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PowerWAVE 6000 Series 3 60

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1. Maintenance 4 3 4 4 4 5 5 1 5 2 5 3 5 4 Troubleshooting Options Specification 6 1 6 2 6 3 6 4 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 8 1 8 2 System shutdown to maintenance bypass System start up from maintenance bypass Individual module stop start procedure 4 5 1 Single module system and capacity parallel module system 4 5 2 Redundant parallel module system 4 5 3 Complete system shutdown Introduction User responsibilities Routine maintenance Battery testing Alarms LCD Control panel Troubleshooting table Contacting service Introduction Customer inputs X1 7 2 1 Remote shutdown Emergency Power Off 7 2 2 Generator ON facilities Customer outputs USB Serial RS232 Computer interface USB amp JD1 Smart Port RS485 Interface for multidrop SNMP Card slots WAVEMON Shutdown and monitoring software instead of SNMP card PowerREPORTER management software 7 8 1 Functional description General specifications 60 120kVA Fuses amp cables quick reference 39 40 41 41 43 44 45 45 45 45 46 47 47 47 48 48 49 49 50 50 51 51 52 52 53 55 55 57 57 61 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 14 1 Safety 1 Description of symbols used in this manual WARNING The warning symbol is used where there is danger of an electrical shock equipment damage or personal injury CAUTION The caution symbol is used to highlight
2. Figure 3 7 Dual feed input fuse and cable ratings 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 27 Uninterruptible Supplies Ltd ta 3 Installation KOHLER COMPANY 3 6 3 Power cable termination details All the UPS input output power cables are bolted to busbar terminals as illustrated in Figure 3 8 The table below details the maximum size of the cable terminations and the correct torque that should be applied to the termination bolts um en Bypass UT UPS Output e Tightening 3 N PE 3 N 3 N PE paa Torque Nm m 2x MB nM ave Sme 125 08 80kVA 2x M8 1x M8 am 5x M8 25D 400kVA 2x M8 1x M8 ete 5x M8 265 0410 420kVA 2x M8 1x M8 E 5x M8 zu UPS Power terminals UPS Output Bypass Supply 3 L1 3 L2 3 L3 2 L1 2 L2 2 L3 Neutral Input Supply 1 N 2 N 3 N 1 L1 1 L2 1 L3 Battery Negative BATT Protective Earth PE Battery Positive BATT 2 L1 2 L2 2 L3 Single Feed Input Links x3 1 L1 L lt Protective Earth 1 L2 1 L3 Figure 3 8 Input output and battery power terminals 28 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta KOHLER COMPANY 3 Installation 3 6 4 Power cabling in a parallel system In order to achieve equal load sharing between the various UPS cabinets in a multi cabinet insta
3. LINE 2 BY PASS LOAD LINE 1 INVERTER ini ENS BATTERY LINE 2 BY PASS a Ge RR l LOAD LINE 1 INVERTER E BATTERY LINE 2 BY PASS i LOAD LINE 1 INVERTER E BATTERY E Note This completes the procedure The UPS is now operating in on line mode and supply protected load power 42 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 Operation 4 5 2 Redundant parallel module system Module shutdown In a redundant parallel module system one module can be shut down without affecting the load supply provided the remaining modules are operating 1 A Turn OFF the UPS module by pressing both ON OFF buttons simultaneously then releasing them a The module control panel will display LOAD OFF and SUPPLY FAILURE b The module control panel mimic indications should be as shown here Open the module s parallel switch 1A2 Open the battery fuses breaker located in the external battery cabinet rack a The BATTERY led on the module mimic should change to flashing green b The module control panel mimic indications should be as shown here Open the UPS input isolator IA3 and bypass isolator IA4 a The module is now fully powered down Module start up 1 2 3 Close the UPS input isolator IA3 and bypass isolator IA4 Close the parallel switch IA2 Close the battery fuses breaker located in the external battery
4. c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key d The module control panel will display LOAD PROTECTED e The module control panel mimic indications should be as shown here LINE 2 BY PASS LOAD LINE 1 INVERTER EE BATTERY LINE 2 BY PASS Ee i LOAD LINE 1 INVERTER ENS BATTERY LINE 2 BY PASS RENI LOAD LINE 1 INVERTER ENSE BATTERY LINE 2 BY PASS LOAD LINE 1 INVERTER E BATTERY L T Note This completes the procedure The UPS is now operating in On Line mode and supplying protected load power 40 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta KOHLER company 4 Operation 4 5 Individual module stop start procedure 4 5 1 Single module system and capacity parallel module system Module shutdown In a single module or capacity rated parallel module system this action will automatically transfer the load to the bypass supply CAUTION Warn the critical load user that the load will not be supplied with processed backed up power when the UPS is operating on bypass When shutting down a single module installation if you want to maintain the load you should follow paragraph 4 3 System shutdown to maintenance bypass 1 Onthe UPS control panel press the ENTER key once to access the menu system Using the UP DO
5. maintenance bypass see operating instructions n a parallel module system the UPS module will shutdown and its output will be disconnected from the parallel load bus However the load may or may not transfer to bypass depending on whether or not the number of remaining live modules satisfies the system s redundancy i e if there are a sufficient number of modules remaining to support the system s 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 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 13 Uninterruptible Power Supplies Ltd 2 Description A KOHLER COMPANY 2 5 3 Power Management Display PMD The 2 x 20 character LCD Power management display simplifies communication with the UPS and also provides UPS monitoring information Status screens DESCRIPTION LCD DISPLAY 1 Load is protected by UPS power supplied by inverter normal operation LOAD Fed FROTECTED 2 Load is not protected by UPS power supplied by mains power load on bypass LOAD Fed HOT PROTECTED 3 Load supply interrupted UPS has been switched off by ON OFF buttons LOAD OFF Fed SUPPLY FAILURE 4 The UPS module is not supplying load LOAD DISCOMMEC TED Fai The output switch is open FARALLEL SiHITCH OPEN On the right hand side of the LCD Display there is a 3 digit indicator which shows a module s position in a multi module s
6. wooden crate is used for sea freight Good Upon receiving the UPS you should carefully examine the packing container for any sign of physical damage The external Tiltwatch indicators 2 off should be intact if the Bad equipment has been correctly transported in an upright position If the packaging has been ruptured in transit or if a Tiltwatch indicator is red inform both the carrier and Figure 3 1 Tiltwatch indicators Uninterruptible Power Supplies Ltd immediately shipping damage claims must be filed immediately when found and the carrier must be informed within a maximum of 7 days following receipt of the equipment If shipping damage is discovered you must store all packing materials for further investigation i CAUTION Claims for visible shipping damage must be notified to the carrier immediately on receipt Other Ensure that the received UPS equipment corresponds to the description indicated in the delivery note 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 20 Uninterruptible Supplies Ltd ta KOHLER COMPANY 3 Installation 3 2 1 Site transportation Please observe the following precautions when you transport the UPS equipment from the off loading site to its intended installation or storage location intended installation location e Donotat any time tilt the cabinet by more than 10 from vertical CAUTION Potential dangers e Ifthe UPS battery cabinet is tilted by more than
7. 10 it could cause internal damage lf tilting occurs do not connect the UPS to the mains electrical supply The weight of the UPS battery equipment can cause serious personal injury and or structural damage to the surrounding area if dropped in transit Always take extreme care when handling the equipment CAUTION Transportation A Do not remove the shipping packaging until the UPS Battery cabinet has been moved to its CAUTION Storage e Ifthe UPS is to be stored before installation it must be stored in its original shipping packaging e The recommended storage temperature for the UPS system and batteries is shown below 3 3 Storage UPS Cabinet If you plan to store the UPS cabinet prior to use it should be held it in a clean dry environment with a temperature between 25 C to 70 C and RH lt 95 non condensing An ideal storage temperature between is 20 C to 25 C The UPS should be stored in the original packing and shipping carton If the packing container is removed you must take measures to protect the UPS from dust Battery The UPS uses sealed maintenance free batteries whose storage capacity depends on the ambient temperature It is important not to store the batteries for longer than 6 months at 20 C 3 months at 30 C or 2 months at 35 C storage temperature without recharging them For longer term storage the batteries should be fully recharged every 6 months 20 C Extreme temperature under charge overcharg
8. 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 Description Due to its Decentralised Parallel Architecture DPA design any one of the PowerWAVE PW6000 S3 UPS can take the leadership role when operating in a multi module system This ensures the highest possible level of power availability and avoids a single point of failure that can exist in other more traditional parallel systems Parallel system expansion Most data centres present a low initial power demand which increases as the data centre grows to its full capacity and it is essential that any installed power protection system can be expanded to meet the growing demand without compromising the existing load This situation is easily managed in a PowerWAVE PW6000 S3 multi module installation which allows an additional module s to be connected to an existing parallel system without having to temporarily transfer the load to the raw by pass mains supply Thus the load receives UPS protected power at all times during the upgrade process without interruption 2 3 PowerWAVE PW6000 S3 UPS module functional description Maintenance Bypass Line Figure 2 1 PowerWAVE PW6000 S3 UPS module block diagram 2 3 1 UPS module block diagram Figure 2 1 shows the major power blocks contained within the UPS module UPS Input supplies The UPS has two sets of three phase input supply terminals The mains supply 1 is connected to the UPS rectifier via the input i
9. 2 L3 see Figure 3 8 lower diagram Connect the UPS input supply cables to terminals 1 L1 1 L2 1 L3 Ensure correct clockwise phase rotation Connect the input neutral 1 N to the Neutral busbar A CAUTION The input Neutral cable must be unswitched and permanent 6 Secure the cables to the fixing rail under the connection terminals 30 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 Installation Dual Input Feed 7 Remove the single input feed links if fitted see Figure 3 8 lower diagram 8 Connect the UPS input supply cables to terminals 1 L1 1 L2 1 L3 Ensure correct clockwise phase rotation 9 Connect the input neutral 1 N to the Neutral busbar A CAUTION The input Neutral cable must be unswitched and permanent 10 Connect the earth cable from the mains distribution board to the protective earth PE busbar see Figure 3 8 11 Connect the UPS bypass supply cables to terminals 2 L1 2 L2 2 L3 Ensure correct clockwise phase rotation 12 Connect the bypass neutral 2 N to the Neutral busbar A CAUTION The bypass Neutral cable must be unswitched and permanent 13 Secure the cables to the fixing rail under the connection terminals Note The UPS commissioning engineer will re configure the UPS electronics to operated with a dual feed input at the time of commissioning 3 7 2 Connecting the UPS output cables It is re
10. RS 232 serial port Figure 7 14 shows the connector pinout Note that the maximum length for the interconnecting RS232 cable is 15m LES 00000 N S i 0000 i i Ri Pin Signal Description VO gs TXD Transmit to external device Output RXD Receive from external device Input GND Ground tied to chassis Input Figure 7 14 Connector Cable PC Serial Port 7 5 RS485 Interface for multidrop Multidrop cables are connected between the modules to enable the system to be remotely monitored over ethernet The cables supplied are terminated with RJ45 plug connectors that fit into the multi drop socket on the communications interface board see Figure 7 15 An RJ45 splitter plug supplied with the fitting kit is required when fitting the cables to the middle cabinets 1 Connect a multidrop cable between the communications interface board in UPS cabinet 1 and UPS cabinet 2 using a splitter plug in cabinet 2 if it is a middle cabinet 2 Connect a multidrop cable between he communications interface board in UPS cabinet 2 and UPS cabinet 3 using a splitter plug in cabinet 3 if it is a middle cabinet Figure 7 15 Multi drop 3 Continue with the above steps until a multidrop cable is connected as a daisy chain between all modules 52 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta KOHLER COMPANY T Options 7 6
11. SNMP Card slots Simple Network Management Protocol SNMP is a world wide standardised communication protocol that can be used to monitor any network connected device via a simple control language and display the results in an application running within a standard web browser The PowerWAVE PW6000 S3 contains an SNMP slot SLOT 1 which is designed to house a Modem Ethernet SNMP adapter card Alternatively SNMP connectivity can also be implemented using an external SNMP adapter connected to the UPS RS232 output JD1 The SNMP Ethernet adapter contains an RJ 45 connector which allows it to be connected to the network using a standard network cable Once connected the UPS Management software agent which is already installed in the SNMP adapter then monitors the UPS operating parameters and communicates the operating data to the connected PC In a multi module UPS system the SNMP interface can communicate system wide data or data for an individual UPS module The SNMP card enables event alarm emails server shutdown with optional licenses and other tasks The SNMP card can also be integrated with BMS software over a local area network LAN for SNMP or Modbus information over IP An optional card enables Modbus comms over RS485 SNMP Card P T di 2 a RS232 JD1 z External SNMP Adaptor UPS Communications Interface Board Figure 7 16 SNMP Internal and
12. adjacent to the UPS cabinet and requires a minimum rear clearance of 100mm to allow adequate ventilation A 24 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 Installation 3 6 Planning the installation cabling considerations 3 6 41 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 fuses to protect the bypass and rectifier mains inputs It is the customer s responsibility to ensure the UPS external supply fuses or other devices are correctly sized to provide the recommended level of UPS protection We also recommend that a spare set of fuses are held locally to ensure they are easily available if required The UPS input and bypass terminals should be connected to the utility mains supply through a suitable LV Distribution board containing a circuit breaker or fused isolator to provide suitable overload protection and a means of isolating the UPS from the mains supply when required Similarly the UPS output supply terminals should be connected to the load equipment via a suitably fused load distribution board Input neutral grounding A permanently connected input neutral is required to enable the rectifier to operate correctly and allow the UPS to function properly when operating on battery The input neut
13. and cable ratings are bespoke to the installation and supplied by the customer Ensure that the fused isolators and or circuit breakers in the external battery cabinet or racks are open 3 Connect a protective earth cable PE between the external battery cabinet earth point and the protective earth PE busbar in the UPS see Figure 3 8 4 Connect the battery positive power cable s between the positive output terminal in the external battery cabinet and the battery positive BATT busbar in the UPS see Figure 3 8 5 Connect the battery negative power cable s between the negative output terminal in the external battery cabinet and the Neutral N busbar in the UPS see Figure 3 8 6 Secure the cables to the fixing rail located under the UPS connection terminals and to any available securing point within the battery cabinet 32 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 Installation 3 9 Multi module control cabling and configuration To facilitate various control functions such as load sharing frequency synchronisation and load transfer all the UPS modules connected to a parallel system communicate with each other continuously by means of communication bus cables that are daisy chained between each module as shown below in figure 3 10 Once the cables are fitted each module must be configured by means of DIP switches according to its position in
14. and the load transferred to the static bypass supply in all modules from where it is connected to the unprotected bypass mains supply The UPS cabinet contains a maintenance bypass switch which when closed connects the cabinet s output terminals directly to the bypass mains supply When operating via the maintenance bypass switch the UPS modules can be repaired or tested off line as required Note All the switches and control panel operations mentioned in this chapter are identified and described in chapter 2 This chapter contains the following procedures Initial system power up and functional testing Paragraph 4 2 System shutdown to maintenance bypass Paragraph 4 3 System start up from maintenance bypass Paragraph 4 4 Individual module stop start procedure Paragraph 4 5 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 35 Uninterruptible Power Supplies Ltd 4 Operation KOHLER COMPANY 4 2 lnitial system power up and functional testing A WARNING This procedure must be carried out by a trained engineer or service agent approved by UPS Ltd This procedure outlines the steps taken by the commissioning engineer when energising the UPS system for the first time It can also be used to restart the system following a total shutdown Preliminary checks for each UPS cabinet Check that the UPS input bypass supply fuses or breakers are open OFF at the mains distribution board Check that t
15. cabinet rack a The module control panel will display LOAD OFF SUPPLY FAILURE b The BATTERY led on the module control panel mimic should change from flashing to permanent green c The module control panel mimic indications should be as shown here Turn ON the UPS module by simultaneously pressing both ON OFF buttons then releasing them a The UPS module s will start up over about 60 seconds b The INVERTER will start up and come on line Green c The module control panel will display LOAD PROTECTED d The module control panel mimic indications should be as shown here LINE 2 BY PASS LINE 1 INVERTER ENSE BATTERY LINE 2 BY PASS LINE 1 INVERTER E BATTERY LINE 2 BY PASS LINE 1 INVERTER ENSE BATTERY LINE 2 BY PASS i LINE 1 INVERTER EEE BATTERY L T LOAD LOAD WARNING The UPS module is still live at its input and output power terminals Allow 10 minutes for the internal DC capacitors to discharge before touching any UPS internal components LOAD LOAD Note This completes the procedure The UPS is now operating in On Line mode and supply protected load power 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 43 Uninterruptible Supplies Ltd ta 4 Operation KOHLER COMPANY 4 5 3 Complete system shutdown The UPS system may be shutdown completely if
16. planning will help ensure a smooth and trouble free installation of the UPS system The following guidelines should be taken into account when planning a suitable UPS location and operating environment 1 The route to the installation location must allow the equipment to be transported in an upright position 2 The floor at the proposed installation site and en route from the off loading point must be able to safely take the weight of the UPS and battery equipment plus the fork lift during transit 3 Locations with high ambient temperature moisture or humidity must be avoided a Theinstallation site humidity should be 9596 non condensing b The prescribed ambient temperature is 0 C to 40 C An ambient temperature of 20 C to 25 C is recommended to achieve a long battery life c The prescribed cooling air flow must be available The air entering the UPS must not exceed 40 C d The air conditioning system must be able to provide a sufficient amount of cooling air to keep the room within the prescribed temperature range 4 The following environmental conditions should also be considered a Fire protection standards must be respected b The location must be free of dust and corrosive or explosive gases c The location must be vibration free d Ifthe UPS is located in bayed enclosures partition walls must be installed e The available space must permit the minimum cabinet clearances shown below 3 5 1 Clearances D 50
17. power down a UPS module 6 Turn OFF the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them a The module control panel will display LOAD OFF and LOAD SUPPLY FAILURE LINE 1 INVERTER b The module control panel mimic indications should be as shown here mE BATTERY 7 Open the module s parallel switch IA2 L T 8 Open the battery fuses breaker located in the external battery cabinet rack LINE 2 BY PASS a The BATTERY led on the module mimic should change to flashing green LOAD b The module control panel mimic indications should be as shown here LINE 1 INVERTER 9 Open the UPS input isolator IA3 and bypass isolator IA4 Co a The module is now fully powered down BATTERY Maintenance Bypass circuit Allow 10 minutes for the internal DC capacitors to discharge before touching any WARNING The UPS module is still live at its input and output power terminals due to the activation of A UPS internal components 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 39 4 Operation Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 4 System start up from maintenance bypass This procedure applies to both single module and multi module systems and describes how to return the UPS system to normal on line operation from working on the maintenance bypass Note If all the UPS modules are already running begin this procedure at step 5 otherwise begin at st
18. switches located in each cabinet and is set up during commissioning see paragraph 3 9 Module redundancy If a system is designed with module redundancy then it contains at least one UPS module more than the number required to provide the specified system full load power For example if the system shown in figure 2 5Figure 2 5 comprised 3x100kVA modules it could be employed as a redundant module system for a load of 200kVA In this case under normal circumstances each module shares the load equally and supplies up to 66 6kVA at full load but if one module fails or is shut down the two remaining modules can sustain the full rated load by each supplying 100kVA The ability to lose one module yet still supply the full load with processed backed up power significantly increases the overall system reliability Two or more PowerWAVE PW6000 S3 UPS modules can be connected to a common battery to allow them to share the battery charging However by employing a separate battery bank for each module as illustrated in figure Figure 2 5 it again avoids a potential single point of failure and effectively extends the system redundancy to include the batteries We highly recommend the use of individual batteries for each module Isolating a module from the system If a parallel system incorporates module redundancy a module can be isolated from the system for service repair purposes without affecting the operation of the remaining modules or load Ever
19. the parallel system 3 9 1 Connecting the parallel communication bus cables 1 To protect personnel during the UPS installation ensure that the connections are performed under the following conditions Oo O0 oO a No mains voltage is present at the UPS mains bypass distribution board terminals All loads are shut down and disconnected at the load distribution board The UPS is fully shut down and voltage free The UPS and battery connection terminals are voltage free The UPS Maintenance Bypass Isolator IA1 is open OFF f The UPS Parallel Isolator IA2 is open OFF Fit a parallel adaptor board over connector JD8 on the communications interface board in all UPS cabinets and secure it in place with 2 screws as shown in Figure 2 8 The parallel adapter board contains a DIP switch SW2 2 and two connectors JD5 amp JD6 Set DIP switch SW2 2 on each parallel adaptor board according to the position of the UPS cabinet in the parallel configuration See Figure 3 10 Connect a bus cable between JD6 of UPS cabinet 1 parallel adaptor and JD5 of UPS cabinet 2 parallel adaptor Connect a bus cable between JD6 of UPS cabinet 2 parallel adaptor and JD5 of UPS cabinet 3 parallel adaptor Continue with the above steps until a bus cable is connected to all modules as shown below UPS Cabinet 1 UPS Cabinet 2 UPS Cabinet 3 Parallel Adaptor Parallel Adaptor Parallel Adaptor Meine Nese lve sw22 Moaersive Meter 10 5 Ma
20. 100mm gt 100mm lt BATT UPS BATT CAB CAB CAB gt 100mm gt 100mm gt 100mm Y Figure 3 4 UPS Cabinet access space requirements Figure 3 4 illustrates the space requirements when installing a single or multi module PowerWAVE PW6000 S3 system with or without an adjacent battery cabinet s All cables enter the UPS via the bottom of the cabinet no service installation access is required from the rear or sides of the cabinets All cabinets are force cooled by top mounted extraction fans which require a minimum of 400mm space at the top of the cabinet to allow adequate exhaust air flow A minimum of 1000mm clearance is required at the front of the cabinets for service access C and where possible this should be increased to allow safe passage in front of the UPS with the doors open The cabinet s do not rear or side clearance D However it is necessary to open the door by slightly more than 90 to gain access to some components so if the cabinet is located adjacent to a partition or wall that extends beyond the front of the cabinet B a side clearance of 50 100mm B should be provided between the cabinet and the partition wall to allow the doors to open adequately Note that if this is not possible the doors have been designed to be easily removable to aid the required internal access If a battery cabinet forms part of the UPS suite it is normally situated immediately
21. 2014 15 2 Description Uninterruptible Supplies Ltd uw KOHLER COMPANY 14 Output Power all three phases 15 Battery capacity Commands menu screen OUTPUT POHER 523 06 660 66 660 88 86 BATT CAPACITY C9 1 Transfer Load to inverter 2 Transfer Load to bypass 3 Battery Test 4 Deep Battery Test 5 Abort Battery Test 6 Perform Alarm Test UPS Data menu screen gt LOAD TO INVERTER LOAD TO BYPASS gt LOAD TO BYPASS PERFORM BATT TEST gt FERFORM BATT TEST PERF DEEP BATT TEST gt FERF DEEF BATT TEST ABORT BATT TEST gt ABORT BATT TEST PERF ALARM TEST gt FERF ALARM TEST HO MORE COMMANDS 1 These general UPS Data are installed at the manufacturing plant 2 Manufacturing date 3 EPROM Version 4 Hardware Version 5 Dynamic Password 6 Actual Date and Time UPS SERIAL HUMBER nmm Timmnnn DATE OF MANUFACTURE 13 61 2614 EPROM VERS TOM VV CECE HARTHARE VERS ION DYNAMIC PASSEORD TESNO DATE TIME ddl hh mmi ss 1 6 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta KOHLER COMPANY 2 Description Set up user menu screen DESCRIPTION 1 Set up language 2 Set up Date and Time 3 Set up battery test 4 Set up operation with Gen Set Set up service menu screen DESCRIPTION 1 This Menu is re
22. 21 Uninterruptible Supplies Ltd 3 Installation A KOHLER COMPANY Figure 3 2 Unpacking the UPS cabinet standard packaging 22 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta KOHLER COMPANY 3 Installation Removing the sea freight UPS packaging see Figure 3 3 1 2 Disassemble the wooden box A by removing all screws Remove the plastic film and bag B from the UPS by cutting it away without damaging the cabinet Note the edges are not protected by a cardboard fillet as in the standard packaging Remove the accessories package which should contain a user manual 2 painted kick plates with screws 4 feet and a set of door keys from its shipping location beneath the cabinet Using the keys from the accessories package open the door of the UPS then remove the humidity absorbent strip inside the front of the cabinet D by tearing it away Similarly remove the humidity absorbent strip from the back of the UPS cabinet Following steps 6 to 8 in previous procedure Removing the standard UPS packaging fit the UPS adjustable feet and front rear kick plates Figure 3 3 Unpacking the UPS cabinet sea freight packaging 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 23 3 Installation Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 5 Planning the installation site considerations A certain amount of pre
23. 8 230 Colour Graphite Grey RAL 7024 Batteries Fitted internally with optional external battery enclosure available Input and output power cable entry Bottom with front access for connection Exhaust cooling air Rear SYSTEM CHARACTERISTICS Topology On line double conversion Voltage and Frequency Independent VFI Technology Second generation transformerless design Parallel configuration expansion For added redundancy and or capacity a parallel system can be extended to up to 10 modules on request Load 60 80 100 120 Double conversion AC AC efficiency with 100 95 5 95 5 95 7 95 7 fully charged battery and linear load PF 1 Tolerance of 0 2 75 95 8 95 8 96 0 96 0 50 96 0 96 0 96 0 96 0 25 95 0 95 0 95 0 95 0 Eco mode efficiency gt 99 0 INPUT CHARACTERISTICS 60 80 100 120 Nominal input voltage 3x 380 220V N 3x 400 230V N 3x 415 240V N Input voltage tolerance ref to 3x400 230V 23 to 15 3x308 177 V to 3x460 264 V for lt 100 load for Loads in 30 to 15 3x280 161 V to 3x460 264 V for lt 80 load 40 to 15 3x240 138 V to 3x460 264 V for lt 60 load Input frequency Hz 35 70 Inrush current A Limited by soft start Max Input Power with rated output power kW 64 85 105 126 and charged battery pf 1 0 Max Input Current with rated output power A 92 122 152 183 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 57 8 Specification Uninterruptible Power Supplies
24. COMPANY 1 3 Declaration of Safety conformity and CE marking The PowerWAVE PW6000 S3 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 2006 95 EC Low voltage directive e 2004 108 EC Electromagnetic Compatibility directive EMC Standards as reference EN IEC 62040 1 Uninterruptible power supply UPS Part 1 1 General and safety requirements for UPS s used in accessible areas by end users EN IEC 60950 1 IT equipment Safety Part 1 General requirements EN IEC 62040 2 Uninterruptible power supply UPS Part 2 EMC requirements EN IEC 62040 3 Uninterruptible power systems UPS Part 3 Performance and test requirements e 2011 65 EU Restriction of the use of certain hazardous substances RoHS DIRECTIVE The supplier s responsibility is excluded in the event of any modification or intervention in the product carried out be the customer Product Standards Standards Safety EC EN 62040 1 EC EN 60950 1 Electromagnetic Compatibility EMC IEC EN 62040 2 C1 IEC EN 61000 4 2 IEC EN 61000 4 3 IEC EN 61000 4 4 IEC EN 61000 4 5 IEC EN 61000 4 6 IEC EN 61000 4 8 IEC EN 61000 2 2 RoHS EN50581 2012 EN50581 2012 2 765 01 00 PW6000 S3 60 120 kVA User Manual Dat
25. INE 1 INVERTER c The module control panel will display LOAD DISCONNECTED and PARALLEL SW OPEN TER BATTERY d The module control panel mimic indications should be as shown here 4 On the module control panel LINE 2 BY PASS 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 LOAD COMMANDS and then press the ENTER key E dips o c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key d The UPS module output should transfer to inverter and the module control panel mimic indications should be as shown here E BATTERY 5 Scroll through the measurements menu and check that the module s input and output supply indications are correct 36 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 Operation 6 Ina parallel system repeat steps 2 to 5 for all the other modules and ensure that each module is in the state shown above before continuing with this procedure 7 Check the battery voltage and polarity at the live side of the battery fuses breaker located in the external battery cabinet rack with the fuses breaker still open 8 Ifan external battery cabinet rack is installed check the cabling between the UPS cabinet and battery cabinet rack to confirm that it is safe to connect the batter
26. LER COMPANY 6 3 Troubleshooting table ALARM CONDITION MEANING SUGGESTED SOLUTION UFS FAULT There is a fault in the UPS and Call the authorised service centre for assistance MAINS BYPARECT FAULT QUTPUT SHORT OVERLOAD OVER TEMPERATURE BATTER CHARGER OFF INVERTER FAULT SYNCHRON FAULT BATTERY IM DISCHARGE RAMUAL BYP IS CLOSED therefore normal operation cannot be guaranteed Mains power supply is outside prescribed tolerance There is a short circuit at the output of UPS on load side Load exceeds the UPS rated power UPS temperature has exceeded the allowed value The attached battery and the battery charger set up do not correspond or battery charger fault Inverter is faulty The inverter and mains are not synchronised Battery is near end of autonomy Maintenance bypass closed Load supplied by mains The input power to UPS is too low or missing If site power appears to be OK check the input circuit breakers etc supplying the UPS Check all output connections and repair as required Identify which piece of equipment is causing the overload and remove it from the UPS Do not connect laser printers photocopiers electric heaters kettles etc to the UPS Check the ambient temperature of the UPS is less than 30 C If the ambient temperature is normal call the authorised service centre for assistance Call the authorised service centre for assistance Call the authorise
27. Ltd A KOHLER COMPANY INPUT CHARACTERISTICS Continued Max Input Power with rated output power kW and discharged battery pf 1 0 Max Input Current with rated output power A and discharged battery pf 1 0 400 230V Input power factor leading Input harmonic distortion THDi 96 Rated short time withstand current AC Power distribution system Required input connection Rated short time withstand current 60 80 100 120 70 93 116 139 101 134 167 201 gt 0 99 100 load lt 4 100 load 10kA for 1 5 seconds TN S TN C TN C S TT 3 phases an neutral required 10kA for 1 5 seconds BATTERY CHARACTERISTICS 60 80 100 120 Battery type Maintenance free VRLA vented lead acid NiCd Variable number of 12V battery blocks No 42 48 Autonomies gt 60 min are only available for loads lt 90 For loads between 90 100 the maximum allowed autonomy is 60 mins For autonomy s less than 20 mins UPS supports 42 50 x12 V blocks Variable number of 1 2V NiCd cells No 420 480 Autonomies gt 60 min are only available for loads lt 90 For loads between 90 100 the maximum allowed autonomy is 60 mins For autonomy s less than 20 mins UPS supports 420 500 x1 2V cells Max battery charger current A 37 49 61 61 Max battery charger power kW 18 24 30 30 Battery float voltage VRLA NiCd VDC 2 25 1 40 End of discharge voltage VRLA NiCd VDC 1 65 1 05 Temperature controlled charger Yes temperat
28. OHLER COMPANY 2 3 3 System operating modes Paragraph 2 3 2 described the various UPS internal operating modes but UPS systems are also categorised according to the way in which they operate at a system level and are typically described as being either an on line off line or line interactive UPS system The PowerWAVE PW6000 S3 can be operated in all three of the above categories On line operation When used as an on line UPS the PowerWAVE PW6000 S3 module s is configured to normally operate in the load on inverter mode In the unlikely event of an inverter fault or during an overload the UPS will transfer the load to the static bypass automatically and without interruption transfer time 0 If the transfer is due to an overload the system will transfer back to the load on inverter mode if the overload clears and the UPS will return to its normal load on inverter operation Operating in the on line mode provides the highest degree of load protection especially in the event of a mains disturbance or failure and is always recommended if the critical load e g computer system will not tolerate even a very brief supply interruption Off line line interactive operation When the PowerWAVE PW6000 S3 is used in an off line or line interactive mode the UPS module s normally operated in the load on bypass mode with the load being supplied from the static bypass s
29. OMMANDS and then press the ENTER key c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO BYPASS then press the ENTER key d The module control panel will display LOAD NOT PROTECTED e The module control panel mimic indications should be as shown here 17 Close the maintenance bypass switch IA1 in all cabinets a The module control panel will display MANUAL BYP IS CLOSED b The system control panel mimic should show the system running on maintenance bypass c The module control panel mimic indications should be as shown here LINE 2 BY PASS LINE 1 INVERTER EE BATTERY LINE 2 BY PASS LINE 1 INVERTER EEN BATTERY L LINE 2 BY PASS enu LINE 1 INVERTER ipi ENSE BATTERY LINE 2 BY PASS LOAD LOAD LOAD a Ee RR io LINE 1 INVERTER E BATTERY 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 37 Uninterruptible Power Supplies Ltd 4 Operation A KOHLER COMPANY WARNING The next action will apply mains power to the load equipment Check that the load is ready to receive power and that it is safe to do so before you continue 18 Close the UPS output supply fuses breakers at the load distribution panel a The load is now live and receiving power through the maintenance bypass circuit Transferring the load to the UPS 19 Ensure that the BYPASS led is green on ALL UPS mod
30. PowerWAVE 6000 Series 3 Uninterruptible Supplies Ltd A KOHLER COMPANY Uninterruptible Supplies Ltd A KOHLER COMPANY Document Control 765 01 00_A 25 11 2014 Initial draft copy published for proof reading 765 01 00 20 12 2014 Initial issue 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta KOHLER COMPANY Uninterruptible Power Supplies Ltd has taken every precaution to produce an accurate complete and easy to understand manual and will therefore assume no responsibility nor liability for direct indirect or accidental personal or material damage due to any misinterpretation of or accidental mistakes in this manual 2005 Uninterruptible Power Supplies Ltd This manual may not be copied nor reproduced without written permission of Uninterruptible Power Supplies Ltd 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY Table of Contents Safety Description Installation Operation 1 1 1 2 1 3 2 1 2 2 2 3 2 4 2 5 2 6 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 1 4 2 Description of symbols used in this manual User precautions Declaration of Safety conformity and CE marking Introduction 2 1 1 Reliability and quality standards 2 1 2 Key features PowerWAVE PW6000 S3 Model r
31. REMOTE SHUTDOWN Emergency Power Off X1 7 In 12Vdc Do not remove the factory fitted bridge if this feature is not used f X1 6 Gnd Gnd BATTERY TEMPERATURE SENSING xl X1 5 In 3 3V If connected this input is battery temperature dependent X1 4 Gnd Gnd CUSTOMER SPECIFIC INPUT X1 3 In 12Vdc Function on request to be defined X1 2 Out Gnd GENERATOR OPERATION X1 1 Gnd 12Vdc___ NC Generator on line Radon ee i nM 7 2 1 Remote shutdown Emergency Power Off The remote shutdown facility comprises a normally closed circuit Remote shutdown connected between terminal X1 7 and X1 8 see Figure 7 12 UPS Remote 2 T Me T Shutdown Port It is recommended that a terminal block with linking facilities is installed between the UPS and the remote shutdown button as shown in order to allow the removal maintenance or testing of the remote circuit without affecting the UPS normal operation On a standard UPS the remote shutdown EPO function is disabled and a bridging link is fitted between X1 7 X1 8 If this option is required it must be activated by a hardware code on the SETUP SERVICE menu and the link removed X1 7 X1 8 Terminal block Figure 7 12 Remote emergency stop cablin Please contact your distributor to enable this operation igu SUO Stop ing 1 Use a screened cable with 1 pair section of wires 0 5 mm 1 5 mm and maximum length of 100m 2 Connect the cable as shown in Figure 7 12 i WARNING the UPS has a
32. RISTICS 60 80 100 120 Heat dissipation without load Relative air humidity Max altitude above sea level without derating De rating factor for use at altitudes above 1000m sea level according IEC 62040 3 410 530 640 640 lt 95 non condensing 1000m 3300ft without derating Height above sea level m ft Electromagnetic compatibility Performance Product certification Degree of protections Manufacturing 1500 4850 2000 6600 2500 8250 3000 9900 STANDARDS Safety IEC EN 62040 1 IEC EN 62040 2 EN 62040 3 CE IP20 ISO 9001 2008 ISO 14001 2004 COMMUNICATION OPTIONS Power Management Display PMD Customer Interfaces Dry Ports RS232 on Sub D9 port RS485 on RJ45 port RS485 on RJ45 port Slot for SNMP Card Slot for SNMP Card LCD display and mimic diagram showing UPS operational status 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 For monitoring and integration in network management Remote monitoring system with graphical display option For multidrop purposes option Ethernet card for monitoring and integration in network management option USB Port and relay card Customer outputs 60 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Sup
33. WN keys move the cursor so that it is adjacent to COMMANDS and then press the ENTER key 3 Using the UP DOWN keys move the cursor so that it is adjacent to LINE 2 BY PASS LOAD TO BYPASS and then press the ENTER key Gee ERR a The UPS system will transfer the load to static bypass on all UPS Lica modules in a capacity rated parallel module system LINE 1 INVERTER CAUTION When performing with the next step you will lose the UPS EE BATTERY output load supply in a single module installation In a capacity rated parallel system the remaining on line modules will continue to power the load through the unprotected bypass supply 4 Turn OFF the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them a The module control panel will display LOAD OFF and SUPPLY LOAD FAILURE LINE 1 INVERTER b The module control panel mimic indications should be as shown here EE BATTERY 5 Open the module s parallel switch IA2 6 Open the battery fuses breaker located in the external battery cabinet rack LINE 2 BY PASS a The BATTERY led on the module mimic should change to flashing green E LOAD b The module control panel mimic indications should be as shown here LINE 1 INVERTER 7 Open the UPS input isolator IA3 and bypass isolator IA4 a The module is now fully powered down E BATTERY WARNING Allow 10 minute
34. actice especially in larger UPS installations the overall UPS system often includes a standby generator which starts automatically in the event of a mains supply failure and provides an alternative UPS input supply source until the utility mains supply returns to normal 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 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta KOHLER COMPANY 2 Description Load on bypass In the load on bypass mode the Bypass Maintenance Bypass Hne load supply is connected to the Supply Static Bypass Line unprocessed static bypass line via Output the static switch i Supply i INVERTER Depending on circuit conditions when operating in this mode the rectifier and charger sections can be turned off entirely or remain running and continue to provide battery charging Similarly the inverter can also remain in an operating standby state ready to be brought back into use Figure 2 3 Load on bypass Inverter Bypass load transfer As illustrated in the above diagrams the load supply is connected to the inverter or static bypass line by means of the static switch This is a solid state switch operate
35. ail Scheduled UPS service mode and other systems status Graphical user interface for Windows compatible platforms Automatic unattended local shutdown Special modules for MS Office software to close and save open documents Compatible with all optional modules like UPSDIALER SNMP adaptors temperature sensors etc Functional description WAVEMON is a client server software application for networks and local workstations In general it consists of two parts the server module of the UPS management software is UPSMAN which communicates with the UPS via an RS232 USB interface Running as a background application UPSMAN collects and interprets the messages received from the UPS and places them at the disposal of the client module UPSMON as well as any connected SNMP based instrumentation and control system 54 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd KOHLER company 7 Options If UPSMAN detects voltage variations or a power failure it can execute various system event routines by means of which for example the server is switched off or a warning alarm is sent to the connected users These system event routines are a part of the management software and can be configured in to suit local application requirements The software of your PowerWAVE PW6000 S3 UPS unit can be integrated into a network in two ways 1 By the server which is supplie
36. ange 2 2 1 Single Multi system configurations PowerWAVE PW6000 S3 UPS module functional description 2 3 1 UPS module block diagram 2 3 2 UPS internal operating modes 2 3 3 System operating modes 2 3 4 Multi cabinet parallel system concept PowerWAVE PW6000 S3 User Controls 2 4 1 Power isolators 2 4 2 UPS Control panel LCD Control Panel 2 5 1 Module mimic LED indicators 2 5 2 Operator keys 2 5 3 Power Management Display PMD UPS Communication interface Introduction Taking receipt of the UPS 3 2 1 Site transportation Storage Unpacking Planning the installation site considerations 3 5 1 Clearances Planning the installation cabling considerations 3 6 1 General requirements 3 6 2 Cable and fuse sizing 3 6 3 Power cable termination details 3 6 4 Power cabling in a parallel system UPS Cabling procedure 3 7 1 Connecting the input cables 3 7 2 Connecting the UPS output cables Battery connections 3 8 1 External battery enclosure Multi module control cabling and configuration 3 9 1 Connecting the parallel communication bus cables 3 9 2 Configuration DIP switch selection Introduction 4 1 1 Operating procedure summary Initial system power up and functional testing Noa a oonan AR WWW Q X 22 c3 c c3 l OCRWNN DN C N e WWWWWWWWNNNNNNNNNNNN BRBOONN ACO GAHGAAKRRAABAO OS www Ww oan Oo 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY
37. art power protection devices that will provide your critical equipment with a steady and reliable power supply for many years 2 1 2 Key features High reliability upgrade ability low operating costs and excellent electrical performance are just some of the highlights afforded by this innovative UPS solution Other key features are shown below KEY FEATURES Compact size small foot print Space saving on expensive floor space Flexible battery management Advanced management of battery charging and preventive failure diagnostics avoids premature deterioration of battery life Best in class ac ac efficiency up to 9696 Energy operational cost savings TCO Low input power factor near unity Cost savings during installation and the entire life cycle TCO Blade server friendly power full power from No de rating required with leading power factor loads 0 9 lead to 0 9 lag Very low input current distortion THDi Gen set power and installation cost saving THDi 4 0 100 load 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta 2 Description A KOHLER COMPANY 2 2 PowerWAVE PW6000 S3 Model range The PowerWAVE PW6000 S3 UPS range includes 60 80 100 and 120kVA models all of which are contained in the same size cabinet Mechanical details Unit 60 80 100 120 Photograph front view with doors open Rated output powe
38. ass Line Output Supply In this mode the mains supply is Mains converted to DC by the rectifier Supply which then charges the battery and provides operating power for the inverter which converts the rectifier output back into an AC supply that is suitable to power the load Battery If the mains supply fails or strays outside a preset acceptable voltage window the rectifier shuts down and the battery provides an alternative DC power source for the inverter which continues to operate until the battery is discharged Maintenance Bypass Line Static Bypass Line When operating in the load on inverter mode the inverter output frequency is synchronised to the bypass supply provided the bypass supply frequency remains within preset limits If the bypass supply fails altogether the inverter frequency is controlled by a free running oscillator that will maintain the output frequency at a constant 50 60Hz Battery Figure 2 2 Load on inverter from Mains or Battery power On battery operation Various alarms are generated as the battery discharges when the UPS is operating from battery power This enables the operator to shut down the load in an orderly manner if necessary e g to save data before the battery eventually reaches its end of discharge voltage and the UPS shuts down Various options are available to automate the load shut down process as described in Chapter 7 of this manual Options In pr
39. at remote shutdown of servers can take place initiated by the SNMP card or WAVEMON software further licenses must be purchased The license is for the RCCMD client or listening software that resides in each target server 7 8 PowerREPORTER management software PowerREPORTER is a remote monitoring and management service which provides peace of mind protection by offering a continuous 24 7 365 watch over mission critical facilities Continuous monitoring is an affordable insurance policy to detect issues and provide an early warning before they develop into a crisis The main features and benefits offered by PowerREPORTER are Realtime email notification sent directly to UPSL Service Centre in response to alarm critical events Acquisition of key performance data and productivity information Empowers you with the details needed to better understand machine performance and quickly troubleshoot downtime events Combined with a service contract PowerREPORTER improves service levels The engineer can determine if site attendance is necessary and bring relevant spare parts Monthly Status Report detailing trends and alarms Optional battery analysis and care service PowerNSURE measures battery voltage temperature impedance and prolongs battery service life through the application of battery charge equalization 7 8 1 Functional description PowerREPORTER communicates constantly with your UPS system in order to automatically det
40. battery installation must be carried out by the commissioning engineer Do not attempt to fit the batteries complete the battery wiring or close the battery isolators before the system has been commissioned 3 8 1 External battery enclosure In a redundant system it is recommended that each UPS module is connected to a dedicated battery so that the system redundancy is expanded to also include the batteries A range of bespoke battery enclosures can be supplied for use with the PowerWAVE PW6000 S3 UPS modules which are designed specifically to suit particular site requirements In all cases the battery enclosure will be fitted with suitably rated fused isolators which are connected on site to the battery terminals inside the UPS module Connecting the batteries WARNING This procedure must be carried out by or under the supervision of an approved UPS commissioning engineer 1 To protect personnel during the battery installation ensure that the connections are performed under the following conditions a No mains voltage is present at the UPS mains bypass distribution board terminals b Allloads are shut down and disconnected at the load distribution board c The UPS is fully shut down and voltage free d The UPS and battery power connection terminals are voltage free e The UPS Maintenance Bypass Isolator IA1 is open OFF f The UPS Parallel Isolator IA2 is open OFF g The battery fuses and cables must be suitably rated Note that Battery fuse
41. ble on the Communication Interface Board which is located in the lower right hand corner of the UPS Figure 2 8 shows a photograph of the Communication Interface Board with the Parallel Adapter Board fitted A detailed explanation of the interface facilities is contained in the Options chapter of this manual SLOT 2 for optional USB and Relay card Provides customer outputs JD6 Parallel Adapter Board output cable to the next module in the parallel chain SW2 2 Parallel configuration DIP switch located on Parallel Adapter Board JD5 Parallel Adapter Board input cable from the previous module in the parallel chain SW1 9 Multi cabinet configuration DIP switch SW2 Module selector switch used in conjunction with Multi Drop configuration Multi Drop RJ45 used to interconnect parallel modules to allow the system to be remotely monitored over ethernet X1 Customer inputs via Pheonix terminals LEDs red and green indicate the Customer interface board operational status JD1 RS232 user interface to PC for monitoring and control purposes SLOT 1 Optional SNMP card interface facility Parallel Adapter Board This photograph shows the Parallel Adapter Board installed This board which is used only in a parallel system plugs into JD8 on the Communication Interface Board and secured in place by 2 screws as shown Figure 2 8 Communication inte
42. by Uninterruptible Power Supplies Ltd before it is put into use The commissioning engineer will Connect the UPS batteries Checkthe UPS electrical installation and operating environment Checkthe UPS cabinet paralleling configuration settings Check the correct installation of any optional equipment Perform a controlled UPS start up and functionally test the system for correct operation and configuration Carry out customer operator training and equipment handover WARNING Uninterruptible Power Supplies Ltd accepts no responsibility for the equipment or the safety of any personnel when operating this equipment before it has been properly commissioned The manufacturer s warranty is immediately invalidated if power is applied to any part of the UPS system before it has been fully commissioned and handed over to the customer 4 1 1 Operating procedure summary Under normal circumstances all the UPS modules in a multi module system are running and operating in their on line on inverter mode If a UPS module fails or is turned off in a redundant module system the module will shut down but will not affect the remaining on line modules which will continue to supply the load with processed power The shut down module can then be repaired or tested off line without affecting the remaining working modules If a UPS module fails or is turned off in a capacity rated or single module system the module immediately shuts down
43. cation Uninterruptible Supplies Ltd ta KOHLER COMPANY Battery fuses and cable NOTE Battery cabling Cable E and battery fuses Fuse E are bespoke to the installation Details given here are for guidance only Power kVA Fuse E gl CB Cable E Qty x mm 60 2x 160A 2x 200A 80 2x 250A 100 2x 300A 120 2x 1x 50 2x 1x 95 for 42 45 battery blocks 2x 1x 70 for 46 50 battery blocks 2x 1x 120 or 2x 2x 50 for 42 45 battery blocks 2x 1x 95 for 46 50 battery blocks 2x 1x 150 or 2x 2x 50 for 42 45 battery blocks 2x 1x 120 or 2x 2x 50 for 46 50 battery blocks 62 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014
44. ce board operations status leds X1 Customer control inputs see paragraph 7 2 SW2 Multidrop configuration DIP switch MULTIDROP JR45 multidrop cable connection see paragraph 7 5 Figure 7 11 UPS Interfacing connectors 7 41 Introduction Each UPS is fitted with a communication interface board as shown in Figure 7 11 which enables various external monitoring and control applications to be connected to the UPS system to satisfy particular site requirements These interfaces are described below Two leds 4 are located on the communications interface board to indicate its status The green led indicates the UPS cabinet s master slave status only one cabinet can be master flashing twice sec interface is master 1st cabinet of a parallel system flashing once sec Interface is slave 2nd 10th cabinet of a parallel system The red led signifies a board malfunction and possibly needs replacing 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 49 Uninterruptible Power Supplies Ltd Fe Options KOHLER COMPANY 7 2 Customer inputs X1 Terminal bock X1 provides a range of standard input interfaces that can be used by the customer as required All connections are made to Phoenix spring terminals using wires up to 1 5 mm Terminal Contact Signal Function X1 10 Gnd Gnd 12Vdc Power source max 200mA X1 9 In 12Vdc k 3 2 X1 8 Gnd Gnd
45. commended that a separate load distribution board is provided for the load Before you begin connecting the UPS output cables to the load distribution board Check that the potential full load does not exceed the UPS output power rating OUTPUT POWER on the nameplate Ensure the load circuit breakers on the load distribution board are correctly sized with respect to the load rating and associated cabling Ensure that the maximum total load rating and maximum load rating of each individual load socket is indicated on the load distribution board The circuit breakers must comply with the prescribed IEC Standards e g BS7671 2008 1 Gain internal access to the UPS as described above 2 Connectthe earth cable from the load distribution board to the protective earth PE busbar see Figure 3 8 3 Connectthe UPS output supply cables to terminals 3 L1 3 L2 3 L3 Ensure correct clockwise phase rotation 4 Connectthe output neutral 3 N to the Neutral busbar A CAUTION The output Neutral cable must ALWAYS be connected 5 Secure the cables to the fixing rail located under the UPS connection terminals 6 Ensure the output cables are connected to the correct power terminals on the load distribution board 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 31 Uninterruptible Power Supplies Ltd 3 Installation A KOHLER COMPANY 3 8 Battery connections WARNING The final assembly and connection of the
46. cordance with the prescribed IEC standards or local regulations for example BS7671 2008 also see figures 3 6 and 3 7 Once the electrical installation is completed the UPS must be commissioned by an engineer authorised by the manufacturer before it is brought into use A WARNING Do not apply electrical power to the UPS before it has been commissioned 7 When installing the UPS cables ensure that the connection procedures are performed under the following conditions a No mains voltage is present at the UPS mains bypass distribution board terminals All loads are shut down and disconnected at the load distribution board The UPS is fully shut down and voltage free Q Oo g The UPS Maintenance Bypass Isolator IA1 is open OFF The UPS Parallel Isolator IA2 is open OFF 7 3 7 1 Connecting the input cables 1 2 Gain internal access to the UPS a Unlock and open the UPS door b Remove the two lower cover plates to expose the power connection busbars c Remove the perspex covers from in front of the power connections to gain full access Note The connection terminals are identified on the perspex cover Connect the earth cable from the mains distribution board to the protective earth PE busbar see Figure 3 8 Single Input Feed 3 4 5 Ensure the single input feed links are connected between the input supply terminals and bypass input terminals 1 L1 to 2 L1 1 L2 to 2 L2 and 1 L3 to
47. d by the UPS itself and has been integrated into the network In most cases this server is used as a sub agent and you only need the WAVEMON software without an SNMP adapter You will also need to establish an RS232 USB connection between the UPS and computer server 2 In many cases the use of what is referred to as an SNMP adapter is to be preferred in order to integrate the UPS into the network In this case up to 50 computers can be shut down in one RCCMD environment RCCMD remote console command is an additional software module that is used in order to execute a command typically a shutdown command in a remote system Licensing A licence is issued with every software serial number for use of what is known as the UPS service on a single server in connection with one UPS and an unlimited number of connected WINDOWS workstations For operation with two or more servers a further licence is required for each additional server In this case it is of no importance whether the UPS service on these servers is active or whether the server was stopped by a remote UPS service The same applies to the use of RCCMD with the remote send receive modules for multi server shutdown under NT UNIX and other operating systems The service programs are generally supplied as single licences In order to use a single CD ROM for several multi server shut down units you must acquire additional licence codes RCCMD Server shutdown In order th
48. d by the UPS microprocessor control system which allows the load on inverter or load on bypass operating modes to be selected either manually via the UPS control panel or automatically by the UPS control logic see paragraph 2 3 3 Load on maintenance bypass Maintenance Bypass Line In this mode of operation the Bypass manually closed maintenance Supply Static Bypass Line bypass switch IA1 connects the load supply directly to the raw It is used to keep the load supplied SUPP albeit without any power CHARGER i BOOSTER protection whilst allowing the remainder of the UPS to be shut down for service repair Note that when operating in the maintenance bypass mode live voltages are still present on the UPS input and output power terminals Figure 2 4 Load on maintenance bypass To prevent possible inverter damage it is important that the inverter output and maintenance bypass lines are never connected in parallel Therefore when transferring from the load on inverter mode to the load on maintenance bypass mode it is important that the load is first transferred to the static bypass load on bypass mode before the maintenance bypass switch is closed CAUTION Always follow the operating instructions in Chapter 4 of this manual when starting or shutting down N the UPS 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 7 Uninterruptible Power Supplies Ltd 2 Description A K
49. d service centre for assistance The frequency of the input voltage to the UPS is outside operational limits and the UPS static bypass has been temporarily disabled Shutdown load connected to UPS before the UPS switches itself off to protect its batteries This alarm is only displayed if the UPS is on maintenance bypass 6 4 Contacting service Uninterruptible Power Supplies Limited 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 Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Business Park Hook Hampshire RG27 9XA Tel 01256 386700 0800 731 3269 24 Hr Fax 01256 386701 Email service upspower co uk We recommend that your UPS is protected by an extended warranty agreement see Chapter 2 for details These agreements assist us in caring for your UPS ensuring that it is well maintained and attended to promptly should any problems occur 48 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Options SLOT 2 for optional USB and Relay card Provide UPS MAINS status via volt free relay switching USB provides an alternative RS232 output to communicate with remote computer see paragraph 7 3 SLOT 1 for optional SNMP card see paragraph 7 6 JD1 RS232 Communications for computer interface see paragraph 7 3 Communications interfa
50. dently regulated Overload capability on inverter 96 150 load for 30 seconds min 125 load for 5 minutes 110 load for 20 minutes Inverter short circuit capability A 2 7x 2 0x 2 3x 1 8x x rated output for 40ms Fault clearing capability 100ms 2x In for normal mode and battery mode Bypass short circuit capability 10x rated In for 10ms Crest factor 3 1 Bypass operation V At 15 0 of nominal input voltage With 48 battery blocks only STATIC BYPASS 60 80 100 120 Transfer time ms 1 0 Inverter to bypass 5 0 bypass to inverter 6 0 in Eco mode Rated current A 87 116 145 174 Bypass mode fault clearing capability A 10x In for 20ms with recommended fuses fitted Overload protection on bypass mode l 150 load for 30 seconds min 125 load for 5 minutes 110 load continuously Maintenance bypass Fitted as standard Bypass protection fuses or circuit breaker Not included ENVIRONMENTAL CHARACTERISTICS 60 80 100 120 Audible noise 100 50 load dBA lt 65 lt 69 Ambient temperature for UPS C 0 40 Ambient temperature for batteries C 20 recommended Battery storage time at ambient temperature Maximum 6 months Fan assisted cooling air flow Front entry top exit Heat dissipation with 100 linear load WwW 2850 3800 4750 5700 BTU h 9730 12970 16220 19460 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 59 8 Specification Uninterruptible Power Supplies Ltd A KOHLER COMPANY ENVIRONMENTAL CHARACTE
51. e PowerWAVE PW6000 S3 UPS WARNING All cabling operations must be supervised by an authorised electrician or other suitably qualified person All installation and operating procedures must be carried out in strict accordance with the instructions contained in this manual Uninterruptible Power Supplies Ltd will take no responsibility for any personal injury or material damage caused by the incorrect installation cabling or operation of this product WARNING Once the UPS equipment is installed it must be commissioned by an engineer approved by Uninterruptible Power Supplies Ltd before it is powered up Uninterruptible Power Supplies Ltd will take no responsibility for any personal injury or material damage caused by the application of electrical power to this equipment before it has been fully commissioned 3 2 Taking receipt of the UPS The UPS cabinet and accessories are delivered on purpose designed pallets that are easy to off load and move using a forklift or suitable pallet jack CAUTION Observe the following precautions when off loading and moving the UPS e Always keep the packages in an upright position Do not drop the equipment Due to the high energy batteries involved and heavy weight do not stack the pallets The standard packaging protects the UPS from mechanical and environmental damage during transit This protection is further increased by wrapping the UPS with a plastic sheet Additional packaging in the form of a
52. e or over discharge will destroy batteries Charge the battery both before and after storing e Always store the batteries in a dry clean cool environment in their original packaging e Ifthe packaging is removed protect the batteries from dust and humidity i CAUTION Sealed batteries must never be stored in a fully or partially discharged state 3 4 Unpacking Removing the standard UPS packaging see Figure 3 2 1 Remove the plastic film from the UPS by cutting it where there is a cardboard fillet underneath A 2 Carefully remove the 4 cardboard edge protectors B while taking care that the accessory package C placed on top of the UPS does not fall off 3 With the aid of a suitable stool or step ladder carefully retrieve the accessories package C which should contain a user manual 2 painted kick plates with screws 4 feet and a set of door keys Remove the bubble wrap and securing tape D Remove the front and back fixing bars E by unscrewing 8x M8 hexagonal screws F Mount the 4x adjustable feet G from the accessory package and secure using 4x M8 tensilock nuts H NOs Place the UPS in its final position them disassemble the left and right securing brackets I by removing the 8x M8 screws J 8 Fit the kick plates K from the accessories package to the lower front and back of the cabinet and secure it using the screws provided L 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014
53. ect any error or alarm messages In the event of an incident being detected PowerREPORTER automatically connects with UPS Limited Service Centre via an email transmitting a status message The email which provides details relating to the fault a snapshot of the UPS performance parameters and a device identification string is automatically processed and UPS Limited Service Centre personnel are alerted UPS Limited Service Centre personnel are then able to liaise with the company s field service team and will remotely diagnose the UPS incident before reaching the facility with appropriate spare parts within the contracted service agreement time frame 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 55 Uninterruptible Supplies Ltd ta T Options A KOHLER COMPANY UPS UPS with Power REPORTER Batteries Site manager Email Alarm Event Data Servers with amp monthly report Power REPORTER software UPS Email i server Consultant specialists UPS Service Engineer Figure 7 18 PowerREPORTER operation 56 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 8 Specification 8 1 General specifications MECHANICAL CHARACTERISTICS 60 120kVA No Battery Enc and charged battery pf 1 0 400 230V Rating kVA 60 80 100 120 Dimensions WxHxD mm 615 x 1954 x 480 Dimensions with elevation kit WxHxD mm 615 x 1978 x 480 Weight without batteries kg 198 206 22
54. ed 20 12 2014 2 Description 2 1 Introduction Congratulations on your purchase of the PowerWAVE PW6000 S3 UPS Continuous power availability is essential in today s dynamic IT and process related work environments It is equally important that any installed power protection system is sufficiently resilient and adaptable to handle any requirement changes brought about by the introduction of new server technologies migration and centralization Such demands are well met by the PowerWAVE PW6000 S3 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 2 1 4 Reliability and quality standards The PowerWAVE PW6000 S3 UPS is available over a model range of 60kVA to 120kVA and incorporates the latest technological developments in power engineering Representing a completely new generation of high power three phase UPS systems its advanced double conversion VFI Voltage and Frequency Independent topology responds fully to both the highest availability and environmentally friendly requirements compliant with IEC 62040 3 VFI SS 111 standards Uninterruptible Power Supplies 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
55. ep 1 to turn on any non working module s 1 2 Close the battery fuses breaker located in the external battery cabinet rack Close the UPS input isolator IA3 and bypass isolator IA4 a The module control panel will display LOAD OFF SUPPLY FAILURE b The BATTERY led on the module control panel mimic should change from flashing to permanent green c The module control panel mimic indications should be as shown here Close the parallel switch IA2 for each module a The module control panel will display PARALLEL SW CLOSED on every module Turn ON the UPS module s by simultaneously pressing both ON OFF buttons then releasing them a The UPS module s will start up over about 60 seconds b The module control panel will display MANUAL BYP IS CLOSED c The module control panel mimic indications should be as shown here Ensure that the BYPASS LED is green on ALL UPS module control panels Open the maintenance bypass switch IA1 in all UPS cabinets a The module control panel will display MANUAL BYPASS OPEN followed by LOAD NOT PROTECTED b Thered INVERTER LED will extinguish c The module control panel mimic indications should be as shown here Continue with this procedure only when ALL modules indicate the state shown On ANY UPS module control panel 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 and then press the ENTER key
56. erWAVE PW6000 S3 parallel system has a decentralised bypass architecture in that each UPS module contains its own static bypass and static switch This eliminates the need for a separate bypass cabinet as required by some manufacturers systems and so eliminates a potential single point of failure In a multi module parallel system the topology and internal operation of each UPS module is identical to that described previously for a stand alone module except that the UPS control logic is subject to additional system level control functions which are delivered via a parallel control bus connected between each module As described below the parallel control bus performs many functions including System wide load transfer control Inter module and bypass frequency synchronisation Load sharing 8 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd B 2 Description A KOHLER COMPANY Maintenance Bypass Line Static Bypass Line t e S o E T Maintenance Bypass Line G a Static Bypass Line v t E S o E T Maintenance Bypass Line G a Static Bypass Line Figure 2 5 PowerWAVE PW6000 S3 UPS Parallel system 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd 2 Description A KOHLER COMPANY System wide load transfer operation All the modules that are connected to the load must be w
57. erformed by an authorised electrician who has received the appropriate level of training on this UPS system As there are no user serviceable parts contained within the UPS the maintenance requirements are minimal However to maximise the useful working life and reliability of the UPS and its batteries we recommend that the UPS system and batteries are inspected and checked for calibration on a 6 monthly basis as part of a preventative maintenance schedule 5 2 User responsibilities The operator should inspect the UPS equipment daily to ensure that the environment in which the UPS operates is kept cool and dust free at all times and that the operating temperature and humidity is within the limits given in the specifications chapter of this manual Any active alarm or status indication that indicates that the UPS is not functioning correctly should be dealt with immediately by referring to the troubleshooting chapter of this manual or contacting the manufacture s service desk 5 3 Routine maintenance When the UPS is commissioned the commissioning engineer will attach a service record book to the UPS which will be used to record the UPS service history To ensure optimum UPS operation and continuous efficient protection of the connected load we recommend that the system s operating parameters are checked and logged every six months and recalibrated where necessary WARNING When working inside the UPS cabinet there is a risk of exposure t
58. ervice mode Carry out diagnostic actions service mode 2 5 LCD Control Panel The LCD control panel is composed of three parts shown below Mimic LED indicators Alarm LED Operator Keys LCD Power Management Display Uninterruptible Supplies Ltd www upspower co uk Figure 2 7 LCD Control panel 2 5 14 Module mimic LED indicators The module mimic LEDs change colour between GREEN RED and OFF to indicate the operational status of key UPS stages and thereby serve to show the active power path through the UPS LINE 1 rectifier and LINE 2 bypass LEDs indicate the availability of the input mains and bypass mains supplies INVERTER and BYPASS leds illuminate green to indicate which of the two sources is providing the load power BATTERY illuminates green when the battery is being charged and flashes when the battery is discharging e g when supplying the load following a mains failure ALARM provides a visual indication that an internal or external alarm condition has been detected When activated it is accompanied by an audible alarm 12 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 Description LED Indication summary INDICATOR STATUS INTERPRETATION LINE 1 GREEN Mains available RED Mains not available LINE 2 GREEN Mains bypass OK RED Mains bypass not OK or not present ALARM OFF No alarm condition Flashing RED buzzer A
59. external adapters 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 53 Uninterruptible Supplies Ltd ta T Options KOHLER COMPANY 7 7 WAVEMON Shutdown and monitoring software instead of SNMP card WAVEMON is designed to operate in conjunction with many of the systems supplied by Uninterruptible Power Supplies Ltd and features both UPS monitoring and automatic UPS server shutdown facilities UPS Monitor Fle View Chart Functions UPS Help ag M Server DELLXP Model Conceptpower modular 30 KVA Location Status Chart Uninterruptible 01 10 2003 11 42 System Connected to UPS Supplies Ltd System Available UPS ajaja Figure 7 17 Monitoring screen image WAVEMON comprises a bespoke software package which is installed on a local PC and communicates with the UPS via the customer interface contacts X1 X2 optional USB port or the standard RS232 port JD1 using a serial cable of up to 15m in length The facilities afforded by this software can be viewed as an alternative to that offered when using the SNMP adaptor card option and it is only required when an SNMP card or adapter box is not purchased The main features of WAVEMON are On screen autonomy time battery time countdown On screen server log off and shutdown procedure Time and date stamp event log Extensive logging of all UPS activity and power quality data Permits alarm warnings to be monitored remotely via em
60. he UPS power cabling has been performed correctly and the input phase rotation is correct Check that all the UPS module parallel switches IA2 and maintenance bypass switches IA1 are open OFF Ensure that the UPS input isolator IA3 and bypass isolator IA4 are open Ensure that the battery fuses breakers fitted in the UPS cabinet or external battery cabinets racks are open OFF Oa e w gt Check that the parallel configuration DIP switches SW1 9 are set correctly in all cabinets see paragraph 3 9 2 Starting the UPS modules 1 Close the UPS input bypass supply fuses or breakers at the mains distribution board 2 On the UPS module close the UPS input isolator IA3 and bypass isolator IA4 a The UPS mimic panel LINE 1 LED will be permanent green b The BATTERY LED will be flashing green c TheLCD display will indicate LOAD OFF SUPPLY FAILURE BY PASS BATTERY this point e g Set Time Date Module ID etc This requires access to a password protected menu area P Key Point During commissioning the commissioning engineer can set up the module s configuration data at and must be carried out only by an approved engineer 3 Turn ON the UPS module by pressing both ON OFF buttons simultaneously LINE 2 BY PASS then releasing them E 3j a The UPS module will power up over approximately 60 seconds LOAD b Initially LINE 2 LED will be red then change to green L
61. idance only Power kVA Fuse E gl CB Cable E Qty x mm 60 2x 160A 2x 1x 50 80 2x 200A 2x 1x 95 for 42 45 battery blocks 2x 1x 70 for 46 50 battery blocks 100 2x 250A 2x 1x 120 or 2x 2x 50 for 42 45 battery blocks 2x 1x 95 for 46 50 battery blocks 120 2x 300A 2x 1x 150 or 2x 2x 50 for 42 45 battery blocks 2x 1x 120 or 2x 2x 50 for 46 50 battery blocks 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 25 Uninterruptible Supplies Ltd ta 3 Installation KOHLER company Mains Supply 3x380 400 415 UPS MAINS SUPPLY lt 2 Single Feed Link Cables 2 amp S5 n Bypass Power kVA Fuse A gl CB Cable A Qty x mm Cable D Qty x mm 60 3x100 5x35 5x35 80 3x125 5x50 5x50 100 3x160 5x50 5x50 120 3x200 5x70 5x70 Figure 3 6 Single feed input fuse and cable ratings 26 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power upplies 3 A KOHLER COMPANY Installation Mains Supply 3x380 400 415 Mains Supply 3x380 400 415 UPS MAINS SUPPLY UPS BYPASS SUPPLY c v o m a gt ea p 5 S wn Power kVA Fuse B gl CB Cable B Qty x mm Fuse C gl CB Cable C Qty x mm Cable D Qty x mm 60 3x100 5x35 3x100 5x35 5x35 80 3x125 5x50 3x125 5x50 5x50 100 3x160 5x50 3x160 5x50 5x50 120 3x200 5x70 3x200 5x70 5x70
62. important information to avoid possible equipment malfunction or damage gt gt 2 User precautions WARNING Keep this manual with the UPS for future reference WARNING The UPS and peripheral equipment must be installed and commissioned by suitably qualified and trained personnel who are aware of the potential shock hazards WARNING Do not attempt to install this UPS system until you are satisfied that ALL the safety instructions and hazard warnings contained in this manual are read and fully understood WARNING High leakage current Ensure that the UPS has been correctly earthed before you connect the mains power supply WARNING This UPS must not be started up or put into use without having first been commissioned by a fully trained engineer authorised by the manufacturer WARNING This UPS must be serviced by qualified personnel You run risk of exposure to dangerous voltages if you open or remove the UPS covers Uninterruptible Power Supplies Ltd will assume no responsibility nor liability due to incorrect operation or manipulation of the UPS WARNING The PowerWAVE PW6000 S3 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 gt gt oeeo 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd q1 Safety A KOHLER
63. larm system x2 X22 Com Common z 15 x21 N C MES LOAD_ON_MAINS Load On Inverter SAGE dius X2 10 N O Load On Bypass mains X2 9 Com Common x1 X2 8 N C ALARM BATTERY_LOW Battery OK X2 7 N O Battery Low 2s Y 1 X2 6 Com Common a USB X215 N C a LOAD_ON_INV Load On Bypass mains X2 4 N O Load On Inverter X2 3 Com Common X2 2 N C ALARM MAINS OK Mains Failure X2 1 N O Mains Present 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 51 Uninterruptible Power Supplies Ltd K Options A KOHLER COMPANY 7 4 Serial RS232 Computer interface USB amp JD1 Smart Port A serial RS 232 interface which allows the UPS to be connected to a computer is available through a standard 9 pin D Type female socket JD1 or via the USB port on the optional relay card fitted to Slot 2 Only one communication port can be active at a time and the priority is given to the USB port When appropriate power management software such as WAVEMON is installed the computer can continuously monitor the input mains voltage and UPS status and display a message in response to any UPS system changes USB Port To establish communication between the UPS and a computer connect the USB cable that is supplied with the UPS between the UPS USB port and the USB port on the computer The USB port is compliant with USB 1 1 protocol JD1 RS232 Port JD1 is a standard 9 pin D Type female socket which provides an intelligent
64. larm condition RED Alarm condition has been reset INVERTER GREEN Load on inverter RED Inverter fault OFF Inverter not operating BY PASS GREEN Load on bypass OFF Bypass not operating BATTERY GREEN Battery OK RED Battery fault or discharged Flashing RED Battery fuses blown Flashing GREEN On Battery 2 5 2 Operator keys The operator keys allow the user to Set operating parameters and make adjustments via the menu driven LCD display Start and stop the UPS and transfer the load between inverter and bypass Select the UPS operating voltages currents frequencies and other parameters to monitor on the LCD display Key function summary KEYS FUNCTION ON OFF Used to switch on or switch off the UPS ON OFF UP A Scroll upwards through a displayed menu DOWN W Scroll downwards through a displayed menu RESET Cancels the audible alarm If the alarm condition was transient the ALARM LED will also extinguish otherwise the LED will remain ON red ENTER Confirms selects a chosen menu item ON OFF Start up and shutdown buttons The UPS can be switched ON or OFF by simultaneously pressing both ON OFF keys on the control panel The requirement to press both buttons is to help avoid accidental operation During normal operation pressing the two ON OFF buttons simultaneously will immediately shutdown the UPS n a single module installation this will disconnect the UPS output unless the load is first transferred to the
65. llation the input cables from the mains distribution board to each UPS cabinet should be of equal length Similarly the UPS output cables to the load distribution board should be of equal length See Figure 3 9 Mains distribution board CORRECT INCORRECT Load distribution board Figure 3 9 Cable lengths for multi cabinet configurations 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 29 3 Installation Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 7 UPS Cabling procedure is connected to the UPS WARNING Opening or removing the UPS covers will create a risk of exposure to dangerous voltages if power Safety notes Please ensure you read and understand the following safety notes before you begin the UPS electrical installation 1 2 3 4 Do not commence this procedure until the UPS mechanical installation is completed All the cable installation procedures detailed below must be supervised by a qualified electrician Do not connect or operate the UPS if there is water or moisture present Before you work on the UPS power cables or terminals you must ensure that the UPS input and load supplies are isolated and locked out at their respective distribution boards Warning notices should be posted to prevent any inadvertent operation of the UPS supply isolators Before you connect the UPS input cables ensure that the customer provided fuses and cables are suitably rated in ac
66. n emergency bypass which is automatically enabled in a single module installation In this case the EPO function will be disabled and must be achieved in the building s facility which must be designed to also open the bypass path 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY T Options 7 2 2 Generator ON facilities The generator ON facility must use a normally open contact which closes when the standby generator is running and Generator Alarm Panel supplying the UPS input power When used this facility enables dns FREE the option to inhibit the operation of the battery charger and or static bypass X1 1 1 Use a screened cable with 1 pair section of wires 0 6 mm X1 2 and maximum length of 100 m 2 Connect the cable as shown in Figure 7 2 1 Figure 7 13 Generator ON Connection 7 3 Customer outputs USB The customer output interfaces are on an optional relay card which can be fitted to Slot 2 on the communications interface board The relay card contains 5 relay switched volt free outputs that can by connected to the external site monitoring BMS facilities The relays are rated at GOVAC and 500mA and the connections are made to Phoenix spring terminals using wires up to 1 5mm Terminal Contact Signal Display Function X2 15 Com Common X2 14 N C ALARM COMMON_ALARM No Alarm Condition X2 13 N O Common A
67. o potentially lethal AC and DC voltages All work that requires internal cabinet access must be carried out by trained personnel only During a preventative maintenance inspection the field service engineer will check the following Site environmental conditions Integrity of the electrical installation Cooling airflow Rectifier booster operation and calibration Inverter operation and calibration Static switch operation Battery status Load characteristics Integrity of alarm and monitoring systems Correct operation of all installed options Preventative maintenance inspections form an integral part of all Extended Warranty Agreements maintenance contracts offered by Uninterruptible Power Supplies Ltd For further details on Extended Warranty Agreements see Chapter 2 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 45 Uninterruptible Supplies Ltd ta 5 Maintenance KOHLER COMPANY 5 4 Battery testing A battery test sequence can be instigated from the UPS control panel and takes approximately 3 minutes to complete The test which can be carried out independent of the operating mode off line or on line and whether or not the load is connected should be undertaken only if there are no alarm indications and the battery is initially fully charged 46 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 6 Troubleshooting 6 1 Alarms Various UPS operating
68. orking in the same internal mode of operation at all times i e it is not permissible for one module to operate in the load on inverter mode while the remaining modules are in the load on bypass mode such a situation would likely damage the UPS modules inverter or static switch In a parallel system therefore if you activate the LOAD TO BYPASS command on any one module then all the modules will simultaneously switch to the load on bypass mode Conversely when operating on bypass if you select the command LOAD TO INVERTER on any one module then all the UPS modules will simultaneously transfer the load to their inverters provided a sufficient number of modules are operating to satisfy any system redundancy requirements Inter module frequency synchronisation and load sharing Using sensing signals passed over the parallel control bus each UPS module can compare its own frequency and output current with that of its neighbouring module This allows each module s control logic to carry out fine adjustments necessary to achieve balanced conditions The parallel control logic always observes one of the modules as being the master and the other module s as slaves However if the master module goes faulty at any time the next module in the chain a former slave will immediately take over the role of master and the former master module will turn off Master slave configuration is achieved through selector
69. parameter and conditions are monitored and will initiate an alarm or warning notification on the UPS control panel if an error is detected In the event that an alarm occurs you should 1 Silence the audible warning 2 Identify the alarm by inspecting the UPS module s event register see Page 15 3 Interpret the cause of the alarm see below and seek assistance from your nearest service centre if the cause of the alarm is beyond simple rectification 6 2 LCD Control panel The LCD Control panel is described in paragraph 2 5 If an alarm condition occurs the red ALARM led will flash accompanied by an audible warning 1 Cancel the audible warning by pressing the RESET button If the alarmed condition was transient the audible warning will stop and the red warning light will extinguish If the red warning remains ON it indicates that the cause of the alarm is still present and must be investigated 2 Investigate the cause of the alarm by making a note of the EVENT LOG which is accessed from the MAIN MENU this will present a list of time stamped events that took place preceding the detected alarm 3 Access the MEASURMENTS screen from the MAIN MENU and note the value of the UPS input output battery parameters etc 4 Referto the troubleshooting table below for possible fault resolutions 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 47 6 Troubleshooting Uninterruptible Power Supplies Ltd A KOH
70. plies Ltd ta A KOHLER COMPANY 8 Specification 8 2 60 120kVA Fuses amp cables quick reference DUAL FEED INPUT option Mains Supply 3x380 400 415 Mains 3x380 400 415 Bypass 3x380 400 415 Fuse A Cable A___ IA3 E lA4 N Rectifier Static Bypass Line Static Bypass Line Maintenance Bypass Line Maintenance Bypass Line atic Switch H _ EXTERNAL EXTERNAL BATTERY BATTERY Figure 8 19 Fuse and cable ratings IMPORTANT NOTE The UPS does not contain internal fuses to protect the bypass and rectifier mains inputs It is the customer s responsibility to ensure the UPS external supply fuses or other devices are correctly sized to provide the recommended level of UPS protection We also recommend that a spare set of fuses are held locally to ensure they are easily available if required Single feed input Power kVA Fuse A gl CB Cable A Qty x mm Cable D Qty x mm 60 3x100 5x35 5x35 80 3x125 5x50 5x50 100 3x160 5x50 5x50 120 3x200 5x70 5x70 Dual feed input Power kVA Fuse B gl CB Cable B Qty x mm Fuse C gl CB Cable C Qty x mm Cable D Qty x mm 60 3x100 5x35 3x100 5x35 5x35 80 3x125 5x50 3x125 5x50 5x50 100 3x160 5x50 3x160 5x50 5x50 120 3x200 5x70 3x200 5x70 5x70 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 61 8 Specifi
71. r KVAIKW 60 60 80 80 100 100 120 120 Cabinet dimensions w xhxd mm 615 x 1954 x 480 without feet 615 x 1978 x 480 with feet Weight excluding batteries 7 kg 198 206 228 230 See Chapter 8 for a complete equipment specification 2 2 1 Single Multi system configurations The PowerWAVE PW6000 S3 UPS can be configured to operate as a single stand alone UPS or as a multi module parallel UPS system with up to ten UPS cabinets connected in parallel A multi module configuration is generally chosen either to increase a system s total power capacity or enhance the system s overall reliability by providing module redundancy Note In this manual the terms multi module system and parallel system are synonymous Key Point In a parallel system ALL the connected modules must be of the same output rating e g it is not permissible to connect 60kVA and 120kVA cabinets together in a parallel system Parallel system operation When operating as part of a parallel UPS system it is critical that various control functions such as load sharing frequency synchronisation and load transfer are observed by all the connected UPS modules This is achieved in the PowerWAVE PW6000 S3 UPS system by connecting by a parallel control bus between the UPS modules which allows them to communicate with each other continuously and carry out all necessary synchronous control operations 4 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20
72. r or servicing procedures IA3 Input mains isolator IA3 connects the UPS input mains supply to the rectifier and is CLOSED during normal operation If this isolator is opened while the UPS is turned on the UPS will immediately switch to on battery mode and a several alarms will operated to inform the operator that the input supply has failed and the battery is on load discharging IA4 Bypass mains isolator IA4 connects the UPS bypass mains supply to the static switch and is CLOSED during normal operation If this isolator is opened while the UPS is turned on the UPS will continue to operate but the bypass supply will be unavailable to take over the UPS output supply in the event of an inverter failure 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 1 1 Uninterruptible Power 2 Description A KOHLER COMPANY 2 4 2 UPS Control panel An LCD control panel located on the front of the cabinet provides the means for day to day UPS operation and performance monitoring From the UPS control panel the operator can Stop and start the UPS module Transfer the UPS output load between the inverter and bypass Monitor the UPS input output voltage current and frequency Monitor the battery charge discharge current and battery status nteract with monitored alarm and warning messages Configure the UPS operating parameters service mode Interrogate the UPS operating events and alarm history s
73. ral must also be grounded to permit correct operation when the UPS is running on battery Key Point As the input neutral must be P unswitched and connected to the UPS at all Y times a 4 pole input switch or isolator must ov 230V not be used at the LV Distribution board on a TN S system Figure 3 5 Input neutral grounding UPS 3 6 2 Cable and fuse sizing Single feed Dual feed inputs The UPS can be wired for a single feed input standard whereby the UPS input mains terminals and bypass mains terminals are internally linked or it can be wired for a dual feed input where the UPS bypass mains terminals are connected to a dedicated bypass supply Both configurations are shown in Figure 3 6 single feed and Figure 3 7 dual feed together with details of the recommended fuse and cable ratings Fuse and cable recommendations are to IEC 60950 1 2001 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 2008 e External DC Cables and battery fuses are bespoke to the installation P Key Point The information in figures 3 6 and 3 7 is given for guidance only Battery fuses and cables Figure 3 6 single feed and Figure 3 7 dual feed do not show battery fuse and cable sizing details as these are bespoke to the installation The following table is given for gu
74. rface facilities 18 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 Description Extended Service enquiry form Fax to 01256 386701 www upspower co uk Uninterruptible Power Supplies Ltd Woodgate Bartley Wood Business Park Hook Hampshire RG27 9XA Tel 01256 386700 Name y y OOO a a IU MMILUNID LC EDIPSMEE Job Title ce cee Company uuedeeeeete teen oerte eie tai euer i aiaia ese dn Address EENEMMMMMMMMMMEMMMMMMMMMMMMM Post COQde uenerit ries tevsetoE DUEni e Qo Lern TeQu YR Ea CEP CUN Q a Pe vaa vd sv ERE EE RERS MM ZZ Z2 2 oO RERUMS FAX muaad sitsnscneitsiesvenietavEeis AA Cot A Ea deans zr RN ror Please contact me to discuss Extended Warranty options for my PowerWAVE PW6000 S3 UPS Extended warranty options for my UPS System as below MEINT IelU p nine lH Rating KVA 4o ona IDEM Replacement Bateries C Oth l uci er A ch eis please specify Thank you for your enquiry which will receive our prompt attention If you need to contact us immediately call free on Freephone 0800 731 3269 or E mail us on service upspower co uk www upspower co uk 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 19 Installation 3 14 Introduction This chapter contains essential information concerning the unpacking positioning installing and cabling of th
75. s for the internal DC capacitors to discharge before touching any UPS internal components 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 41 4 Operation Uninterruptible Power Supplies Ltd A KOHLER COMPANY Module start up 1 Close the battery fuses breaker located in the external battery cabinet rack 2 Close the UPS input isolator IA3 and bypass isolator IA4 a The module control panel will display LOAD OFF SUPPLY FAILURE b The BATTERY led on the module control panel mimic should change from flashing to permanent green c The module control panel mimic indications should be as shown here 3 Close the parallel switch IA2 a The module control panel will display PARALLEL SW CLOSED 4 Turn ON the UPS module by simultaneously pressing both ON OFF buttons then releasing them a The UPS module will start up over about 60 seconds b The module control panel mimic indications should be as shown here 5 Onthe UPS module control panel 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 and then press the ENTER key c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key d The module control panel will display LOAD PROTECTED e On ALL module control panels the mimic indications should be as shown here
76. served for authorized service engineers It is not to be used by end users 2 Type in password P Key Point It is essential to enter the password LCD DISPLAY gt SET LANGUAGE SET DATE AMD TIME ENGL ISH FRANCAIS DEUTCH DUTCH SPANISH FOL ISH POR TOGUESE gt SET UP DATES TIME SET UP BATT TEST DD MM HH MM SS gt SET BATTERY TEST SET GENERATOR OF DAY OF MONTH 1 315 HOUR OF DAY 8 2 REPETITIVE Yeh TES MO gt SET GENERATOR OF HO MORE SETTINGS BATT CHARGE LOCK Tu BYPASS LOCK LCD DISPLAY 2 SET UP SERVICE PASSWORD gt FhRSSMH RDX From within the SET UP SERVICE menu a service engineer can adjust the UPS voltages frequencies currents power and autonomies together with setting up UPS Rated Power Module configuration S P01 P02 Single standard or Dual input feed Frequency converter 50 60Hz and 60 50Hz Synchronisation window 2 496 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 17 Uninterruptible Supplies Ltd ta 2 Description KOHLER COMPANY 2 6 UPS Communication interface The UPS provides various input output communication interfaces that can be used by the customer for remote monitoring and control purposes together with the providing the inter module communication signals required for parallel operation in a multi module system The module interface connections are made availa
77. solator IA3 and during normal operation it is rectified to provide a DC input to the inverter and battery charger The second three phase input is connected to the bypass supply terminals 2 In practise the bypass supply terminals 2 are often linked to the mains supply terminals 1 within the UPS cabinet so the UPS effectively requires only one mains supply connection see paragraph 3 6 2 for details concerning single feed amp dual feed input configurations The bypass supply is shown connected to the static switch 4 and the maintenance bypass line 5 UPS Output load supply Figure 2 1 shows that the UPS output load supply can be provided through one of three power paths from within the UPS depending on the UPS operating mode From the inverter 3 via the static switch and isolator IA2 From the static bypass line 4 via the bypass isolator IA4 the static switch and isolator IA2 From the maintenance bypass line 5 via the maintenance bypass isolator IA1 The criteria for operating under each of these UPS modes is described below 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 5 2 Description Uninterruptible Supplies Ltd ta KOHLER COMPANY 2 3 2 UPS internal operating modes Load on Inverter This is the normal operating mode and the only one that provides the load with continuously processed and backed up power Bypass Supply Maintenance Bypass Line Static Byp
78. sse Magers 0 5 206 05 E E 3 JD5 JD5 Parallel adapter board fitted to JD8 on UPS communications interface board Parallel Adaptor Master Slave Master Slave n pon SW2 2 SW2 2 Configuration Switch JD6 JD5 Single First Middle Last Cabinet Cabinet Cabinet Cabinet SW 2 1 ON OFF OFF ON SW 2 2 ON ON OFF OFF Figure 3 10 Bus lines connections 3 Modules shown 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 33 Uninterruptible Power Supplies Ltd 3 Installation A KOHLER COMPANY 3 9 2 Configuration DIP switch selection DIP Switch SW1 9 DIP Switch SW1 9 on the UPS communications interface board see Figure 2 8 must be set to indicate the position of the cabinet in the parallel chain The three options are First cabinet Middle cabinet there may be several middle cabinets Last cabinet 1 In each cabinet set Switch SW1 9 according to the table below z a Ee 1 ON OFF ON 2 ON OFF ON 3 ON OFF ON 4 ON OFF ON 5 OFF OFF OFF 6 OFF OFF ON 7 ON OFF OFF 8 ON OFF ON 9 ON OFF ON 34 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 4 Operation 4 1 Introduction The PowerWAVE PW6000 S3 UPS system must be commissioned by a fully trained field service engineer authorised
79. td Ea A KOHLER COMPANY 2 Description Event log menu screen 1 Logging Control a log of the last 64 events is stored in the Power Management Display 2 Every stored event is identified with a sequential number and time stamp 3 By pressing ENTER the code of the event will be displayed Measurements menu screen 10 11 12 13 Battery Runtime UPS Output Frequency Bypass Frequency Battery Voltage Battery Charger Current Discharge Current Rectifier Input Voltage all three phases Bypass Input Voltage all three phases Output Voltage all three phases Output Current all three phases Active Output Power all three phases Reactive Output Power all three phases Apparent Output Power all three phases 81 83 16 85 LOAD TO IM Be 83 16 85 14 35 29 LOAD TOBY BS 03 16 03 14 35 14 BATT RUN TIME MIH Beh Elem OUTPUT FREQUENCY Hz BYPASS FREQUENCY HZ BATTERY VOLTAGE v 8 8 B 8 BATT CHARGE CUR P 8 8 8 8 DISCHARGE CURRENT m Be BIE RECTIFIER VOLTAGE V s BYPASS VOLTAGE v OUTPUT VOLTAGE 26 QUTPUT CURRENT CAT A BE Be ae Be cu ACTIVE POHER CEP REACTIVE POHER k MAr pA GG 86 66 86 686 APPARENT POHER EMAD 66 66 86 66 86 686 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12
80. the load does not require power for an extended period of time Use this procedure to totally turn of the load power and shut down the entire UPS system CAUTION This procedure will totally disconnect load power Ensure that it is safe to lose power to all the loads connected to the UPS system before you begin this procedure 1 Isolate all load equipment connected to the output of the UPS system by opening the fused isolators or circuit breakers at the UPS load distribution panel A WARNING Perform the following steps only after the load has been fully isolated N Carry out the following actions on every module in turn in a multi module system On the UPS control panel simultaneously press both ON OFF buttons a TheLCD panel will indicate LOAD OFF SUPPLY FAILURE Open the battery fuses breaker located in the external battery cabinet rack Open the UPS input isolator IA3 and bypass isolator IA4 The module is now fully powered down e Open the module s parallel isolator switch IA2 Open the UPS input and bypass supply isolators or circuit breakers at the UPS input supply distribution panel The UPS is now voltage free Qo o ND oi e components WARNING Allow 10 minutes for the internal DC capacitors to discharge before touching the UPS internal 44 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 5 Maintenance 5 1 Introduction WARNING The procedures described in this chapter must be p
81. ule control panels 20 Open the maintenance bypass switch IA1 in all UPS cabinets LINE 2 BY PASS a The module control panel will display MANUAL BYPASS OPEN followed m L by LOAD NOT PROTECTED LOAD b The red INVERTER led will extinguish gc INVERTER c The module control panel mimic indications should be as shown here ENE BATTERY 21 On ANY UPS module control panel LINE2 BY PASS a Press the UP key once to access the menu system al b Use the UP DOWN keys to move the cursor so that it is adjacent to LOAB COMMANDS and then press the ENTER key sit c Use the UP DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key a BATTERY d The module control panel on ALL modules will display LOAD L PROTECTED e The module control panel mimic indications should be as shown here T 22 The UPS system is now operating in the on line mode and providing the load with protected power supplied by the modules inverters P Key Point The UPS System single or multi module is now in its normal operating mode 38 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 Operation 4 3 System shutdown to maintenance bypass It may be necessary to transfer the load to the maintenance bypass supply to perform certain service or maintenance operations for example when repairing a mod
82. ule in a single module or capacity parallel module system CAUTION Warn the critical load user that the load will not be supplied with processed backed up power when the UPS is operating on maintenance bypass 1 On the UPS control panel on any module in a multi module system press the ENTER key once to access the menu system Using the UP DOWN keys move the cursor so that it is adjacent to COMMANDS and then press the ENTER key 3 Using the UP DOWN keys move the cursor so that it is adjacent to LINE 2 BY PASS LOAD TO BYPASS and then press the ENTER key 3 a The UPS system will transfer the load to static bypass on all UPS LOAD modules in a multi module system LINE 1 INVERTER 4 Onall modules check and confirm that a The INVERTER LED has extinguished b The BYPASS LED is green c TheLCD displays LOAD NOT PROTECTED d The module control panel mimic indications should be as shown here E BATTERY 5 Close the maintenance bypass switch IA1 in ALL cabinets LINE 2 BY PASS a The module control panel will display MANUAL BYP IS CLOSED E b The module control panel mimic indications should be as shown here LOAD LINE 1 INVERTER Note The system is now operating in the maintenance bypass mode with the UPS modules running but totally off line If you want to shut down any or all the modules continue with the procedure as follows EE BATTERY To
83. upply However the rectifier and battery charger are still powered up to maintain battery charging and the inverter section is turned on and operating on standby In the event of a bypass supply error or total failure the load is automatically transferred to the inverter load on inverter by the static switch within 3 to 5 milliseconds and if the rectifier mains supply is also missing when the transfer takes place the inverter will support the load operating from battery power as described above If the bypass supply returns to normal the load is transferred back to the static bypass and the inverter returns to standby This mode of operation is slightly more energy efficient than the on line mode due to the reduced rectifier inverter losses during normal operation and it is sometimes referred to as the ECO mode However this mode is recommended only if the connected load equipment can tolerate power interruptions of 3 to 5 ms during the transfer period A WARNING The on line mode must always be used for critical load protection 2 3 4 Multi cabinet parallel system concept Up to ten PowerWAVE PW6000 S3 UPS cabinets can be connected in parallel for increased capacity or redundancy operation An example 3 module parallel system is shown in figure 2 5Figure 2 5 Note If a PowerWAVE PW6000 S3 is purchased as a stand alone UPS it will require a field upgrade in order to be connected to a parallel system at a later time A Pow
84. ure sensor optional Ripple current rms 2 of the battery capacity Battery test Automatic and periodic adjustable OUTPUT CHARACTERISTICS 60 80 100 120 Output rated power kVA 60 60 80 80 100 100 120 120 min 42 battery blocks kW Load power factor rated 1 0 Nominal output current In A 87 116 145 174 PF 1 0 min 42 battery blocks Output rated voltage V Output waveform Output voltage stability normal battery mode 96 Total harmonic distortion with 10096 load 96 operating in normal mode Total harmonic distortion with 10096 load 96 operating in battery mode 3x 380 220 or 3x 400 230 or 3x 415 250 Sinewave with Odeg phase imbalance 100 unbalanced load 1 5 41 5 lt 2 with linear load lt 2 with linear load 58 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 8 Specification OUTPUT CHARACTERISTICS Continued o Voltage imbalance and phase displacement with 10096 load imbalance 60 80 100 120 T Voltage transient and recovery time with l lt 4 linear load 100 step load sec Output frequency Hz 50 or 60 Output frequency tolerance 0 1 free running quartz oscillator 2 or 4 selectable with mains synchronised Frequency slew rate Hz s 1 0 Max synch phase error lt 2 referred to a 360 cycle Permissible unbalanced load 100 all 3 phases indepen
85. y 9 Close the battery fuses breaker located in the external battery cabinet rack 10 The BATTERY led on the module control panel mimic should change from flashing to permanent green 11 Repeat the above steps for every UPS module so that the BATTERY led shows a permanent green on every module control panel Testing the parallel function 12 Ensure that the UPS output fuses breakers are open OFF at the load distribution board 13 Turn OFF each UPS module in sequence by pressing both ON OFF buttons simultaneously then releasing them a The module control panel will display LOAD OFF and SUPPLY FAILURE b The module control panel mimic indications should be as shown here 14 Close the parallel switch IA2 in each UPS module a Each module control panel will display PARALLEL SW CLOSED 15 Turn ON each UPS module in sequence by pressing both ON OFF buttons simultaneously then releasing them a The UPS modules will all turn on and operate in their on line mode b There is now power at the UPS output terminals although the load is still isolated at the output distribution board c The module control panel will display LOAD PROTECTED d The module control panel mimic indications should be as shown here Transferring the output to maintenance bypass 16 On ANY UPS module control panel 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 C
86. y module has a parallel output isolator A2 which can be used to isolate the module from the load bus When IA2 is open there is no load power being drawn from the module and it can be shut down in the normal way using the ON OFF buttons on the UPS control panel but in this case using these buttons will shut down the associated module only and will not cause the remaining modules to shutdown or transfer the load to bypass WARNING When the UPS module is shut down its output terminals will be live even if the module s input mains and bypass supplies are isolated 1 0 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies Ltd ta KOHLER COVPANY 2 Description 2 4 PowerWAVE PW6000 S3 User Controls 2 4 4 Power isolators Input Mains Bypass Mains Static Bypass Line Maintenance Bypass Line B UPS Output Figure 2 6 PowerWAVE PW6000 S3 power isolators The PowerWAVE PW6000 S3 power isolators shown in figure 2 6 are used during the UPS operating procedures when starting and shutting down the UPS IA1 Maintenance bypass isolator IA1 connects the UPS output directly to the raw bypass mains supply and is OPEN during normal operation IA2 Parallel isolator IA2 connects the UPS to the output load terminals and is normally CLOSED This isolator can be used to disconnect the module from the load in a multi module parallel system where necessary to carry out repai
87. ystem The maximum number of modules that can be used in a parallel system is 10 Stands for Single module The system consists only of one UPS cabinet Stands for Parallel system and 01 identifies the cabinet as the 1st module MASTER in the system Stands for Parallel system and 02 identifies the cabinet as the 2nd module SLAVE in the system This number can range from 02 to 10 depending on the cabinet s position in the parallel system Setting the module position in a single multi module chain Note The position of a module in a multi module configuration is set by DIP Switch SW1 9 which is located on the and set by the commissioning engineer This switch should not be touched by the operator Main menu screen DESCRIPTION LCD DISPLAY 1 Alog of the last 64 events is stored in the Power Management Display gt EVENT LOG MEASUREMENTS 2 Allows monitoring of voltages power frequencies currents autonomy etc 3 Enables the commands Load to inverter Load to bypass and battery test to be gt CORMANDS executed SET LIP DATA 4 Allows the UPS personalized information such as serial number to be entered gt SET UP DATA SET UP USER 5 Allows user to set up Date Time automatic battery test etc gt SET UP USER SET LIP SERY ICE 6 Password protected area for service engineer use only gt SET UF SERVICE 14 765 01 00 PW6000 S3 60 120 kVA User Manual Dated 20 12 2014 Uninterruptible Supplies L

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