Kohler PW 9000DPA User Manual Pioneering solutions for total power protection...
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Document Control ISSUE DATE REVISION SUMMARY 01-06-10 Initial issue. UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010...
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Kohler Uninterruptible Power 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.
UPS yourself. You run risk of exposure to dangerous voltages by opening or removing the UPS-covers! Kohler Uninterruptible Power will assume no responsibility nor liability due to incorrect operation or manipulation of the UPS. WARNING: The PowerWAVE 9000 DPA is a Class A UPS product (according to EN 50091- 2).
UPS solution. Kohler Uninterruptible Power specialises in the design, building, installation and maintenance of Uninterruptible Power Systems. This compact and powerful UPS is just one example of our wide range of state of the art power protection devices and will provide your critical equipment with a steady and reliable power supply for many years.
2: Description 2.3.2 Single/Multi cabinet configurations Single cabinet system A single-cabinet system comprises a stand-alone cabinet containing one or more UPS power module(s) operating as a single-module or module-module system (as defined in paragraph 2.3.1). Multi-cabinet system To further increase the overall system capacity it is possible to connect up to 10 standard cabinets in parallel. Depending on the model type, each cabinet can contain up to 5 UPS power modules, thereby potentially resulting in a system comprising up to 50 parallel modules if 10x UPGRADE DPA-125 or 10x UPGRADE DPA-250 cabinets are employed.
2: Description The high power factor presented by the UPS on the incoming mains supply minimises cabling and fusing costs due to the resulting lack of reactive power consumption. This, together with the accompanying low harmonic currents, provide the following benefits: •...
God or inappropriate application. If the UPS fails to conform to the above within the warranty period then Kohler Uninterruptible Power will, at its sole option, repair or replace the UPS. All repaired or replaced parts will remain the property of Kohler Uninterruptible Power.
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Other ..............(please specify) Thank you for your enquiry, which will receive our prompt attention. If you need to contact us immediately on +65 6264 6422 , or E-mail us on serviceUPS.sg@kohler.com www.kohlerups.sg UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010...
WARNING: All the operations described in this section must be performed by authorised electricians or suitably qualified personnel. Kohler Uninterruptible Power will take no responsibility for any personal or material damage caused by incorrect cabling or operations, or activities which are not carried out in strict accordance with the instructions contained in this manual.
20°C. If the UPS is delivered without batteries, Kohler Uninterruptible Power is not responsible for any damage or malfunctioning caused to the UPS by the incorrect storage, installation or connection of batteries by third parties.
3: Installation Storage 3.5.1 UPS If you plan to store the UPS prior to use, store it in a clean dry environment with a temperature between 5°C to +40°C and RH of less than 90%. If the packing container is removed, you must protect the UPS from dust. 3.5.2 Battery The UPS utilizes sealed, maintenance-free batteries, whose storage capability depends on ambient temperature.
3: Installation Battery Cabinet Front Front Clearance (mm) Minimum 200* 1000 *Rear access is essential for maintenance. Figure 3.1 UPS & Battery Cabinet Space Requirements UPS Power Cabling (preparation and planning) 3.7.1 General requirements It is the customer’s responsibility to provide all external fuses, isolators and cables used to connect the UPS input and output power supplies.
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3: Installation These illustrations show that the UPS cabinet requires the following power cables: Rectifier (In): • three-phase (1L1, 1L2, 1L3) • neutral (1N) • protective earth (PE) connection for the rectifier input Bypass (In): • three-phase (2L1, 2L2, 2L3) •...
3: Installation 3.7.2 Multi-cabinet installation cabling considerations In order to achieve equal load sharing between the UPS cabinets in a multi-cabinet installation, the input cables from the input distribution board to each UPS cabinet should be of equal length. Similarly the UPS output cables to the output distribution board should be of equal length (See Figure 3.3).
3: Installation Connecting the UPS input supply WARNING: Opening or removing the UPS enclosure covers will create the risk of exposure to dangerous voltages if power is connected to the UPS. 3.8.1 Safety notes Please ensure you read and understand the following safety notes before you begin the UPS electrical installation.
3: Installation Dual Input Feed Refer to the schematic drawing and connection table in Figure 3.6. The UPS is supplied (as standard) with facilities for a single cable feed for the rectifier and bypass supplies. For a dual feed configuration remove the links between 1L1 - 2L1; 1L2 - 2L2; 1L3 - 2L3 and 1N - 2N, on the input terminal block.
3: Installation 3.9.3 Connecting the UPS output cables To protect personnel during the UPS installation ensure that the connections are performed under the following conditions: a) No mains voltage is present. b) Loads are shut down and disconnected. The UPS is shut down and voltage-free. d) The UPS Maintenance Bypass Isolator IA1 is OFF.
3: Installation 3.9.4 Connection Terminal Details DPA-25 DPA-50 DPA-75 DPA-150 DPA-125 DPA-250 Single Input Dual Input Batts Input / Bypass Output Battery Input* Output* Separate Bypass Rectifier 3+N+PE FRAME (+ / N / -) +PE 3+N+PE DPA-25 DC Fuses and cables 4 x 10/16mm 5 x 10/16mm 5 x 10/16mm...
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3: Installation SINGLE INPUT FEED Mains (3x400/230V) Fuse A Cable A Rectifier Rectifier Rectifier Inverter Inverter Inverter Static Switch Static Switch Static Switch IA2-1 IA2-2 IA2-3 Upgrade BATTERY Maintenance Bypass IA1 Frame CABINET Cable D Load Power Single Input Output (kVA) (3 x 400V) (3x400V, 0.8 pf)
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3: Installation INPUT FEED BYPASS FEED Mains (3x400/230V) Mains (3x400/230V) Fuse B Fuse C Cable B Cable C Rectifier Rectifier Rectifier Inverter Inverter Inverter Static Switch Static Switch Static Switch IA2-1 IA2-2 IA2-3 BATTERY Maintenance Bypass IA1 CABINET Cable D Load Frame Power...
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3: Installation 9 10 11 12 X1-X4 Customer interface on Phoenix Terminals: X1 Customer Inputs X2…X4 = Potential free contacts SW1-9 Multi-Cabinet Configuration Switch JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter: JD5 Parallel BUS - Input Connector JD6 Parallel BUS - Output Connector JD11 RS232 / Sub D9/ female, PC interface JD12 RS232/ Sub D9 / male for Multidrop ONLY...
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3: Installation 9/9* X1-X4 Customer interface on Phoenix Terminals: X1 Customer Inputs X2…X4 = Potential free contacts SW1-9 Multi-Cabinet Configuration Switch JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter: JD5 Parallel BUS - Input Connector JD6 Parallel BUS - Output Connector JD11 RS232 / Sub D9/ female, PC interface JD12 RS232/ Sub D9 / male for Multidrop ONLY USB PC Interface...
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3: Installation 14 15 16 17 18 13 9/9* 11 12 X1-X4 Customer interface on Phoenix Terminals: X1 Customer Inputs X2…X4 = Potential free contacts SW1-9 Multi-Cabinet Configuration Switch JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter: JD5 Parallel BUS - Input Connector JD6 Parallel BUS - Output Connector JD11 RS232 / Sub D9/ female, PC interface...
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3: Installation 9 10 11 12 X1-X4 Customer interface on Phoenix Terminals: X1 Customer Inputs X2…X4 = Potential free contacts SW1-9 Multi-Cabinet Configuration Switch JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter: JD5 Parallel BUS - Input Connector JD6 Parallel BUS - Output Connector JD11 RS232 / Sub D9/ female, PC interface JD12 RS232/ Sub D9 / male for Multidrop ONLY...
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3: Installation 21 14 15 16 10 11 X1-X4 Customer interface on Phoenix Terminals: X1 Customer Inputs X2…X4 = Potential free contacts SW1-9 Multi-Cabinet Configuration Switch JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter: JD5 Parallel BUS - Input Connector JD6 Parallel BUS - Output Connector JD11 RS232 / Sub D9/ female, PC interface JD12 RS232/ Sub D9 / male for Multidrop ONLY...
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3: Installation 10/11 9/9* X1-X4 Customer interface on Phoenix Terminals: X1 Customer Inputs X2…X4 = Potential free contacts SW1-9 Multi-Cabinet Configuration Switch JD8 Parallel BUS connector Only for paralleling cabinets use optional adapter: JD5 Parallel BUS - Input Connector JD6 Parallel BUS - Output Connector JD11 RS232 / Sub D9/ female, PC interface JD12 RS232/ Sub D9 / male for Multidrop ONLY USB PC Interface...
3: Installation 3.10 Connecting the batteries 3.10.1 Safety Notes WARNING: Opening or removing the UPS enclosure covers will create the risk of exposure to dangerous voltages if power is connected to the UPS. The final assembly and connection of the battery units must be carried out by (or under the supervision of) the commissioning engineer.
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3: Installation EXTERNAL BATTERY CABINET UPS CABINET TO UPS Modules For reasons of clarity, the wiring for modules 1,3,5 only is shown in detail EXTERNAL BATTERY CABINET UPS CABINET TO UPS Modules Figure 3.14 External battery cabinet wiring (5-module UPS cabinet shown) 3-20 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010...
3: Installation 3.10.3 Connecting the battery cables WARNING: This procedure must be carried out by (or under the supervision of) the system commissioning engineer. Ensure that the UPS input/bypass supply isolators/fuses are open on the input distribution board and verify that no power is being fed to the UPS. Ensure that the MAINTENANCE BYPASS isolator (IA1) is open (OFF).
3: Installation 3.11.2 DPA-75 In a DPA-75 FRAME there is space for up to 180 x 9Ah internal batteries. Figure 3.16 shows the different battery and system configurations. The batteries may be wired as separate strings for each UPS-module or as a common battery for all three UPS-Modules.
3: Installation 3.11.4 DPA-150 In a DPA-150 FRAME there is space for up to 240 x 9Ah internal batteries. Figure 3.17 shows the different battery and system configurations. The batteries may be wired as separate strings for each UPS-module or as a common battery for all three UPS-Modules.
3: Installation CAUTION: In DPA 10kVA, DPA 15kVA, DPA 20kVA, 30-50 12V-battery blocks are permitted (even numbers only). In DPA 25kVA, DPA 30kVA and DPA 50kVA, 40-50 12V-battery blocks are permitted (even numbers only). The correct number of battery blocks is set up on Control Panel Menu: Service-Set-Up).
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3: Installation U P S-Cabinet 1 U P S-C abinet 2 U PS -Cabinet n-1 UPS -C abinet n P arallel Adaptor Parallel Adaptor P arallel Adaptor Parallel Adaptor Master-Slave Master-Slave Master-Slave Master-Slave Master-Slave Master-Slave Master-Slave Master-Slave SW 2-2 O utput Input SW 2-2 O utput...
3: Installation 3.14 Interfacing Facilities Each UPS cabinet contains an Interface Board which has a number of communications interface connectors that can be uses with a range of I/O options. 3.14.1 Interface Board The Interface board has two LEDs: • Green LED showing the status of the Interface: - Blinking: 2/sec = Interface is Master (1st Cab.
3: Installation 3.14.2 Smart Port (Serial RS 232) The SMART PORT is an intelligent RS 232 serial port that allows the UPS to be connected to a computer. The connector is a standard D-Type, 9-pin, male. When installed the optional SMART PORT software, WAVEMON allows the computer to monitor the mains voltage and the UPS-status continuously.
3: Installation Output Interfaces Terminal blocks X2, X3, X4 (DRY PORTs) Provides signals for the automatic and orderly shutdown of servers, AS400 or Automation building systems. Term Contact Signal Display Function X2/1 ALARM MAINS_OK Mains Present X2/2 Mains Failure X2/3 Common X2/4 Message...
The PowerWAVE 9000 DPA UPS is a high quality electronic machine that must be commissioned by a fully trained and authorised Kohler Uninterruptible Power field service engineer before being put into use. Commissioning the UPS involves connecting the UPS battery, checking the electrical installation and operating environment of the UPS, performing a controlled start-up and testing of the UPS system, and customer training.
4: Operation • Diagnostic (service mode) • Adjustments and testing (service mode) 4.2.2 Mimic LED indicators The mimic diagram indicates the status of the general UPS power flow and change colour between Green and Red (and OFF) to indicate the UPS operating conditions. (rectifier) and LINE 2 (bypass) indicate the availability status of the mains power supply.
4: Operation ON/OFF Start-up and shutdown buttons The UPS may be switched ON or OFF by simultaneously pressing both ON/OFF keys on the control panel. This is to prevent accidental UPS start-up or shutdown. When the UPS is under normal operation, pressing the two ON/OFF simultaneously will immediately Note: shutdown the UPS.
4: Operation 4.3.2 Main menu screen DESCRIPTION LCD-DISPLAY → EVENT LOG A log of the last 64 events is stored in the Power Management Display MEASUREMENTS (See paragraph 4.3.3). → MEASUREMENTS Allows monitoring of voltages, power, frequencies, currents, autonomy COMMANDS etc (See paragraph 4.3.4) →...
4: Operation DESCRIPTION LCD-DISPLAY OUTPUT VOLTAGE (V)0 Output Voltage (all three phases) 0.00 00.00 00.00 OUTPUT CURRENT (A)0 10. Output Current (all three phases) 0.00 00.00 00.00 ACTIVE POWER (KW) 11. Active Output Power (all three phases) 00.00 00.00 00.00 REACTIVE POWER (kVAr) 12.
4: Operation 4.3.7 Set-up User menu screen DESCRIPTION LCD-DISPLAY → SET LANGUAGE Set-up language SET DATE AND TIME ENGLISH FRANCAIS DEUTCH DUTCH SPANISH POLISH PORTOGUESE → SET-UP DATE/TIME Set-up Date and Time SET-UP BATT. TEST DD-MM-YY HH-MM-SS → SET-UP BATT. TEST Set-up battery test SET-UP GEN-SET OPER.
4: Operation Operating Modes 4.4.1 On-Line (Inverter) mode LINE 2 BY PASS Colour LINE 1 Green LOAD LINE 1 INVERTER LINE 2 Green BY PASS INVERTER Green BATTERY BATTERY Green When the UPS is operating in the On-Line mode the load is supplied through the LINE 1 (RECTIFIER) and INVERTER.
4: Operation 4.4.3 Maintenance Bypass mode Switch IA1 MAINTENANCE BYPASS MAINS LOAD Figure 4.2 Maintenance Bypass Mode Each module is fitted with a Maintenance Bypass switch (IA1) which, when closed, connects the UPS module output terminals directly to the UPS Bypass Mains supply. This facility enables a UPS module to be shut down for maintenance or repair whilst maintaining the load on the raw (unprotected) bypass supply.
4: Operation Operating Instructions Under normal operating conditions all the UPS modules in a multi-module system are running, and operating in the ‘On Line’ (On Inverter) mode. The following procedures are provided in this section: How to transfer the load to the Maintenance Bypass and shut down the UPS system for maintenance purposes –...
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4: Operation LINE 2 BY PASS Colour LOAD LINE 1 Green LINE 1 INVERTER LINE 2 Green BY PASS Green BATTERY INVERTER BATTERY Green Closing the Maintenance Bypass switch: Close the Maintenance Bypass switch IA1 (in all cabinets in a multi-cabinet system). On all UPS modules check and confirm that: a) The INVERTER LED has turned to red.
4: Operation 10. Open the Bypass Line fuse holder F2 and the Rectifier Line fuse holder F1. WARNING: The UPS cabinet is still live at its input and output power terminals due to the activation of Maintenance Bypass circuit. WARNING: Allow 10 minutes for the internal DC capacitors to discharge before touching any UPS internal components.
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4: Operation LINE 2 BY PASS Colour LINE 1 Green LOAD LINE 1 INVERTER LINE 2 Green BY PASS Green INVERTER BATTERY BATTERY Green When powering up a multi-module system ensure that ALL the modules are in the state shown above before continuing with this procedure.
4: Operation 11. The UPS is now operating in ‘On-Line’ mode. The load is protected and supplied by inverter power. 4.5.3 Complete system shutdown The UPS system may be shutdown completely if the load does not need input power for an extended period of time.
4: Operation 4.5.4 Individual module start/stop procedure If a multi-module system is designed with built-in redundancy, it is possible to stop and start one module without affecting the operational status of the overall system – e.g. one module can be taken off-line for servicing whilst the remaining modules maintain a protected load supply.
4: Operation Module shut-down: Use this procedure to power down a single module in a redundant module system. Simultaneously press the two ON/OFF buttons on the UPS control panel. a) The LED display will give the following indications: LINE 2 BY PASS Colour LINE 1...
4: Operation LINE 2 BY PASS Colour LINE 1 Green LOAD LINE 1 INVERTER LINE 2 BY PASS INVERTER BATTERY BATTERY Green Open the fused battery isolator for the UPS module in the UPS cabinet or in the external battery cabinet/ rack, as applicable.
4: Operation Replacing a UPS Module in a REDUNDANT Multi-Module System WARNING: All the operations in this section must be performed by authorised and trained personnel. By opening or removing the UPS modules and module covers you run risk of exposure to dangerous voltages! WARNING: When removing a UPS module wait for at least 2 minutes after it has been disconnected in order to alllow the DC Capacitors to fully discharge.
4: Operation 4.7.2 Inserting a UPS Module Remove the UPS module compartment protection cover (if fitted) by unscrewing four screws on the front. Using two persons to lift the UPS module, slide two thirds of the module into the UPS-compartment (make sure not to plug the UPS-Module into the rear connector).
4: Operation LINE 2 BY PASS Colour LOAD LINE 1 Green LINE 1 INVERTER LINE 2 Green BY PASS Green BATTERY INVERTER BATTERY Green Close Maintenance Bypass Switch IA1 (ON) On all modules check and confirm that: a) The INVERTER LED has turned to red. b) The BYPASS LED is green.
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4: Operation Tighten the four screws on the front of module to secure it to the UPS cabinet / frame. Connect the control panel cable to connector JD7. Start the UPS module and transfer the load from ‘Maintenance Bypass’ to ‘On Line’ mode (See paragraph 4.5.2).
Preventative maintenance inspections involve working inside the UPS which contains hazardous AC and DC voltages. WARNING: Only Kohler Uninterruptible Power trained and authorised field service engineers are fully aware of all of the hazardous areas within the UPS. During a preventative maintenance inspection the field service engineer will check: •...
The battery test procedure can be performed from the UPS front panel (See paragraph 4.3.5). Battery Maintenance The battery maintenance shall be done by an authorized Kohler Uninterruptible Power Service Partner. Battery Disposal and Recycling Batteries contain dangerous substances that will harm the environment if thrown away. If you change the batteries yourself, call qualified organizations for battery disposal and recycling.
Identify the cause of the alarm condition by means of the events register in the main menu (See paragraph 4.3.3). In case of doubt please contact your nearest service agent or call Kohler Uninterruptible Power on +65 6302 0708. Fault identification and rectification information is given on the following pages.
Maintenance Bypass Contacting Service Kohler Uninterruptible Power 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.
Kohler Uninterruptible Power offer a wide range of local and remote monitoring and control systems, offering maximum protection for computer systems. Figure 7.3 Monitoring screen image.
7: Options 7.4.2 Wavemon Shutdown and Monitoring Software Wavemon is an external monitoring and shutdown software which is designed to operate with many of Kohler Uninterruptible Power UPS products, both with the DRY PORT (Relays) on terminal block X2..X4 and RS232 port JD11 on the communication card.
7: Options • If the UPS is powering network hardware such as routers, then an SNMP adapter is necessary. Up to 50 computers can be shut down in a RCCMD (Remote Console Command) environment. RCCMD is an additional module, which executes a command in a distant system. SNMP CARD/ADAPTER For Network Management /Remote Monitoring The Simple Network Management Protocol (SNMP) is a worldwide-standardized communication-protocol.
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7: Options Internal SNMP Adapter .The Internal SNMP-Card can also be inserted into an appropriate expansion slot in the PowerWAVE 9000 Modules or Cabinet. This adapter communicates via the serial port of the UPS and makes a direct multiple server shut down possible without additional SNMP management software.
8: Specifications Input Characteristics Module Range Module Type Φ Output Rated Power per Module cos Φ Output Rated Power per Module cos Nominal Input Voltage 3x380/220V+N, 3x400V/230V+N, 3x415/240V+N Input Voltage Tolerance (-23%/+15%) 3x308/177 V to 3x460/264 V for <100 % load (ref to 3x400/230V) for Loads in %: (-30%/+15%) 3x280/161 V to 3x460/264 V for <...
8: Specifications Output Module Range Module Type DPA 10 DPA 15 DPA 20 DPA 25 DPA 30 DPA 40 DPA 50 Output Rated Power per Module 45 1) Output Rated Power per Module Φ 11.6 17.4 23.2 46.5 Output Current In @ cos 1.0 (400 V) Output Rated Voltage 3x380/220V or 3x400/230V or 3x415/240V...
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