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Kohler PowerWave 9000DPA S2 User Manual

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  • Page 1 User Manual...
  • Page 2 TS_619_00 PW9000DPA S2 User Manual 13/3/17...
  • Page 3 Document Control PDF ISSUE DATE REVISION SUMMARY TS_619_00B 19/01/17 Second draft copy TS_619_00C 27/01/17 Third draft copy TS_619_00D 09/03/17 Fourth draft copy TS_619_00 13/03/17 First Issue TS_619_00 PW9000DPA S2 User Manual 13/3/17...
  • Page 4 USEFUL CONTACTS www.upspower.co.uk UPS Limited web site service@upspower.co.uk Service department – booking service, fault reporting etc. technical@upspower.co.uk Technical queries sales@upspower.co.uk Hardware sales servicesales@upspower.co.uk Extended warranty agreements etc Uninterruptible Power Supplies Ltd has taken every precaution to produce an accurate, complete and easy to understand manual and will therefore assume no responsibility nor liability for direct, indirect or accidental personal or material damage due to any misinterpretation of or accidental mistakes in this manual.

  • Page 5: Table Of Contents

    Table of Contents Safety 1 1.1 Description of symbols used in this manual 1.2 User precautions General Description 2 2.1 General introduction 2.1.1 Reliability and quality standards 2.1.2 Advanced design features 2.2 PW9000DPA S2 Model range 2.3 Functional description of operation 2.3.1 PW9000DPA S2 module block diagram 2.3.2 UPS Module operating modes 2.3.3 UPS System operating modes...
  • Page 6 3.4.4 UPS Power connections 3-32 3.4.5 Battery configuration 3-33 External battery enclosure with separate battery configuration 35 External battery enclosure with common battery configuration 36 3.5 UPS Cabling procedure 3-37 3.5.1 Safety notes 3-37 3.5.2 Preparing the UPS power cabling 3-37 3.5.3 Connecting the UPS AC power cables 3-37...
  • Page 7 Specification 56 8.1 Mechanical Characteristics 8-56 8.2 Input Characteristics 8-57 8.3 Battery 8-57 8.4 Output 8-58 8.5 Standards 8-58 8.6 Environmental 8-59 TS_619_00 PW9000DPA S2 User Manual 13/3/17...
  • Page 8 TS_619_00 PW9000DPA S2 User Manual 13/3/17...

  • Page 9: Safety

    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.

  • Page 10: General Description

    General Description General introduction Congratulations on your purchase of the PW9000DPA S2 UPS. Continuous power availability is essential in today’s dynamic IT and process-related work environments. It is equally important that any installed power protection system is sufficiently resilient and adaptable to handle any changes brought about by the introduction of new server technologies, migration and centralization.
  • Page 11 2: General Description Hot-swappable modules In a redundant module system the unique ‘hot-swappable’ feature enables a UPS module to be added or removed from its cabinet whilst the system is still powered. This can be done without disturbing the load or transferring it to the bypass supply.

  • Page 12: Pw9000Dpa S2 Model Range

    2: General Description PW9000DPA S2 Model range The PW9000DPA S2 UPS incorporates a rack-mountable design based on 30kVA, 40kVA and 50kVA plug-in UPS modules fitted into one of three purpose-built cabinets. Each module is a self-contained UPS comprising a rectifier, battery charger, inverter and static switch;...

  • Page 13: Functional Description Of Operation

    2: General Description Functional description of operation This section describes: • The internal operation of an individual UPS module at block-diagram level (see paragraph 2.3.1) • The various operational modes of an individual UPS module (see paragraph 2.3.2) • UPS system operational modes – ‘On-line’ versus ‘Off-line’ system operation (see paragraph 2.3.3) •...
  • Page 14 2: General Description Battery connections (3) Each UPS module is connected to a battery string via a dedicated fused isolator. Ideally, each module is connected to an individual battery but in some installations a common battery is shared between two (or more) modules. The battery fuse (F3) is fitted inside the module and is not accessible to the operator.

  • Page 15: Ups Module Operating Modes

    2: General Description Inverter output contactor (10) The inverter output contactor is driven by the UPS module’s control logic and operates in conjunction with the static switch as part of the bypass/inverter load transfer process. The contactor is also used to isolate the inverter from the UPS output within the module following certain overload or fault conditions.
  • Page 16 2: General Description to three minutes, whereupon it begins flashing red. This allows the operator to gauge the remaining autonomy time and, where necessary, shut down the load in an orderly manner (e.g. save data) before the battery is fully discharged. Various options are available to automate the load shut down process and if an automated data protection application is installed it usually begins its automatic shut down routine at this point.

  • Page 17: Ups System Operating Modes

    2: General Description 2.3.3 UPS System operating modes Section 2.3.2 described the operating modes for the individual UPS modules: but UPS systems are also categorised according to the way in which they operate at a ‘system’ level, and are typically described as being either an ‘on-line’, or ‘off-line’...

  • Page 18: Parallel System Operation

    2: General Description 2.3.4 Parallel system operation All the modules fitted in a UPS cabinet inherently operate as a parallel system as their outputs are connected in parallel at the cabinet’s output terminals. The electronic control system built into each module ensures that: •...

  • Page 19: Pw9000Dpa S2 User Controls

    2: General Description To JD5 in UPS CABINET 3 Parallel Adapter Board Parallel Adapter Board Parallel Control Logic Parallel Control Logic UPS Module P05 UPS Module P10 Parallel Control Logic Parallel Control Logic UPS Module P04 UPS Module P09 Parallel Control Logic Parallel Control Logic UPS Module P03 UPS Module P08...

  • Page 20: Dpa-50 Component Identification

    2: General Description 2.4.1 DPA-50 Component identification IA-1 Maintenance bypass line Static bypass line Bypass Mains STATIC SWITCH Bypass UPS Output Contactor to critical load IA-2 UPS Input Mains RECTIFIER INVERTER Input Inv. Output Contactor Contactor BOOSTER / CHARGER UPS MODULE EXTERNAL BATTERY CABINET...
  • Page 21 2: General Description 2.4.2 DPA-150 Component identification Up to three UPS modules can be fitted, with the lower-most module identified as module 1. The battery fuses are identified F4 to F6. F4 is associated with module 1, F5 with module 2 and F6 with module 3. The parallel isolator switches (IA2) are labelled to identify their associated UPS module –...
  • Page 22 2: General Description 2.4.3 DPA-250 Component identification The DPA-250 contains no batteries and can be fitted with up to five UPS modules, with the lower-most module identified as module 1. The module parallel isolator switches (IA2) are labelled to identify their associated UPS module – e.g. IA2-2 pertains to power module 2.

  • Page 23: Ups Interface Facilities

    2: General Description UPS Interface facilities Customer Interface Board Customer inputs (terminal block) X2-X4 Customer dry port output (terminal blocks) JD11 RS232 PC interface (Sub D-9 Female) JD12 RS232 Multidrop (Sub D-9 Male) PC Interface SLOT 1 Slot for SNMP (CS141 adapter) SLOT 2 Slot for optional Modem/Ethernet card Parallel Interface Board (fitted in a parallel UPS cabinet only)

  • Page 24: Parallel Interface Board

    2: General Description This facility requires a purpose designed ‘Multidrop’ cable to be connected between each module’s customer interface board JD12. Note that when the multidrop feature is used, the I/O facilities of customer interface board in the ‘slave’ cabinets are all disabled, but the customer interface board fitted to the ‘master’...

  • Page 25: Module Mimic Leds

    2: General Description Pressing the two ON/OFF buttons during normal operation will immediately shut down the UPS module. • In a single module system (e.g. DPA-50) this disconnects the UPS from the load unless the load is first transferred to the maintenance bypass. •...
  • Page 26 2: General Description Status screens DESCRIPTION LCD-DISPLAY 1. Load is protected and being supplied by UPS inverter LOAD (Normal Operation). PROTECTED 2. Load is not protected by UPS. It is either connected to the bypass (load on bypass) or LOAD connected to the inverter but with a battery problem.
  • Page 27 2: General Description Measurements menu screen DESCRIPTION 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.
  • Page 28 2: General Description 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 15-03-16 3. EPROM Version EPROM VERSION V-000 4. Actual Date and Time DATE TIME dd-mm-yyyy...

  • Page 29: Warranty

    2: General Description Warranty The PW9000DPA S2 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.

  • Page 30: Installation

    Installation Introduction This chapter contains essential information concerning the unpacking, installation planning and cabling of the PW9000DPA S2 UPS system. Key Point: If you are installing an external battery cabinet supplied by Uninterruptible Power Supplies Ltd. you should refer to the manual that is provided with the cabinet for installation instructions. WARNING: All the operations described in this chapter must be supervised by suitably qualified personnel and all aspects of the electrical installation must be carried out by an authorised electrician.

  • Page 31: Weight And Dimensions

    3: Installation 3.2.2 Weight and dimensions Packed weight and dimensions Number 30kVA Modules 40kVA Modules 50kVA Modules Packed Model w/o Batt (kg.) w/o Batt (kg.) w/o Batt (kg.) Dimensions Modules UPS Module 43.1 45.3 46.8 WxHxD DPA 50 890 x 1800 x 920 DPA150 890 x 2120 x 920 890 x 2120 x 920...

  • Page 32: Storage

    3: Installation 3.2.4 Storage If you plan to store the UPS prior to its installation it should be kept (preferably in its shipping packaging) in a clean, dry environment with a temperature between -25°C to +70°C and RH <90%. If the storage period is likely to exceed seven days the packaging should be removed and the UPS inspected for shipping damage before it is placed into storage.

  • Page 33: Installation Planning (Environmental & Mechanical)

    3: Installation Installation planning (environmental & mechanical) 3.3.1 Environmental considerations A certain amount of pre-planning will help provide a trouble-free installation process. You should consider the following guidelines when planning a suitable UPS location and operating environment. The route to the installation location must allow the equipment to be transported in an upright position. The floor at the proposed installation site and en-route from the off-loading point must be able to safely support the weight of the UPS and battery equipment, plus fork lift or trolley jack during transit.
  • Page 34 3: Installation PW9000DPA S2 PW9000DPA S2 (DPA‐50) E  F  (DPA‐150) (DPA‐50) (DPA‐250) (DPA‐150) (DPA‐250) REAR FANS REAR FANS Min. Clearance Min. Clearance A  A  1000mm 1000mm 300mm 300mm 200mm 200mm C2  315mm 315mm  C2  400mm 400mm 115 115 *400mm *400mm It is necessary to open the door fully to remove some internal assemblies during maintenance  procedures. If the cabinet is placed against a wall ensure sufficient space is provided (C2). If the cabinet is not positioned immediately adjacent to any other cabinet or battery enclosure, the  clearance behind the unit can be reduced from 300mm (B1) to 200mm (B2) if the total combined side  clearance (E+F) is at least 400mm. *A TOP clearance of 400mm is only required if there is no other   route at the rear of the UPS to  dissipate the cooling air flow.

  • Page 35: Installation Planning (Electrical)

    3: Installation Installation planning (electrical) 3.4.1 General requirements UPS SYSTEM INPUT SUPPLY UPS SYSTEM INPUT SUPPLY UPS INPUT  UPS INPUT  UPS BYPASS  MAINS DEVICE MAINS DEVICE MAINS DEVICE MAINT. MAINT. BYP (IA1) EXTERNAL  EXTERNAL  BYP (IA1) BATTERY BATTERY FUSES FUSES Rectifier Rectifier Inverter Inverter Static Switch Static Switch Parallel  Parallel  Isolator  Isolator  (IA2) (IA2) EXTERNAL EXTERNAL BATTERY BATTERY CABINET...
  • Page 36 3: Installation Single feed / dual feed inputs The UPS input mains and bypass mains terminals can be linked inside the UPS cabinet in what is known as a ‘single feed’ configuration. This configuration, which is used in the majority of installations, only requires one mains supply as illustrated in the left illustration of Figure 3.2.

  • Page 37: 3.4.2 External Maintenance Bypass Switches

    3: Installation 3.4.2 External maintenance bypass switches An external maintenance bypass is a required part of a multi- UPS SYSTEM  UPS SYSTEM  UPS SYSTEM INPUT  UPS SYSTEM INPUT  cabinet system but is optional in the case of a single cabinet OUTPUT OUTPUT SUPPLY SUPPLY installation. The external bypass is bespoke to the installation but generally UPS INPUT ...

  • Page 38: Cable Sizing

    3: Installation 3.4.3 Cable sizing UPS SYSTEM INPUT SUPPLY UPS INPUT  MAINS DEVICE INPUT/ BYPASS LINKS FITTED 1L1 – 2L1, 1L2 – 2L2, 1L3 – 2L3, 1N – 2N Cable D Maint. Bypass N N N N N N N N IA 1 IA2‐1 IA2‐2 IA2‐3 PW9000DPA  BATTERY 1 CABINET UPS OUTPUT  DEVICE UPS SYSTEM OUTPUT Figure 3.6 ‘Single feed’ input block diagram Figures 3.6 and 3.7 identify (in red) the power cables, fuses and other protective devices that must be provided by the customer for a single-feed and dual-feed connected installation respectively.
  • Page 39 3: Installation UPS SYSTEM INPUT SUPPLY UPS INPUT  UPS BYPASS  MAINS DEVICE MAINS DEVICE Cable D Maint. Bypass N N N N N N N N IA 1 IA2‐1 IA2‐2 IA2‐3 PW9000DPA  BATTERY 1 CABINET UPS OUTPUT  DEVICE UPS SYSTEM OUTPUT Figure 3.7 ‘Dual feed’ input block diagram MODEL 400V / 230V BATTERY INPUT MAINS (A) BYPASS MAINS (B) UPS OUTPUT (C)

  • Page 40: Ups Power Connections

    3: Installation 3.4.4 UPS Power connections Figures 3.8 and 3.9 illustrate the UPS cabinet power terminal connections. The DPA-150 and DPA-250 cabinet diagrams show the optional common battery links fitted so that the battery is connected to all the fitted power modules. If the installation is to include separate batteries see paragraph 3.4.5 and figures 3.10 to 3.12 for cabling details.

  • Page 41: Battery Configuration

    3: Installation DPA-250 Single Feed Power UPS Module Batt. Connections Connections Links shown in yellow linking the mains input terminals to the PE Busbar bypass input terminals. Common battery links shown in yellow can be removed for a separate battery External Batt.
  • Page 42 3: Installation Each UPS module must be connected to between 42-50 12V battery blocks that are connected in series to form a battery string of the required voltage and capacity. Within the UPS cabinet the battery string is connected to three power terminals annotated ‘+’...

  • Page 43: External Battery Enclosure With Separate Battery Configuration

    3.4.6 External battery enclosure with separate battery configuration Battery Battery Battery Battery Battery UPS CABINET String A String B String C String D String E To UPS Modules’ Battery Connections String A String B String C String D String E Fuses Fuses Fuses...

  • Page 44: External Battery Enclosure With Common Battery Configuration

    3.4.7 External battery enclosure with common battery configuration Battery Battery Battery Battery Battery UPS CABINET String A String B String C String D String E To UPS Modules’ Battery Connections String A String B String C String D String E Fuses Fuses Fuses...

  • Page 45: Ups Cabling Procedure

    3: Installation UPS Cabling procedure WARNING: If you open or remove any UPS cabinet internal cover there is a risk of exposure to dangerous voltages if power is connected to the UPS. WARNING: DC cabling for the battery system(s) must be completed by an Uninterruptible Power Supplies Ltd. engineer or one of its approved service agents.

  • Page 46: Connecting The Battery Cables

    3: Installation 3.5.4 Connecting the battery cables DC cabling for the battery system(s) must be completed by an Uninterruptible Power Supplies Ltd. engineer or one of its approved service agents. Customer Interface Board CAUTION: The customer interface board contain several DIP switches and jumper links which must be configured by the commissioning engineer.

  • Page 47: Customer Interface Output Terminals - X2, X3, X4

    3: Installation 3.6.2 Customer interface output terminals – X2, X3, X4 Term Contact Signal Display Function X2/1 ALARM MAINS_OK Mains Present X2/2 Mains Failure X2/3 Common X2/4 Message LOAD_ON_INV Load on Inverter X2/5 Load not on Inverter X2/6 Common X2/7 ALARM BATT_LOW Battery Low...

  • Page 48: Parallel-Cabinet Control And Configuration

    3: Installation Parallel-cabinet control and configuration Key Point: The parallel interface board is only fitted to the cabinet if it is used as part of parallel cabinet system. CAUTION: All parallel control cables must be installed by the commissioning engineer. 3.7.1 Parallel control bus When several UPS cabinets are connected as a parallel system the modules’...

  • Page 49: Operating Procedures

    Operating Procedures Introduction 4.1.1 Commissioning The PW9000DPA S2 UPS is a high quality, complex electronic system which must be commissioned by an authorised Uninterruptible Power Supplies Ltd engineer before it is put into use. The commissioning engineer will: • check the UPS electrical and mechanical installation, and operating environment •...

  • Page 50: General Warnings

    4: Operating Procedures 4.1.3 General warnings WARNING: The procedures given below must be performed by a trained operator. WARNING: When the UPS system is operating on BYPASS or via the MAINTENANCE BYPASS SWITCH, the load supply is unprotected if the bypass mains supply fails. It is essential that the load user is informed of this possibility before you select these operating modes.
  • Page 51 4: Operating Procedures Power-up the load: Connect the UPS system input supply. LINE 2 BY PASS a) Power will be applied to the UPS modules, but they will be turned OFF. LOAD On every module control panel, verify that: LINE 1 INVERTER a) The LINE 1 LED is green.

  • Page 52: How To Start The Ups System From The Maintenance Bypass

    4: Operating Procedures Transfer the load to inverter: 15. If the BYPASS LED is green (on ALL modules), open the maintenance bypass switch. Note: If the BYPASS LED is not green, repeat step 7. Seek trained advice if it still fails to light green. 16.

  • Page 53: How To Transfer The Load To Maintenance Bypass

    4: Operating Procedures How to transfer the load to maintenance bypass IMPORTANT NOTE In the following procedures, all references to the ‘Maintenance Bypass Switch’ apply to the internal maintenance bypass switch (IA1) in the case of a single cabinet if it is not connected to an external maintenance bypass facility.

  • Page 54: How To Shut Down The Complete Ups System

    4: Operating Procedures On all module control panels, verify that: LINE 2 BY PASS a) The INVERTER LED is extinguished. b) The BYPASS LED is green. LOAD LINE 1 INVERTER The LCD displays LOAD NOT PROTECTED. BATTERY Transfer the load to maintenance bypass: Close the maintenance bypass switch.

  • Page 55: Operating In 'On Bypass' Mode

    4: Operating Procedures Operating in ‘on bypass’ mode When operating the UPS system in ‘on bypass’ mode, the load is powered normally through the UPS bypass (‘on bypass’) and switches to inverter (‘on inverter’) if the bypass supply fails. CAUTION: When operating in the ‘on bypass’ mode there is a short supply break when the UPS switches to the ‘on-inverter’...

  • Page 56: Maintenance

    Maintenance Introduction WARNING: All the operations described in this chapter must be performed by trained personnel. The UPS does not contain any user-serviceable parts, so the maintenance requirements are minimal other than to ensure the environment in which the UPS is installed is kept cool and dust free. A clean operating environment will help maximise the useful working life and reliability of both the UPS and its batteries.

  • Page 57: Battery Maintenance And Testing

    5: Maintenance 5.2.3 Battery maintenance and testing The batteries should be checked and tested by a trained engineer every six months, depending on the ambient temperature. The battery test takes approximately two minutes to complete and can be performed only if: •...

  • Page 58: Troubleshooting

    Troubleshooting Alarms If an alarm condition occurs, the red ALARM LED will illuminate on the module control panel and an audible alarm will sound. In this case proceed as follows: Silence the audible alarm by pressing the RESET button. Identify the cause of the alarm by viewing the EVENTS LOG in the main menu (See paragraph 2.6.3). In case of doubt, contact your nearest service agent or call Uninterruptible Power Supplies Ltd.

  • Page 59: Fault Identification Messages And Alarms

    6: Troubleshooting Fault identification 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 Interpretation Suggested Solution MAINS RECT FAULT UPS input mains power supply to the The UPS input mains supply is too low or missing.

  • Page 60: Options

    Options Introduction The PW9000DPA S2 UPS system offers a range of monitoring and control interfaces that can be connected to external facilities management systems. Depending on the system configuration, these interfaces can be applied at ‘UPS module’, ‘cabinet’ or ‘system’ level. Interfacing at UPS module level A ‘Smart Port’...

  • Page 61: Remote Shut Down Customer Input

    7: Options Customer interface board The customer interface board connections include: • Dry-port inputs for customer remote control options (X1) – see paragraph 3.6.1. • Relay operated dry-port alarm outputs for remote monitoring (X2-X4) – see paragraph 3.6.2. • RS232 computer interface for remote monitoring/control applications (JD11) •...

  • Page 62: Battery Temperature Sensor

    7: Options Key Point: In a parallel cabinet system only one remote shutdown switch is required, connected to the customer interface board in the master cabinet. All the UPS cabinets will shut down when the remote emergency shutdown switch is operated. 7.2.3 Battery temperature sensor If required, the battery temperature monitor will be installed by the commissioning engineer.

  • Page 63: Snmp/ Cs141 Slots - Slot 1/ Slot 2

    7: Options 7.2.6 SNMP/ CS141 slots – SLOT 1/ SLOT 2 Simple Network Management Protocol (SNMP) is a world-wide, standardised communication protocol that can be used to monitor any network-connected device via a simple control language and display the results in an application running within a standard web browser.

  • Page 64: Specification

    Specification Mechanical Characteristics TRIPLE UPGRADE CLASSIC DPA-150 DPA-250 DPA-50 Capacity Max. 1 module (30-45kVA) 3 modules (30-45kVA) 5 modules (30-45kVA) 280 x 7/9Ah batteries 240x 7/9Ah batteries no batteries Max. Power connection Dimensions (WxHxD) 730x1650x800 730x1975x800 730x1975x800 Weight of Empty Cabinet Weight of Cabinet with 305 - 309 368 - 379...

  • Page 65: Input Characteristics

    8: Specification Input Characteristics Module Type DPA 30 DPA 40 DPA 50  Output Rated Power per Module cos  Output Rated Power per Module cos Nominal Input Voltage 3x380/220V+N, 3x400V/230V+N, 3x415/240V+N Input Voltage Tolerance (-23%/+15%) 3x308/184 V to 3x460/264 V for <100% load (ref to 3x400/230V) for Loads in %: (-30%/+15%) 3x280/170 V to 3x460/264 V for <...

  • Page 66: Output

    8: Specification Output Module Type DPA 30 DPA 40 DPA 50 Output Rated Power per Module Output Rated Power per Module  46.5 Output Current In @ cos 1.0 (400 V) Output Rated Voltage 3x380/220V or 3x400/230V or 3x415/240V Output Voltage Stability Static: <...

  • Page 67: Environmental

    8: Specification Environmental Module Type DPA 30 DPA 40 DPA 50 Audible Noise with 100% / 50% Load 70 / 63 74 / 67 76 / 69 Operation temperature °C 0 to +40 Ambient Temperature for Batteries °C +20 to +25 (recommended) Storage Temperature °C -25 to +70...

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