Kohler PowerWAVE 8000DPA RI (S2) Series User Manual
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Kohler PowerWAVE 8000DPA RI (S2) Series User Manual

Kohler PowerWAVE 8000DPA RI (S2) Series User Manual

Up to 80 kva/kw
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  • Page 1 User Manual...
  • Page 2 TS_615_01 PowerWAVE 8000DPA RI (S2) User Manual 8/6/20...
  • 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_615_01 PowerWAVE 8000DPA RI (S2) User Manual 8/6/20...
  • Page 5 God or inappropriate application. If the UPS fails to conform to the above within the warranty period then Kohler Uninterruptible Power Ltd will, at its sole option, repair or replace the UPS.
  • Page 6 TS_615_01 PowerWAVE 8000DPA RI (S2) User Manual 8/6/20...

  • Page 7: Table Of Contents

    Table of contents 1: Safety 1.1 Description of symbols used in this manual 1.2 User precautions 1.3 Declaration of Safety conformity and CE marking 2: General Description 2.1 Introduction 2.1.1 Reliability and quality standards 2.2 PowerWAVE 8000DPA RI (S2) system 2.2.1 System configuration 2.2.2 Advanced Design Features 2.3 Functional description of operation...
  • Page 8 4.5.2 Power connections 4.5.3 Connecting the power cables (single-feed input) 4.5.4 Connecting the power cables (dual-feed input) 4.5.5 Connecting the UPS output cables 4.5.6 Connecting the battery 4.6 Remote monitoring and control facilities 4.6.1 PW8000DPA RI communications interface 4.7 Installation completion 5: Operating Instructions 5.1 Introduction 5.1.1 Operating procedure summary...

  • Page 9: 1: Safety

    WARNING: Do not attempt to service the UPS yourself. You run risk of exposure to dangerous voltages if you open or remove the UPS covers! WARNING: Kohler Uninterruptible Power Ltd will assume no responsibility or liability for accidents or injuries due to incorrect operation or manipulation of the UPS or peripheral equipment.

  • Page 10: Declaration Of Safety Conformity And Ce Marking

    1: Safety Declaration of Safety conformity and CE marking The PowerWAVE 8000DPA RI (S2) 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: 2: General Description

    IEC 62040-3 (VFI-SS-111) standards. Kohler Uninterruptible Power Ltd specialises in the installation and maintenance of Uninterruptible Power Systems; and this powerful UPS is just one example of our wide range of state-of-the-art power protection devices that can provide your critical equipment with a steady and reliable power supply for many years.

  • Page 12: Advanced Design Features

    2: General Description RI-10 Frame RI-11 Frame RI-12 Frame RI-20 Frame RI-22 Frame 1 x module 1 x module 1 x module 2 x module 2 x module External Batt. 40 x 7/9Ah Batt. 80 x 7/9Ah Batt. External Batt. 80 x 7/9Ah Batt.

  • Page 13: Functional Description Of Operation

    2: General Description Advanced input booster/rectifier technology The PowerWAVE 8000DPA RI (S2) UPS module’s advanced booster technology results in an input power factor of 0.99 with a harmonic content of < 3% THD(i). This enhances the system reliability and minimises the winding losses of any generator or transformer connected to the UPS input, which in turn reduces the generator/transformer costs.

  • Page 14: Ups Power Module Internal Operation

    2: General Description 2.3.1 UPS Power module internal operation STATIC SWITCH Bypass Mains AC/DC (PFC) DC/AC DC BOOST RECTIFIER CONVERTER INVERTER UPS AC Input Output Mains Input Output Relay Relay Automatic Batt. Switch BATTERY BATT. CHARGER UPS MODULE Figure 2.2 UPS module functional block diagram UPS input/bypass mains supplies Figure 2.2 illustrates separate UPS module input mains and bypass mains supplies.

  • Page 15: Ups Module Operational States

    2: General Description Note: A brief load break will occur when transferring from bypass to inverter following a bypass supply failure, or if the bypass/inverter are not synchronised when a transfer is demanded. (See ‘Off Line Mode’ in section 2.3.4). Automatic battery changeover switch If the UPS mains input supply fails, or undergoes a sustained dip (brownout), the automatic battery switch will close to connect the battery to the DC boost converter input.
  • Page 16 2: General Description UPS ON-BATTERY mode STATIC SWITCH Bypass Mains AC/DC (PFC) DC BOOST DC/AC CONVERTER INVERTER CONVERTER UPS AC Input Output Mains Input Output Relay Relay Automatic Batt. Switch BATTERY BATT. CHARGER UPS MODULE Figure 2.4 UPS ON-BATTERY The UPS automatically changes to the ON-BATTERY mode if the mains input supply fails during normal operation: •...

  • Page 17: Parallel System Operation

    2: General Description UPS ON MAINTENANCE BYPASS MAINTENANCE BYPASS STATIC SWITCH Bypass Mains AC/DC (PFC) DC BOOST DC/AC CONVERTER CONVERTER INVERTER UPS AC Input Output Mains Input Output Relay Relay Automatic Batt. Switch BATTERY BATT. CHARGER UPS MODULE Figure 2.6 UPS ON MAINTENANCE BYPASS Although the maintenance bypass switch is not fitted within the UPS module, the maintenance bypass mode of operation is shown here for completeness.

  • Page 18: Ups System Operation

    2: General Description For example, a fully populated RI-40 frame (4 x 20 kW UPS modules) would operate with a redundancy of one module when connected to a 60 kW load. Under normal circumstances, with all four UPS modules operating, each module would provide 15 kW when the full 60 kW load is applied.
  • Page 19 2: General Description Operating in this mode is slightly more energy efficient than operating in the ON-LINE mode due to the reduced rectifier and inverter losses during normal system operation; and it is sometimes referred to as the ‘ECO’ (economy) mode. However, this mode is recommended only if the connected load equipment can tolerate power interruptions of up to 3~5 ms during the transfer period.

  • Page 20: Component Identification

    2: General Description Component identification UPS Module 4 Module Control Panel UPS Module 3 UPS Module 2 RI-40 Frame UPS Module 1 Module 4 Battery Isolator (F4-4) UPS Interface Connections Module 3 Battery Isolator (F4-3) Module 2 Battery Isolator (F4-2) Maintenance Bypass Module 1 Battery Isolator (F4-1) Switch (IA1)
  • Page 21 Battery installation details are provided later in this manual but note that all battery cabling must be carried out by a Kohler Uninterruptible Power Ltd approved engineer as part of the system commissioning procedure.

  • Page 22: Module Control Panel

    2: General Description Module control panel LCD Power management display Operator Module ON/OFF menu buttons buttons (x2) Mimic LED indicators Alarm LED/Reset Figure 2.9 LCD Control panel 2.5.1 Module mimic LED indicators The module mimic LED colours change between GREEN, RED and OFF to LINE 2 BYPASS indicate the operational status of key UPS stages, and thereby serve to...

  • Page 23: Operator Buttons

    2: General Description LED Indication summary INDICATOR STATUS INTERPRETATION LINE 1 GREEN Input mains supply is available and within acceptable parameters Input mains supply is unavailable or not within acceptable parameters – this is the normal display during an input mains power failure LINE 2 GREEN Bypass mains supply is available and within acceptable parameters...

  • Page 24: Lcd Power Management Display

    2: General Description 2.5.3 LCD Power management display Working in conjunction with the UP, DOWN and ENTER buttons, the LCD screen presents a range of selectable menus which allows the user to operate the UPS and monitor its performance – the menu tree is shown in Figure 2.11. Status screens During normal operation the LCD displays a UPS status screen similar to those shown below.
  • Page 25 2: General Description 01 dd‐mm‐yy          hh:mm:ss BATT. RUN TIME (MIN) TOP LEVEL MENU [EVENT 01 DESCRIPTION] 00h 00m 02 dd‐mm‐yy          hh:mm:ss OUTPUT FREQUENCY (HZ) EVENT LOG [EVENT 02 DESCRIPTION] 50.00 BYPASS FREQUENCY (HZ) MEASUREMENTS 50.00 BATTERY VOLTAGE (V) COMMANDS LOAD TO INVERTER      +0.0            ‐ 0.0 BATT. CHARGE CUR. (A) UPS DATA LOAD TO BYPASS      +0.0            ‐ 0.0 DISCHARGE CURRENT (A) SET‐UP USER PERFORM BATT. TEST 00.00 RECTIFIER VOLTAGE (V) SET‐UP SERVICE PERFORM DEEP BATT. TEST 000      000       000 BYPASS VOLTAGE (V) ABORT BATT. TEST 000      000       000 OUTPUT VOLTAGE (V) PERF. ALARM TEST 000      000       000 OUTPUT CURRENT (A)

  • Page 26: Pw8000Dpa Ri Communication Interface

    2: General Description PW8000DPA RI Communication interface PW8000-RI Communications interface RJ45 Port: Network interface Customer output dry ports: Up to 5 output dry contacts used for signalling of the status of the UPS system (e.g. Mains failure, JD1 (RS232) load on inverter, battery low, common alarm). (RS485) Serial Port 15 1...
  • Page 27 2: General Description JD1 (RS232) (E) JD1 is a Sub D-9 female connector that provides an RS232 user interface for remote systems monitoring using a computer application, such as WAVEMON. This allows the computer terminal to continuously monitor the mains voltage and computer operating status, and process any alarm messages.

  • Page 28: 3: Installation Planning

    PowerWAVE 8000DPA RI (S2) 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 29: Installation

    3: Installation Planning 3.2.2 Installation The PW8000DPA RI UPS is of rack/sub-rack construction designed to be installed in a standard 19 inch cabinet. The table below shows the rack height required by each model. We recommend that the UPS is installed at the bottom of the rack cabinet, especial if the UPS assembly includes internal batteries.

  • Page 30: Electrical And Cabling Planning

    3: Installation Planning Electrical and cabling planning 3.3.1 General requirements The information in this section should help with the preparation and planning of the UPS power cabling. IMPORTANT NOTE: The UPS does not contain internal fuse protection for the bypass mains or input mains supplies. It is the customer’s responsibility to ensure that external supply fuses (or other protective devices) are fitted and correctly sized to provide the recommended level of UPS protection.

  • Page 31: Cable And Fuse Sizing

    3: Installation Planning 3.3.2 Cable and fuse sizing Key Point: All external fuses, isolators and power cables must be rated and installed in accordance with the prescribed IEC standards or local regulation – e.g. BS7671. Input/bypass mains supply cables The UPS cabinet can be wired for a ‘single feed’ or UPS Frame ‘dual feed’...
  • Page 32 • The battery and DC cables must be connected by the commissioning engineer. • The battery cables and fuses are bespoke to the installation and will be provided by Kohler Uninterruptible Power Ltd. but it is the customer’s responsibility to install any cable containment where necessary.
  • Page 33 3: Installation Planning UPS FRAME IA-1 (MBP) Fuse D EARTH Cable D Sta c  Switch Common Input Links Fuse A Cable A Input Mains Rect. Inv. Load DC/DC  Conv Module 1 Fuse F F4-1 Sta c  Switch EARTH Rect. Inv. DC/DC  Conv Module 2 F4-2 Sta c ...
  • Page 34 3: Installation Planning UPS FRAME IA-1 (MBP) Fuse D EARTH Cable D Sta c  Switch Common Input Links Fuse A Cable A Input Mains Rect. Inv. Load DC/DC  Conv Module 1 Fuse E F4-1 Sta c  Switch EARTH Rect. Inv. Cable E Fuse E DC/DC ...
  • Page 35 3: Installation Planning UPS FRAME IA-1 (MBP) Fuse D EARTH Fuse B Cable B Cable D Sta c  Bypass Mains Switch Fuse A Cable A Input Mains Rect. Inv. Load DC/DC  Conv Module 1 Fuse F F4-1 Sta c  Switch EARTH Rect. Inv.
  • Page 36 3: Installation Planning UPS FRAME IA-1 (MBP) Fuse D EARTH Fuse B Cable B Cable D Sta c  Bypass Mains Switch Fuse A Cable A Input Mains Rect. Inv. Load DC/DC  Conv Module 1 Fuse E F4-1 Sta c  Switch EARTH Rect. Inv.

  • Page 37: External Maintenance Bypass

    Depending on size and location, the isolators may be installed in a dedicated maintenance bypass cabinet or included in an Inverter existing (or dedicated) switch panel. Kohler Uninterruptible Power Ltd can provide a range of external maintenance bypass solutions to suit all of its UPS systems. Static Switch Module...

  • Page 38: 4: Installation Procedure

    All installation procedures must be carried out in strict accordance with the instructions contained in this manual. Kohler Uninterruptible Power Ltd will take no responsibility for any personal injury or material damage caused by the incorrect installation, cabling or operation of this product.

  • Page 39: Local Transportation

    4: Installation Procedure 4.2.2 Local transportation Please observe the following precautions when you transport the UPS equipment after it has been off-loaded. CAUTION: Local transportation: • When moving the UPS cabinet using a forklift or pallet jack, insert the lifting equipment forks below the package and ensure they support both front and back of the packed equipment.

  • Page 40: Unpacking

    4: Installation Procedure Unpacking Key Point: Remove all packaging materials carefully, causing as little damage as possible, and temporarily store them in case the UPS has to returned to the manufacturer for any reason prior to commissioning. Removing the standard UPS packaging Figure 4.2 Cut and remove the two sealing bands (A) that are wrapped around the cardboard packing container cover.

  • Page 41: Mechanical Installation

    4: Installation Procedure Removing the alternative wooden crate packaging Cut and remove the two sealing bands that are wrapped around the wooden crate. Remove the wooden crate sides and top by removing the securing screws from the bottom and sides of each panel Carefully lift away the wooden crate and remove any accessories (C) that are shipped in the top of the package –...
  • Page 42 Figure 4.3 RI-10 (Type X1)
  • Page 43 Figure 4.4 RI-11 (Type 1)
  • Page 44 Figure 4.5 RI-12 (Type 2)
  • Page 45 Figure 4.6 RI-20 (Type x2)
  • Page 46 Figure 4.7 RI-22 (Type 3)
  • Page 47 Figure 4.8 RI-24 (Type x4)
  • Page 48 Figure 4.9 RI-40 (Type x4)

  • Page 49: Power Cabling

    Before you connect the UPS power cables ensure that the fuses and cables are suitably rated in accordance with the prescribed 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 50: Power Connections

    4: Installation Procedure 4.5.2 Power connections Cable access The PW8000DPA RI power cables are connected to a terminal block which is located in the lower rear of the UPS frame behind a safety cover plate. Figure 4.10 shows details for the RI-11 UPS but all models are of similar design.
  • Page 51 4: Installation Procedure Terminal block connections External Batt. RI-10 connections The RI-10 model requires an external battery connected to the battery terminals on the left hand side of the terminal block. PE 3L1 3L3 RI-11 & RI-12 connections The RI-11 and RI-12 models have internal batteries so no battery terminal block is provided.

  • Page 52: Connecting The Power Cables (Single-Feed Input)

    4: Installation Procedure 4.5.3 Connecting the power cables (single-feed input) Connect an earth cable from the input mains switchboard to the UPS protective earth terminal (PE). If an external battery cabinet is used, connect an earth cable between the battery cabinet and the UPS battery earth terminal (PE).

  • Page 53: Connecting The Battery

    Connecting the battery IMPORTANT NOTE The batteries must be installed and connected to the UPS by an approved 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 54: 5: Operating Instructions

    Operating Instructions Introduction The PowerWAVE 8000DPA RI (S2) 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 55 5: Operating Instructions STATIC SWITCH Bypass Mains AC/DC (PFC) DC BOOST DC/AC RECTIFIER CONVERTER INVERTER UPS AC Input Output Mains Input Output Relay Relay Automatic Batt. Switch BATTERY BATT. CHARGER UPS MODULE MAINTENANCE BYPASS STATIC SWITCH Bypass Mains AC/DC (PFC) DC BOOST DC/AC CONVERTER...

  • Page 56: How To Start The Ups System From A Fully Powered-Down Condition

    5: Operating Instructions How to start the UPS system from a fully powered-down condition IMPORTANT NOTE In the following procedures, all references to the ‘Maintenance Bypass Switch’ apply to the internal maintenance bypass switch (IA1) unless the system is connected to an external maintenance bypass facility. If an external maintenance bypass facility is installed all references to the ‘Maintenance Bypass Switch’...
  • Page 57 5: Operating Instructions Start the UPS modules Carry out steps 8 to 10 below (for each module in a parallel module system). Close the fused battery isolator (F4-x) (also close the battery fuse in the LINE 2 BY PASS external battery cabinet where used). a) The LINE 1 LED is green.

  • Page 58: Operating In Eco (On Bypass) Mode

    5: Operating Instructions Operating in ECO (on bypass) mode When the UPS system is operated in ECO (on bypass) mode the load is powered from the UPS bypass mains supply, via the static switch, under normal conditions and transfers to the inverter (on inverter mode) automatically if the bypass mains supply fails.

  • Page 59: How To Transfer To On-Line (On Inverter) Fro Eco (On Bypass) Mode

    5: Operating Instructions 5.3.3 How to transfer to on-line (on inverter) fro ECO (on bypass) mode The UPS can be manually switched to on-line (on inverter) from the ECO (on bypass) mode using the module control panel load transfer menu. On the module control panel (of any module in a parallel-module system) press the ENTER key once to access the menu system.

  • Page 60: How To Transfer The Load To The Maintenance Bypass

    5: Operating Instructions How to transfer the load to the maintenance bypass It may be necessary to transfer the load to the maintenance bypass supply to perform certain UPS service or maintenance operations – for example, when replacing a module in non-redundant system. This procedure is usually carried out by a trained service engineer and is not part of the normal day-to-day management of the UPS system.
  • Page 61 5: Operating Instructions Transfer the load to maintenance bypass: Close the maintenance bypass switch (see the IMPORTANT NOTE above). On the module control panel(s), verify that: LINE 2 BY PASS a) The INVERTER LED is red. b) The BYPASS LED is green. LOAD LINE 1 INVERTER...

  • Page 62: How To Shut Down The Complete Ups System

    5: Operating Instructions How to shut down the complete UPS system The UPS system can be completely shut down if the load does not require power for an extended period of time. CAUTION: Before you carry out this procedure, warn the critical load user that power is about to be removed. If the UPS system is not already operating on maintenance bypass, transfer the load to the maintenance bypass and turn OFF the UPS module(s) as described in paragraph 5.4.

  • Page 63: 6: 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 64: 7: 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. Module control panel The module control panel is described on page 14.

  • Page 65: 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 66: 8: Options

    Options Customer communications JD1 (RS232) PW8000-RI Communications interface (RS485) Serial Port 15 1 RJ45 Port: Network interface Customer output dry ports: Customer input dry ports: LEDs Status LEDs: SLOT 2 SLOT 1 RS232 Smart port computer interface: Standard USB interface: SLOT 1 Slot for optional modem/Ethernet card ONLY.
  • Page 67 UPS 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. To fit an external remote shutdown facility: Use a screened cable with 1 pair (section of wires 0.5 mm...

  • Page 68: Dry Port Outputs (X2)

    Key Point: The battery temperature features will only function with the battery temperature sensor supplied by Kohler Uninterruptible Power Ltd. If you attempt to use any other type of sensor it could have a damaging effect on the UPS operation.

  • Page 69: Serial Rs232 Computer Interface - Usb & Jd1 (Smart Port)

    8: Options 8.1.3 Serial RS232 Computer interface – USB & JD1 (Smart Port) A serial RS 232 interface is available through a standard 9-pin D-Type female socket (JD1) or via the USB port. The RS232/USB interface allows the UPS to be connected to a computer which, when used with appropriate power management software, allows the computer to continuously monitor the input mains voltage and UPS status, and display messages in response to any UPS system changes.

  • Page 70: Ups Monitoring And Automated Control Software

    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 71: Powerreporter™ Management Software

    The main features and benefits offered by PowerREPORTER are: • real time alarm or critical event email notification sent directly to Kohler Uninterruptible Power Ltd service centre • acquisition of key performance data and productivity information to allow a better understanding of the UPS system performance and quickly troubleshoot downtime events •...
  • Page 72 PowerREPORTER communicates constantly with your UPS system to automatically detect any error or alarm messages. If it encounters an incident, PowerREPORTER will automatically transmit a status message, via email, to the Kohler Uninterruptible Power Ltd service centre providing details relating to the identified fault, a snapshot of the UPS performance parameters and a device identification string.

  • Page 73: 9: Specification

    Specification Mechanical characteristics RI-10 RI-11 RI-12 Configuration Max. 1 module 1 module (10 or 20kVA) 1 modules (10 or 20kVA) accommodates: (10 or 20kVA) with 40 x 7/9Ah batteries with 80 x 7/9Ah batteries Max. sub-rack capacity Dimensions (WxHxD) 448x310x565 (7 HU) 448x487x735 (11 HU) 448x665x735 (15 HU) (with front mounting wings)

  • Page 74: Ups Module Characteristics

    9: Specification RI-40 Configuration Max. 4 modules (10 or 20 kVA) accommodates: Max. sub-rack capacity Dimensions (WxHxD) 448x798x735 (18 HU) (with front mounting wings) 482x798x735 (18 HU) Weight of empty frame Weight of frame with 124 up to 136 modules and w/o batteries (with 4 modules) UPS Module characteristics Mechanical...
  • Page 75 9: Specification Output characteristics 10 kVA UPS module 20 kVA UPS module Output rated power per module cosφ 0.8 Output rated power per module cosφ 1.0 Output current in @ cosφ 1.0 (400 V) 14.5 Output rated voltage 3x380/220V or 3x400/230V or 3x415/240V Output voltage stability Static: <...

  • Page 76: Battery Characteristics

    9: Specification Environmental Characteristics 10 kVA UPS module 20 kVA UPS module Audible noise with 100% / 50% load 55 / 49* 57 / 49* Operation temperature °C 0 – 40 Ambient temperature for batteries °C (recommended) Storage temperature °C -25 - +70 Battery storage time at ambient temperature Max.

  • Page 77: Communication Options

    9: Specification Communication Options Communication options (All systems) Module control panel LCD display 1 x LCD display fitted to module control panel of each module RJ45 Plug (Not used) RJ45 Plug (for future options) Customer interfaces: outputs 5 Voltage free contacts DRY PORT X2 For remote signalling and automatic computer shutdown Customer interfaces: inputs...
  • Page 78 9: Specification TS_615_01 PowerWAVE 8000DPA RI (S2) User Manual 8/6/20...

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