Kohler MF1500DPA User Manual
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Kohler MF1500DPA User Manual

Kohler MF1500DPA User Manual

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  • Page 2 TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...
  • 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_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...
  • Page 5 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. All repaired or replaced parts will remain the property of Kohler Uninterruptible Power Ltd..
  • Page 6 TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...

  • Page 7: Table Of Contents

    Safety 1.1 Description of symbols used in this manual 1.2 User precautions 1.3 Declaration of Safety conformity and CE marking General Description 2.1 Introduction 2.2 Model range 2.2.1 Cabinet construction 2.2.2 System expansion and parallel cabinets 2.3 Parallel module operation 2.3.1 Parallel control in a single cabinet 2.3.2 Control in a parallel-cabinet system 2.3.3 ‘Capacity’...
  • Page 8 4.3.4 Battery cabling 4.3.5 Control cables 4.3.6 Fuse & cable sizing 4.3.7 Input/output supply protection Installation Procedure 5.1 Introduction 5.2 Taking receipt of the UPS 5.2.1 Reporting transportation damage 5.2.2 Local transportation 5.2.3 Storage 5.3 Unpacking 5.4 1500 kVA Cabinet installation 5.4.1 Cabinet installation kit 5.4.2 Joining the cabinets 5.4.3 Connecting the busbars...
  • Page 9 7.1 Introduction 7.2 User responsibilities 7.3 Routine maintenance 7.4 Battery testing Troubleshooting 8.1 Introduction 8.1.1 Alarms 8.1.2 Events log 8.2 Troubleshooting procedure 8.3 Troubleshooting table 8.4 Contacting service Options 9.1 UPS Communications panel 9.2 Communications interface 9.2.1 Input dry port (X1) 9.2.2 Output dry port (X2) 9.2.3 Battery temperature sensor (X3) 9.2.4 MODBUS Communications bus (X4)
  • Page 10 TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...

  • Page 11: Safety

    WARNING: Do not open or remove the UPS covers. You run a risk of exposure to potentially lethal voltages if you open or remove the UPS covers! All servicing must be performed by a Kohler Uninterruptible Power Ltd. approved engineer.

  • Page 12: Declaration Of Safety Conformity And Ce Marking

    1: Safety Declaration of Safety conformity and CE marking The PowerWAVE MF1500 DPA UPS system is designed and manufactured in accordance with Quality Management Systems standard ISO 9001 / EN 29001. 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 13: 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 will provide your critical equipment with a steady and reliable power supply for many years.

  • Page 14: Model Range

    2: General Description Model range PowerWAVE MF1500 DPA 1000 kW Frame The 1000 kW cabinet comprises a distribution frame and frames for four UPS modules. The distribution frame can be positioned on either the left or right of the UPS module frames but must be stipulated when placing an order. SYSTEM SYSTEM UPS MODULE...
  • Page 15 2: General Description PowerWAVE MF1500 DPA 1500 kW Frame The 1500 kW cabinet comprises a distribution frame and frames for six UPS modules. The distribution frame is positioned in the centre of the cabinet. SYSTEM CONTROL PANEL UPS MODULE CONTROL PANEL (x6) Module 01 Module 03...

  • Page 16: Cabinet Construction

    2: General Description 2.2.1 Cabinet construction UPS MODULE MODULE CONTROL PANEL INSERTION HANDLES POWER LOCKING HANDLE MODULE SLIDER Figure 2.3 UPS module insertion The system input, output and battery power cables are connected to busbars located in the ‘distribution frame’ which then run across the back of the cabinet to the module frames.
  • Page 17 2: General Description Figure 2.4 Power locking handle OFF (open) Figure 2.5 Power locking handle ON (closed) TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...

  • Page 18: System Expansion And Parallel Cabinets

    2: General Description 2.2.2 System expansion and parallel cabinets Some UPS applications initially present a low power requirement which increases over time as the application grows. It is therefore essential that an installed UPS system can be expanded to meet a growing load demand without compromising the existing load.

  • Page 19: Parallel Module Operation

    2: General Description Parallel module operation Communications UPS Power Interface Board (CIB) blocks System Battery Cont. Panel Input/output Dry-port Supplies Volt-free UPS Control system Outputs contacts for Power (data collection) remote alarms Contactors Dry-port panel or BMS Inputs UPS Module 1 Server (PC) Data I/O UPS Power...

  • Page 20: Control In A Parallel-Cabinet System

    2: General Description 2.3.2 Control in a parallel-cabinet system External parallel interface bus (ring connection) Cabinet 2 Cabinet 1 [First] Cabinet 3 Figure 2.7 Parallel cabinet system A parallel-cabinet system requires the same inter-module parallel control mechanisms as that just described for a single cabinet installation.

  • Page 21: Functional Description Of Operation

    2: General Description Functional description of operation This section contains: • a functional description of the MF1500 DPA at block-diagram level (see paragraph 2.4.1) • a description of the UPS module operating modes (see paragraph 2.4.2) • a description of the UPS system operational modes – ‘On-line’ versus ‘Off-line’ operation (see paragraph 2.4.3) 2.4.1 PowerWAVE MF1500 DPA module block diagram Figure 2.8 illustrates an internal block diagram of a single UPS module inserted into the MF1500 DPA cabinet rack.
  • Page 22 The maintenance bypass switch shown in Figure 2.8 is an optional, but widely used, external wrap-around facility that enables the load to be connected to a raw mains supply while the entire PowerWAVE MF1500 DPA cabinet is powered down. The Maintenance Bypass facility is bespoke but a suitable solution can be provided by Kohler Uninterruptible Power Ltd.

  • Page 23: Ups Module Operating Modes

    2: General Description 2.4.2 UPS Module operating modes This sections uses simplified block diagrams to illustrate the three main UPS module operating modes. Note that the module internal fuses and some contactors have been omitted for reason of clarity, however the inverter output relay remains shown.

  • Page 24: Ups System Operating Modes

    2: General Description Load on bypass In the ‘load on bypass’ mode the inverter is turned off and the static switch connects the Static bypass line STATIC load to the unprotected static bypass line. SWITCH This mode can be selected manually (see ‘ECO Mode’...

  • Page 25: Xtra Vfi

    2: General Description Inverter fault If a UPS module experiences an internal fault (or is turned off) while it is operating ‘on inverter,’ its inverter output relays will open. The system response will depend on the prevailing system redundancy. If the number of ‘healthy’ modules remaining connected to the system is sufficient to power the applied load demand then the system will continue to operate in the ‘on inverter’...
  • Page 26 Kohler Uninterruptible Power Ltd. trained engineer. Once set, the ‘Xtra VFI’ configuration will not require further attention unless there is a significant change in load usage.
  • Page 27 2: General Description Examples Consider a 6x 250 kW module system (1500 kW capacity): Conditions # Active modules Comments Load = 500 kW 3 (750 kW capacity) 3 modules can be used for 500 kW (N+1). Redundancy = 1 module The redundant module provides a sufficient headroom to handle HSL (and below) = 100 kW the 100 kW HSL when required.

  • Page 28: Module Control Panel

    2: General Description Module Control Panel A module control panel is fitted to the front of each UPS module. It allows the module to be individually controlled and monitored, and comprises an ON/OFF button, LED status indicators, LCD display and control/navigation buttons. BYPASS LED ON/OFF BUTTON RECTIFIER LED...

  • Page 29: Lcd Display

    2: General Description 2.5.3 LCD Display During normal operation the module control panel LCD display appears as shown in Figure 2.16. The screen enters MODULE LOCATION (ID) a screensaver mode, which turns off the background OPERATING illumination, after 5 minutes of control button inactivity. STATUS Screensaver mode is deactivated when any control button is pressed or an alarm is activated.

  • Page 30: Module Control Panel Menu Configuration

    2: General Description 2.5.5 Module control panel menu configuration BATTERY EVENTS LOG Runtime (hh:mm): [EVENT 01 DESCRIPTION] dd‐mm‐yy       hh:mm:ss      0xnnnn Charge level (%): OUTPUT [EVENT 01 DESCRIPTION] MAIN MENU dd‐mm‐yy       hh:mm:ss      0xnnnn Voltage (V): Voltage (V): [EVENT 01 DESCRIPTION] Event log dd‐mm‐yy       hh:mm:ss      0xnnnn Current (A): Current (A): Measurements MEASUREMENTS Frequency (Hz): Conv. Temperature (°C): Commands Battery COMMANDS Batt. Temperature (°C): UPS data Load to inverter Output Setup user Load to bypass Output power OUTPUT POWER Setup service Perform battery test...

  • Page 31: Ups Communication Facilities

    2: General Description – [Perform alarm test] activates the ‘common’ alarm. Used mainly during commissioning to check the alarm interface with an external alarm panel or BMS system. The alarm will automatically clear after five minutes. UPS DATA – This is a read-only menu and shows the UPS build and revision details input by the manufacturer/ commissioning engineer.

  • Page 32: Communications Interface Board

    The input to this port is programmable and can be customised according to the customer’s requirements. All customisation must be carried out in the factory, before despatch. Battery temperature sensor input X3 – for use with the standard battery sensor option offered by Kohler Modbus communication power X4 – differential 5V RS485 signals CAN bus communication port X5 –...

  • Page 33: Parallel Interface Board

    2: General Description 2.6.2 Parallel interface board The inter-module and inter-cabinet parallel control bus functions are described in paragraph 2.3. Figure 2.21 UPS module parallel bus connectors The UPS cabinet’s internal parallel control bus is connected between the parallel interface board and each UPS module in a ring-like configuration.

  • Page 34: High Voltage I/O Interface

    2: General Description 2.6.3 High voltage I/O interface Figure 2.23 High Voltage I/O Interface High voltage interface connections can be made to terminal blocks X12, X13, X14 which are located below the high voltage test point panel, as shown in Figure 2.19 and Figure 2.23. WARNING: There is a risk of exposure to lethal voltages when the high voltage I/O terminals are exposed.

  • Page 35: System Control Panel

    System Control Panel Introduction Figure 3.1 System control panel default display The system control panel is located on the door of the cabinet’s distribution frame. In a parallel-cabinet MF1500 DPA UPS system the system control panel is fitted to the cabinet that is configured as the ‘master’ cabinet – i.e. the cabinet that contains the master UPS module [Module 1-01].

  • Page 36: Display Header Bar

    3: System Control Panel 3.1.1 Display header bar Figure 3.2 illustrates the display header bar that is presented at the top of every screen. It contains number of touch- sensitive icon buttons and also displays some key system status information. Home button Accesses the HOME screen from any other screen (see paragraph 3.2).

  • Page 37: Home Screen

    3: System Control Panel HOME screen The HOME screen is accessed by pressing the Home icon on the display header bar. At the bottom of this screen are six touch-sensitive buttons that provide access to various monitoring, control and set-up function screens. Events Displays a list of recently occurred events with date, time, event name, description and sequential ID number.

  • Page 38: Measures

    3: System Control Panel 3.2.2 Measures Pressing the HOME screen Measures button will open the MEASURES screen, shown here, which displays the working values of various UPS, Battery and Xtra VFI operating conditions. You can select the parameters to be displayed by pressing the UPS Meas, Battery and Xtra VFI buttons on the left side of the screen.

  • Page 39: Commands

    3: System Control Panel Measures summary UPS Measurements Output Voltage (V) Output Current (A) Output Frequency (Hz) Output Power (%) Active Power (kW) Reactive Power (kVAr) Apparent Power (kVA) Inverter Voltage (V) Bypass Voltage (V) Bypass Frequency (Hz) Rectifier Voltage (V) Bypass Temperature ( Battery Measurements Discharge Current (A)

  • Page 40: Mimic Screen

    3: System Control Panel MIMIC screen The MIMIC screen is the default screen shown on the system control panel during normal operation. It shows the path of the power flowing through the UPS system and provides basic input, battery and output metering. This screen can also be accessed by pressing the Mimic button on the display header bar or by pressing a particular UPS Module icon button on the MODULE SELECTION screen (see paragraph 3.5).

  • Page 41: Mimic Screen Indications

    3: System Control Panel 3.3.1 MIMIC screen indications Key Point: The input mains (L1) and bypass mains (L2) are shown as separate connections on the mimic diagram; however, these two inputs are connected to a common input mains supply in the distribution frame. The status of the major UPS power blocks and power paths is colour-coded as follows: GREEN: ACTIVE –...
  • Page 42 3: System Control Panel ON-BYPASS This mimic indicates that the load is being supplied via the static bypass line, and it is the normal indication if the system is operating in ‘ECO’ mode. If the system is not set to operate in ECO mode, this state indicates that the load has Load either been:...

  • Page 43: Metering From The Mimic Screen

    3: System Control Panel 3.3.2 Metering from the MIMIC screen On the MIMIC screen, the icons representing the rectifier, inverter, static bypass and battery power blocks also act as touch-sensitive buttons which, when pressed, open a version of the MEASURES screens related to the selected power block.

  • Page 44: Xtra Vfi Screen(S)

    3: System Control Panel XTRA VFI screen(s) There are two screens directly related to the Xtra VFI function; the XTRA VFI STATUS BAR screen and the ‘XTRA VFI MEASURES’ screen. These can be accessed by pressing the Xtra VFI button on the display header bar, which is only visible if the Xtra VFI function is enabled.
  • Page 45 3: System Control Panel Figure 3.18 Xtra VFI measures screen The ‘XTRA VFI MEASURES’ screen, which can also be access by pressing the Measures button on the HOME screen, provides numerical data concerning the Xtra VFI module status and saved energy, and is described in detail on page 28. ON-STANDBY This mimic indicates that the inverter is operating on Standby as part of the Xtra...

  • Page 46: Module Selection Screen

    3: System Control Panel MODULE SELECTION screen The module selection screen, shown below, is accessed by pressing the Module Selection button on the display header bar. On opening, the MODULE SELECTION screen displays an icon for each UPS module installed in the system and immediately indicates its operational status by means of its displayed colour.

  • Page 47: Installation Planning

    PowerWAVE MF1500 DPA UPS system. Key Point: If you are installing an external battery cabinet or battery rack supplied by Kohler Uninterruptible Power Ltd. you should refer to the manual that is provided with the cabinet for installation instructions.
  • Page 48 4: Installation Planning Distribution UPS 1 UPS 2 UPS 3 UPS 4 UPS 5 UPS 6 Frame Cabinet Dimensions (WxHxD) 3045 x 2000 x 1000 (mm) Min. Clearance 0.0 mm 0.0 mm 100 mm 1555 mm min 95º 500mm Distribution UPS 1 UPS 2 UPS 3...

  • Page 49: Floor Fixings

    UPS cabinets to minimise the length of the DC cable runs. The battery cables should be sized to compensate for the DC voltage drop between the battery installation and UPS – contact Kohler Uninterruptible Power Ltd. for installation advice and technical support if necessary.
  • Page 50 4: Installation Planning 2228 Dist. Frame Dist. Frame Module 1 Module 1 Module 2 Module 2 Module 3 Module 3 Module 4 Module 4 2228 Module 1 Module 2 Module 3 Module 4 Dist. Frame 3042 Module 1 Module 2 Module 3 Dist.

  • Page 51: Electrical Planning

    4: Installation Planning Electrical planning The information in this section should help with the preparation and planning of the UPS power cabling. Key Point: All cable containment provisions should be completed (and cables laid if necessary) before the cabinet is placed in its final position. This is especially relevant if the cabinet is to be installed with no rear or side access.
  • Page 52 The MBP is bespoke and may be contained in a dedicated switchgear cabinet or fitted to a pre-existing switch panel. Kohler Uninterruptible Power Ltd. can supply a range of MBP switchgear.
  • Page 53 4: Installation Planning Load A Load C Load B 415V Utility Supply OUTPUT DIST. PANEL MAINS SWITCHBOARD System Input System Device Output Device Maint. Bypass Switch System System Input Output Switch Switch EXTERNAL MAINTENANCE BYPASS PANEL UPS CABINET 1 Distribution Frame UPS Cab.
  • Page 54 4: Installation Planning Input neutral grounding A permanently connected input neutral is required to enable the rectifier to function correctly and provide the inverter with a neutral reference when the input mains supply is unavailable and the UPS is operates from battery power.

  • Page 55: Power Cabling Options

    4: Installation Planning 4.3.2 Power cabling options The UPS input mains, output supply and battery power cables are connected to busbars fitted in the distribution frame and fully accessible from the front of the cabinet. The busbar connections are identified on a label attached to the inside of the distribution frame door, as shown in Figure 4.9 (TOP).
  • Page 56 4: Installation Planning Figure 4.10 AC & DC Top cable entry Figure 4.11 AC Top & DC Bottom cable entry TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...
  • Page 57 4: Installation Planning Figure 4.13 DC Top & AC Bottom cable entry Figure 4.12 AC & DC Bottom cable entry TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...

  • Page 58: Battery Configuration

    4: Installation Planning 4.3.3 Battery configuration The previous illustrations show three sets of battery connection busbars (red & dark blue) located on each side of the distribution frame. These busbars are connected to the modules’ DC connections using flexible busbars to enable various battery configurations to be used.
  • Page 59 4: Installation Planning Common battery configuration Figure 4.15 illustrates a plan view of the battery busbars in the distribution frame and shows the busbar annotations when connected in the ‘common battery’ configuration. In this configuration the battery positive and negative busbars on both sides of the distribution frame are fitted with common shorting links (busbars), as shown.

  • Page 60: Battery Cabling

    The DC cables and battery fuses/breakers are bespoke to the installation and the cable/fuse ratings depend on the battery type, quantity and configuration. All DC cables and fuses are provided by Kohler Uninterruptible Power Ltd., however the DC cable containment method should be taken into account when planning the UPS installation and the cables pre-laid where necessary.

  • Page 61: Fuse & Cable Sizing

    • The UPS must be installed to prescribed IEC or local regulations (e.g. BS7671). • The DC cables and battery fuses/breakers are bespoke to the installation and are provided by Kohler Uninterruptible Power Ltd., and the ratings shown on the following pages are for guide reference only.

  • Page 62: Installation Procedure

    WARNING: The customer installation team should not install the batteries or connect the DC cables between the UPS cabinet(s) and battery system. This MUST be carried out by a Kohler Uninterruptible Power Ltd. trained engineer and is usually completed during commissioning.

  • Page 63: Reporting Transportation Damage

    WARNING: If the TiltWatch/ShockWatch indicators indicate that the equipment has been tilted or dropped in transit DO NOT connect the equipment to the mains electricity supply. You must inform the carrier and Kohler Uninterruptible Power Ltd. immediately if the TiltWatch/ShockWatch indicators are red, or there are other signs of suspected transportation damage.

  • Page 64: Unpacking

    5: Installation Procedure Unpacking Removing the module extraction slider packaging (see Figure 5.2) A module extraction slider is required to insert or remove a UPS module from the cabinet frame. Unpack the module extraction slider following the illustrations in Figure 5.2. Figure 5.2 Module extraction slider packaging Removing the standard UPS cabinet packaging (see Figure 5.3) Note: Store the packaging for later use in case the cabinet has to be returned...
  • Page 65 5: Installation Procedure Nails or Staples Figure 5.3 Unpacking the UPS cabinet (standard packaging) TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...

  • Page 66: 1500 Kva Cabinet Installation

    (see Figure 5.4). WARNING: This procedure must be performed or supervised by a service engineer trained by Kohler Uninterruptible Power Ltd. or one of its service agents. WARNING: This procedure requires handling heavy components that can cause injury if not done correctly.

  • Page 67: Joining The Cabinets

    5: Installation Procedure 5.4.2 Joining the cabinets Ensure that all packaging materials have been removed. Move the two cabinet frame assemblies as close as possible to their intended final location and position them adjacent to each other on level ground (see Figure 5.5). Allow at least 600 mm rear access to enable the reassembly. Note: The two halves of the cabinet are identified as ‘Frame A’...
  • Page 68 5: Installation Procedure Remove all three of the UPS modules (if fitted) from Frame A as follows: a) In Frame A, place a module extraction slider in front of the UPS module with the runners on the top of the slider aligned to the runners in the module’s frame, as shown in Figure 5.5 (C).
  • Page 69 5: Installation Procedure Move the Frame A so that it is adjacent to Frame B. (see Figure 5.8), taking care not to trap the control cables at the top of Frame A between the frames – see Figure 5.13 (C). Ensure the two frame are correctly aligned.
  • Page 70 5: Installation Procedure Figure 5.10 Connecting the frames TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...
  • Page 71 5: Installation Procedure Connect together the adjoining frame front pillars using five M5x12mm self-threading bolts (supplied,) as shown in Figure 5.10 (B). 10. Connect together the adjoining frame back pillars using five M5x12mm self-threading bolts (supplied), as shown in Figure 5.10 (C). 11.

  • Page 72: Connecting The Busbars

    5: Installation Procedure 5.4.3 Connecting the busbars From the back of the cabinet, insert 16x flexible busbars links between the power busbars in Frame A and Frame B, as shown in Figure 5.12 (A). Secure the flexible busbars using 32x M8 nuts (supplied) but do NOT tighten them.

  • Page 73: Connecting The Control Cables

    5: Installation Procedure 5.4.4 Connecting the control cables The two parallel bus control cables emerging from A– Frame A, shown in Figure 5.13 (C), must be connected to the communications interface board located at the top front of the distribution frame in Frame B.

  • Page 74: Final Positioning

    5: Installation Procedure 5.4.5 Final positioning Once Frames A & B, power busbars and the parallel bus control wiring are connected, the cabinet can be moved to its final position using two forklifts or pallet trolleys inserted into the cabinet front. Key Point: If the cabinet is to be secured to the floor ensure that the holes in the cabinet feet align accurately with any prepared fixings.

  • Page 75: 1000 Kva Cabinet Installation

    The configuration must be stipulated at the time of order as it cannot be changed on-site. WARNING: This procedure must be performed or supervised by a service engineer trained by Kohler Uninterruptible Power Ltd. or one of its service agents.

  • Page 76: Electrical Installation

    When the electrical installation is complete the UPS system must be commissioned by an engineer authorised by Kohler Uninterruptible Power Ltd. before it is powered up and brought into use. WARNING: Do not apply electrical power to the UPS before it has been commissioned.
  • Page 77 X7.PE X7.PE 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 78 5: Installation Procedure UPS OUTPUT X2.1 (L1) X2.2 (L2) X2.3 (L3) X6 (N) INPUT MAINS X6 (N) X7 (PE) X3.3 (L3) X3.2 (L2) X3.1 (L1) BATTERY X5.1 (+) X5.2 (-) UPS OUTPUT X2.1 (L1) X2.2 (L2) X2.3 (L3) X6 (N) INPUT MAINS X6 (N) X7 (PE)
  • Page 79 5: Installation Procedure UPS OUTPUT X2.1 (L1) X2.2 (L2) X2.3 (L3) X6 (N) INPUT MAINS X6 (N) X7 (PE) X3.3 (L3) X3.2 (L2) X3.1 (L1) BATTERY X501.1 (+) X501.2 (-) X502.1 (+) X502.2 (-) X503.1 (+) X503.2 (-) X504.1 (+) X504.2 (-) UPS OUTPUT X2.1 (L1)

  • Page 80: Operating Instructions

    Operating Instructions Introduction The PowerWAVE MF1500 DPA 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 81: External Maintenance Bypass Switch

    6: Operating Instructions 6.2.2 External maintenance bypass switch The UPS cabinet does not contain any input or output power switches or circuit breakers: these are usually incorporated in a UPS SYSTEM UPS SYSTEM INPUT SUPPLY OUTPUT SUPPLY bespoke external maintenance bypass facility such as the example shown for a single cabinet installation in Figure 6.2.
  • Page 82 6: Operating Instructions MODULE POWERED DOWN ON MAINTENANCE BYP ON STATIC // MAINTENANCE BYP ON BYPASS (ECO) ON INVERTER Figure 6.3 Operating procedure transitions TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...

  • Page 83: How To Start The Ups System From A Fully Powered Down Condition

    6: Operating Instructions How to start the UPS system from a fully powered down condition Initial conditions: This procedure assumes the following initial conditions: • The load is fully powered down. • The external maintenance bypass switch (Q1) is open. •...

  • Page 84: Transfer The Load To Static Bypass

    6: Operating Instructions 11. Close the external UPS output switch Q2. a) Verify that Q1 and Q2 both indicate CLOSED. Note: The connected load is now being powered via the static bypass in parallel with the maintenance bypass. 6.3.3 Transfer the load to static bypass 12.

  • Page 85: How To Start The Ups System From The Maintenance Bypass

    6: Operating Instructions How to start the UPS system from the maintenance bypass Summary This procedure describes the sequence of actions required to re-start the UPS system if it had been shut down for operational reasons whilst supporting the load via the unprotected maintenance bypass supply. This is very similar to the previous procedure, "How to start the UPS system from a fully powered down condition", except that in this case the maintenance bypass switch is already closed, making load power is already available.

  • Page 86: How To Transfer The Load From Inverter To The Maintenance Bypass

    6: Operating Instructions How to transfer the load from inverter to the maintenance bypass Summary It may be necessary to transfer the load to the maintenance bypass supply to perform certain service or maintenance operations – for example, when replacing a UPS module in a capacity (non-redundant) rated system. This procedure is normally carried out by a trained service engineer and is not usually part of the day-to-day management of the UPS system.

  • Page 87: Transfer The Load To Maintenance Bypass

    6: Operating Instructions 6.5.2 Transfer the load to maintenance bypass Close the maintenance bypass switch (Q1). The load is now being powered through the maintenance bypass switch in parallel with the UPS static bypass, and the module control panel mimic should appear as shown here. On the module control panel verify that: a) The operating status shows BYPASS MODE.

  • Page 88: How To Completely Shut Down The Ups System

    6: Operating Instructions How to completely shut down the UPS system Summary 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 disconnected.

  • Page 89: Operating In Eco Mode

    6: Operating Instructions Operating in ECO mode Summary When operating the UPS system in ECO mode, the load is normally powered through the UPS bypass supply and automatically switches over to inverter mode if the bypass supply fails. If the bypass supply then returns to normal while the UPS is operating in inverter mode it will automatically transfer back to bypass mode.

  • Page 90: Load Transfer Using The System Control Panel

    6: Operating Instructions To transfer the UPS system from inverter mode to bypass mode On the module control panel of any UPS module: a) Press the UP key once to access the menu system. b) Use the UP/DOWN keys to move the cursor so that it is adjacent to COMMANDS then press the ENTER key. Use the UP/DOWN keys to move the cursor so that it is adjacent to LOAD TO BYPASS then press the ENTER key The UPS will transfer the load to the static bypass, and the module control panel mimic should appear as shown here.

  • Page 91: Individual Module Stop/Start Procedure (Redundant System Only)

    6: Operating Instructions Individual module stop/start procedure (redundant system only) Summary If the UPS system is operating with module redundancy one module can be turned OFF without affecting the overall system operation. Situations where this might be put into effect are usually managed by a qualified service engineer when undertaking service checks or module replacement.

  • Page 92: Cold Start

    6: Operating Instructions Cold start Summary The ‘cold start’ feature allows a UPS module to be started using battery power without the presences of the UPS input mains supply – i.e. when the UPS is turned OFF. As the battery is immediately placed on load when starting in this manner the UPS run time is limited unless the input mains supply is restored.

  • Page 93: Maintenance

    Preventative maintenance inspections form an integral part of all Extended Warranty Agreements (maintenance contracts) offered by Kohler Uninterruptible Power Ltd. – see the extended warranty information at the front of this manual. A preventative maintenance inspection carried out as part of an Extended Warranty Agreement typically includes the following checklist: •...

  • Page 94: Troubleshooting

    Troubleshooting Introduction A number of internal and external UPS parameters and conditions are monitored and any changes are recorded in the UPS module’s ‘event log.’ These include changes in the UPS operating mode (e.g. ‘Manual byp is closed’), abnormal operating conditions (e.g. ‘Mains bypass fault’) or direct UPS faults (e.g. ‘Inv. Phase fault’). Most abnormal and fault conditions are accompanied by an audible warning and an ‘alarm’...

  • Page 95: Troubleshooting Procedure

    Kohler Uninterruptible Power Ltd. Service Department. Note and record any available information that might help diagnose the problem.

  • Page 96: 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 97: Options

    Options UPS Communications panel Communications Interface Board Parallel Interface Board High Voltage Interface Board High Voltage Test Point Panel Figure 9.1 External interface facilities A communications panel located near the top of the distribution frame contains a number of interface facilities that can be divided into three functional areas, as depicted in Figure 9.1.

  • Page 98: Communications Interface

    9: Options Communications interface Dry port inputs +24 Vdc output Dry port outputs Dry port outputs (configurable) Battery temperature sensor Dry port outputs (configurable) MODBUS communications port Serial RS-232 CAN BUS communications port System control panel Analog input port Laptop USB serial interface Dry port inputs (configurable) SD Card Not used...
  • Page 99 9: Options Communications UPS Power Interface Board (CIB) blocks System Battery Cont. Panel Input/output Dry-port Supplies Volt-free UPS Control system Outputs contacts for Power (data collection) remote alarms Contactors Dry-port panel or BMS Inputs UPS Module 1 Server (PC) Data I/O RS232/485 etc UPS Power Interface...

  • Page 100: Input Dry Port (X1)

    9: Options The effects of multidrop on the dry port interface connections In a multi-cabinet system the functionality of the input and output dry-ports are affected by multidrop, as follows: • In a multi-cabinet UPS system where ‘multidrop’ is not used: –...
  • Page 101 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 102: Output Dry Port (X2)

    Signal Function X3 /2 Battery temperature Only use the battery temperature sensor supplied by Kohler Uninterruptible Power Ltd. X3 /1 +3.3 Vdc When fitted it displays the battery temperature on the module LCD display. The battery temperature sensor option can be used to regulate the battery charging current according to battery temperature (e.g.

  • Page 103: Modbus Communications Bus (X4)

    9: Options 9.2.4 MODBUS Communications bus (X4) Term Signal Function X4 /3 MODBUS This port is not currently implemented X4 /2 MODBUS RS485L X4 /1 MODBUS RS485H 9.2.5 CAN BUS Communications bus (X5) Function Term Can Bus RS485 X5 /3 CAN BUS This port is not currently implemented X5 /2...

  • Page 104: Configurable Input Dry Port (X8)

    9: Options 9.2.8 Configurable input dry port (X8) Term Contact Signal Function X8 / 8 CUSTOMER IN 8 X8 / 7 +24 Vdc X8 / 6 CUSTOMER IN 7 X8 inputs are used for customer-defined functions. These inputs are connected to volt-free switch contacts and can be X8 / 5 +24 Vdc configured by the commissioning engineer to be N/O or N/C according...

  • Page 105: Configurable Output Dry Port (X11)

    9: Options 9.2.11 Configurable output dry port (X11) Terminal Contact Function Relay X11 /12 CUSTOMER OUT 8 X11 /11 X11 /10 X11 /9 CUSTOMER OUT 7 X11 outputs are used for customer-defined functions. X11 /8 These outputs are switched by volt-free relay contacts and X11 /7 can be configured by the commissioning engineer to be N/O or N/C according to the function requirements.

  • Page 106: High Voltage Interface Board

    9: Options High voltage interface board The high voltage interface contains three connectors, X12, X13 and X14. These are located behind a safety cover adjacent to the high voltage test points. 9.3.1 High voltage configurable input dry port (X12) Term Contact Function X12 / 8...

  • Page 107: Parallel Interface

    9: Options Parallel interface Figure 9.7 Parallel interface board The parallel interface board is used to connect the external parallel bus cables between the UPS cabinets in a parallel- cabinet system, as described on page 9. The cables are supplied as part of the paralleling kit and will usually be connected by the commissioning engineer who will also set the parallel configuration DIP switches (SW1-SW3).

  • Page 108: Network Interface Card Slots

    9: Options Network interface card slots The communications panel contains two card slots that can be used with a range of network interface cards (NICs) to interface the UPS with a building management system or computer network (WAN/LAN). Using a suitable network interface card the UPS can be monitored and interrogated by the following protocols: •...

  • Page 109: 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 110: 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 111 9: Options UPS with Users Reporting software Batteries Site manager Server Email Alarm Event Data Battery Care & monthly report System Servers with Power REPORTER UPS Email software server Analyst Consultant specialists KUP 24Hr Help-desk Service co-ordinator UPS Service Engineer Figure 9.10 Remote monitoring communications chain TS_627_02 - PowerWAVE MF1500 DPA User Manual 21/4/22...

  • Page 112: Specification

    Specification 10.1 UPS Cabinet general specification 10.1.1 1000 kVA/kW Cabinet Number of UPS Modules System power rating (per cabinet) (kVA/kW) 1000 UPS type On-line, transformerless, modular, DPA Parallel cabinet capability (MVA/MW) 4.0 (up to 4 cabinets) Battery Bespoke. Housed externally. Performance specification VFI-SS-111 UPS Frame Dimensions (W x D x H) mm...

  • Page 113: Electrical Characteristics

    10: Specification 10.2 Electrical characteristics Input Characteristics 1000 kVA 1250 kVA 1500 kVA Input AC power distribution system compatibility (earthing system) TN-S, TN-C, TN-C-S Input AC power distribution system wiring 3ph + Neutral + PE Input rated short-time withstand current (Icc) 120 kA Additional information Single feed (rectifier and internal bypass fed by separate circuits...

  • Page 114: 10.3 Battery

    10: Specification Efficiency 1000 kVA 1250 kVA 1500 kVA Double conversion efficiency –100% load 96.5% Double conversion efficiency –75% load 97.0% Double conversion efficiency –50% load 97.4% Double conversion efficiency –25% load 97.3% Static Bypass Characteristics 1000 kVA 1250 kVA 1500 kVA Rated current –...

  • Page 115: 10.4 Environmental And Standards

    10: Specification 10.4 Environmental and standards Environmental UPS Cabinet operating temperature range 0 to 40°C (recommended +20 to +25°C) Relative humidity range < 95% non-condensing Battery temperature VLRA, 20-25°C LIB, 18-28°C Storage temperature -25 to +70°C with humidity < 95% non-condensing Ideally storage between +5°C and +35°C at RH up to 75% Maximum altitude without derating 1000m...

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