Kohler PowerWAVE 6000 User Manual
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Kohler PowerWAVE 6000 User Manual

Kohler PowerWAVE 6000 User Manual

60-120 kva s3
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Summary of Contents for Kohler PowerWAVE 6000

  • Page 2 TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 3 All product, product specifications and data are subject to change without notice to improve reliability, function, design or otherwise. Kohler Uninterruptible Power Ltd has taken every precaution to produce an accurate, complete and easy to understand specification document and will assume no responsibility nor liability for direct, indirect or accidental personal or material damage due to any misinterpretation of, or accidental errors, in this manual.
  • Page 4 TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 5: Extended Warranty

    Warranty The PowerWAVE 6000 S3 (60-120 kVA) 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 6 TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 7: Table Of Contents

    1.3 Declaration of Safety conformity and CE marking General Description 2.1 Introduction 2.1.1 Reliability and quality standards 2.1.2 Key features 2.2 PowerWAVE 6000 S3 (60-120 kVA) model range 2.3 UPS module functional description 2.3.1 UPS module block diagram 2.3.2 UPS Module operating modes 2.3.3 System operating modes 2.4 Multi-module parallel UPS system...
  • Page 8 8.4 Serial RS232 Computer interface – USB & JD1 (Smart Port) 8.5 RS485 Interface for multidrop 8.6 SNMP Card slots 8.7 UPS Monitoring and automated control software 8.7.1 The importance of UPS management Specification 9.1 GENERAL SPECIFICATIONS TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 9: Safety

    UPS or peripheral equipment. CAUTION: The PowerWAVE 6000 S3 (60-120 kVA) is a Class A UPS product (according to EN 62040-3). In a domestic environment the UPS may cause radio interference. In such an environment the user may be required to undertake additional measures.

  • Page 10: Declaration Of Safety Conformity And Ce Marking

    Declaration of Safety conformity and CE marking The PowerWAVE 6000 S3 (60-120 kVA) UPS system is designed and manufactured in accordance with Quality Management Systems standard EN ISO 9001. The CE marking indicates conformity to the EEC Directive by the application of the following standards in accordance with the specifications of the harmonized standards: •...

  • Page 11: General Description

    Such demands are well met by the PowerWAVE 6000 S3 (60-120 kVA) UPS system, which provides the foundation for continuous power availability of network-critical infrastructures both in enterprise data centres, where business continuity has paramount importance, and in process control environments, where manufacturing continuity is essential.

  • Page 12: Powerwave 6000 S3 (60-120 Kva) Model Range

    The UPS batteries are installed in a separate cabinet or mounted in a purpose-designed battery rack. The battery arrangement will vary from site to site depending on the battery specification and environmental requirements; however, Kohler Uninterruptible Power Ltd can provide a range of external battery cabinets to suit the vast majority of installations.

  • Page 13: Ups Module Functional Description

    CHARGER BOOSTER Battery String Batt. Fuse Figure 2.2 PowerWAVE 6000 S3 (60-120 kVA) UPS module block diagram 2.3.1 UPS module block diagram Figure 2.2 shows the major power blocks contained within the UPS system. UPS Input supplies IA4 (1), IA3 (2) The UPS has two sets of three-phase input supply terminals: •...
  • Page 14 • From the maintenance bypass line – via the maintenance bypass isolator (IA1). Only one of these output supply sources can be active at any given point in time and the criteria for operating under each of these UPS modes is described below. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 15: Ups Module Operating Modes

    In this scenario the battery is only required to support the inverter (load) until the generator comes on-line, and as a modern generator can be automatically started very quickly this results in a relatively short battery discharge period – which helps to prolong the battery life. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 16 (‘load on bypass’) before the maintenance bypass switch is closed. CAUTION: Always follow the operating instructions in Chapter 5 of this manual when starting or shutting down the UPS. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 17: System Operating Modes

    This situation is easily managed in a PW6000 (S3) multi-module installation, which allows an additional module to be installed in an existing parallel system without having to temporarily transfer the load to the raw by-pass TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 18: Parallel Ups System Operation

    Key Point: If a PowerWAVE 6000 S3 (60-120 kVA) module is purchased as a standalone, single unit UPS it will require a field upgrade to make it suitable for parallel operation at a later time. For this reason, if you know that your load is likely to expand in the future it is advisable to install a parallel-capable module at the outset.

  • Page 19: Common Battery

    Maintenance Bypass Line Bypass Mains Static Bypass Line STATIC SWITCH Output Supply RECTIFIER INVERTER Output Input Mains Contactor CHARGER BOOSTER Battery String Batt. Fuse Figure 2.7 PowerWAVE 6000 S3 (60-120 kVA) power isolators TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 20: Ups Control Panel

    When an alarm condition is activated the LED is accompanied by an audible alarm. Figure 2.9 Module mimic diagram TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 21: Operator Buttons

    – i.e. if the number of remaining modules is sufficient to support the connect load then the load will not be transferred. To shut down all the modules in a parallel system you must press both ON/OFF buttons on every module. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 22: Power Management Display (Pmd)

    Event Log, set up the automatic battery test operation and configure the UPS options when running on standby generator. SET-UP SERVICE – This menu is used by the commissioning engineer and is password-protected to restrict access. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 23 DYNAMIC PASSWORD BATT.CAPACITY (%) YES/NO 000      000       000 DATE                        TIME BATTERY TEMPERATURE dd‐mm‐yyyy            hh:mm:ss 00.0 MODULE TEMP BST/INV 00.0      00.0       00.0 ENGLISH FRANCAIS DEUTCH SET LANGUAGE SPANISH POLISH PORTUGUESE SET‐UP DATE AND TIME DD‐MM‐YYYY        HH:MM:SS SET‐UP BATT.TEST DAY OF MONTH (1‐31) HOUR OF DAY (0‐23) REPETITIVE (Y/N) SET GENERATOR OP. BATT. CHARGE LOCK (Y/N) BYPASS LOCK (Y/N) Figure 2.10 Module control panel menus TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 24: Ups Communication Interface

    This board is used only in a parallel system and plugs into JD8 on the Communication Interface Board. It is secured in place by 2 screws, as shown. Figure 2.11 Communication interface facilities TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 25: Installation Planning

    PowerWAVE 6000 S3 (60-120 kVA) UPS system. Key Point: If you are installing an external battery cabinet supplied by Kohler Uninterruptible Power Ltd you should refer to the manual that is provided with the cabinet for installation instructions.

  • Page 26: Installation Clearances

    CBAT 150T battery cabinet. Key Point: The CBAT 150T battery cabinet is recommended by Kohler Uninterruptible Power Ltd for use with the PW6000 (S3) system. If an alternative battery cabinet is used then the dimensions shown in Figure 3.1 must be adapted to suit the recommendations of the particular battery cabinet manufacture.
  • Page 27 UPS cabinets to minimise the length of the DC cable runs. The battery cables must be sized to compensate for the DC voltage drop between the battery installation and UPS. Contact Kohler Uninterruptible Power Ltd for installation advice and support if necessary. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 28: Electrical And Cabling Planning

    Figures 3.3 and 3.4 do not show battery fuse and cable sizing details as these are bespoke to the installation.The DC cables and fuses will be provided by Kohler Uninterruptible Power Ltd but it is the customer’s responsibility to provide any necessary cable containment.
  • Page 29 (Cable D) Fuse A and Cable A 60 kVA 101A Cable D 80 kVA 134A 116A 100 kVA 167A 145A 120 kVA 201A 174A Figure 3.3 Single feed input fuse and cable ratings TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 30 101A Fuse C and Cable C 80 kVA 134A 116A 116A Cable D 100 kVA 167A 145A 145A 120 kVA 201A 174A 174A Figure 3.4 Dual feed input fuse and cable ratings TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 31: Power Cabling In A Parallel System

    (see Figure 3.5). Mains distribution board CORRECT Load distribution board Mains distribution board INCORRECT Load distribution board Figure 3.5 Cable lengths for multi cabinet configurations TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 32: External Maintenance Bypass Switch

    ‘system’ load. This will require additional protective devices to be connected in the feed(s) to the UPS input mains (and UPS bypass mains) – e.g. to protect ‘Cable A’ in the example shown. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 33: Installation Procedure

    This chapter contains essential information concerning the unpacking, positioning, installing and cabling of the PowerWAVE 6000 S3 (60-120 kVA) UPS. Key Point: If you are installing an external battery cabinet supplied by Kohler Uninterruptible Power Ltd you should refer to the manual that is provided with the cabinet for installation instructions.

  • Page 34: Local Transportation

    Place the UPS in its final position, then disassemble the left and right securing brackets (I) by removing the 8x M8 screws (J). Fit the kick-plates (K) (from the accessories package) to the lower front and back of the cabinet and secure in place using the screws provided (L). TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 35 4: Installation Procedure Figure 4.2 Unpacking the UPS cabinet (standard packaging) TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 36 Similarly, remove the humidity absorbent strip from the back of the UPS cabinet. Following steps 6 to 8 in the previous procedure (Removing the standard UPS packaging), fit the UPS adjustable feet and front/rear kick-plates. Figure 4.3 Unpacking the UPS cabinet (sea freight packaging) TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 37: Ups Cabling Procedure

    2-L1, 2-L2, 2-L3 3-L1,3-L2, 3-L3 N / BATT- BATT+ Identification Termination size 2x M8 1x M8 1x M8 5x M8 2x M8, 1x M10 5x M8 Tightening torque 12.3 Nm (M8), 25.1 Nm (M10) TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 38: Safety Notes

    IEC standards or local regulations – for example BS7671. Once the electrical installation is completed the UPS must be commissioned by an engineer authorised by Kohler Uninterruptible Power Ltd before it is powered up and brought into use.

  • Page 39: Connecting The Ups Input Mains Cables

    Connect the earth cable from the load distribution board to the UPS protective earth (PE) busbar – see Figure 4.4. Connect the UPS 3-phase output cables between terminals 3-L1, 3-L2, 3-L3 and the appropriate connections at the load distribution board. Ensure correct (clockwise) phase rotation. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 40: Connecting The Battery

    Connecting the battery IMPORTANT NOTE The batteries must be installed and connected to the UPS by the Kohler Uninterruptible Power Ltd commissioning engineer. High voltage battery strings can be extremely dangerous and should not be installed by the customer’s installation team.
  • Page 41 These cables must be installed and configured by the commissioning engineer; however, depending on the position of the cabinets, it may be necessary for the customer to provide any necessary cable containment. Contact Kohler Uninterruptible Power Ltd for further installation advice if required. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 42: Operating Instructions

    Operating Instructions Introduction The PowerWAVE 6000 S3 (60-120 kVA) UPS system must be commissioned by a fully trained engineer authorised by Kohler Uninterruptible Power Ltd before it is put into use. The commissioning engineer will: • check the UPS electrical and mechanical installation, and operating environment •...

  • Page 43: General Warnings

    If necessary press the RESET button to obtain this display. Close the external UPS system output isolation device on the load distribution panel. Close the UPS maintenance bypass switch (see the "IMPORTANT NOTE" above). TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 44 17. The load is now being powered through the UPS static bypass. a) Check the UPS input and output metered parameters to ensure that they are correct. b) Note any active alarms and take appropriate actions if an alarm cannot be reset. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 45: How To Start The Ups System From The Maintenance Bypass

    If the UPS system is operating on maintenance bypass it can be powered up using the procedure described in paragraph 5.2 ("How to start the UPS system from a fully powered-down condition") beginning at step 7. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 46: How To Transfer The Load To The Maintenance Bypass

    On the module control panel(s), verify that: LINE 2 BY PASS a) The INVERTER LED has extinguished. b) The BYPASS LED is green. LOAD LINE 1 INVERTER The LCD displays LOAD NOT PROTECTED. BATTERY TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 47 DO NOT OPEN THE BYPASS MAINS SUPPLY FUSES/ CIRCUIT BREAKER. If an external maintenance bypass facility is used, the UPS modules’ input/bypass supply can be turned off – see the operating instructions for the bespoke external maintenance bypass facility for details. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 48: How To Shut Down The Complete Ups System

    Using the UP/DOWN keys, move the cursor so that it is adjacent to LOAD TO BYPASS and then press the ENTER key. a) The UPS system will transfer the load to the static bypass (on all UPS modules in a parallel-module system). TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 49: Individual Module Stop/Start Procedure (Redundant Parallel System)

    WARNING: The load will be transferred to bypass and not supported by the UPS system if: • You turn off the module in a standalone system, or • You turn off a module in a capacity rated system (which may overload the remaining on-line modules). TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 50 INVERTER b) The INVERTER will start-up and come on line (Green). The module control panel will display LOAD PROTECTED. d) The module control panel mimic indications should be as shown here. BATTERY TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 51: Maintenance

    Preventative maintenance inspections form an integral part of all Extended Warranty Agreements (maintenance contracts) offered by Kohler Uninterruptible Power Ltd. For further details on Extended Warranty Agreements see the warranty information at the front of this manual.

  • Page 52: Troubleshooting

    Investigative action is necessary only if it is not possible to reset the alarm or if the alarm occurrence is repetitive, in which case you should seek advice or assistance from the Kohler Uninterruptible Power Ltd Service Department.

  • Page 53: Troubleshooting Table

    Contacting service Kohler Uninterruptible Power Ltd 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 Ltd...

  • Page 54: Options

    X1 – Customer control inputs (see paragraph 8.2) SW2 – Multidrop configuration DIP switch MULTIDROP – JR45 multidrop cable connection (see paragraph 8.5) Figure 8.1 UPS Communications interface board connectors TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual User Manual 21/10/19...

  • Page 55: Customer Control Inputs (X1)

    This will be done as part of the system commissioning process. If you wish to activate this feature after the system has been commissioned please contact Kohler Uninterruptible Power Ltd service department for advice. Use a screened cable with 1 pair (section of wires 0.5 mm - 1.5 mm...

  • Page 56: Generator On Facilities

    BATT_LOW Common X2/8 Battery OK X2/7 Battery Low X2/6 MESSAGE LOAD_ON_INV Common X2/5 Load On Bypass (mains) X2/4 Load On Inverter X2/3 ALARM MAINS_OK Common X2/2 Mains Not Present X2/1 Mains Present TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 57: Serial Rs232 Computer Interface - Usb & Jd1 (Smart Port)

    2 and UPS cabinet 3, using a splitter plug in cabinet 3 if it is a ‘middle’ cabinet. Figure 8.5 Multi-drop Continue with the above steps until a multidrop cable is connected as a daisy chain between all modules. TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

  • Page 58: Snmp Card Slots

    Kohler Uninterruptible Power Ltd considers it important to have a complete solution for its UPS systems and offers its customers a number of remote control and monitoring tools to provide optimum protection.

  • Page 59: Specification

    (pf=1.0) Max. Input Current with rated output power and discharged battery (pf=1.0) @400/230V Input power factor (leading) > 0.99 @100% load Input harmonic distortion (THDi) (%) < 4% @100% load TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 60 150% load for 30 seconds 125% load for 5 minutes 110% load for 20 minutes Fault clearing capability (100ms) 2x In for normal mode and battery mode Bypass short circuit capability 10x rated In for 10ms TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 61 Volt-free output interface provide status and alarm outputs for remote indication and interfacing with BMS systems. Together with customer inputs interface for connecting an Emergency Stop, On Generator status etc. RS232 on Sub-D9 port For monitoring and integration in network management TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...
  • Page 62 RS485 on RJ45 port For multidrop purposes (option) Slot for SNMP Card Ethernet card for monitoring and integration in network management (option) Slot for SNMP Card USB Port and relay card. Customer outputs TS_610_01 PowerWAVE 6000 S3 (60-120kVA) User Manual 21/10/19...

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