3.16 shows the different
battery and system configurations. The batteries may be wired as separate strings for each UPS-module or
as a common battery for all three UPS-Modules.
A
6
B
C
A
B
C
A
B
C
UPS Module 3
UPS Module 3
UPS Module 3
UPS Module 2
UPS Module 2
UPS Module 2
UPS Module 1
UPS Module 1
UPS Module 1
10x7Ah
2x5x7Ah
10x7Ah
5 2x5x7Ah 2x5x7Ah 2x5x7Ah
10x7Ah
10x7Ah
10x7Ah
4
10x7Ah
2x5x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
3
10x7Ah
10x7Ah
10x7Ah
2x5x7Ah 2x5x7Ah 2x5x7Ah
10x7Ah
10x7Ah
10x7Ah
2 2x5x7Ah 2x5x7Ah 2x5x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
1
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
3x(2x30)x7Ah
(3x50)x7Ah
(3x40)x7Ah
Figure 3.16 DPA-75 Battery Configurations
3.11.3 DPA-50
In a DPA-50 FRAME there is space for up to 280 x 9Ah internal batteries. Figure 3.17 shows the different
battery and system configurations.
A
B
C
D
A
UPS Module
B
C
D
A
UPS Module
B
C
D
UPS Module
7
10x7Ah
10x7Ah
6
10x7Ah
2x5x7Ah
10x7Ah
5
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
10x7Ah
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 3.17 DPA-50 Battery Configurations
3-22
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
3.11.4 DPA-150
In a DPA-150 FRAME there is space for up to 240 x 9Ah internal batteries. Figure 3.17 shows the different
battery and system configurations. The batteries may be wired as separate strings for each UPS-module or
as a common battery for all three UPS-Modules.
A
B
C
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 3.18 DPA-150 Battery Configurations
3.12 External Battery Cabinets and Battery Connections
In the UPS-cabinet DPA 125 or DPA 250 there is no space provided for batteries, instead there are 2 external
matching battery cabinets available:
• CBAT DPA-120 for battery configurations of 24Ah or 28Ah blocks (max. 120 Blocks)
• CBAT DPA-200 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
120 Batt. block x 24Ah/28Ah on
8 shelf
3x5=15 blocks/shelf
200 Batt. blocks x 24Ah/28Ah on
7 shelf
6x5=30 blocks/shelf
BATTERY FRAMES
Configuration accommodates:
Max.
Battery fuses / Max. Batt. Strings
Terminals:
S-type
Battery fuses / Max. Batt. Strings
Terminals:
C-type
Fuse Type (Very Fast acting)
3/3
5/5
(Terminal 9 x 16/25mm2)
(Terminal 15 x 16/25mm2)
3/3
+ Com. Connection Bar
3 x (2xM8) +PE 2xM8
5/5
+ Com. Connection Bar
3 x (2xM10) +PE 2xM10
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.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-23
3: Installation
CAUTION: In DPA 10kVA, DPA 15kVA, DPA 20kVA, 30-50 12V-battery blocks are permitted
(even numbers only). In DPA 25kVA, DPA 30kVA and DPA 50kVA, 40-50 12V-battery blocks
are permitted (even numbers only). The correct number of battery blocks is set up on Control
Panel Menu: Service-Set-Up).
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
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 3.19 External cabinet battery configurations
3.13 Multi-cabinet Parallel Communication Cables (Bus-lines)
Key Point: This section is required only if two (or more) cabinets are to be connected in a multicabinet parallel configuration, as described paragraph 2.3.2.
In a multi-cabinet system a series of communication bus lines must be connected between each cabinet to
enable various parallel control functions to be carried out.
Communication BUS lines are connected as shown below (See Figure 3.20).
WARNING: Before making the following connections ensure that all the UPS cabinets are
powered down and each parallel isolator IA2 is open.
Connect the parallel cabinet control cables
Note: Refer to Figures 3.7 to 3.12 to identify the location of the components mentioned below.
1.
Fit a Parallel Adapter over the Connector JD8 on all UPS-cabinets.
Note: The Parallel Adapter contains two connectors, JD5 and JD6 and a DIP switch (SW2)
(see Figure 3.20).
3-24
2.
Set DIP Switch SW2-2 on each Parallel Adapter depending on the UPS Cabinet in the parallel cabinet
configuration
3.
Connect PORT JD6 of the Parallel Adapter in Cabinet 1 to PORT JD5 of the Parallel Adapter in Cabinet
2 using the corresponding BUS-Cable (supplied).
4.
Connect PORT JD6 of the Parallel Adapter in Cabinet 2 to PORT JD5 of the Parallel Adapter in Cabinet
3 using the corresponding BUS-Cable (supplied).
5.
Continue in the same manner for the remaining UPS-Cabinets, as illustrated in Figure 3.20.
6.
In each cabinet, set DIP Switch SW2-2 on the Parallel Adapter according to the cabinet configuration, as
shown in Figure 3.20.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
U P S-Cabinet 1
U P S-C abinet 2
P arallel Adaptor
Master-Slave
O utput
JD 6
Master-Slave
Input
JD5
U PS -Cabinet n-1
Parallel Adaptor
SW 2-2
Master-Slave
O utput
JD6
Master-Slave
Input
JD 5
UPS -C abinet n
P arallel Adaptor
Master-Slave
O utput
SW 2-2
JD 6
Master-Slave
Input
JD5
Parallel Adaptor
Master-Slave
O utput
S W 2-2
JD 6
Single
Unit
First
Unit
Middle
Unit
Last
Unit
SW1
ON
OFF
OFF
ON
SW2
ON
ON
OFF
OFF
Master-Slave
Input
JD 5
S W 2-2
Figure 3.20 Connection of the Bus-lines when paralleling UPS-Cabinet Parallel Adaptors
Configuration DIP Switch SW1-9
DIP Switch SW1-9, located in every cabinet, is used to configure the position of the cabinet in a multi-cabinet
parallel chain. Using this switch you can define the cabinet’s position as:
• the first cabinet in the chain (e.g. cabinet 1 in Figure 3.20).
• The middle cabinet in the chain (there may be more than one).
• the last cabinet in the chain (e.g. cabinet n in Figure 3.20).
7.
Set DIP Switch SW1-9 on the Parallel Adaptor Board (PCB NW8141) of each cabinet according to the
table below:
First UPS
Middle UPS
Last UPS
Single UPS
SW 1a 1
ON
OFF
ON
ON
SW 1b 2
OFF
OFF
ON
ON
SW 1c 3
ON
OFF
OFF
ON
SW 1d 4
ON
OFF
ON
ON
SW 1e 5
ON
OFF
ON
ON
SW 1f 6
ON
OFF
ON
ON
SW 1g 7
ON
OFF
ON
ON
SW 1h 8
ON
OFF
ON
ON
SW 1i 9
ON
OFF
ON
ON
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3-25
3: Installation
3.14 Interfacing Facilities
Each UPS cabinet contains an Interface Board which has a number of communications interface connectors
that can be uses with a range of I/O options.
3.14.1 Interface Board
The Interface board has two LEDs:
• Green LED showing the status of the Interface:
- Blinking: 2/sec = Interface is Master (1st Cab. of a System)
- Blinking: 1/sec = Interface is Slave (2nd.. nth cab. of a System)
• Red LED Board Alarm (indicates a possible faulty board)
Master Interface Board
The following ports are active on the Interface Board when fitted to the Master cabinet:
• The Input ports (X1)
• The Output port (X2, X3, X4)
Slave Interface Boards
The following ports are active on the Interface Board when fitted to a Slave cabinet:
• 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
Note: Figure 3.21 shows the interface Board fitted to the DPA-75 cabinet. For details of the other cabinets
refer to Figures 3.7 to 3.12 to identify the location of the components mentioned below.
1.
X1-X4 Customer interface on Phoenix
Terminals:
X1 Customer Inputs
X2…X4 = Outputs Potential free contacts
2.
SW1-9 Multi-Cabinet Configuration Switch
3.
JD8 Parallel BUS connector
ONLY For paralleling cabinets use optional
adapter:
JD5 Parallel BUS - Input Connector
JD6 Parallel BUS - Output Connector
4.
JD11 RS232 / Sub D9/ female, PC
interface
5.
JD12 RS232/ Sub D9 / male for Multidrop
ONLY
6.
USB PC Interface
7.
SNMP Slot for optional SNMP card ONLY
8.
Slot for optional Modem/Ethernet card
ONLY
Figure 3.21 DPA-75 Cabinet interface connections
3-26
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3: Installation
3.14.2 Smart Port (Serial RS 232)
The SMART PORT is an intelligent RS 232 serial port that allows the UPS to be connected to a computer.
The connector is a standard D-Type, 9-pin, male.
When installed the optional SMART PORT software, WAVEMON allows the computer to monitor the mains
voltage and the UPS-status continuously.
Figure 3.22 shows the connection to a PC from the UPS.
Interface Cable
UPS End
Interface Cable
Computer End
(9-Pin, D-Type Male)
(9-Pin, D-Type Female)
Connects to UPS
SMARTPORT
1
1
2
2
3
3
5
5
9
9
Connects to
Computer
Figure 3.22 Connector Cable - PC Serial Port with 9-pin Connection
3.14.3 Dry Port (volt-free contacts)
All the Input and Output interfaces are connected to Phoenix terminals (cable 0.5 mm2)
Input Interfaces Terminal block X1
Connection of Remote Shut down facilities, Generator Operation, Customers specials (see Section 9,
chapter 1.2 OPTIONS).
Term
X1/1
X1/2
X1/3
X1/4
X1/5
X1/6
X1/7
X1/8
X1/9
X1/10
Contact
Signal
Display
Function
+3.3Vdc
GND
Remote Shut down - (Do not remove the factory mounted
bridge until external Remote Shut down is connected)
+3.3Vdc
GND
Generator Operation
+3.3Vdc
GND
Customer IN 1
+3.3Vdc
GND
Customer IN 2
+3.3Vdc
GND
Temperature Battery
Figure 3.23 Dry Port (X1) Connections
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
3-27
3: Installation
Output Interfaces Terminal blocks X2, X3, X4 (DRY PORTs)
Provides signals for the automatic and orderly shutdown of servers, AS400 or Automation building systems.
Term
X2/1
Contact
Signal
ALARM
Display
MAINS_OK
Function
Mains Present
X2/2
Mains Failure
X2/3
Common
X2/4
Message
LOAD_ON_INV
Load on Inverter
X2/5
Load on Bypass
X2/6
Common
X2/7
ALARM
BATT_LOW
Battery Low
X2/8
Battery OK
X2/9
Common
X2/10
Message
LOAD_ON_MAINS
Load on Bypass
X3/1
Load on Inverter
X3/2
Common
X3/3
ALARM
COMMON_ALARM
Common Alarm
X3/4
No Alarm
X3/5
Common
X3/6
ALARM
MODUL_ALARM1
Module 1 Alarm
X3/7
No Alarm
X3/8
Common
X3/9
ALARM
MODUL_ALARM2
Module 2 Alarm
X3/10
No Alarm
X4/1
Common
X4/2
ALARM
MODUL_ALARM3
Module 3 Alarm
X4/3
No Alarm
X4/4
Common
X4/5
ALARM
MODUL_ALARM4
Module 4 Alarm
X4/6
No Alarm
X4/7
Common
X4/8
ALARM
MODUL_ALARM5
Module 5 Alarm
X4/9
No Alarm
X4/10
Common
Figure 3.24 Dry Port (X2..X4) Connections
3.14.4 JD11/RS232 Computer Interface
The Computer Interface JD11is a standard D-Type, 9-pin, female. It is an intelligent RS 232 serial port
allowing the UPS system to be connected to a computer. When used with the optional PowerREPORTER
software it allows the computer to monitor the mains voltage and the UPS system status continuously and
display a message in the event of any changes.
3.14.5 JD12/RS232 Interface for Multidrop
The Computer Interface JD12 (5) l 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.
3.14.6 USB/2 Computer Interface
The Computer Interface USB (6) is in parallel with the intelligent RS 232 serial port JD11.
When installed, the USB Computer Interface and the optional WAVEMON software allows the computer to
monitor the mains voltage and the UPS system status continuously.
3-28
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4
4.1
Operation
Commissioning
The PowerWAVE 9000 DPA UPS is a high quality electronic machine that must be commissioned by a fully
trained and authorised Kohler Uninterruptible Power field service engineer before being put into use.
Commissioning the UPS involves connecting the UPS battery, checking the electrical installation and
operating environment of the UPS, performing a controlled start-up and testing of the UPS system, and
customer training.
WARNING: Any PowerWAVE 9000 DPA UPS system not commissioned by an Kohler
Uninterruptible Power field service engineer must be considered an electrical hazard and
Kohler Uninterruptible Power accepts no responsibility for its safe operation or the safety of
any personnel. Additionally, the manufacturer's warranty is immediately invalidated if the UPS
is put into use before it has been correctly commissioned.
4.2
Control Panel
The user-friendly control panel is composed of three parts:
• Power Management Display (PMD).
• Mimic LED Indicators
• Operating keys.
Mimic LED Indicators
Operating Keys
Power Management Display (PMD)
Figure 4.1 Control Panel
4.2.1 Power Management Display (PMD)
The 2 x 20 character LCD Power Management Display simplifies communication with the UPS and also
provides UPS monitoring information.
The menu driven LCD enables the access to:
•
•
•
•
The ‘Event register’
Monitoring the input and output voltage, current, frequency & power
Monitoring battery run time
Perform commands such as UPS start-up and shut-down, Load transfer from INVERTER to BYPASS
and vice-versa
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4-1
4: Operation
• Diagnostic (service mode)
• Adjustments and testing (service mode)
4.2.2 Mimic LED indicators
The mimic diagram indicates the status of the general UPS power flow and change colour between Green
and Red (and OFF) to indicate the UPS operating conditions.
LINE 1 (rectifier) and LINE 2 (bypass) indicate the availability status of the mains power supply.
INVERTER and BYPASS, if green, indicate which of the two sources is supplying the critical load power.
The BATTERY LED indicator flashes when the battery is supplying the load – e.g. following a mains failure.
The ALARM LED is a visual indication of any internal or external alarm condition. When activated, it is
accompanied by an audible alarm.
LED Indication summary
Indicator
Indicator Status
Interpretation
LINE 1
GREEN
RED
Mains available
Mains not available
LINE 2
GREEN
RED
Mains bypass OK
Mains bypass not OK or not present
ALARM
OFF
Flashing RED + buzzer
RED
No alarm condition
Alarm condition
Alarm condition (has been reset)
INVERTER
GREEN
RED
OFF
Load on inverter
Inverter fault
Inverter not operating
BY-PASS
GREEN
OFF
Load on bypass
Bypass not operating
BATTERY
GREEN
RED
Flashing RED
Flashing GREEN
Battery OK
Battery fault or discharged
Battery fuses blown
On Battery
4.2.3 Operator keys
The operator keys allow the user to:
• Make settings and adjustments via the 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
Key function summary
KEYS
Used to switch-on or switch-off the UPS
UP (
Scroll upwards through a displayed menu
)
DOWN (
4-2
FUNCTION
ON/OFF
ON/OFF
)
Scroll downwards through a displayed menu.
RESET
Cancels the audible alarm. If the alarm condition was transient the
ALARM LED will also extinguish, otherwise it will remain ON (red).
ENTER
Confirms (selects) a chosen menu item.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4: Operation
ON/OFF Start-up and shutdown buttons
The UPS may be switched ON or OFF by simultaneously pressing both ON/OFF keys on the control panel.
This is to prevent accidental UPS start-up or shutdown.
Note: When the UPS is under normal operation, pressing the two ON/OFF simultaneously will immediately
shutdown the UPS. In a single module installation this will disconnect the UPS from the load. In a parallel
module system the UPS module will shutdown and the module will effectively be removed from the parallel
load bus; however, the load may or may-not transfer to the bypass supply in the remaining modules
depending on the available module redundancy. To shut down all the modules in a parallel system you must
press both ON/OFF buttons on every UPS cabinet!
CAUTION: If the ON/OFF buttons are operated while the UPS is not in Maintenance Bypass it
will interrupt the load power supply.
LOAD OFF in a PowerWAVE 9000 DPA Single module system
If, for security or emergency reasons, it is necessary to immediately disconnect the load from the UPS, press
the two red ON/OFF Buttons simultaneously. The simultaneous action of both buttons is necessary to avoid
any accidental manipulation.
LOAD OFF in a PowerWAVE 9000 DPA Parallel module system
If, for security or emergency reasons, it is necessary to immediately disconnect the load from the UPS in a
multi-module system, the two ON/OFF buttons must be pressed simultaneously on one module and then
action repeated on all remaining modules sequentially.
4.3
Description of the LCD
4.3.1 Status screens
DESCRIPTION
LCD-DISPLAY
1.
Load is protected by UPS power Load is
supplied by inverter (Normal Operation).
LOAD
PROTECTED
Unit:01/1
2.
Load is not protected by UPS
Load is supplied by mains power (load on
bypass).
LOAD
NOT PROTECTED
Unit:01/1
3.
Load supply completely interrupted. UPS has
been switched off by “ON/OFF” buttons.
LOAD OFF
SUPPLY FAILURE
Unit:01/1
4.
UPS/module is not supplying load. The output
switch is open
LOAD DISCONNECTEDPARALLEL
SWITCH OPEN
Unit:01/1
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 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 UPS module number 3 in system Cabinet number 5.
DESCRIPTION
LCD-DISPLAY
1.
Single Systems.
SYSTEM CONFIGURATION
SINGLE
Unit:01/1
2.
Parallel System eg. First Cabinet/Master
Modules no 2 in slot 2.
SYSTEM CONFIGURATION
PARALLEL
Unit:02/2
3.
Parallel System eg. Second Cabinet/Slave
Modules no 5 in slot 3.
LOAD OFF
SUPPLY FAILURE
Unit:05/3
4.
Parallel System eg. Second Cabinet/Slave
Modules no 6 in slot 2.
LOAD DISCONNECTEDPARALLEL
SWITCH OPEN
Unit:06/4
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4-3
4: Operation
4.3.2 Main menu screen
DESCRIPTION
LCD-DISPLAY
1.
A log of the last 64 events is stored in the Power Management Display
(See paragraph 4.3.3).
→ EVENT LOG
MEASUREMENTS
2.
Allows monitoring of voltages, power, frequencies, currents, autonomy
etc (See paragraph 4.3.4)
→ MEASUREMENTS
COMMANDS
3.
Enables the commands “Load to inverter”, “Load to bypass” and battery
test to be executed (See paragraph 4.3.5).
→ COMMANDS
SET-UP DATA
4.
Allows the UPS personalized information (such as serial number) to be
entered (See paragraph ).
→ SET-UP DATA
SET-UP USER
5.
Allows user to set up Date/Time, automatic battery test, etc.
(See paragraph 4.3.7)
→ SET-UP USER
SET-UP SERVICE
6.
Password-protected area for service engineer use only (See paragraph
4.3.8).
→ SET-UP SERVICE
4.3.3 Event log menu screen
DESCRIPTION
LCD-DISPLAY
1.
Logging Control; a log of the last 64 events is stored in the Power
Management Display.
01 05-10-08
LOAD TO INV.
14-38-56
2.
Every stored event is identified with a sequential number and time
stamp.
02 05-10-08
LOAD TO BYP.
14-38-59
3.
By pressing ENTER the code of the event will be displayed.
03 05-10-08
LOAD OFF
14-39-14
4.3.4 Measurements menu screen
DESCRIPTION
4-4
LCD-DISPLAY
1.
Battery Runtime
BATT. RUN TIME (MIN)
00h 00mm
2.
UPS-Output Frequency
OUTPUT FREQUENCY (HZ)
50.00
3.
Bypass Frequency.
BYPASS FREQUENCY (HZ)
50.00
4.
Battery Voltage
BATTERY VOLTAGE (V)
+0.0
- 0.0
5.
Battery Charger Current
BATT. CHARGE CUR. (A)
+ 0.0
- 0.0
6.
Battery Discharge Current.
DISCHARGE CURRENT (A)
00.00
7.
Rectifier Input Voltage (all three phases)
RECTIFIER VOLTAGE (V)
00.00
00.00
00.00
8.
Bypass Input Voltage (all three phases)
BYPASS VOLTAGE (V)
00.00
00.00
00.00
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4: Operation
DESCRIPTION
LCD-DISPLAY
Output Voltage (all three phases)
OUTPUT VOLTAGE (V)0
0.00
00.00
00.00
10. Output Current (all three phases)
OUTPUT CURRENT (A)0
0.00
00.00
00.00
11. Active Output Power (all three phases)
ACTIVE POWER (KW)
00.00
00.00
00.00
12. Reactive Output Power (all three phases)
REACTIVE POWER (kVAr)
00.00
00.00
00.00
13. Apparent Output Power (all three phases)
APPARENT POWER (KVA)
00.00
00.00
00.00
14. Output Power (all three phases)
OUTPUT POWER (%)
00.00
00.00
00.00
15. Battery capacity
BATT. CAPACITY (%)
00.00
9.
4.3.5 Commands menu screen
DESCRIPTION
LCD-DISPLAY
1.
Transfer Load to inverter
→ LOAD TO INVERTER
LOAD TO BYPASS
2.
Transfer Load to bypass.
→ LOAD TO BYPASS
PERFORM BATT.TEST
3.
Battery Test
→ PERFORM BATT.TEST
4.3.6 UPS Data menu screen
DESCRIPTION
LCD-DISPLAY
1.
These general UPS Data are installed at the manufacturing plant.
UPS SERIAL NUMBER
nn-nnnnn
2.
Manufacturing date
DATE OF MANUFACTURE
15-03-09
3.
EPROM Version
EPROM VERSION
V-000
4.
Actual Date and Time
DATE
dd-mm-yyyy
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
TIME
hh:mm:ss
4-5
4: Operation
4.3.7 Set-up User menu screen
DESCRIPTION
1.
LCD-DISPLAY
→ SET LANGUAGE
SET DATE AND TIME
Set-up language
ENGLISH
FRANCAIS
DEUTCH
DUTCH
SPANISH
POLISH
PORTOGUESE
2.
→ SET-UP DATE/TIME
SET-UP BATT. TEST
Set-up Date and Time
DD-MM-YY
3.
HH-MM-SS
→ SET-UP BATT. TEST
SET-UP GEN-SET OPER.
Set-up battery test
DAY OF MONTH
(1-31)
HOUR OF DAY
(0-23)
REPETITIVE (Y/N)
000
4.
→ SET-UP GEN-SET OPER.
Set-up operation with Gen-Set
BATT.CHARGE LOCK
(Y/N)
BYPASS LOCK
(Y/N)
4.3.8 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-Users.
→ SET-UP SERVICE
PASSWORD
2.
Type in password.
→ PASSWORD*
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:
•
•
•
•
•
4-6
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 (2-4%)
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4: Operation
4.4
Operating Modes
4.4.1 On-Line (Inverter) mode
LINE 2
BY PASS
LINE 1
INVERTER
LED
LOAD
BATTERY
Colour
LINE 1
Green
LINE 2
Green
BY PASS
OFF
INVERTER
Green
BATTERY
Green
When the UPS is operating in the On-Line mode the load is supplied through the LINE 1 (RECTIFIER) and
INVERTER. This mode provides the highest degree of protection, especially in the event of a mains
disturbance or failure, and is always recommended if the critical loads (computer systems) will not tolerate
any (even very brief) interruption of the supply.
In the unlikely event of an inverter fault or overload condition the UPS will transfer the load automatically, and
without interruption, to the static bypass supply (transfer time = 0).
4.4.2 OFF-Line (also known as ECO or Bypass) mode
LINE 2
BY PASS
LINE 1
INVERTER
LED
LOAD
BATTERY
Colour
LINE 1
Green
LINE 2
Green
BY PASS
Green
INVERTER
OFF
BATTERY
Green
In the Off-Line (ECO/Bypass) mode the load is supplied from the bypass mains (LINE 2) and the static
BYPASS. In the event of a mains failure the load is automatically transferred to the inverter within 3 to 5 msec
– this is valid for single and parallel module systems. The battery charger remains active in this mode.
Although this mode of operation offers greater efficiency than the On-Line mode, it is recommended only if
the load can tolerate interruptions of 3 to 5 ms – which is the transfer time taken to change from Bypass mode
to On-Line mode.
WARNING: The On-Line mode must always be used to provide maximum load protection.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4-7
4: Operation
4.4.3 Maintenance Bypass mode
MAINTENANCE
BYPASS
MAINS
Switch IA1
LOAD
UPS
Figure 4.2 Maintenance Bypass Mode
Each module is fitted with a Maintenance Bypass switch (IA1) which, when closed, connects the UPS module
output terminals directly to the UPS Bypass Mains supply. This facility enables a UPS module to be shut
down for maintenance or repair whilst maintaining the load on the raw (unprotected) bypass supply.
WARNING: In a multi-module system ensure that ALL the UPS modules are operating in the
Bypass mode before transferring the load to Maintenance Bypass (IA1)
Maintenance Bypass switch (IA1)
Switch IA1
Effect
ON
Maintenance Bypass-Switch Closed (Load on bypass mains)
LCD-indication: MAINTENANCE BYP CLOSED
LED Indicators will indicate as shown in table below
OFF
Bypass-Switch Open – Normal operating condition (Load on inverter)
LCD-indication MAINTENANCE BYP OPEN
LED Indicators will indicate as shown in table below.
When the UPS is operating on Maintenance bypass the module mimic indications will be as follows
LED Indicator
ON
OFF
LINE 1
Green
Green
LINE 2
Green
Green
BYPASS
Green
OFF
INVERTER
RED
ON
BATTERY
Green
Green
CAUTION: If the UPS is operating in the Maintenance Bypass mode the load will not be
protected in the event of a mains failure. It is therefore strongly recommended to switch over to
the On-line mode or Bypass mode as soon as possible.
4.4.4 Parallel Isolator switch(IA2)
Each UPS module is provided with an output isolator (IA2). When this isolator is opened it totally disconnects
the UPS module from the output load bus. In a parallel module system this isolates the UPS modules and
allows it to be replaced without having to disturbe the remainder of the system (provided the loss of modules
does not exceed the system redundancy).
CAUTION: In a single module configuration the load must be transferred to the maintenance
bypass before the isolator is opened otherwise it will cause a loss of supply.
4-8
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4: Operation
4.5
Operating Instructions
Under normal operating conditions all the UPS modules in a multi-module system are running, and operating
in the ‘On Line’ (On Inverter) mode.
The following procedures are provided in this section:
How to transfer the load to the Maintenance Bypass and shut down the UPS system for maintenance
purposes – (See paragraph 4.5.1).
How to start up the UPS system and transfer the load from the Maintenance Bypass to the inverters (‘On
Line’ mode) (See paragraph 4.5.2).
How to shut down the entire UPS system (See paragraph 4.5.3).
How to stop/start one module in a redundant multi-module system (See paragraph 4.5.4).
4.5.1 Transfer to Maintenance Bypass Mode
If needed, to perform service or maintenance, it is possible to transfer the load to Maintenance Bypass Mode
and power down the UPS module(s) whilst leaving the load connected to the raw bypass mains supply.
WARNING: Before you close the Maintenance Bypass isolator ensure that the UPS is
operating in the Bypass Mode.
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 cabinets in a multimodule system):
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
Colour
LINE 1
Green
LINE 2
Green
BY PASS
OFF
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 ‘Bypass’ mode:
1.
On any 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, move the cursor so that it is adjacent to LOAD TO BYPASS and then press the
ENTER key.
a)
4.
The UPS system will transfer the load to static bypass.
On all modules check and confirm that:
a)
b)
c)
The INVERTER LED has extinguished.
The BYPASS LED is green.
The LCD displays LOAD NOT PROTECTED.
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4: Operation
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
Colour
LINE 1
Green
LINE 2
Green
BY PASS
Green
INVERTER
OFF
BATTERY
Green
Closing the Maintenance Bypass switch:
5.
6.
Close the Maintenance Bypass switch IA1 (in all cabinets in a multi-cabinet system).
On all UPS modules check and confirm that:
a)
b)
c)
The INVERTER LED has turned to red.
The BYPASS LED is green.
The LCD displays MANUAL BYP IS CLOSED.
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
Colour
LINE 1
Green
LINE 2
Green
BY PASS
Green
INVERTER
RED
BATTERY
Green
Powering down a UPS module:
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.
On the UPS control panel simultaneously press both ON/OFF buttons.
a)
8.
Identify the associated battery fuse for the UPS module (in external battery cabinet if fitted).
a)
9.
The LCD panel will indicate: LOAD OFF, SUPPLY FAILURE.
Open the battery fuses/breaker .
On the UPS module open the module’s Parallel Isolator (IA2).
LINE 2
BY PASS
LINE 1
INVERTER
LED
LOAD
BATTERY
4-10
Colour
LINE 1
Green
LINE 2
Off
BY PASS
Off
INVERTER
Off
BATTERY
Green Flashing
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4: Operation
10. Open the Bypass Line fuse holder F2 and the Rectifier Line fuse holder F1.
WARNING: The UPS cabinet is still live at its input and output power terminals due to the
activation of Maintenance Bypass circuit.
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.
4.5.2 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) (‘OnLine’ mode).
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 UPS system status:
• The load is supplied via the Maintenance Bypass switch (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.
On the UPS module close the Bypass Line fuse holder F2 and the Rectifier Line fuse holder F1 if they
are 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) The LCD display will indicate LOAD OFF, SUPPLY FAILURE.
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
Colour
LINE 1
Green
LINE 2
Off
BY PASS
Off
INVERTER
Off
BATTERY
Green Flashing
3.
Close the Parallel Isolator switch (IA2) and check that the PARALLEL SW CLOSED message is shown on
the LCD display.
4.
On the 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.
a) Initially LINE 2 LED will be red, then change to green.
a) At this stage the LCD display will indicate LOAD NOT PROTECTED and the module mimic LED
indications should be as follows:
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4-11
4: Operation
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
5.
LINE 1
Colour
Green
LINE 2
Green
BY PASS
Green
INVERTER
RED
BATTERY
Green
When powering up a multi-module system ensure that ALL the modules are in the state shown above
before continuing with this procedure.
Transferring 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) The LCD panels will display MANUAL BYPASS OPEN.
b) The INVERTER LED will be extinguished.
c) An audible alarm will sound.
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
8.
Colour
LINE 1
Green
LINE 2
Green
BY PASS
Green
INVERTER
RED
BATTERY
Green
Press the RESET button to cancel the audible alarm (on all modules).
a)
The LCD display(s) will now indicate LOAD NOT PROTECTED.
Transferring the load to the inverter:
9.
On the Control Panel (of any one module in a parallel module system):
a)
b)
c)
Press the UP key once to access the menu system.
Use the UP/DOWN keys to move the cursor so that it is adjacent to COMMANDS and then press the
ENTER key.
Use the UP/DOWN keys move the cursor so that it is adjacent to LOAD TO INVERTER and then press
the ENTER key.
10. The UPS system will transfer the load to Inverter (on all modules in a paralleli-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:
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
4-12
Colour
LINE 1
Green
LINE 2
Green
BY PASS
Off
INVERTER
Green
BATTERY
Green
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4: Operation
11. The UPS is now operating in ‘On-Line’ mode. The load is protected and supplied by inverter power.
4.5.3 Complete system shutdown
The UPS system may be shutdown completely if the load does not need input power for an extended period
of time. Use this procedure to totally turn of the load power and shutdown the entire UPS system.
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 connected to the output of the UPS system by opening the fused isolators or
circuit breakers in the UPS output load distribution board.
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 multimodule system.
3.
On the UPS control panel simultaneously press both ON/OFF buttons.
a)
4.
Identify the associated battery cabinet/rack for the UPS module.
a)
5.
The LCD panel will indicate: LOAD OFF, SUPPLY FAILURE.
Open the battery fuses/breaker on the battery cabinet/rack.
Open the module’s Parallel Isolator switch (IA2).
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
Colour
LINE 1
Green
LINE 2
Off
BY PASS
Off
INVERTER
Off
BATTERY
Green Flashing
6.
Open the Bypass Line fuse holder F2 and the Rectifier Line fuse holder F1.
7.
Open the UPS Input and Bypass supply fused isolators (or breakers) in the building power distribution
panel.
8.
The UPS is now voltage free.
WARNING: Allow 10 minutes for the internal DC capacitors to discharge before touching the
UPS internal components.
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4-13
4: Operation
4.5.4 Individual module start/stop procedure
If a multi-module system is designed with built-in redundancy, it is possible to stop and start one module
without affecting the operational status of the overall system – e.g. one module can be taken off-line for
servicing whilst the remaining modules maintain a protected load supply.
WARNING: All the operations in this section must be performed by authorised and trained
personnel.
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:
• UPS input isolators are open on the building’s LV supply switchboard
• The fused battery isolators are open in the battery cabinet
• In the UPS cabinet, the fused isolators F1, F2 and the parallel isolator (IA2) are open
1.
In the UPS cabinet, close the Input supply and Bypass supply fused isolators F1, F2 and the Parallel
Isolator IA2.
2.
Close the UPS input supply isolator at the LV switchboard.
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 this display.
3.
Identify the associated battery cabinet/rack for the UPS module and close the fused battery isolators.
4.
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 2 LED lights red then changes to green.
INVERTER LED lights green.
BATTERY LED lights green (constant).
b) LCD displays the LOAD PROTECTED message.
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
5.
4-14
Colour
LINE 1
Green
LINE 2
Green
BY PASS
Off
INVERTER
Off
BATTERY
Green
The UPS module is now On Line and connected to the parallel system.
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4: Operation
Module shut-down:
Use this procedure to power down a single module in a redundant module system.
1.
Simultaneously press the two ON/OFF buttons on the UPS control panel.
a)
The LED display will give the following indications:
LINE 2
BY PASS
LINE 1
INVERTER
LED
LOAD
BATTERY
4.6
Colour
LINE 1
Green
LINE 2
Off
BY PASS
Off
INVERTER
Off
BATTERY
Green
2.
Open the Parallel Isolator switch IA2.
3.
In the UPS Cabinet, open the Input supply and Bypass supply fused isolators F1 and F2.
4.
Identify the associated battery cabinet/rack for the UPS module and open the fused battery isolators.
5.
Open the UPS input supply isolator and UPS output isolator on the LV Switchboard.
6.
The UPS module is now totally shut-down.
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 2 minutes after it has been
disconnected in order to alllow 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 kVA module is 24kg).
Employ suitable lifting aids and safety platforms where possible.
If a UPS-module goes faulty in a Single Module system, the load will automatically transfer to the UPS
bypass supply (BYPASS mode) and the load is unprotected against a mains supply failure.
4.6.1 Removing a UPS Module
If your PowerWAVE 9000 DPA consists of only one single UPS Module then perform the following steps to
extract the module:
1.
Transfer the load to the Maintenance Bypass (see paragraph 4.5.1).
a)
2.
The load is now directly supplied by mains and is not protected
Simultaneously press the two ON/OFF buttons on the UPS control panel.
a)
The LED display will give the following indications:
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4-15
4: Operation
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
3.
Colour
LINE 1
Green
LINE 2
Off
BY PASS
Off
INVERTER
Off
BATTERY
Green
Open the fused battery isolator for the UPS module in the UPS cabinet or in the external battery cabinet/
rack, as applicable.
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
are fixing it to the cabinet / UPS-frame.
5.
Pull the UPS module forwards until the rear connectors are disconnected. DO NOT FULLY EXTRACT
THE UNIT
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 module from the cabinet by pulling it horizontally.
7.
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.
4.6.2 Refitting the UPS Module
4-16
1.
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.
Push UPS-module 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 it to the UPS cabinet / frame.
5.
Connect the control panel cable to connector JD7.
6.
Start the UPS module and bring it on line (See paragraph 4.5.2).
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4: Operation
4.7
Replacing a UPS Module in a REDUNDANT 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 alllow 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 kVA module is 24kg).
Employ suitable lifting aids and safety platforms where possible.
If a UPS-module goes faulty in a REDUNDANT parallel system, the load will continue to be protected by the
remaining modules which will continue to operate in the ON-LINE mode (INVERTER mode). Under these
circumstances the faulty UPS module may be replaced without having to transfer the load to bypass.
4.7.1 Removing the UPS Module
1.
On the UPS module to be replace, simultaneously press the two ON/OFF buttons on the UPS control
panel.
a)
The LED display will give the following indications:
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
Colour
LINE 1
Green
LINE 2
Off
BY PASS
Off
INVERTER
Off
BATTERY
Green
2.
Open the UPS module’s Parallel Isolator (IA2).
3.
Open the fused battery isolator for the UPS module in the UPS cabinet or in the external battery cabinet/
rack, as applicable.
4.
The UPS module is now totally shut-down.
5.
Disconnect the control panel cable to connector JD7.
6.
Remove the four screws on the front of the UPS module that are fixing it to the cabinet.
7.
Pull the UPS module forwards until the rear connectors are disconnected. DO NOT FULLY EXTRACT
THE UNIT.
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.
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4-17
4: Operation
4.7.2 Inserting a UPS Module
1.
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.
Push UPS-module 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 it to the UPS cabinet / frame.
5.
Connect the control panel cable to connector JD7.
6.
Start the UPS module and bring it on line (See paragraph 4.5.4).
Note: The module must be previously set according to system personalization. Please make sure with your
nearest service centre for correct settings.
4.8
Replacing a Module In 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 alllow 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 kVA module is 24kg).
Employ suitable lifting aids and safety platforms where possible.
If, in a capacity parallel system, 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 be transferred to bypass (Bypass Mode
or ECO-Mode) and will continue to be supplied by the mains supply.
4.8.1 Removing a Module
1.
Verify that the load is on BYPASS and is supplied by the mains power (Bypass Mode or Eco-Mode) on
ALL UPS modules.
a)
In the majority of the events the LED indicators on Control Panel of the faulty module will show:
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
b)
4-18
LINE 1
Colour
Green
LINE 2
Green
BY PASS
Green
INVERTER
RED
BATTERY
Green
Whereas the LED indicators on the Control Panels of the other two Operating Modules will show:
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
4: Operation
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
2.
Close Maintenance Bypass Switch IA1 (ON)
3.
On all modules check and confirm that:
a)
b)
c)
LINE 1
Colour
Green
LINE 2
Green
BY PASS
Green
INVERTER
RED
BATTERY
Green
The INVERTER LED has turned to red.
The BYPASS LED is green.
The LCD displays MANUAL BYP IS CLOSED.
LINE 2
BY PASS
LED
LOAD
LINE 1
INVERTER
BATTERY
LINE 1
Colour
Green
LINE 2
Green
BY PASS
Green
INVERTER
RED
BATTERY
Green
4.
Open the Parallel Isolator Switch IA2 (switch to position “OFF”) of UPS module to be replaced.
5.
Open the fused battery isolator for the affected UPS module in the UPS cabinet or in the external battery
cabinet/rack, as applicable.
6.
The UPS module is now totally shut-down.
7.
Disconnect the control panel cable to connector JD7.
8.
Remove the four screws on the front of the UPS module that are fixing it to the cabinet.
9.
Pull the UPS module forwards until the rear connectors are disconnected. DO NOT FULLY EXTRACT
THE UNIT.
WARNING: Wait at least 2 minutes to allow the module’s electrolytic capacitors time to
discharge.
10. After waiting two minutes, fully withdraw the UPS-Module from the cabinet by pulling it horizontally.
11. 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.
CAUTION: While the UPS is operating in the maintenance bypass mode the load is not
protected and in the event of a mains failure the load supply will be interrupted.
4.8.2 Refitting a Module in a Capacity Multi-Module System
1.
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.
Push UPS-module firmly into its final position, to assure good contact on the rear plugs.
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4-19
4: Operation
4-20
4.
Tighten the four screws on the front of module to secure it to the UPS cabinet / frame.
5.
Connect the control panel cable to connector JD7.
6.
Start the UPS module and transfer the load from ‘Maintenance Bypass’ to ‘On Line’ mode (See
paragraph 4.5.2).
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
5
5.1
Maintenance
Introduction
WARNING: All the operations described in this chapter must be performed by authorised
electricians or otherwise qualified 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 six 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 Kohler Uninterruptible Power 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 monitoring systems
Operation of all installed options
Preventative maintenance inspections form an integral part of all Extended Warranty Agreements
(maintenance contracts) offered by Kohler Uninterruptible Power.
For further details on Extended Warranty Agreements see Paragraph 2.6.
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5-1
5: Maintenance
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 Kohler Uninterruptible Power 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.
5-2
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
6
6.1
Troubleshooting
Alarms
In the event of an alarm condition the red ALARM 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 4.3.3).
3.
In case of doubt please contact your nearest service agent or call Kohler Uninterruptible Power on +65
6302 0708.
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 in Section 4.
Event Log Screen
DESCRIPTION
LCD-DISPLAY
1.
Logging Control
05-10-00
LOAD TO INV.
14-38-56
2.
A log of the last 64 events is stored in the Power Management Display.
05-10-00
LOAD TO BYP.
14-38-59
3.
All events and alarms are indicated with their date and time of occurrence.
05-10-00
LOAD OFF
14-39-14
The full list of Alarms and Messages are shown in section 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.
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6-1
6: Troubleshooting
6.3
Fault Identification and Rectification Messages and Alarms
Messages will not appear automatically on the LCD as they occur, but will be recorded in the Event Log, with
the time and date of their occurrence.
Alarm Condition
6.4
Meaning
Suggested Solution
UPS FAULT
There is a fault in the UPS and therefore
normal operation cannot be guaranteed
Call the authorised service centre for
assistance
MAINS BYP/RECT FAULT
Mains power supply is outside
prescribed tolerance
The input power to UPS is too low or
missing.
If site power appears to be OK, check the
input circuit breakers etc. supplying the
UPS
OUTPUT SHORT
There is a short circuit at the output of
UPS (on load side)
Check all output connections and repair as
required.
OVERLOAD
Load exceeds the UPS rated power
Identify which piece of equipment is
causing the overload and remove it from
the UPS.
Do not connect laser printers,
photocopiers, electric heaters, kettles etc.
to the UPS
OVERTEMPERATURE
UPS temperature has exceeded the
allowed value
Check the ambient temperature of the
UPS is less than 30° C.
If the ambient temperature is normal call
the authorised service centre for
assistance.
BATTERY CHARGER OFF
The attached battery and the battery
charger set-up do not correspond or
battery charger fault
Call the authorised service centre for
assistance.
INVERTER FAULT
Inverter is faulty.
Call the authorised service centre for
assistance.
SYNCHRON FAULT
The inverter and mains are not
synchronised.
The frequency of the input voltage to the
UPS is outside operational limits and the
UPS static bypass has been temporarily
disabled.
BATTERY IN DISCHARGE
Battery is near end of autonomy
Shutdown load connected to UPS before
the UPS switches itself off to protect its
batteries
MANUAL BYP IS CLOSED
Maintenance Bypass closed. Load
supplied by mains
This alarm is only displayed if the UPS is
on Maintenance Bypass
Contacting Service
Kohler Uninterruptible Power 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.
Kohler Uninterruptible Power.
7 Jurong Pier Road
Singapore 619159
Tel:
+65 6302 0708
Fax:
+65 6302 0717
Email:
E: [email protected]
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.
6-2
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
7
7.1
Options
Introduction.
The PowerWAVE 9000 DPA UPS has the following options available:
•
•
•
•
•
•
•
7.2
Remote Emergency Stop facilities
Generator ON facilities
2 Customer-input functions (customer defined)
Temperature sensor for temperature-dependent battery charging
WaveMON shutdown and management software
SNMP Card for network management and remote monitoring
Modem/Ethernet interface for PowerReporter™ management software
Remote Emergency Stop Facilities
The remote emergency stop facility must use a normally-closed contact which opens to operate the
emergency stop sequence.
The emergency stop port X1/1 and X1/2 is located at the bottom of the DPA Cabinet on the communication
card with terminal blocks X1..X4. See Figure 3.7 for a location drawing.
In order to permit removal, maintenance or testing of any remote emergency stop facility without disturbing
the normal UPS operation, it is recommended that a terminal block with linking facilities be installed between
the communications card and the remote emergency stop button.
Use a screened cable with 1 pair (section of wires 0.6 mm2) and maximum length of 100 m and connect the
cable as shown in Figure 7.1.
Emergency Stop Switch
(N.C. =Normally Closed)
Link Facility
UPS Emergency
Stop (X1)
X1/1
X1/2
Terminal
Block
Figure 7.1 Remote Emergency OFF Switch Cabling
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
7-1
7: Options
7.3
Generator ON Facilities
The Generator ON facility must use a normally-open contact which closes to indicate that a generator is
running and supplying input power to the UPS.
The UPS Generator port X1/3 and X1/4 is located at the bottom of the DPA Cabinet on the communication
card with terminal blocks X1..X4. See Figure 3.7 for a location drawing.
When used, this facility enables an option to inhibit the operation of the battery charger and/or static bypass
(See paragraph 4.3.7).
UPS
Generator
Port (X1)
Generator
Alarm
Panel
X1/3
X1/4
Figure 7.2 Generator ON Connection
7.4
WAVEMON Shutdown and Management Software
7.4.1 Why is UPS Management important?
By combining a UPS with a variety of network management products, such as orderly shutdown software and
SNMP adaptors, system-administrators can be assured that their electricity supplies are monitored for power
disruptions and depleted battery conditions. Such conditions pose the greatest threat through power
disturbance, to valuable computer data by causing possible corruption or loss. By installing UPS/Mains
monitoring software, administrators are able to monitor the utility power from a central location, allowing early
warning of problems even across more complex systems like Wide Area Networks (WAN) and Enterprise
Wide Networks of multinational companies.
A prolonged mains failure may outlast the battery autonomy of the UPS system. If this situation occurs UPS
management software will initiate an automatic, graceful shutdown of the operating system, protecting
valuable data.
Kohler Uninterruptible Power offer a wide range of local and remote monitoring and control systems, offering
maximum protection for computer systems.
Figure 7.3 Monitoring screen image.
7-2
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
7: Options
7.4.2 Wavemon Shutdown and Monitoring Software
Wavemon is an external monitoring and shutdown software which is designed to operate with many of Kohler
Uninterruptible Power UPS products, both with the DRY PORT (Relays) on terminal block X2..X4 and RS232
port JD11 on the communication card.
The software packet consists of a CD ROM for most commonly used operating systems, a standard cable set
and a user manual.
The dry port X2…X4 with voltage-free contacts may also be used for automatic shutdown in connection with
WAVEMON Software. It is necessary to provide a cable of 0.5 mm2 to connect Terminals X2..X4 of the UPS
and the serial port of the server.
The main characteristics of Wavemon software are (assuming RS232 port used):
•
•
•
•
•
•
•
•
•
Automatic unattended master/slave shutdown in heterogeneous networks.
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.
Scheduled UPS economy mode, service mode, other systems status.
Graphical user interface for Windows compatible platforms.
Automatic unattended local shutdown.
Special modules for the MS-Office software to close and save open documents.
Compatible with all optional modules like UPSDIALER, SNMP adapters, Temperature sensors, etc.
The UPS-Management software is a client-/server-application for networks and local workstations. Basically
WAVEMON-software consists of two parts: the server-module of the UPS-Management Software is
UPSServ, which communicates via RS-232 cable with the UPS.
Working as a background process the UPSServ collects messages, received from the UPS, interprets the
messages and then makes them available to the client-module UPSCli and to any SNMP-based
management station.
When UPSServ detects voltage variations or a power failure it can execute various so called system ‘event
routines’, which for example may shutdown the server or send a warning to connected users. These system
event routines are a part of the UPS-Management Software can be adjusted to suit the customer’s demands.
The UPS management software includes the licence for using the UPS service on one server with one UPS
and an unlimited numbers of connected Windows workstations. When operating with two or more servers, a
licence is required for every additional server, irrespective of whether the UPS service runs at that location, or
if the server is halted by a UPS service via remote command.
The same regulations apply to the remote send/receive modules (RCCMD) and multiserver shutdown under
NT, UNIX and other operating systems. The service programs are generally delivered as a single-licence. To
use a single CD ROM to shutdown multiple servers you have to purchase additional CD license keys.
Parallel/redundant UPS systems are also manageable by the software. The main principle is to introduce a
shutdown of a server only when strictly necessary. Correct parallel handling has therefore to manage a
parallel system as a whole and always consider the system redundancy.
The following statements apply:
• Every alarm on any unit is immediately notified, but a reaction to a serious fault is introduced only
when the minimum number of UPS Modules necessary to supply the load exhibits an alarm situation.
• Battery autonomy time of the parallel system is computed continuously.
• Maintenance on a redundant unit may be executed without affecting the management system
(supervisor).
The PowerWAVE 9000 DPA can be integrated in a network in two ways:
• By means of the server which is being powered by the UPS and is integrated in the network. In most
cases the server is used as a sub-agent and only the Wavemon software is needed, without any
SNMP Adapter. The standard connection is between the RS232 SMART port of UPS and RS232 port
of computer/server.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
7-3
7: Options
• If the UPS is powering network hardware such as routers, then an SNMP adapter is necessary. Up to
50 computers can be shut down in a RCCMD (Remote Console Command) environment. RCCMD is
an additional module, which executes a command in a distant system.
7.5
SNMP CARD/ADAPTER For Network Management /Remote Monitoring
The Simple Network Management Protocol (SNMP) is a worldwide-standardized communication-protocol. It
is used to monitor any device in the network via simple control language. The UPS-Management Software
also provides its data in this SNMP format with its internal software agent. The operating system you are
using must be SNMP compatible. We offer our software with SNMP functionality together with NetWare, OS/
2, all Windows NT systems on INTEL and ALPHA.
There are two types of SNMP-Adapters available: External SNMP-Adapter and Internal SNMP-Card (both
have the same functions).
External SNMP-Adapter
9
W IN N T
N o v e ll
U N IX
In te rn a l S N M P -C a rd
SNMP Adapter
The SNMP adapter requires a PC with terminal connections. For normal operation at least one network
connection (Ethernet) is also required.
The SNMP adapter is used to monitor any device in the network and can be used, utilising the RCCMD send
function, for an automatic network wide shut down or informing connected users. The shut down procedure
can be initiate from the remaining time (downtime) or as countdown timer from the beginning of the alarm. A
shut down is therefore possible without extra input from the operator, but fully software controlled.
For detailed information please refer to the Software Manual provided with the WAVEMON CD ROM. This
adaptor communicates via the serial port of the UPS and makes a direct multiple server shut down possible
without additional SNMP management software.
RCCMD - Remote Console Command module for a multi-server shutdown. The RCCMD modules are
independent programs that may be activated on the computer that is running UPSMAN. This makes a
shutdown call possible in any LAN and WAN, regardless of the network type or operating system.
External SNMP Adapter
The External SNMP adapter is small, 12 x 7 cm. and is supplied with
the following accessories:
•
•
•
•
•
•
•
7-4
RJ-45 connector for 10/100 Base-T (autoswitchable)
Serial Port (COM2) or optional ModBus interface.
Error/Link LED for UPS status
Aux Port
DIP Switch
Serial Port to the UPS (COM1)
DC Supply (9 VDC or 9-36 VDC supply, depending on
model);
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
7: Options
Internal SNMP Adapter
.The Internal SNMP-Card can also be inserted into an appropriate
expansion slot in the PowerWAVE 9000 Modules or Cabinet.
This adapter communicates via the serial port of the UPS and
makes a direct multiple server shut down possible without
additional SNMP management software.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
7-5
7: Options
7-6
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8
8.1
Specifications
Mechanical Characteristics
CLASSIC
DPA-25
TRIPLE
DPA-75
UPGRADE
DPA-125
1 module (10-25kVA)
200 x 7/9Ah batteries
3 modules (10-25kVA)
180 x 7/9Ah batteries
5 modules (10-25kVA)
No batteries
‘MD’ Cabinets (Frames)
Capacity
Max.
Max. Power connection
kVA
25
75
125
Dimensions (WxHxD)
mm
550x1650x780
550x1975x780
550x1975x780
Weight of Empty Cabinet
kg
200
220
160
Weight of Cabinet with
modules and no batteries
kg
224 - 233
(with 1 Module)
292 - 319
(with 3 Modules)
280 - 325
(with 5 Modules)
Colours
Front: RAL 9007 + black (inlets). Side walls: Graffito grey
DPA 10
DPA 15
DPA 20
DPA 25
PowerWAVE DPA
UPSModules
Output Apparent Power
KVA
10
15
20
25
Output Active Power
KW
8
12
16
20
Output Power (PF=1)
KVA/
KW
8/8
12 / 12
16 /16
20 /20
Variable Number of 12V
Battery Blocks
No.
30 – 50
30 – 50
30 – 50
40-50
Dimensions (WxHxD)
mm
Weight UPS Module
kg
483 x 225 x 700
24
Colours
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
33
Front: RAL 9007
8-1
8: Specifications
CLASSIC
TRIPLE
UPGRADE
DPA-50
DPA-150
DPA-250
1 module (30-45kVA)
280 x 7/9Ah batteries
3 modules (30-45kVA)
240x 7/9Ah batteries
5 modules (30-45kVA)
no batteries
‘MX’ Cabinets (Frames)
Capacity
Max.
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
modules and no batteries
kg
300 - 310
(with 1 Module)
420 - 450
(with 3 Modules)
440 - 490
(with 5 Modules)
Colours
Front: RAL 9007 + black (inlets). Sidewalls: Graffito grey
DPA 30
DPA 40
DPA 50
45*
PowerWAVE DPA
MODULES
Output Apparent Power
KVA
30
40
Output Active Power
KW
24
32
40
Output Power (PF=1)
KVA /
KW
24 / 24
32 / 32
40 /40
Number of 12V Battery Blocks
No.
40-50
40-50
40-50
Dimensions (WxHxD)
mm
Weight UPS Module
kg
Colours
663 x 225 x 720
50
57
60
Front: RAL 9007
* On Inverter mode 50 KVA/40kW on Bypass mode 45 KVA/40kW
8-2
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8: Specifications
8.2
Input Characteristics
Module Range
Module Type
DPA
10
DPA
15
MD
DPA
20
DPA
25
DPA
30
MX
DPA
40
DPA
50
Output Rated Power per Module cosΦ 0.8
kVA
10
15
20
25
30
40
451
Output Rated Power per Module cosΦ 1.0
KW
8
12
16
20
24
32
40
Nominal Input Voltage
V
3x380/220V+N, 3x400V/230V+N, 3x415/240V+N
Input Voltage Tolerance
(ref to 3x400/230V) for Loads in %:
V
(-23%/+15%) 3x308/177 V to 3x460/264 V for <100 % load
(-30%/+15%) 3x280/161 V to 3x460/264 V for < 80 % load
(-40%/+15%) 3x240/138 V to 3x460/264 V for < 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 % @ 100% load
Max. Input Power with rated output power and
charged battery per Module
kW
8.5
12.8
17.0
21.3
25.4
33.9
42.9
Max. Input Current with rated output power and
charged battery per Module
A
12.3
18.5
24.7
30.8
36.8
49.1
62.1
Max. Input Power with rated output power and
discharged battery per Module
kW
9.3
14.0
18.6
23.3
27.8
37.1
46.9
Max. Input Current with rated output power and
discharged battery per Module
A
13.5
20.2
27.0
33.7
40.3
53.7
68.0
(output CosΦ = 1.0)
(output CosΦ = 1.0)
(output CosΦ = 1.0)
(output CosΦ = 1.0)
1) On Inverter mode 50 KVA/40kW on Bypass mode 45 KVA/40kW
8.3
Battery
Module Range
MD
Module Type
DPA 10
DPA 15
DPA 20
DPA 25
DPA 30
DPA 40
DPA 50
30-50
30-50
40-50
40-50
40-50
40-50
Variable Number of 12V Battery Blocks
No.
30-50
Maximum Battery Charger Current
A
6A Standard
(10 A optional)
Battery Charging Curve
MX
10A Standard
(15 A optional)
Ripple free ; IU (DIN 41773)
Temperature compensation
Standard (temp. sensor optional)
Battery Test
Automatic and periodically (adjustable)
Battery Type
Maintenance free VRLA or NiCd
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8-3
8: Specifications
8.4
Output
Module Range
Module Type
DPA 10
MD
DPA 15 DPA 20
DPA 25
DPA 30
MX
DPA 40
DPA 50
Output Rated Power per Module
kVA
10
15
20
25
30
40
45 1)
Output Rated Power per Module
KW
8
12
16
20
24
32
40
Output Current In @ cosΦ 1.0 (400 V)
A
11.6
17.4
23.2
29
35
46.5
58
Output Rated Voltage
V
3x380/220V or 3x400/230V or 3x415/240V
Output Voltage Stability
%
Static: < +/- 1% Dynamic
(Step load 0%-100% or 100%-0%) < +/- 4%
Output Voltage Distortion
%
With Linear Load < +/- 2% With Non-linear Load
(EN62040-3:2001) < +/- 4%
Output Frequency
Hz
50 Hz or 60 Hz
Output Frequency Tolerance
%
Synchronized with mains < +/- 2 % (selectable) or
< +/- 4 % Free running +/- 0.1 %
Bypass operation
At Nominal Input voltage of 3x400 V +/- 15 % or
190 V to 264 V ph-N
Permissible Unbalanced Load
(All 3 phases regulated independently)
%
100%
Phase Angle Tolerance
(With 100 % Unbalanced load)
Deg.
Overload Capability on Inverter
%
125 % load 10 min. 150 % load 60 sec.
Output short capability (RMS)
A
Inverter: 2 x In during 250 ms
Bypass: 10 x In during 10 ms
+/- 0 deg.
Crest - Factor
3:1
1) On Inverter mode 50 KVA/40kW on Bypass mode 45 KVA/40kW
8-4
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8: Specifications
8.5
Environmental
Module Range
Module Type
DPA 10
55/49
MD
DPA 15 DPA 20
57/49
57/49
DPA 25
DPA 30
MX
DPA 40
DPA 50
57/49
59/51
65/55
65/55
Audible Noise with 100% / 50% Load
dBA
Operation temperature
°C
0 - 40
Ambient Temperature for Batteries
°C
20 - 25 (recommended)
Storage Temperature
°C
-25 - +70
Battery Storage Time at Ambient Temperature
Max. altitude (above sea level)
Max. 6 months
m
1000m (3300ft) without de-rating
Above sea level (m / ft)
Power De-Rating Factor
1500 / 4850
0.95
2000 / 6600
0.91
2500 / 8250
0.86
3000 / 9900
0.82
De-rating factor for use at altitudes above
1000m sea level according
( IEC 62040-3)
Relative Air-humidity
Max. 95% (non-condensing)
Accessibility
Totally front accessibility for service and maintenance (no need for side, top or
rear access)
Positioning
Min. 20 cm rear space (required for fan)
Input and Output Power Cabling
Efficiency AC-AC up to (cosΦi 1.0) (depending
on Module power)
From the bottom on the front
%
Load : 100 % 75 % 50% 25%
DPA 30-50 : 94.5% 94.5% 94% 93
DPA 10-25 : 94% 94% 93.5% 91%
Efficiency Linear Load at cosΦ=0.8ind
Efficiency Non-linear Load
(EN 62040-1-1:2003)
Typically up to 1 % higher of above values
Typically up to 1 % lower of above values
Eco-Mode efficiency at 100% load
%
Heat Dissipation with 100% Non-linear Load
per Module (EN 62040-1-1:2003)
W
600
900
1200
98 %
1500
1670
2225
2780
Heat Dissipation with 100% Non-linear Load
per Module (EN 62040-1-1:2003)
BTU
2047
3070
4094
5118
5698
7592
9485
Airflow (25° - 30°C) with Non-linear Load per
Module (EN 62040-1-1:2003)
m3/h
150
150
150
150
380
380
380
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8-5
8: Specifications
Packed weights
Figure 8.1
Figure 8.5
DPA 20 or 25
no Batt.
Packed
Dimension mm
DPA 10 or 15
no Batt.
DPA 20 or 25
no Batt.
Unpacked Weight
Figure 8.6
DPA 10 or 15
no Batt.
Packed Weight (Kg)
Figure 8.4
8.1
DPA-25
1
284
293
700x1825x895
224
233
8.2
DPA-75
1
304
313
700x2150x895
244
253
TBA
550x1975x780
2
328
346
700x2150x895
268
286
TBA
550x1975x780
3
352
379
700x2150x895
292
319
TBA
550x1975x780
1
244
253
700x2150x895
184
193
550x1975x780
2
268
286
700x2150x895
208
226
550x1975x780
3
292
319
700x2150x895
232
259
550x1975x780
4
316
352
700x2150x895
256
292
550x1975x780
5
340
385
700x2150x895
280
325
550x1975x780
Packed
Dimension mm
DPA 10 or 15
no Batt.
DPA 20 or 25
no Batt.
Unpacked Weight
DPA 20 or 25
no Batt.
Packed Weight (Kg)
DPA 10 or 15
no Batt.
UPS
Modules
Fig
DPA-125
550x1650x780
Unpacked
Dimension mm
8.3
8.4
DPA-50
1
360
367
370
880x1825x915
300
307
310
8.5
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
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
8.6
8-6
UPS
Figure 8.3
Modules
Fig
Figure 8.2
Unpacked
Dimension mm
8.6
DPA-250
730x1650x800
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8: Specifications
8.7
Cable and fuse sizing (Single feed input)
SINGLE INPUT FEED
Mains (3x400/230V)
Fuse A
Cable A
Inverter
Rectifier
Inverter
F2
F1
UPS Module 3
Rectifier
BATTERY
CABINET
F2
F1
UPS Modules 2
F2
UPS Module 1
F1
Rectifier
Inverter
Static Switch
Static Switch
Static Switch
IA2-1
IA2-2
IA2-3
Upgrade
Frame
Maintenance Bypass IA1
Cable D
Load
Power
(kVA)
Single Input
(3 x 400V)
Fuse A
(A)
FRAME
Cable A
(mm2)
Output
(3x400V, 0.8 pf)
Max Input with batt
charging (A)
Cable D
(mm2)
Nominal Current
(A)
DPA-25
25
3x63
5x10
34
5x10
36
DPA-75
75
3x125
5x50
101
5x50
108
DPA-125
125
3x225
5x95
169
5x95
181
DPA-50
80
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
Notes:
1.
Fuse and Cable recommendations to IEC 60950-1:2001 or locally recoginsed standards.
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.
4.
DC Cables and Battery fuses are bespoke to the installation.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8-7
8: Specifications
Cable and fuse sizing (Dual feed input)
BYPASS FEED
INPUT FEED
Mains (3x400/230V)
Mains (3x400/230V)
Fuse B
Fuse C
Cable B
F2
F1
Inverter
F2
F1
Rectifier
UPS Module 1
Rectifier
F2
UPS Modules 2
F1
Cable C
Inverter
Rectifier
Inverter
Static Switch
Static Switch
Static Switch
IA2-1
IA2-2
IA2-3
BATTERY
CABINET
UPS Module 3
8.8
Maintenance Bypass IA1
Cable D
Load
Frame
Power
(kVA)
Dual Input
(3 x 400V)
Fuse B/C
(A)
Cable B
2)
(mm
Output
(3x400V, 0.8 pf)
Cable C
(mm
2)
Max Input with
battery charging (A)
Cable D
2)
(mm
Nominal
Current (A)
DPA-25
25
3x63
5x10
4x10
34
5x10
36
DPA-75
75
3x125
5x50
4x50
101
5x50
108
DPA-125
125
3x225
5x95
4x95
169
5x95
181
DPA-50
80
3x100
5x25
4x25
67
5x25
72
DPA-150
150
3x250
5x120 or
5x(2x50)
4x120 or
4x(2x50)
202
5x120 or
5x(2x50)
218
DPA-250
250
3x400
5x(2x95)
4x(2x95)
337
5x(2x95)
362
Notes:
8-8
1.
Fuse and Cable recommendations to IEC 60950-1:2001 or locally recoginsed standards.
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.
4.
DC Cables and Battery fuses are bespoke to the installation.
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8: Specifications
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010
8-9
8: Specifications
8-10
UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

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