PW9000DPA User Manual

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KohlerPW 9000DPAUser ManualPioneering solutions fortotal power protection

Document ControlISSUE1.0DATE01-06-10REVISION SUMMARYInitial issue.UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

Kohler Uninterruptible Power Ltd has taken every precaution toproduce an accurate, complete and easy to understand manual andwill therefore assume no responsibility nor liability for direct,indirect or accidental personal or material damage due to anymisinterpretation of or accidental mistakes in this manual. 2010 Kohler Uninterruptible PowerThis manual may not be copied nor reproduced without writtenpermission of Kohler Uninterruptible Power.UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

Table of Contents1Safety1.1 Description of symbols used in this manual1.2 User precautions2Description2.1 Reliability and Quality Standards2.2 PowerWAVE 9000 DPA System2.3 System Configuration2.3.1 Single/Parallel module configurations2.3.2 Single/Multi cabinet configurations2.3.3 ‘Redundant-module’ versus ‘Capacity’ system2.3.4 PowerWAVE 9000DPA MD Frames2.3.5 PowerWAVE 9000DPA MX Frames2.4 Advanced Design Features2.4.1 Hot-swappable modules2.4.2 Advanced booster technology2.4.3 Flexible battery management (FBM)2.4.4 Decentralized Parallel Architecture (DPA)2.5 Warranty2.6 Extended Warranty2.7 Additional Service/Maintenance 2-52-62-62-6Installation3.1 Introduction3.2 Receipt of the UPS3.2.1 Site transportation3.3 Unpacking3.3.1 Nameplate3.4 Batteries3.5 Storage3.5.1 UPS3.5.2 Battery3.6 Positioning3.6.1 Planning the installation3.7 UPS Power Cabling (preparation and planning)3.7.1 General requirements3.7.2 Multi-cabinet installation cabling considerations3.8 Connecting the UPS input supply3.8.1 Safety notes3.8.2 Preparing the input cabling3.8.3 Connecting the UPS input power cables3.9 Connecting the UPS output3.9.1 Safety notes3.9.2 Preparation for the output cabling3.9.3 Connecting the UPS output cablesUPS306-01-00 PowerWAVE 9000 DPA User Manual Dated -63-73-73-73-73-83-83-83-9i

3.9.4 Connection Terminal Details3.10 Connecting the batteries3.10.1 Safety Notes3.10.2 Battery cabling3.10.3 Connecting the battery cables3.11 Internal Battery Systems3.11.1 DPA-253.11.2 DPA-753.11.3 DPA-503.11.4 DPA-1503.12 External Battery Cabinets and Battery Connections3.13 Multi-cabinet Parallel Communication Cables (Bus-lines)3.14 Interfacing Facilities3.14.1 Interface Board3.14.2 Smart Port (Serial RS 232)3.14.3 Dry Port (volt-free contacts)3.14.4 JD11/RS232 Computer Interface3.14.5 JD12/RS232 Interface for Multidrop3.14.6 USB/2 Computer Interface4Operation4.1 Commissioning4.2 Control Panel4.2.1 Power Management Display (PMD)4.2.2 Mimic LED indicators4.2.3 Operator keys4.3 Description of the LCD4.3.1 Status screens4.3.2 Main menu screen4.3.3 Event log menu screen4.3.4 Measurements menu screen4.3.5 Commands menu screen4.3.6 UPS Data menu screen4.3.7 Set-up User menu screen4.3.8 Set-Up Service menu screen4.4 Operating Modes4.4.1 On-Line (Inverter) mode4.4.2 OFF-Line (also known as ECO or Bypass) mode4.4.3 Maintenance Bypass mode4.4.4 Parallel Isolator switch(IA2)4.5 Operating Instructions4.5.1 Transfer to Maintenance Bypass Mode4.5.2 Starting the UPS system from the Maintenance Bypass4.5.3 Complete system shutdown4.5.4 Individual module start/stop procedure4.6 Replacement of the UPS Module in a Single Module System4.6.1 Removing a UPS Module4.6.2 Refitting the UPS Module4.7 Replacing a UPS Module in a REDUNDANT Multi-Module System4.7.1 Removing the UPS Module4.7.2 Inserting a UPS Module4.8 Replacing a Module In a CAPACITY Multi-Module System4.8.1 Removing a Module4.8.2 Refitting a Module in a Capacity Multi-Module 6-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

5Maintenance5.15.25.35.45.55.65.76AlarmsMenu, Commands, Event Log, Measurements,Fault Identification and Rectification Messages and AlarmsContacting .Remote Emergency Stop FacilitiesGenerator ON FacilitiesWAVEMON Shutdown and Management Software7.4.1 Why is UPS Management important?7.4.2 Wavemon Shutdown and Monitoring Software7.5 SNMP CARD/ADAPTER For Network Management /Remote 6.26.36.47IntroductionSystem calibrationUser responsibilitiesRoutine maintenanceBattery TestingBattery MaintenanceBattery Disposal and 8.38.48.58.68.78.8Mechanical CharacteristicsInput CharacteristicsBatteryOutputEnvironmentalPacked weightsCable and fuse sizing (Single feed input)Cable and fuse sizing (Dual feed input)UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-20108-18-38-38-48-58-68-78-8iii

ivUPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

11.1SafetyDescription of symbols used in this manualWARNING: 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 possibleequipment malfunction or damage.1.2User precautionsWARNING: Keep this manual with the UPS for future reference.WARNING: The UPS and peripheral equipment must be installed and commissioned bysuitably 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 safetyinstructions 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 beencommissioned by a fully trained engineer authorised by the manufacturer.WARNING: All servicing must be performed by qualified personnel. Do not attempt to servicethe 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 incorrectoperation 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 environmentthe user may be required to undertake additional measures.UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-20101-1

1: Safety1-2UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

22.1DescriptionReliability and Quality StandardsCongratulations on your purchase of the PowerWAVE 9000 DPA UPS.By using a unique modular construction and incorporating the latest technological developments in powerengineering, the PowerWAVE 9000 DPA represents a completely new generation of transformer-less 3phase UPS-System. High reliability, upgrade ability, low operating cost and excellent electrical performanceare just some of the highlights of this innovative UPS solution.Kohler Uninterruptible Power specialises in the design, building, installation and maintenance ofUninterruptible Power Systems. This compact and powerful UPS is just one example of our wide range ofstate of the art power protection devices and will provide your critical equipment with a steady and reliablepower supply for many years.The criteria and methods which are used in the design, manufacture, and maintenance of UninterruptiblePower Supply systems are certified to International Standard ISO 9001/EN 29001. A full UPS Specification isgiven in Chapter 8 of this manual.2.2PowerWAVE 9000 DPA SystemPowerWAVE 9000 DPA is a truly modular system based on a range of 10kVA to 45kVA UPS power modulesthat 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 cabinetranges 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 possibleto 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 batterycabinet is always required for cabinets designed for 5 UPS modules. A range of battery cabinets of matchingstyle and colour is available to sit alongside the UPS cabinets to provide a matching suite.2.3System ConfigurationThe PowerWAVE 9000 DPA system configurations are described below.2.3.1 Single/Parallel module configurationsWithin the UPS cabinet, the power modules can be configured in one of two ways:Single-module systemAs its name suggests, a ‘single-module’ system comprises a cabinet fitted with just one UPS module, even ifthe 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 systemA ‘parallel-module’ system employs several modules (of the same rating) operating in parallel within thesame cabinet (e.g. TRIPLE DPA-75) using the DPA technology (see paragraph 2.4.4).UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-20102-1

2: Description2.3.2 Single/Multi cabinet configurationsSingle cabinet systemA 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 systemTo 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 potentiallyresulting in a system comprising up to 50 parallel modules if 10x UPGRADE DPA-125 or 10x UPGRADEDPA-250 cabinets are employed. Although, in practice, a typical multi-cabinet system will be made up offewer than 10 cabinets.Every standard PowerWAVE 9000 DPA cabinet is provided with the parallel option, eliminating any need fortime-consuming or expensive upgrading on site.P o w e rW A V E D P ALBI YIONNPVABAESR TST TEER RYNLIENE21P o w e rW A V E D P ALBI YIENLSAETERTMRNEOFNF/O21FREAENLSAETERTMR2E1I YNPBVAE ASRSTTTE I YNPBVAE ASRSTTTE RNF/1OF/OREAENSLEATETRMROFNF/OP o w e rW A V E D P ALBII YLNNPI E VABANESER T2ST T1E ERF2E1BVAE ASRSTTTE OOOFNF/IEN2E1OFFMUPS 1Figure 2.1ON/ORRYFREAENSLEATETRMRFPo weL rW A V BEDPAI YNPBVAE ASRSTTTE ERRYOFNF/OFFOINLOFNF/ONRP o w e rW A V E D P ALBIIYLNNPIEVBAANSEERT2STT1EEPo weL rW A V BEDPAI YNPTEMOIENERONFP o w e rWL AVBEDPAINLNRTMFMONRYI YNPBVAE ASRSTTTE ERRYPo weL rW A V BEDPAIIYNLNPBVAIEESANT2RSET TOREAERRFFFR2EOMP o w e rW A V E D P ALBII YLNNPIEVABANESER T2ST T1E EELSAEOILNIENNPo weL rW A V BEDPAIIYNLNPBVAIEESANT2RSET TOREAERR/ORAEPo weL rW A V BEDPAOILNIENNP o w e rWL AVBEDPAIIYN NPLBIE V AN ESAT2 RSET T1FPo weL rW A V P o w e rWL AVBEDPAP o w e rW A V E D P ALBIIYONNPVABAESR TST TEER RYL NI E/ORAEOINLN/REAELSNTAERTERIENOOFNF/2E1OFFMI YNPBVAE ASRSTTTE ERRYN/REAELSNTAERTEROOFNF/OFFMUPS 2UPS nPowerWAVE 9000 DPA UPS Multi-Cabinet Chain.The multi-cabinet configuration is based on a Decentralised Bypass Architecture (DPA) – i.e. every UPS isprovided with its own static bypass. In a parallel system there is always one master module and the othermodules are slaves. If at any time the master goes faulty the next UPS (former slave) will immediately takeover the master function and the former master will switch off.2.3.3 ‘Redundant-module’ versus ‘Capacity’ systemThe difference between a ‘redundant-module’ system and a ‘capacity’ system is that a ‘capacity’ system israted such that ALL the UPS power modules are required to provide the necessary output load power. This isnot 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 thereforepossible 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 longercontributes to the system’s power output. In a ‘capacity’ system opening this isolator this will cause the loadto transfer to the (unprotected) bypass supply. but in a ‘redundant-module’ system the load will continue toreceive protected power until the number of off-line modules exceeds the inbuilt system redundancy.2-2UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

2: Description2.3.4 PowerWAVE 9000DPA MD FramesCLASSICDPA-25TRIPLEDPA-75UPGRADEDPA-1251 module (10-25kVA)200 x 7/9Ah batteries3 modules (10-25kVA)180 x 7/9Ah batteries5 modules (10-25kVA)External batteriesPowerWAVE DPAMD FramesCapacityMax.Max. Power connectionkVA2575125Dimensions t of Empty Framekg200220160Weight of Frame with modules andno batterieskg224 - 233(with 1 Module)292 - 319(with 3 Modules)280 - 325(with 5 Modules)ColoursFront: RAL 9007 black (inlets). Side walls: Graffito greyDPA 10DPA 15DPA 20DPA 25PowerWAVE DPAModulesOutput Apparent PowerKVA10152025Output Active PowerKW8121620Output Powe