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463-01-02 PW3000TP User Manual.book

1. 6 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY Some installations include a standby generator which is designed to start up and connect power to the UPS input automatically within a short period of time following a mains failure Once the UPS input power is restored from the standby source the rectifier and charger will resume normal operation Battery discharge operation Various options are available to automate the load shut down process as described in Chapter 8 of this manual A SHUTDOWN IMMINENT alarm indicates when the battery is almost exhausted and approximately 3 minutes autonomy time remains and if a data protection application such as WAVEMON is installed it will begin its automatic PC shutdown routine at this point When the battery reaches its fully discharged voltage the UPS will attempt to transfer the load to the bypass supply if it is present Load on Bypass Maintenance Bypass Line A Maintenance Bypass Switch Bypass Static Bypass Line Input RECTIFIER POWER DC CONVERTER INVERTER Output Mains UPS AC Input Output STATIC SWITCH x Automatic External Batt Switch Battery Option Figure 2 4 Load on bypass In the load on bypass mode the AC Output is connected to the unprocessed static bypass line via the bypass side of the static switch During normal operation the load will be transferred from the inverter to
2. UPS 1 UPS2 UPS 3 UPS 4 Output Output Output Output N Breaker l Breaker l Breaker l Breaker System Output Breaker v To Load Dist Panel Figure 4 1 External maintenance bypass circuit In a parallel module system each module will be connected with its own input and output external isolators breakers together with a System Output Breaker that connected the combined system output to the load distribution panel It is also likely that the system will include a wrap around maintenance bypass circuit comprising a System Input Breaker and System Bypass Breaker similar to that shown in Figure 4 1 Before using the parallel module system operating procedures given below you should familiarise yourself with any site specific external switching arrangements and modify the procedures accordingly Key Point The UPS commissioning engineer will explain the function of any external power isolators and maintenance bypass operation during the system handover 40 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Power Supplies Ltd Uninterruptible KOHLER company 4 Operating Procedures 4 9 Parallel system start up Use this procedure to start a multi module parallel UPS system from a completely powered down condition 1 2 Check that all the loads connected to the UPS are turned off Check that the individual modules output breakers and the System Output Bre
3. 7 4 7 5 7 6 Introduction 4 1 1 Operating procedure summary Single module start up with mains supply Single module start up without mains supply Single module changing the operating mode Single module shutdown with mains supply present Single module shutdown with UPS on battery Single module using the internal maintenance bypass Parallel module system procedures Parallel system start up Parallel system changing the operating mode Parallel system start stop one module Parallel module complete system shut down External Maintenance Bypass operation Operating a frequency changing system 4 14 1 Frequency changer starting the UPS 4 14 2 Frequency changer stopping the UPS Emergency Stop Introduction System calibration User responsibilities Routine maintenance Battery testing Battery maintenance Battery disposal and recycling Contacting Service Fault identification and rectification 6 2 1 Troubleshooting without an error message 6 2 2 Troubleshooting based on error message Backfeed protection Emergency Power OFF EPO Computer communication options 7 3 1 USB Port 7 3 2 RS232 Port RS232 and USB Communication options Serial Network Management SNMP card AS400 Interface card UPS Monitoring and automated control software 7 6 4 The importance of UPS management 7 6 2 WAVEMON Shutdown and Management Software 7 6 3 Functional description 7 6 4 Licensing 7 6 5 RCCMD Server shutdown 36
4. Input byp Isolator UPS 4 Output Breaker v System Output Breaker To Load Dist Panel Figure 3 4 External bypass circuit An external maintenance bypass facility such as that shown in Figure 3 4 can be installed to increase the system flexibility This circuit allows an individual module to be isolated from the system for repair or total replacement by opening its input fused isolator and Output Breaker It also allows the total system to be bypassed by closing the System Bypass Breaker and opening the System Output Breaker which in turn allows testing of the entire parallel system When such an external maintenance bypass is used it is crucial that the UPS modules are all operating on bypass or internal maintenance bypass before the System Bypass Breaker is closed to avoid the possibility of module damage For this reason it is usual to incorporate some form of safety interlocking mechanism around the external breakers UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 27 Uninterruptible Power Supplies Ltd 3 Installation A KOHLER COMPANY 3 7 Connecting the UPS power cables WARNING Opening or removing the UPS covers will create a risk of exposure to dangerous voltages if power is connected to the UPS Safety notes Please ensure you read and understand the following safety notes before you begin the UPS electrica
5. PowerWAVE 3000 TP ooo pe L Uninterruptible Power power 3000 TP L J linterruptible ies Ltd A KOHLER COMPANY Uninterruptible Supplies Ltd A KOHLER COMPANY IS DATE 463 01 00 01 08 2014 Document Control Initial draft copy 463 01 01 05 09 2014 Initial issue 463 01 02 25 09 2014 Cable sizing tables corrected and updated to include design note UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 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 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Table of Contents Safety 1 1 Description of symbols used in this manual 1 2 User precautions 1 3 Declaration of Safety conformity and CE marking General Description 2 1 Introduction 2 2 PowerWave PW3000 TP Model range 2 3 Functional description of operation 2 3 1 PowerWave PW3000 TP Module block diagram 2 3 2 UPS Module operating m
6. 1x24 2x24 2x24 Battery capacity 9 Ah 9 Ah 9 Ah Charger current 4A 4A 4A 4A 4A Recharge time 3h to 90 8h to 90 8h to 90 UPS Internal Batteries 16 5 41 16 16 5 UPS 1 Battery cabinet 41 16 59 28 92 42 16 5 42 16 UPS 2 Battery cabinet 92 42 118 49 150 60 42 16 60 27 UPS 3 Battery cabinet 150 60 180 80 213 90 60 27 90 42 UPS 4 Battery cabinet 213 90 245 103 246 132 90 42 118 53 Protection rating IP20 Audible noise 55 dB Measured at 1 metre from the front of the UPS on 100 load and fully charged batteries Storage temperature 15 C to 60 C for UPS 0 35 C for battery Operating temperature 0 C to 40 C Relative humidity 0 95 non condensing Altitude above sea level 1000m without derating User interface Menu driven LCD display Communication card options Network interface SNMP card Dry contact AS400 card USB RS232 Computer interface Safety IEC EN62040 1 EMC IEC EN62040 ROHS EN50581 2012 Performance IEC EN62042 3 Manufacturing ISO 9001 2008 ISO 14001 2004 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 59 8 Specifications Uninterruptible Supplies Ltd uw KOHLER COMPANY Weight xx kg xx kg xx kg Dimensions WxHxD 350x890x712 Colour Pantone Process Black C 60 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14
7. On the back of the UPS cabinet close the input breakers M1 and M2 position ON a The fans will start running b The UPS will perform a self test and will then display the default status menu on the LCD In the case of a multi module system repeat the above procedure for ALL modules On the UPS Operator Control Panel press the POWER ON key for more than one second on ANY module in a multi module system a The alarm buzzer will sound and the UPS will start b After a few seconds the UPS system will switch to its on line mode Check that the LCD indicates the on line status and no warning alarms are present The UPS is now fully operational and providing protected output power You can now switch on the loads If possible turn on the loads sequentially to prevent any UPS overloads occurring due to combined inrush currents 4 14 2 Frequency changer stopping the UPS Use this procedure to totally shut down a frequency changer system and its connected load 1 2 Turn off the individual load items On the Operator Control Panel press the POWER ON key continuously for more than three seconds on ANY module in a parallel system a The alarm buzzer will sound for three seconds b The output power will be immediately cut off c The fans will stop d After a few seconds the UPS LCD display will power down To totally isolate the UPS open the UPS Input bypass Isolators and where used open the exte
8. from the terminal box to gain access to the terminal block 2 The cables enter the UPS through cable glands 2 fitted to the bottom of the terminal box The holes used for the glands are fitted with blanks when the unit is shipped Remove the blanks and fit the supplied glands to suit the individual cable installation 3 Connectthe power cables to the terminal block according to the particular power configuration in use as shown in Figure 3 7 to Figure 3 10 Figure 3 5 Power terminal connections 28 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 Installation Figure 3 6 shows the connection details for the power terminal block _ Mains 1 Input Mains2input UPS Output Parallel Battery 9 oJ lo lo lol lol fo lo lo lo o o o Lo o lo L1 L2 L3 N GND M2 N GND L N GND JP1 JP2 B B GND O O IOI FO JO JO FOF FO FO 1O FO FO LO O FO 1O Line 1 Input L Battery Ground Line 2 Input Battery Neg Pole Line 3 Input Battery Pos Pole Input Line Neutral Parallel Jumper 2 Input Mains Ground Parallel Jumper 1 Bypass L Input Output Ground Bypass Neutral Output Neutral Bypass Input Ground Output Ground Figure 3 6 Power connection details Mains 1 amp Mains 2 Input The terminals that are actually used will var
9. mode Check that the LCD indicates the on line status and no warning alarms are present Close the module s external Output Breaker The UPS is now fully operational and providing protected output power in parallel with the other system modules 42 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 4 Operating Procedures 4 12 Parallel module complete system shut down Use this procedure to totally shut down and power off multi module UPS system 1 Turn off the individual load items 2 Open the System Output Breaker 3 Openthe individual UPS Output Breakers If the modules are on line 4 On the Operator Control Panel of ANY module press the POWER ON key continuously for more than three seconds For ALL modules a The alarm buzzer will sound b The UPS will transfer to on bypass mode and its output will remain live through the unprotected bypass supply 5 Goto step 9 If the modules are on bypass 6 Goto step 9 If the modules are on battery 7 Onthe Operator Control Panel of ANY module press the POWER ON key continuously for more than three seconds For ALL modules a The alarm buzzer will sound for three seconds b The output power will be immediately cut off c The fans will stop d After a few seconds the UPS LCD display will power down 8 Goto step 9 All Modes 9 Onthe back of each UPS cabinet in turn
10. on line mode UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 37 Uninterruptible Power Supplies Ltd 4 Operating Procedures KOHLER COVPANY 4 4 Single module changing the operating mode When the UPS is turned on you can quickly switch between its various operating modes as shown below From To Action ON LINE ON BYPASS Press the POWER ON key for 3 seconds ON BYPASS ON LINE Press the POWER ON key for 3 seconds ON BYPASS ON BATTERY Isolate the mains bypass power supply ON BATTERY ON LINE Restore the mains bypass power supply If the bypass is disabled in the SETTINGS menu when pressing the POWER ON key for three seconds the UPS will go from ON LINE to ON BATTERY mode 4 5 Single module shutdown with mains supply present Use this procedure to totally shut down a single module UPS system and its connected load 1 Switch off the individual load items 2 Ifthe UPS is operating in on bypass mode go to step 4 3 Onthe Operator Control Panel press the POWER ON key continuously for more than three seconds a The alarm buzzer will sound b The UPS will transfer to on bypass mode and its output will remain live through the unprotected bypass supply Note If the bypass has been disabled through the Settings menu when you press the POWER ON key for more than three seconds to shutdown the UPS the unit will change from on line to on battery mode see below 4 Onthe
11. open the input breakers M1 and M2 position OFF a Power will be removed from the UPS output terminals b The fans will stop C After a few seconds the UPS LCD display will power down 10 To totally isolate the modules open the external mains bypass power Input Isolators and where used open the external battery cabinet fuses isolator WARNING With the UPS shut down allow at least 5 minutes for the UPS DC capacitors to discharge before gaining internal access UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 43 4 Operating Procedures Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 13 External Maintenance Bypass operation An external maintenance bypass circuit such as that shown in Figure 4 1 allows the UPS system to be totally powered down while maintaining the load supply through the unprotected bypass supply CAUTION This mode is normally used only by fully trained UPS service engineers for example when adding or removing a module from the system and is not generally required during normal UPS system operation or use Transferring the load from the UPS to the external bypass 1 On the Operator Control Panel of ANY module press the POWER ON key continuously for more than three seconds For ALL modules a The alarm buzzer will sound b The UPS will transfer to on bypass mode and its output will remain live through the unprotected bypass supply 2 Close the external System B
12. 36 36 37 37 38 38 38 39 40 41 41 42 43 44 45 45 45 46 47 47 47 47 47 48 48 48 49 49 49 50 50 51 51 52 52 52 53 53 54 55 55 55 56 56 57 58 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Supplies Ltd t KOHLER COMPANY 1 Safety 7 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 important information to avoid possible equipment malfunction or damage pp 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 v
13. PW3000 TP User Manual UK Dated 25 09 14 57 8 Specifications Uninterruptible Supplies Ltd uw KOHLER COMPANY 8 Specifications Rated output power 9 kW 9 kW 9 kW 18 kW 18 kW Output power factor 0 9 0 9 0 9 0 9 0 9 Weight 56 kg 117 kg 177 kg 66 kg 187 kg Dimensions WxHxD 350x890x712 350x890x712 350x890x712 350x890x712 350x890x712 Colour Pantone Process Black C Topology True on line double conversion Nominal input voltage 1ph N 220 230 240 Vac 3ph N 380 400 415 Vac Input voltage tolerance 1ph N 110 276 Vac 3ph N 190 486 Vac Input current THD lt 5 linear load lt 7 non linear load Frequency range 45 55 Hz for 50 Hz system 55 65 Hz for 60 Hz system Frequency tolerance 2 Power factor gt 0 99 Rate output voltage 220 230 240 Vac Voltage tolerance 2 Voltage distortion lt 2 linear load lt 5 non linear load Overload capability linear load 5 minutes 105 110 1 minute 110 130 10 seconds 130 150 2 seconds gt 150 Nominal frequency 50 or 60 Hz 0 1 Hz Crest factor 3 1 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Supplies Ltd Ww KOHLER COMPANY 8 Specifications 2596 Load 89 7 93 3 50 Load 92 7 93 6 75 Load 93 5 93 5 100 Load 93 5 91 5 In ECO mode Up to 97 Inbuilt batteries No Yes Yes No Yes Number of batteries
14. Press the SELECT key a The cursor will flash on NO 1 Buzzer mute V o If you want to turn OFF the module use the UP DOWN keys so that the cursor indicates YES then select it 4 by pressing the SELECT key for less than one second B The UPS module will turn OFF without affecting the rest of the system 1 eas 1 1 den 1 o B To isolate the shit downmodule Figure 4 2 Turning of one module in a parallel system open its external input and output breakers and isolate the external battery cabinet fuses if used WARNING With the UPS shut down allow at least 5 minutes for the UPS DC capacitors to discharge before gaining internal access To turn on the module 1 2 3 Ensure the module s external Output Breaker is open Close the external UPS Input bypass Isolators as required to connect power to the UPS If an external battery cabinet is used close the fused isolator on the back of the battery cabinet together with any circuit breaker connected in the battery line On the back of the UPS cabinet close the input breakers M1 and M2 position ON a The fans will start running b The UPS will perform a self test and will then display the default status menu on the LCD On the UPS Operator Control Panel press the POWER ON key for more than one second a The alarm buzzer will sound and the UPS will start b After a few seconds the UPS will switch to its on line
15. SIX MONTHS TO PREVENT DEEP DISCHARGING BATTERIES THAT HAVE BEEN FOR WHATEVER REASON DEEP DISCHARGED ARE NOT COVERED BY THE WARRANTY 2 8 Extended Warranty The Standard Warranty may be enhanced by protecting the UPS with an Extended Warranty Agreement maintenance contract An Extended Warranty Agreement enhances the standard warranty by providing the following Regular preventative maintenance inspections Guaranteed speed of response to operational problems 24 hour telephone support Fully comprehensive excluding batteries cover Contact the Service Support Hotline on 0800 731 3269 for further details 2 9 Additional Service Maintenance Support In addition to providing support for the PowerWave PW3000 TP Uninterruptible Power Supplies Ltd can provide maintenance and support of a wide range of different UPS products If you are interested in an extended warranty for your PowerWave PW3000 TP or any other UPS you may have please complete the enquiry form shown opposite and return or FAX to 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 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 21 Uninterruptible Power Supplies Ltd 2 General Description KOHLER company Fax to 01256 386701 WWW upspower co uk Uninterruptible Power Suppl
16. UP DOWN keys To modify a parameter you must first highlight the parameter in the Control sub menu using the UP DOWN keys then press the SELECT key for less that a second to access the available parameter values Highlight the wanted parameter value using the UP DOWN keys then press the SELECT key for longer than one second to select the chosen value and return to the Control sub menu To exit the Control sub menu screen you must press the SELECT key for greater than one second Table 2 6 below provides details of the available settings and the default values 16 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description Control Description Values Default Buzzer Mute Mute the audible warning alarm No Yes No Turn OFF Single UPS Allows an individual module to be turned off in a No Yes No parallel system UPS Battery Test Initiate test of the batteries of a single UPS Schedule No Yes No Parallel UPS battery test Initiate test of the batteries of a group of UPS s Seg1 and Seg2 On Off On Off Clear EPO status Reset the UPS from emergency power off status No Yes No Reset Fault state Reset warning and alarming status and buzzer No Yes No Clear Event Log Reset all the events from the log file No Yes No Restore factory setting Rests the following parameters No Yes No Recover all settings in the LCD menu restore the E
17. air vents are not blocked Alarm code 81 is too high and the ambient temperature is not too high Wait for 10 minutes for the UPS to cool down before turning it on again If failed contact the service centre DC BUS over voltage UPS internal fault Contact UPS supplier Alarm code 21 DC BUS under voltage UPS internal fault Contact UPS supplier Alarm code 22 DC BUS unbalanced UPS internal fault Contact UPS supplier Alarm code 23 DC BUS softstart failure UPS internal fault Contact UPS supplier Alarm code 25 INV over voltage UPS internal fault Contact UPS supplier Alarm code 32 INV under voltage UPS internal fault Contact UPS supplier Alarm code 33 INV under voltage UPS internal fault Contact UPS supplier Alarm code 33 50 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY T Options Options 7 14 Backfeed protection Neutral Line Internal board Bypass Line Mains Backfeed Rela inactive Bypass No Supply Terminals E o Backfeed Terminals UPS CABINET BACKFEED CAUTION DO NOT OPEN EXCEPT QUALIFIED TECHNICIAN 60A 250V 100A 250V NEUTRAL INPUT BREAKER INPUT BREAKER SWITCH Figure 7 1 Backfeed protection option An external isolation contactor can be fitted in the UPS bypass supply line as shown in Figure 7 1 to protect the UPS against back feedi
18. back of the UPS cabinet open the input breakers M1 and M2 position OFF a Power will be removed from the UPS output terminals b The fans will stop c After a few seconds the UPS LCD display will power down 5 To totally isolate the UPS open the UPS Input bypass Isolators and where used open the external battery cabinet fuses isolator WARNING With the UPS shut down allow at least 5 minutes for the UPS DC capacitors to discharge before gaining internal access 4 6 Single module shutdown with UPS on battery 1 Turn off the individual load items 2 Onthe Operator Control Panel press the POWER ON key continuously for more than three seconds a The alarm buzzer will sound for three seconds b The output power will be immediately cut off c The fans will stop d After a few seconds the UPS LCD display will power down 3 To totally isolate the UPS open the UPS Input bypass Isolators and where used open the external battery cabinet fuses isolator WARNING With the UPS shut down allow at least 5 minutes for the UPS DC capacitors to discharge before gaining internal access 38 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 4 Operating Procedures 4 7 Single module using the internal maintenance bypass The inbuilt maintenance bypass circuit allows the UPS to be powered down while maintaining the load through the unprotected bypass s
19. into use without having been commissioned by a fully trained and authorised person This warranty does not apply to any losses or damages caused by misuse abuse negligence neglect unauthorised repair or modification incorrect installation inappropriate environment accident act of God or inappropriate application If the UPS fails to conform to the above within the warranty period then Uninterruptible Power Supplies Ltd will at its sole option repair or replace the UPS All repaired or replaced parts will remain the property of Uninterruptible Power Supplies Ltd As a general policy Uninterruptible Power Supplies Ltd does not recommend the use of any of its products in life support applications where failure or malfunction of the product can be reasonably expected to cause failure of the life support device or to significantly affect it s safety or effectiveness Uninterruptible Power Supplies Ltd does not recommend the use of any of its products in direct patient care Uninterruptible Power Supplies Ltd will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to Uninterruptible Power Supplies Ltd that the risks of injury or damage have been minimized the customer assumes all such risks and the liability of Uninterruptible Power Supplies Ltd is adequately protected under the circumstances THE UPS SYSTEM MAY CONTAIN BATTERIES WHICH MUST BE RE CHARGED FOR A MINIMUM OF 24 HOURS EVERY
20. 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 A WARNING always follow the operating instructions in this manual when starting or shutting down the UPS 2 3 3 UPS System operating modes The previous section described the internal operating modes of an individual UPS module but UPS systems are also categorised according to the way in which they are used at a system level and are typically described as being an on line off line or line interactive UPS system The PowerWave PW3000 TP can be operated in all three categories On line operation When used as an on line UPS system the PowerWave PW3000 TP UPS normally operate in its load on inverter mode and will automatically change over to load on bypass in the event of an inverter fault or overload This will transfer the load to the static bypass without interruption transfer time 0 If the transfer is due to an overload the UPS will attempt to switch back to the load on inverter mode if the overload clears and the inverter returns to normal operation An on line system therefore provides the highest degree of load protection and is always recommended if the critical load will not tolerate even a very bri
21. standards By using a unique modular construction and incorporating the latest technological developments in power engineering the PowerWave PW3000 TP represents a completely new generation of transformerless 3 phase UPS System 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 A full UPS Specification is given in Chapter 8 of this manual High reliability upgrade ability low operating cost and excellent electrical performance are just some of the highlights of this innovative UPS solution 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 art power protection devices that will provide your critical equipment with a steady and reliable power supply for many years Key features The highlights of this innovative UPS solution include its high reliability upgrade ability low operating costs and excellent electrical performance Energy savings thanks to 9396 AC AC efficiency 97 efficiency in ECO mode Low harmonic distortion 5 THDi and active power factor correction 0 99 input PF eliminates interference from other network equipment Paralleling and redundancy capability up to 4 units in parallel increases system capacity a
22. ta 3 Installation KOHLER COMPANY 3 5 1 Clearances The following notes are applicable to both the UPS and external battery cabinet The cabinet is force ventilated with extractor x x fans mounted on the back panel drawing cooling air through the inlet grills on the front TE of the unit Sufficient space must be provided y at the back and sides of the cabinet to permit adequate air flow Battery Cabinet UPS Front Rear access is required for connecting the power and control cables and also to operate the UPS power switches If direct rear access is not available sufficient space must be provided at the side of the cabinet to allow the Clearance mm X Y Z operator to reach around the cabinet to operate the power switches Minimum 500 500 1000 1000 Allow a minimum of 1000mm at the front of Figure 3 2 UPS amp Battery cabinet clearance requirements the unit for maintenance access and the safe passage of personnel 3 6 Planning the installation cabling considerations 3 6 1 General requirements The information in this section should help with the preparation and planning of the UPS power cabling It is the customer s responsibility to provide all external fuses isolators and cables that are used to connect the UPS input and output power supplies The UPS input and bypass terminals should be connected to the utility mains supply through a suitable LV Distribution board containing a circuit breake
23. 0 card into the slot 3 Secure the AS400 card in position using the screws removed in step 1 Note For more information on the AS400 card see the AS400 User s Manual 54 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY T Options 7 6 UPS Monitoring and automated control software 7 6 1 The importance of UPS management The utility supply is inevitably unreliable every now and then and assuring continuous power to all the facilities connected to it can be a difficult task The situation is further complicated if worldwide systems are managed via a Local Area Network LAN or Wide Area Network WAN However by using the PowerWave PW3000 TP UPS system in conjunction with purpose designed network management tools a systems administrator can take measures to back up data and prevent system errors or data loss even in the event of a relatively long utility supply outage In the case of an abnormal utility supply suitable UPS management software will also enable a system administrator to monitor all concerned networks from a central point and identify bottlenecks at an early stage Despite extensive system monitoring serious damage can still occur if an administrator fails to intervene in a timely manner so it is important that the installed UPS software will react automatically in such a case and shut down the supplied system in a safe and controlled manner Unin
24. 10 kVA Back View 20 kVA Back View 1 Operator Panel LCD Display 8 Cooling extractor fans 2 Operator Panel LEDs 9 Network interface AS400 slots 3 Operator Panel Control Keys 10 Emergency Power Off EPO contact 4 Ventilation inlets 11 RS232 port USB port 5 Power terminal block cover 12 Parallel port for parallel control bus cable 6 Mains and Bypass input supply circuit breakers 13 Wheels support brackets and brakes 7 Backfeed protection connection terminals 14 Maintenance Bypass Isolator cover plate Figure 2 6 PowerWave PW3000 TP Controls identification 1 0 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Supplies Ltd Ea A KOHLER COMPANY 2 General Description Battery Cabinet Front View Battery Cabinet Back View Figure 2 7 PW3000 TP Matching battery cabinet a kwON Ventilation inlets Fuse holder Connection terminals Wheels Support UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 11 Uninterruptible Power Supplies Ltd 2 General Description KOHLER company ntrol panel 2 5 UPS Control pane oe o o o The UPS Control Panel is located on the front of the UPS cabinet Normal Battery Bypass Fault The panel contains five status LED indicators an LCD display and a row of selection keys which include an ON OFF key and three navigation keys that are used to select various monitoring and configuration menu options presen
25. 9 14 Supplies Ltd ta Uninterruptible 3 Installation KOHLER COMPANY 10kVA 20kVA Fuse A 3x50A 3x100A UPS Mains Supply 3 x 380 400 415V Cable A 5x 10 mm 5x 35 mm Cable D 3x 10 mm 3x 35 mm Cable E Bespoke Bespoke Note Cable ratings are indicative based on clipped direct or in free air perforated cable tray and must be checked by the circuit designer against local regulations WIRING NOTES 1 eu sm cg m Connect the neutral cable to the bypass neutral terminal Main 2 which is connected to the mains input neutral terminal within the UPS There is no need to connect the input mains neutral Mains 1 Connect a one pole fork to terminal L3 Connect the mains input cable to L1 L2 Fit a ring termination to cable L3 supplied Using the M5 screw provided connect cable L3 and the link cable supplied to the fork fitted in terminal L3 Then connect the other end of the link cable to terminal M2 Connect the battery cables to the external battery cabinet if used see paragraph 3 8 Remove the link between JP1 and JP2 if the module is part of a parallel module system Connect the output terminals to the output breaker load distribution board The load distribution breakers should have a leakage current protective function to suit to the UPS voltage and current ratings Internal neutral link Remove link for
26. A 1x 50A 1x 100A UPS Mains Supply 3x 380 400 415V Cable A 3x 10 mm 3x 35 mm Cable D 3x 10 mm 3x 35 mm Cable E Bespoke Bespoke Note Cable ratings are indicative based on clipped direct or in free air perforated cable tray and must be checked by the circuit designer against local regulations 7 E ai WIRING NOTES 1 Connect the neutral cable to the bypass neutral terminal Main 2 which is connected to the mains input neutral terminal within the UPS There is no need to connect the input mains neutral Mains 1 2 Connect the 3 pole fork provided with the UPS between terminals L1 L2 and L3 3 Fita ring termination to the mains Line input cable supplied 4 Usingthe M5 screw provided connect the mains Line input cable and the link cable supplied to the fork fitted in terminals L1 L3 Then connect the other end of the link cable to terminal M2 5 Connect the battery cables to the external battery cabinet if used see paragraph 3 8 6 Remove the link between JP1 and JP2 if the module is part of a parallel module system 7 Connect the output terminals to the output breaker load distribution board The load distribution breakers should have a leakage current protective function to suit to the UPS voltage and current ratings Internal neutral link Remove
27. Log o surements SINIS amp le 6 4 Buzzer mute t Identification V o io 8 k Settings ig E LU Buzzer mute no Status battery test ok UPS iiien teel Schedule battery test no v Clear EPO Status fe Status EPO active Clear no Reset fault state Clear event log Restore factory settings Figure 2 12 Control sub menu single module installation e Status fault active Rest fault no Total events 50 Clear event log no UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 15 Uninterruptible Power Supplies Ltd 2 General Description KOHLER company t A Measurements Identification Turn OFF Single Single UPS Turn off no t 9 UPS fe Status battery test ok UPS Beiter iesi Schedule battery test no iB Parallell UPS Status battery test ok battery test Schedule battery test no A H Clear EPO Status ej Status EPO active Clear no H Reset fault state B e Gear eveni Total events 50 9 Clear event log no Restore factory e Reset no settings Figure 2 13 Control sub menu multi module installation its Cty To access the Control sub menu you must highlight the Control option in the Main Menu then press the SELECT key for longer than one second This opens the Control sub menu screen which allows you to scroll through the monitored parameters using the
28. N a parallel system O O JO JO JO JO JO FO JO O O O L1 L2 L3 N GNDM2 N GND L B B GND OJ JO Ol O O O O O O Line 1 Input d Battery Ground Line 2 Input Battery Neg Pole Line 3 Input Battery Pos Pole Input Line Neutral Input Mains Ground Output Ground Output Neutral Output Ground Figure 3 8 Three phase single input diagram with recommended cable and fuse sizing O O O O z 0 Zz o ie U br gt U mm O O O QO O O O UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 31 3 Installation Uninterruptible Supplies Ltd ta KOHLER COMPANY 10kVA 20kVA Fuse A 1x 50A 1x 100A UPS Mains Supply 3 x 380 400 415V Cable A 3x 10 mm 3x 35 mm Fuse C 1x 50A 1x 100A Cable C 3x 10 mm 3x 35 mm Cable D 3x 10 mm 3x 35 mm lt M Cable E Bespoke Bespoke FORK S Cable rati indicative based lipped RUM Note Cable ratings are indicative based on clippe La Seen MOT NUEND direct or in free air perforated cable tray and must be 1H HES E 2 L He checked by the circuit designer against local regulations WIRING NOTES 1 Cable E _ B Connect the neutral cables to the neutral terminals Mains 1 and Mains 2 2 Connectthe 3 pole fork provided with the UPS between termina
29. OVER IS NOT AN OPERATOR L3 ACCESS AREA D aage CIO e M e e PARALLEL PORT INTELLIGENT SLOT Figure 7 3 RS232 and USB Communication options A USB and an RS232 port are provided to enable communication between the UPS and a remote computer station 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 In the event of a power failure and a predicted UPS shutdown due to low battery autonomy the WAVEMON monitoring System will save the existing load data before initiating a shutdown of the load equipment 7 3 1 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 52 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY f Options 7 3 2 RS232 Port RS232 and USB Communication options Pin Signal Description yo 00000 2 TXD Transmit to external device Output 3 RXD Receive from external device Input 89082090 5 GND Ground tied to chassis Input Figure 7 4 RS232 Pin assignment To establish a communication
30. PO polarity locks the DC start up can be executed only when UPS is in bypass mode Only relevant to multi module installation Table 2 6 Control sub menu options 2 6 4 Identification sub menu The Identification menu allows access to the UPS model tj o data Serial number and firmware revision details as shown in Figure 2 14 This information is often requested Measurements when seeking assistance from the manufacture or service e i agent i o To access the Identification sub menu you must highlight the Identification option in the Main Menu then press the 4 X SELECT key for longer than one second This opens the e ENT Identification sub menu screen which allows you to scroll n gael eie through the stored data using the UP DOWN keys m PW3000 TP 10kVA To exit the Identification screen you must press the UP key for greater than one second ber X Serial Num XXXXXXX UPS firmware XXXX XX Figure 2 14 Identification Menu 2 6 5 Settings sub menu The Settings menu allows various UPS operating parameters to be configured as shown in Figure 2 15 Some Settings can impact on the UPS performance others can enable and disable functions within the UPS WARNING Failures and reduced protection can occur if the equipment is not set in an appropriate way The options presented in this menu should be set up or modified only by a qualified service engineer To access the
31. Power Supplies Ltd or one of its service agents WARNING There are no user serviceable part contained within the UPS WARNING Any operation described in this chapter that requires internal access to the UPS or external battery cabinets must be performed by authorised service personnel WARNING The UPS contains hazardous voltages even when switched off 5 2 System calibration To ensure optimum UPS operation and continuous efficient protection of the connected load it is recommended that the system s operating parameters are checked every six months and recalibrated where necessary The batteries should also be checked every six months depending on the ambient temperature 5 3 User responsibilities As there are no user serviceable parts contained within the UPS the maintenance required by the user are minimal apart from keeping the equipment clean and monitoring the working environment to ensure it is kept cool and dust free This will maximise the useful working life and reliability of the UPS and its batteries 5 4 Routine maintenance It is essential that the UPS system and batteries receive regular preventative maintenance inspection When the UPS is commissioned the commissioning field service engineer will attach a service record book to the UPS which will be used to log the full service history of the UPS Preventative maintenance inspections involve working inside the UPS which contains hazardous AC and DC voltages and should o
32. SELECT key 1s to access the Settings sub menu starting at Language B 3 Using the UP Down keys scroll though the Settings sub menu to Output voltage then press the SELECT key lt 1s to access the Output voltage change screen C Note that this may require password access if set 4 The values shown in the change screen will initially flash 5 Change the indicated value using the UP Down keys to select the required voltage 220V then press the SELECT key for greater than one second to accept the change D 6 This will take you back to the Settings sub menu where 220V will now be displayed in the Output voltage screen E 7 Continue scrolling through the Settings sub menu using the UP DOWN keys and exit to the main Settings menu by pressing the SELECT key for greater than one second from the Language screen 20 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 2 General Description 2 7 Warranty The PowerWave PW3000 TP UPS is supplied with a limited warranty that the UPS and its component parts are free from defects in materials and workmanship for a period of one year from the date of original commissioning or fifteen months from the date of original delivery whichever is the sooner This warranty is the only warranty given and no other warranty express or implied is provided This warranty is invalidated if the UPS is put
33. Settings sub menu you must highlight the Settings option in the Main Menu then press the SELECT key for longer than one second This opens the Settings sub menu screen which allows you to scroll through the available options using the UP DOWN keys To exit the Measurements screen you must press the UP key for greater than one second UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 17 2 General Description Uninterruptible Power Supplies Ltd A KOHLER COMPANY Event Log Language lt English gt GD User Password lt disabled gt co GER Audio alarm enabled Output voltage lt 230V gt UT Output frequency lt 50Hz gt y Power strateg lt normal gt DC start lt enabled gt v Automatic battery tests period lt 7 days gt Ambient temperature warning lt enabled gt Auto restart lt enabled gt in Automatic overload restart lt enabled gt Auto bypass lt disabled gt in Bypass frequency low limit lt 5 47 5Hz gt Bypass frequency high limit lt 5 52 5HZ gt Bypass frequency low limit lt 45Hz gt Bypass frequency high limit lt 55Hz gt Figure 2 15 Settings sub menu ECO mode voltage low limit lt 5 218 5V gt ECO mode voltage high limit lt 5 241 5V gt ECO mode frequency low limit lt 5 47 5H
34. UPS Status symbols Symbol Status Description ON LINE UPS is operating with the load supplied by the inverter ON BATTERY UPS is operating from battery power usually due to a mains failure ON BYPASS UPS is operating with the load supplied from the bypass mains power via an internal filter Note if there is a bypass supply failure while the UPS in on bypass it wil not transfer back to mains or to battery mode unless it is operating in ECO mode a ECO Mode UPS is operating with the load supplied from the bypass mains power via an internal filter In case of bypass mains failure the UPS transfers to Online mode or Battery mode and the load is supplied continuously ECO mode can be enabled disabled through the LCD settings or through the monitoring software ECO mode can be enabled disabled through the LCD settings or through the monitoring software CONVERTER mode UPS is set to operate with a different input and output frequency either 50Hz 60Hz or 60Hz 50Hz In case of input mains power failure the UPS transfers to ON BATTERY mode WARNING UPS is operating in the presence of an abnormal situation that does not stop the UPS from working See the Troubleshooting chapter for details FAULT The UPS has experienced a fault condition It may disconnect the load or transfer the load to bypass depending on the cause of the failure In all cases there will be a constant alarm and the LCD backlight will become red See the Troublesh
35. abled due to overload Auto bypass The automatic bypass can be disabled if the Enabled Disabled Disabled bypass power supply is very unstable UPS runs only on line or on battery Short circuit clearance When enabled short circuit can last for 4s before Enabled Disabled Disabled cutting off the output If short circuit is removed during this time the UPS will continue to run When disabled short circuit will only last for 100ms before the UPS output is cut off Bypass voltage low limit When the voltage in the bypass is below this limit 176 215V 184V the UPS changes operating mode Bypass voltage high limit When the voltage in the bypass is above this limit 245 276V 264V the UPS changes operating mode Bypass frequency low limit When the frequency in the bypass is above this 40 49 5 Hz 45 Hz limit the UPS changes operating mode Bypass frequency high limit When the frequency in the bypass is above this 50 5 70 Hz 55 Hz limit the UPS changes operating mode Eco mode voltage low limit When the voltage in the bypass is below this limit 196 1 096 596 the UPS changes operating mode Eco mode voltage high limit When the voltage in the bypass is above this limit 196 10 5 the UPS changes operating mode Eco mode frequency low When the frequency in the bypass is below this 1 10 5 limit limit the UPS changes operating mode Eco mode frequency high When the frequency in the bypass is above this 1 10 5 limit limit
36. acked in a very low temperature environment A installation to avoid possible electric shock hazard and equipment malfunction 3 4 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 an ambient temperature between 5 C to 60 C max 35 C for batteries and RH lt 95 The UPS should preferably be stored in the original packing and shipping carton but 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 temperature under charge overcharge or over discharge will destroy batteries Charge the battery both before and after storing 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 Extreme 3 5 Planning the installation site considerations A certain amount of pre planning will help ensure a smooth and trouble free installation of the UPS system The following guid
37. ad from the raw mains while the UPS is otherwise shut down for maintenance repair UPS AC Output load supply Figure 2 1 shows that the UPS output Load Supply can be provided through one of three power paths depending on the UPS operating mode the criteria for operating under each of these UPS modes is described in 2 3 2 From the inverter via the static switch and output relay From the static bypass line via the static switch and output relay From the maintenance bypass line via the maintenance bypass switch UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 5 Uninterruptible Supplies Ltd ta 2 General Description KOHLER company 2 3 2 UPS Module operating modes All the diagrams in this section depict a single UPS cabinet Where two or more cabinets are connected as a parallel system they will always adopt the same operating mode due to their parallel control logic signals Load on Inverter Maintenance Bypass Line Bypass Input Mains Input External Battery Option Static Bypass Line RECTIFIER DC CONVERTER Maintenance Bypass Switch POWER INVERTER Output UPS AC Output STATIC SWITCH Figure 2 2 Load on inverter This is the normal operating mode and the only one that provides the load with continuously processed and backed up power In this mode the mains supply is converted to controlled DC by the Rectifier DC Converter then converted back to the rated AC ou
38. aker are all open On each module in turn 3 4 6 Close the external UPS Input bypass Isolators as required to connect power to the UPS If an external battery cabinet is used close the fused isolator on the back of the battery cabinet together with any circuit breaker connected in the battery line On the back of the UPS cabinet close the input breakers M1 and M2 position ON a The fans will start running b The UPS will perform a self test and will then display the default status menu on the LCD Check that no abnormal conditions are shown on any of the modules LCD panel System start up 7 10 11 12 13 14 15 On the UPS operator control panel of ANY module press the POWER ON key for more than one second a The alarm buzzer will sound and ALL the UPS modules will start b After a few seconds ALL the UPS modules should switch to the on line mode simultaneously Check that no abnormal conditions are shown on any of the modules LCD panel On any one of the UPS modules press the POWER ON key continuously for more than three seconds a All UPS modules will transfer to on bypass mode simultaneously Check that no abnormal conditions are shown on any of the modules LCD panel Close the output breaker on ALL modules to parallel the UPS output On any one of the UPS modules press the POWER ON key continuously for more than three seconds a All the UPS modules will switch to the on li
39. battery cabinet is closed and any circuit breaker connected in the battery line is closed On the back of the UPS cabinet close the input breakers M1 and M2 position ON a The fans will start running b The UPS will perform a self test and will then display the default status menu on the LCD m 3 Onthe UPS Operator Control Panel press the POWER ON key for more than one second a The alarm buzzer will sound and the UPS will start b After a few seconds the UPS will switch to its on bypass mode Check that the LCD indicates the on bypass status and no warning alarms are present Switch the Maintenance Switch from BPS to UPS Refit the Maintenance Switch cover plate on the back of the UPS The UPS will automatically transfer to on line mode Check that the LCD indicates the on line status and no warning alarms are present O 0 NO ie The UPS is now fully operational and providing protected output power UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 39 Uninterruptible Power Supplies Ltd 4 Operating Procedures KOHLER Company 4 8 Parallel module system procedures MAINS BYPASS System Input Breaker System Bypass Breaker UPS 1 UPS2 UPS 3 UPS 4 Input bypass Input byp Input byp Input byp Isolator Isolator Isolator Isolator
40. block cover on the back of the battery cabinet to gain access to the main terminal block Connect the protective earth cable GND between the battery GND terminal on the UPS terminal block see Figure 3 7 to Figure 3 10 and the GND terminal on the battery cabinet terminal block 5 Connect the battery positive B and negative B terminals on the UPS terminal block see Figure 3 7 to Figure 3 10 to the corresponding B and B terminals on the battery cabinet terminal block 6 Reconnect the UPS internal batteries at the Main Disconnect and Main Disconnect that were disconnected earlier 7 Refit the battery cabinet terminal block cover Do not close the battery fuses on the battery cabinet until the system has been commissioned Po m 3 9 Multi cabinet configuration and paralleling cables P Key Point This section is required only if two or more cabinets are connected as a parallel system Ensure the cable link is removed from JP1 JP2 on the UPS terminal block see Figure 3 7 to Figure 3 10 For all modules remove the parallel port cover plate on the rear of the UPS see item 12 in Figure 2 6 Connect a parallel bus cable 25 pin 3m cables supplied between the parallel ports of each UPS in a daisy chain Fit the modified parallel port cover plate supplied to the rear of the UPS taking care not to trap the cables Pens 3 10 Optional remote monitoring and control facilities Fit and connect any optional equipmen
41. charge voltage P Key Point When starting the UPS in this manner the batteries will immediately begin to discharge If you want Check that all the loads connected to the UPS are turned off If an external battery cabinet is used close the fused isolator on the back of the battery cabinet together with any circuit breaker connected in the battery line On the UPS Operator Control Panel briefly press the POWER ON key a The fans will start running b The UPS will perform a self test and will then display the default status menu on the LCD Press the POWER ON key again for more than one second a The alarm buzzer will sound and the UPS will start b After a few seconds the UPS will switch to its on battery mode Check that the LCD indicates the on battery status and no warning alarms are present other than those associated with the battery on load status The UPS is now fully operational and providing protected output power but the battery is on load and discharging with the accompanying alarms You can now switch on the loads If possible turn on the loads sequentially to prevent a UPS overload occurring due to combined inrush currents a Ifthe UPS is left to run in this condition sufficiently long the battery will fully discharge and the UPS will shut down with the loss of the output supply b If the mains supply is connected restored while the UPS is on battery it will automatically switch to
42. cted network In a multi module UPS system the SNMP interface can communicate system wide data or data for an individual UPS module SNMP card installation The UPS does not have to be shutdown before installing a communication card 1 Remove the two screws that protect the Intelligent Slot of the UPS 2 Insert the SNMP card into the slot 3 Secure the SNMP card in position using the screws removed in step 1 Note For more information on the SNMP Cards see the SNMP User s Manual UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 53 Uninterruptible Supplies Ltd ta T Options A KOHLER COMPANY 7 5 AS400 Interface card CAUTION THE COVER IS NOT AN OPERATOR ACCESS AREA PARALLEL PORT INTELLIGENT SLOT Pin Description yo 1 UPS Fail Output 2 Summary Alarm Output 3 GND Input 4 Remote Shutdown Input 5 Common Input 6 Bypass Output 7 Battery Low Output 8 UPS ON Output 9 Line Loss Output Figure 7 6 AS400 Pin assignment The optional AS400 interface card fits into the AS400 Slot located on the back of the PowerWave PW3000 TP and provides volt free alarm outputs via a standard 9 pin D type connector It also provides a remote shutdown input which operates on the application of 5 12Vdc AS400 card installation The UPS does not have to be shutdown before installing a communication card 1 Remove the two screws that protect the AS400 Slot of the UPS 2 Insert the AS40
43. d and the carrier must be informed within a maximum of 7 days following receipt of the equipment If shipping damage is discovered store all packing materials for further investigation gt Ensure that the received UPS equipment corresponds to the description indicated in the delivery note The package should contain 1 x PowerWave PW3000 TP UPS 1 x User manual 1 x Parallel cable 1 x Parallel port cover plate 1 x Metal fork 1 pole 1 x Metal fork 3 poles 1 x Cable for connections from M2 to metal fork 2 x M5x12 HEX screw 4 x Cable glands 1 x Monitoring Software CD UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 23 Uninterruptible Powerm 3 Installation Supplies Lt KOHLER COMPANY 3 2 1 Site transportation Please observe the following precautions when you transport the UPS equipment between its off loading site and the intended installation or storage location CAUTION Potential dangers A e Ifthe UPS battery cabinet is tilted by more than 10 it could cause internal damage If tilting occurs do not connect the UPS to the mains electrical supply e The weight of the UPS battery cabinet can cause serious personal injury and or structural damage to the surrounding area if dropped in transit Always take extreme care when moving the equipment CAUTION Storage A e The UPS should be stored in the original packing and shipping carton e The recommended storing temperature for the UPS is betwe
44. e 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 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 is sent to the connected users These system event routines are a part of the management software and can be configured in accordance with local application requirements The software of your PowerWave PW3000 TP UPS unit can be integrated into a network in two ways 1 By the server which is supplied 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 n 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 modul
45. e is less than 50 of specified after full charged When replacing the batteries the whole battery string should be replaced with the same number of batteries of the same battery type Individual batteries should not be replaced If the UPS is not used for a period of time the batteries should be charged at least every 4 6 months When healthy the batteries will charge to 90 in approximately four hours however it is recommended that the batteries are charged for 48 hours after long term storage 5 7 Battery disposal and recycling Batteries contain dangerous substances that will harm the environment if carelessly discarded and should be disposed of in accordance with local recycling recommendations ay ed 48 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY o Troubleshooting 6 Troubleshooting 6 1 Contacting Service Please collect the following information before calling the After Sales Service Department Model number serial number Date on which the problem occurred LCD LED display information buzzer alarm status Mains power condition load type and capacity environment temperature ventilation condition Information on external batteries battery capacity quantity Uninterruptible Power Supplies Limited has a service department dedicated to providing routine maintenance and emergency service cover for your UPS If you have any q
46. e that is used in order to execute a command typically a shutdown command in a remote system 7 6 4 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 56 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY f Options 7 6 5 RCCMD Server shutdown In order that remote shutdown of servers can take place initiated by the SNMP card or WAVEMON software further licenses must be purchased The license s for the RCCMD client or listening software that resides in each target server Note Virtual servers may not need a license per virtual server client Please contact Technical Support to discuss your requirements UPS463 01 02 PowerWave
47. ef supply interruption If the load fails to successfully retransfer to inverter three times within ten minutes further transfer attempts will be locked out the load will remain on bypass and a warning message will appear on the LCD panel Off line and line interactive operation When the PowerWave PW3000 TP is used as an off line or line interactive UPS system it normally operates in its load on bypass mode with the load being supplied through the static bypass supply however the rectifier DC Converter and battery charger are still powered up to maintain battery charging and the inverter section is enabled and on standby If the bypass supply fails the static switch will automatically transfer the load to the inverter within 3 5ms and if the rectifier input mains supply is missing when the transfer takes place the inverter will operate immediately from battery power If the bypass supply returns to normal when operating with the load on inverter the load automatically transfers back to the static bypass load on bypass mode and the inverter returns to its standby operation An off line line interactive system is a slightly more efficient than an on line system due to the reduced rectifier inverter losses during normal operation and this is sometimes referred to as the ECO mode However this mode is recommended only if the connected load equipment can tolerate a power interruption of up to 3 to 5 ms dur
48. elines should be taken into account when planning a suitable UPS location and operating environment 1 The UPS is designed for indoor installation only 2 The route to the installation location must allow the equipment to be transported in an upright position 3 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 fork lift during transit 4 Locations with high ambient temperature moisture or humidity must be avoided a Theinstallation site humidity should be 9096 non condensing b The prescribed ambient temperature is 0 C to 40 C An ambient temperature of 20 C is recommended to achieve a long battery life c Any requested 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 5 The following environmental conditions should also be considered a Fire protection standards must be respected The floor material should be non flammable b The location must be free of dust and corrosive explosive gases c The location must be vibration free d Aminimum clearance of 50cm is required on the sides of the equipment to allow the free passage of cooling air UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Supplies Ltd
49. en 5T and 40T 4 35 C for batteries e The UPS and the batteries must be protected from high humidity which should not exceed 95 RH non condensing 3 3 Unpacking Mounting brackets 4 386mm J 8mm diameter 4 places Mounting brackets Figure 3 1 Unpacking and positioning the PowerWave PW3000 TP 1 Using a forklift move the unit to the location where it is to be installed Note The UPS has wheels to make final positioning easy after it has been unpacked but these are not suitable for moving the unit over long distances 24 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 Installation 2 Cut the wrappers and remove the packing carton by pulling it upwards 3 Remove the protection packaging from the sides and top of the unit then remove the side mounting brackets securing the unit to the pallet Retain the packaging materials for possible future shipment of the UPS 4 Using the wooden piece removed from the top of the UPS as a ramp carefully slide the UPS off the pallet to its final position 5 Reattach the side mounting brackets to increase the cabinet stability 6 If desired the mounting brackets can be fixed to the floor using M8 bolts In this case you must wait until the UPS is fully dried inside and outside before proceeding with the WARNING Water condensation may occur if the UPS is unp
50. estriction 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 Table 1 1 Standards 2 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 2 General Description 2 General Description 2 1 Introduction Congratulations on your purchase of the PowerWave PW3000 TP 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 changes brought about by the introduction of new server technologies migration and centralization Such demands are well met by the PowerWave PW3000 TP 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 Reliability and quality
51. ies Ltd Woodgate Bartley Wood Business Park Hook Hampshire RG27 9XA Tel 01256 386700 Name uhuhguesesoenieneten Gne n edi denti e JOD tles 1 tue e aie a Fei r tes enti ee aed led Company Nr c t Address ss aeecanadetnedtunbcashetdactzesshecvalcedbeyedehbedie pusdesesianconsescesacesseeeseaaaeets POSEGOGG eiiutediuceri A eee E eee eee ee T l AmeeocneerisdtemMaii e UE Ie ALD LUN 2 e emm Emal SP m Please contact me to discuss C Extended Warranty options for my PowerWave PW3000 TP UPS Extended warranty options for my UPS System as below C Other s dive chant Ea a O Re ina 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 Wwww upspower co uk 22 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Supplies Ltd ta KOHLER COMPANY 3 Installation Installation 3 1 Introduction This chapter contains essential information concerning the unpacking positioning installing and cabling of the PowerWave PW3000 TP 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
52. ing the transfer period A WARNING The on line mode must always be used for critical load protection 2 3 4 Multi module parallel system operation To expand the overall UPS system rating several up to four PowerWave PW3000 TP UPS cabinets can be connected together to operate as a parallel UPS system This is achieved by connecting each cabinet s output power terminals in parallel at an external load distribution panel and linking together the parallel control bus in each cabinet to effectively provide a single parallel control bus The parallel control bus cable is connected to a socket located near the top rear of the cabinet which is covered by a blanking plate when not used item 12 in Figure 2 6 8 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 2 General Description It is essential that any installed UPS power protection system can be expanded to meet a growing load demand without compromising the existing load supply This situation is easily managed by a PowerWave PW3000 TP system which makes it possible to add a further cabinet to an existing UPS system without disrupting the load supply Note Every PowerWave PW3000 TP cabinet is supplied with all the features required for parallel operation to eliminate any need for time consuming or expensive upgrading on site Capacity versus redundant module system The paralleled UPS modules can be
53. ioned and handed over to the customer controls as described in Chapter 2 4 and Chapter 2 5 together with all associated external switchgear and WARNING Before you operate this equipment you should understand the location and function of the UPS distribution panels 4 1 1 Operating procedure summary A typical PowerWave PW3000 TP installation is shown in Figure 4 1 This chapter contains the following procedures Paragraph 4 2 Single module start up with mains supply Paragraph 4 3 Single module start up without mains supply Paragraph 4 4 Single module changing the operating mode Paragraph 4 5 Single module shutdown with mains supply present Paragraph 4 6 Single module shutdown with UPS on battery Paragraph 4 7 Single module using the internal maintenance bypass Paragraph 4 8 Parallel module system procedures Paragraph 4 9 Parallel system start up Paragraph 4 10 Parallel system changing the operating mode Paragraph 4 11 Parallel system start stop one module Paragraph 4 12 Parallel module complete system shut down Paragraph 4 13 External Maintenance Bypass operation Paragraph 4 14 Operating a frequency changing system Paragraph 4 15 Emergency Stop 36 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Power Supplies Ltd Uninterruptible KOHLER COMPANY 4 Operating Procedures 4 2 Single module start up with mains supply Use this procedure to start a single mod
54. l installation 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 fx Ww c When carrying out any 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 mains supply isolators 5 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 6 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 or bypass distribution board terminals All loads are disconnected at the load distribution board The UPS is fully shut down and voltage free The UPS Maintenance Bypass Isolator is open OFF and o 3 7 1 Power cabling procedure The input and output power cables are connected to a terminal block which is located in a terminal box on the back of the UPS cabinet behind a removable cover as shown in Figure 3 5 To prepare for power cabling 1 Remove the cover 1
55. les should switch to the on line mode simultaneously 6 Checkthat no abnormal conditions are shown on any of the modules LCD panel 7 Onany one of the UPS modules press the POWER ON key continuously for more than three seconds a All UPS modules will transfer to on bypass mode simultaneously 8 Checkthat no abnormal conditions are shown on any of the modules LCD panel 9 Close the external Output Breaker on ALL modules to parallel the UPS output 10 Close the System Output Breaker to connect the UPS on bypass output to the load distribution panel 11 Open the external System Bypass breaker 12 The parallel UPS system is now fully operational and providing protected output power 44 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Power Supplies Ltd Uninterruptible A KOHLER COMPANY 4 Operating Procedures 4 14 Operating a frequency changing system In a frequency changing system the UPS output frequency is different to its input frequency and therefore it is not possible to implement any form of bypass circuit 4 14 1 Frequency changer starting the UPS 1 2 3 Check that all the loads connected to the UPS are turned off Close the external UPS Input bypass Isolators as required to connect power to the UPS If an external battery cabinet is used close the fused isolator on the back of the battery cabinet together with any circuit breaker connected in the battery line
56. link between the UPS and a computer connect one end of the serial communication cable that is supplied with the UPS to the RS 232 port on the UPS and the other end to the RS 232 port on a computer The cable pins for the RS 232 communication port are described in Figure 7 4 7 4 Serial Network Management SNMP card Internal SNMP Card im Hm m I v 9 o ENSE z ES gee N SNMP MONITOR External SNMP Adapter M Figure 7 5 SNMP connection options 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 SNMP adaptor requires a PC with terminal connections and least one Ethernet network connection The optional SNMP card fits into the Intelligent Slot located on the back of the PowerWave PW3000 TP as shown in Figure 7 5 Alternatively SNMP connectivity can be implemented using an external SNMP adapter connected to the UPS RS232 output as shown An 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 outputs its data in SNMP format to the conne
57. link for a parallel system O FOF O JO JO JO FO FO JOP FO FO O IOIO O O L1 L2 L3 N GND M2 GND L N GND JP1 JP2 B B GND O JO JO O O O Three pole fork Line Input Input Line Neutral Input Mains Ground O O FO 1O O O O O Battery Ground Battery Neg Pole Battery Pos Pole Output Ground Output Neutral Output Ground Figure 3 10 Single phase dual input diagram with recommended cable and fuse sizing UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 33 Uninterruptible Supplies Ltd 3 Installation A KOHLER COMPANY 3 8 Battery cabling procedure Safety Notes dangerous voltages if power is connected to the UPS Battery replacement and connections should only be WARNING Opening or removing the UPS Battery enclosure covers will create the risk of exposure to A carried out by electrically qualified personnel If the UPS is delivered without batteries Uninterruptible Power Supplies Ltd is not responsible for any damage or malfunction caused to the UPS by the incorrect storage installation or connection of batteries by third parties Final battery connection must be supervised by the commissioning engineer Do not attempt to complete the battery wiring or close any battery isolator before the system has been commissioned 3 8 1 Internal battery connections Connection points Connection points 1 x 24 Batteries 2 x 24 Batteries Figure 3 11 UPS Cabine
58. ls L1 L2 and L3 3 Fita ring termination to the mains Line input cable supplied 4 Using the M5 screw provided connect the mains Line input cable to the fork L HN HGND JPT P2 5 Connect the bypass input Line cable to M2 Q 6 Connect the battery cables to the external S battery cabinet if used see paragraph 3 8 7 Remove the link between JP1 and JP2 if the module is part of a parallel module system 8 Connect the output terminals to the output breaker load distribution board The load distribution breakers should have a leakage current protective function to suit to the UPS voltage and current ratings Remove link for parallel system Internal neutral link O JO FO JO JO FOF FOP JO FOF FO LO JO JO FO FO JO L1 L2 L3 GND L N GND JP1 JP2 B B GND OJ 1O OI O OI O O O z 0 Zz iw M2 N Three pole fork Battery Ground Battery Neg Pole Line Input Battery Pos Pole Input Line Neutral Input Mains Ground Bypass L Input Output Ground Bypass Neutral Output Neutral Bypass Input Ground Output Ground Figure 3 9 Single phase dual input diagram with recommended cable and fuse sizing 32 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Supplies Ltd ta 3 Installation KOHLER COMPANY 10kVA 20kVA Fuse
59. m ALL the connected modules must be of the same output rating i e it is not permissible to combine 10kVA and 20kVA cabinets in a parallel The PowerWave PW3000 TP cabinets are identified according to their power rating i e 10kVA or 20kVA 10kVA 20kVA Maximum power connection kW kVA 9 0 10 18 10 UPS Cabinet Dimensions WxHxD mm 350 x 890 x 712 350 x 890 x 712 UPS Cabinet Weight excluding batteries kg 56 66 UPS Cabinet Weight including batteries 5 mins 16 mins kg 117 177 187 N Table 2 1 PowerWave PW3000 TP Cabinet specifications 2 3 Functional description of operation This section describes The internal operation of an individual UPS power module at block diagram level The various operational modes of an individual UPS power module UPS system operational modes On line versus Off line system operation Multi module system operation and paralleling considerations 2 3 1 PowerWave PW3000 TP Module block diagram Maintenance Bypass Line A Maintenance Bypass Switch Bypass Static Bypass Line Input RECTIFIER POWER DC CONVERTER INVERTER Output Relay Mains UPS AC Input Output CHARGER Automatic STATIC SWITCH External Batt Switch Battery Option BATTERY Figure 2 1 PowerWave PW3000 TP UPS block diagram UPS Mains input supply The UPS mains input can be connected to a 3ph N or 1ph N supply It is connected to the Rectifier DC Converter via the Mains 1 input breaker a
60. 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 gt gt 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 e Due to the fitted high energy batteries and heavy weight do not stack the pallets gt The packing container protects the UPS from mechanical and environmental damage during transit This protection is further increased by wrapping the PowerWave PW3000 TP UPS with a plastic sheet Upon receiving the UPS you should carefully examine the packing container for any sign of physical damage CAUTION Claims for visible shipping damage must be notified to the carrier immediately on receipt Other shipping damage claims must be filed immediately when foun
61. nd availability Integrated automatic and manual bypass simplifies maintenance and reduces need for external switchgear Frequency converter operation to convert 50 to from 60 Hz Compact solution that can achieve 5 16min runtime with internal batteries Supports different wiring schemes three phase and single phase input as well as single and dual input feed Matching external battery cabinet available for extended autonomy time UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 3 Uninterruptible Supplies Ltd ta 2 General Description KOHLER COMPANY 2 2 PowerWave PW3000 TP Model range The PowerWave PW3000 TP range comprises 10kVA and 20kVA UPS models contained in identically sized cabinets Depending on the required autonomy time the UPS batteries can be housed within the UPS cabinet with various arrangements or housed in a purpose designed and matching battery cabinet which can be installed adjacent to the UPS cabinet to form an aesthetically pleasing suit Although the UPS produces a single phase output supply its input supply can be connected to either a single or three phase input supply It can also be used in a frequency changer role with 50Hz 60Hz input output or vice versa Up to four UPS cabinets can be connected in parallel either to increase the overall system output capability or introduce a level of module redundancy to further enhance the system availability Key Point In a parallel syste
62. nd the Input RFI Filter where it is fused If a single phase input supply is used the three input line terminals are linked together and the contacts of the input breaker Mains 1 are effectively paralleled 4 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 2 General Description UPS Bypass input supply A single phase bypass supply is connected directly to the Maintenance Bypass Switch and also to the bypass side of the static switch via a fuse on the Input EMI Filter In a standard installation the bypass input terminals are usually linked to the mains input supply L3 terminal so only one mains supply feed is required this is often referred to as a Single Feed input configuration as opposed to a Dual Feed input where a separate bypass supply is used See paragraph 3 7 for details concerning Single Feed amp Dual Feed input supply configurations Battery charger The battery charger is powered from both the Mains Input and Bypass Input supplies and charges the internal or optional external batteries when either of these supplies is present The charger is rated at 2A but can be increased to 4A if required depending on battery topology Rectifier DC Converter The Rectifier DC Converter provides a controlled DC voltage for the Inverter input This can be sourced either from the UPS Mains input supply AC of from the batter
63. ne mode Close the System Output Breaker to connect the UPS output to the load distribution panel The parallel UPS system is now fully operational and providing protected output power You can now switch on the loads If possible turn on the loads sequentially to prevent any UPS overloads occurring due to combined inrush currents 4 10 Parallel system changing the operating mode When the parallel system is turned on and operational you can quickly switch between its various operating modes as shown below From To Action ON LINE ON BYPASS Press the POWER ON key for 3 seconds on ANY module ON BYPASS ON LINE Press the POWER ON key for 3 seconds on ANY module ON BATTERY ON LINE Restore the mains bypass power supply If the bypass is disabled in the SETTINGS menu when pressing the POWER ON key for three seconds the UPS will go from ON LINE to ON BATTERY mode UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 41 4 Operating Procedures Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 11 Parallel system start stop one module If a parallel system includes a redundant module you can use this procedure to stop or start an individual module without affecting the UPS critical load power To turn OFF one module 1 From the default screen press the DOWN key for one second to access g the Main Menu Scroll to the Turn OFF Single H Module screen as shown A
64. ng in the event of a critical static switch failure The external contactor magnetic trip coil is connected to the backfeed contactor control terminals located behind a small cover on the back of the UPS An AC contactor rated at 100A minimum should be used for example a three phase contactor of 3x 40A rating with the three poles wired in parallel The trip coil should be rated according to bypass supply UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 51 Uninterruptible Supplies Ltd ta T Options A KOHLER COMPANY 7 2 Emergency Power OFF EPO RS232 USB CAUTION L4 THE COVER IS NOT AN OPERATOR L3 ACCESS AREA D Mo 7o e PARALLEL PORT INTELLIGENT SLOT Figure 7 2 Emergency Power OFF An external Emergency Power OFF EPO circuit can be connected to the UPS to enable it to be shut down remotely in an emergency situation By default the external EPO circuit requires a normally closed contact which shuts down the UPS when opened A link must be fitted to the EPO connector located on the back of the UPS if the EPO facility is not used as shown above in Figure 7 2 be reconfigured through the USB RS232 port to be a normally open contact However such a Key Point Although the EPO facility is normally factory set to be a normally closed contact it can Pp change must be carried out by an approved service engineer 7 3 Computer communication options EPO RS232 USB 42 CAUTION THE C
65. nly be performed by authorised service personnel During a preventative maintenance inspection the field service engineer will check Site environment conditions Integrity of electrical installation Cooling airflow Rectifier operation and calibration Inverter operation and calibration Static switch operation Battery status Load characteristics Integrity of alarm and monitoring systems Operation of all installed optional equipment 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 Paragraph 2 8 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 47 5 Maintenance Uninterruptible Power Supplies Ltd A KOHLER COMPANY 5 5 Battery testing The battery test takes approximately 3 minutes and should be performed only if There are no alarm conditions The battery is fully charged The mains input supply is present Battery testing can be performed from the Operator Control Panel and carried out independently of the operating mode on line or on bypass and whether or not the load is connected 5 6 Battery maintenance The UPS batteries should be replaced under the following conditions If the battery service life 3 5 years at 25 C ambient temperature has been exceeded When the discharging tim
66. odes 2 3 8 UPS System operating modes 2 3 4 Multi module parallel system operation 2 4 PowerWave PW3000 TP User controls 2 5 UPS Control panel 2 5 1 LED status indicators 2 5 2 LCD Display 2 5 8 UPS Control panel operator keys 2 6 LCD Menu navigation 2 6 1 EventLog 2 6 2 Measurements sub menu 2 6 3 Control sub menu 2 6 4 Identification sub menu 2 6 5 Settings sub menu 2 7 Warranty 2 8 Extended Warranty 2 9 Additional Service Maintenance Support Installation 3 1 Introduction 3 2 Taking receipt of the UPS 3 2 1 Site transportation 3 3 Unpacking 3 4 Storage 3 5 Planning the installation site considerations 3 5 1 Clearances 3 6 Planning the installation cabling considerations 3 6 1 General requirements 3 6 2 UPS Cable and fuse sizing 3 6 3 Power cabling for a parallel system 3 7 Connecting the UPS power cables 3 7 1 Power cabling procedure 3 8 Battery cabling procedure 3 8 1 Internal battery connections 3 8 2 External battery cabinet cabling procedure 3 9 Multi cabinet configuration and paralleling cables 3 10 Optional remote monitoring and control facilities e i 3 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY Operating Procedures Maintenance 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 5 1 5 2 5 3 5 4 5 5 5 6 5 7 Troubleshooting Options Specifications 6 1 6 2 7A 7 2 7 3
67. oltages by opening or removing 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 PW3000 TP 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 PEPPRRPPRP UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 1 Uninterruptible Power Supplies Ltd 1 Safety A KOHLER COMPANY 1 3 Declaration of Safety conformity and CE marking The PowerWave PW3000 TP 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 e 2006 95 EC Low voltage directive 2004 108 EC Electromagnetic Compatibility directive EMC Standards as reference e 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 R
68. ooting chapter for details OVERLOAD UPS is overloaded The load should be reduced to 9096 of the UPS rated capacity in order to stop the alarm BATTERY TEST UPS is performing a battery test BATTERY UPS battery is disconnected or defective accompanied by an alarm DISCONNECTED FANE gt ae Table 2 4 UPS Status Symbols UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 1 3 Uninterruptible Power Supplies Ltd 2 General Description KOHLER company 2 5 8 UPS Control panel operator keys The keys on the operator control panel allow the user to Operator Function Operation KEY Power ON OFF Press for one second to turn ON the UPS Press for three seconds to turn OFF the UPS or change the UPS operating mode between on line and on bypass SCROLL UP If pressed for less than one second this key scrolls UP through the current menu options If pressed for more than one second this key exits the current menu back to the previous menu level SCROLL DOWN If pressed for less than one second this key scrolls DOWN through the current menu options SELECT EDIT This key is used when editing the value of a parameter in the setup configuration screens If pressed for less than one second it accepts the entered value and if pressed for more than one second it saves the setting and exits the screen Lt 7 7 e Table 2 5 UPS Control panel operator keys 2 6 LCD Men
69. operated as either a capacity or redundant module system The difference between the two is that a capacity system is rated such that ALL the UPS modules are required to furnish the specified full load power whereas a redundant module system is designed with one or more UPS module over and above that required to supply the full load In a redundant module system it is therefore possible to lose one or more UPS module without disrupting the load whereas this is not the case in a capacity system where the loss of one UPS module would automatically transfer the load to the bypass supply Parallel control bus All the UPS modules within are connected to a parallel control bus which carries various inter module control signals used for frequency synchronisation load sharing etc By using sensing signals passed over the parallel control bus each module can electronically compare its own frequency and output current with that of its neighbouring module and carry out fine adjustments to achieve balanced conditions UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 9 Uninterruptible Supplies Ltd ta 2 General Description KOHLER Company 2 4 PowerWave PW3000 TP User controls The following illustrations show the location of the PowerWave PW3000 TP power switches and fused isolators that are used when operating the equipment The Operator Control Panel is described in paragraph 2 5 10 20 kVA Front View
70. or message Display Possible Cause Remedy No indication on LCD display No input voltage Check the building wiring and input cable No warning tone even though system is Check that the external Input bypass Isolator is closed connected to mains power supply Bypass LED ON even if the power supply Inverter not switched on Press the POWER ON key to turn on UPS and switch to on is available line mode Battery LED ON and audible alarm Input voltage and or Check that the external Input bypass Isolator is closed sounding frequency out of tolerance Check availability of input power source Check the building wiring and input cable Emergency supply period shorter than Batteries not fully charged or Charge the batteries for at least 12 hours and then check nominal value defective capacity 6 2 2 Troubleshooting based on error message Display Possible Cause Remedy Inv Overload Failure Overload Check the loads remove non critical loads Alarm code 42 Check if some loads have failures Byp Overload Failure Overload Check the loads remove non critical loads Alarm code 43 Check if some loads have failures Output short circuit Short circuited output Remove all the loads Alarm code 31 Turn off the UPS Check if UPS output and loads are short circuited Ensure short circuit is removed before turning on the system again Heat sink Over Temperature Fault Inside temperature of UPS Ensure the UPS is not overloaded the
71. ou must press the UP key for greater than one second Figure 2 10 Menu navigation Main Menu access 14 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 2 General Description 2 6 2 Measurements sub menu The Measurements menu allows various UPS operating parameters to be observed as shown in Figure 2 11 To access the Measurements sub menu you must highlight the Measurement option in the Main Menu then press the SELECT key for longer than one second This opens the Measurements sub menu screen which allows you to scroll through the monitored parameters using the UP DOWN keys To exit the Measurements screen you must press the UP key for greater than one second 2 6 3 Control sub menu The Control menu allows various UPS operating features to be set m m m Event Log il 4 Output Power W Output Power VA Output Current A Load percentage 96 Output voltage V Output frequency Hz Battery voltage V Battery capacity 96 DC Bus voltage V Temperature deg C Figure 2 11 Measurements sub menu There are two versions of the Control sub menu depending on whether or not the UPS is operating as a single module installation or is part of a multi module parallel installation The single module version is shown in Figure 2 12 and the multi module version in Figure 2 13 Event
72. r or fused isolator to provide both overload protection and a means of isolating the UPS from the mains supply when required Similarly the UPS AC output 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 UPS correctly and allow the UPS to function properly when operating on battery The input neutral must also be grounded to permit correct operation when the UPS is running on battery Key Point As the input neutral must ccce rm UU 0 E a P be unswitched and connected to the 7 UPS at all times DO NOT use a 4 A Figure 3 3 Permanent grounded input neutral pole input switch or isolator at the LV Distribution board on a TN S system 3 6 2 UPS Cable and fuse sizing It is possible to wire the UPS input supplies in one of four configurations Three phase dual input Three phase mains input and separate single phase bypass input Three phase single input Three phase mains input with bypass input linked to the mains input L3 Single phase dual input Single phase mains input and separate single phase bypass input Single phase single input Single phase mains input linked directly to the bypass input All four configurations are shown in the following illustrations Figure 3 7 to Figure 3 10 which include detail
73. rnal battery cabinet fuses isolator before gaining internal access WARNING With the UPS shut down allow at least 5 minutes for the UPS DC capacitors to discharge UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 45 4 Operating Procedures Uninterruptible Supplies Ltd ta KOHLER COMPANY 4 15 Emergency Stop Details for the Emergency Power Off EPO circuit operation is given in Paragraph 7 2 If the EPO circuit is activated it must be reset through an LCD menu before the UPS can be returned to normal use To turn OFF one module 1 From the default screen press the DOWN key for one second to access the Main Menu Scroll to the Clear EPO Status screen as shown A Press the SELECT key a The cursor will flash on NO If you want to clear the EPO status use the UP DOWN keys so that the cursor indicates YES then select it by pressing the SELECT key for less than one second B The EPO status will now be cleared Scroll back to the default LCD display Event Log surem Figure 4 3 Turning of one module in a parallel system 46 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 5 Maintenance 5 Maintenance 5 1 Introduction WARNING Do not remove the UPS covers unless you are electrically qualified and trained on the equipment type by the manufacturer Uninterruptible
74. s of the cabling and fuse ratings 26 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd A KOHLER COMPANY 3 Installation P 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 regulations e g BS7671 2008 incorporating amendment No 1 201 1 External DC Cables and battery fuses are bespoke to the installation 3 6 3 Power cabling for a parallel system In order to achieve equal load sharing between the UPS cabinets in a parallel system the length of the input cables from the input distribution board to each cabinet should be as equal as possible with a maximum difference of 2096 This also applies to the UPS output cables Each module should be connected to an output circuit breaker located on a switch panel no further than 20 meters from the cabinets External main tenace bypass MAINS BYPASS System Bypass Breaker System Input Breaker UPS 1 Input bypass Isolator UPS 1 Breaker Output N UPS 2 Input byp Isolator UPS2 Output Breaker A f UPS 3 Input byp Isolator UPS 3 Output Breaker Key Point The information in figures 3 7 and 3 8 is given for guidance only UPS 4
75. t following the instructions in Chapter 7 Backfeed protection see page 51 Emergency Power OFF EPO see page 52 Computer communication options see page 52 Serial Network Management SNMP card see page 53 AS400 Interface card see page 54 UPS Monitoring and automated control software see page 55 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 35 4 Operating Procedures Uninterruptible Power Supplies Ltd A KOHLER COMPANY 4 Operating Procedures 4 1 Introduction The PowerWave PW3000 TP UPS system must be commissioned by a fully trained field service engineer authorised by Uninterruptible Power Supplies Ltd before it is put into use The commissioning engineer will Connect the UPS batteries Check the UPS mechanical and electrical installation and operating environment Check the 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 commiss
76. t internal batteries The UPS cabinet internal batteries are mounted on three shelves at the bottom of the cabinet and connected together as shown All connections are accessible from the front of the cabinet after removing the front panel Each battery string consists or 24 x 12V batteries connected in series to provide a nominal battery voltage of 288V and two battery strings each containing 24 batteries can be housed and connected in parallel to increase the battery capacity Normally internal batteries are shipped securely fitted to the cabinet battery trays and fully connected and no further action is required when connecting the UPS power cables 3 8 2 External battery cabinet cabling procedure P Key Point This section is required only if an external battery cabinet is installed Where an external battery cabinet is installed it contains additional battery strings each comprising 24 x 12V batteries which are connected in parallel with the UPS internal batteries A WARNING Do not close the fused isolators in the battery cabinet before the UPS system is commissioned 34 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 3 Installation Disconnect the UPS internal batteries at the Main Disconnect and Main Disconnect points shown in Figure 3 11 Open the fuse isolator on the back of the battery cabinet see Figure 2 7 Remove the terminal
77. ted on the LCD display 2 5 1 LED status indicators The five LEDs located along the top of the Control Panel indicate the UPS 0 PET operating mode or fault situation Depending on the UPS status the individual LEDs may FLASH or remain constantly OFF or ON and under some circumstances all five LEDs will Figure 2 8 Operator Control Panel illuminate in turn in a rotating sequence Table 2 2 illustrates the LED status for various operating conditions Where the LED state is indicated by a X it means that the status is not specific but depends on a particular failure or warning mode UPS STATUS LED NORMAL LED BATTERY LED BYPASS LED FAULT green amber amber red Bypass Mode With no output power FLASH X Bypass Supply abnormal FLASH Bypass Mode With output power ON X UPS Turning ON SEQUENCE SEQUENCE SEQUENCE SEQUENCE On line mode ON X On battery mode ON ON X ECO Mode ON ON X Battery Test mode SEQUENCE SEQUENCE SEQUENCE SEQUENCE Fault mode X ON Warning X X X FLASH Table 2 2 LED Status Indicators 2 5 2 LCD Display A complete overview of the UPS operating status including the UPS Condition Buzzer Status input output battery and load parameters is provided by the LCD a s displ Active failure Continuous play Active warning Beep once per second Under normal operating conditions the display shows white text on a blue backlight but under fault conditions this changes to dark text UPS on Ba
78. terruptible Power Supplies Ltd considers it important to have a complete solution for its UPS systems and offers its customers a number of remote control and monitoring tools to provide optimum protection Two monitoring system options are available for use with the PowerWave PW3000 TP UPS system SNMP monitoring software The SNMP adapter described above requires a PC with terminal connections and for normal operation at least one Ethernet network connection It also requires that the network operating system in use is SNMP compatible Uninterruptible Power Supplies Ltd offer suitable monitoring software with SNMP functionality for NetWare OS 2 all Windows NT systems on INTEL and ALPHA network platforms WAVEMON UPS monitoring and control software 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 The system comprises a bespoke software package which is installed on a local PC and communicates with the UPS over a standard RS232 cable of up to 15m in length 7 6 2 WAVEMON Shutdown and Management Software WAVEMON is a software application designed to operate with many of the systems supplied by Uninterruptible Power Supplies Ltd and features both UPS monitoring and automatic UPS server shutdown facilities It comprises a bespoke software package which is installed on a local PC and communicates with
79. the UPS changes operating mode External Battery modules Define the number of external battery modules 0 97 0 Set running time Reset the UPS running time for tests purposes Day hour minute second Running time LCD contrast Change the contrast in the LCD display 5 5 0 Battery remaining time When enabled the battery remaining time is Enabled Disabled Enabled displayed in the menu measurements Read section 2 3 before using ECO mode or converter function Ensure the actual battery quantity is same as indicated in the settings otherwise you might damage the batteries Table 2 7 Settings sub menu options UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 19 Uninterruptible Power Supplies Ltd 2 General Description KOHLER company Example How to change the rated output voltage _EventLog Language e lt English gt B H Measurements FD User Password H i2 disabled cn a un Audio alarm enabled Output voltage Output voltage zs lt 230V gt lt 230V gt Output voltage Output voltage lt 220V gt lt 220V gt fe 1s Output frequency D E o Figure 2 16 Settings Menu changing output voltage This example shows the steps necessary to change the UPS output voltage from its current 230V setting to 220V Gain access to the Main Menu and using the UP Down keys scroll though to Settings A 2 Press the
80. the UPS via USB or a standard RS232 serial cable of up to 15m in length It is only required when an SNMP card or adapter box is not purchased Uninterruptible Power Supplies Ltd offer suitable monitoring software with SNMP functionality for NetWare OS 2 all Windows NT systems on INTEL and ALPHA network platforms The main features of WAVEMON are On screen autonomy time battery time countdown e 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 email 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 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 55 Uninterruptible Supplies Ltd ta le Options A KOHLER COMPANY Uninterruptible Eventlist 24 09 2003 12 45 System Serial communication restored Supplies Ltd 24 09 2003 12 39 System Serial communication lost KOHLER coe 24 09 2003 12 35 System Connected to UPS System S Available UPS ajaja Figure 7 7 Typical WAVEMON monitoring screen image 7 6 3 Functional description WAVEMON is a client server softwar
81. the static bypass line in the event of an output overload or loss of system redundancy due to a failed module in a parallel module system Load transfer can also be initiated manually via the UPS operator control panel located on the front cabinet door Depending on the reason for switching to bypass operation i e manually transferred or transferred due to a fault when operating in this mode the Rectifier DC Converter block can be turned off entirely or remain running Similarly the inverter may have been manually turned OFF or shutdown due to a fault Load on Maintenance Bypass Maintenance Bypass Line Maintenance Bypass Switch Bypass Input RECTIFIER POWER EMI DC CONVERTER INVERTER FILTER Output piae Eg UPS AC pt Output FILTER STATIC SWITCH d Automatic External Batt Switch Battery Option Figure 2 5 Load on maintenance bypass UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 2 General Description Uninterruptible Power Supplies Ltd 2 General Description KOHLER company In this mode of operation the manually closed maintenance bypass switch connects the load supply directly to the unprocessed bypass supply This is used to keep the load supplied albeit without any power protection whilst allowing the remainder of the UPS system to be shut down for service repair To prevent possible inverter damage it is important that the inverter output and maintenance bypass lines are
82. to the mains input neutral terminal within the UPS Isolate and do not connect the input mains neutral Mains 1 as there is a possibility that the bypass current could return through and overload the smaller cable of Mains 1 Connect the mains input cable to L1 L2 L3 and the bypass input cable to M2 Connect the battery cables to the external battery cabinet if used see paragraph 3 8 Remove the link between JP1 and JP2 if the module is part of a parallel module system Connect the output terminals to the output breaker load distribution board The load distribution breakers should have a leakage current protective function to suit to the UPS voltage and current ratings L HN FOND QP1JP2 CableD Internal neutral link Remove link for N a parallel system O O JO JO O O JP1 JP2 B B GND OJ O O O O O Line 1 Input Battery Ground Line 2 Input Battery Neg Pole Line 3 Input Battery Pos Pole Input Mains Ground Bypass L Input Output Ground Bypass Neutral Output Neutral Bypass Input Ground Output Ground Figure 3 7 Three phase dual input diagram with recommended cable and fuse sizing O O O O O O O O O O um N Co z 0 Zz o z N Zz 0 Zz UO p z 0 Zz iw O O O O O O e O O O 30 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 0
83. tput voltage by the Inverter and connected to the load via the inverter side of the static switch The inverter output frequency is synchronised to the bypass supply provided it remains within preset limits If these limits are exceeded or if the bypass supply fails altogether the inverter frequency control reverts to a free running oscillator that will produce a constant 50Hz or 60Hz UPS output Load on Battery Maintenance Bypass Line Maintenance Bypass Switch Bypass Static Bypass Line Input INPUT RECTIFIER POWER EMI DC CONVERTER INVERTER FILTER Output ae UPS AC E Output STATIC SWITCH Automatic External Batt Switch Battery Option Figure 2 3 Load on battery If the mains supply fails the rectifier will shut down The battery now provides an alternative DC power source for the inverter via the DC converter and the yellow Battery led will illuminate on the Operator Control Panel to indicate that it is on load An ON BATTERY status indication will be displayed on the LCD accompanied by an audible alarm In the case of a dual feed input if the bypass supply remains live the inverter frequency will remain synchronised to the bypass provided it stays within its preset limits In the case of a single feed input the bypass supply will fail at the same time as the mains supply and under these circumstances the inverter frequency will revert to a free running oscillator that will produce a constant 50 60Hz output
84. ttery Beep every four seconds on an orange backlight accompanied by an audible warning as Low Battery Beep every second shown Table 2 3 On Bypass Beep every two minutes Overload Beep twice per second Table 2 3 Audible alarm Default screen During startup a Welcome logo screen is displayed for around 5 seconds while the UPS initialises then the default status screen shown in Figure 2 9 is displayed The default screen is shown automatically during normal operation if the control panel keys are not operated for 15 minutes 1 2 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 2 General Description The Status screen provides the following Battery Information Battery information including the battery voltage UPS Status and a graphical indication of the available battery charge UPS Status symbolic indication of the UPS operating mode and fault abnormal conditions A list of status symbols is shown in the table below Mains and Bypass Input UPS input information including an indication of Information the input mains bypass voltage and frequency Load information graphical and numerical percentage indication of the connected UPS load m idm ntormation UPS output information including an indication of output voltage frequency and load W UPS Output Information Figure 2 9 LCD Panel Status Screen
85. u navigation All the UPS control monitoring and configuration functions are actioned through a series of menus displayed on the LCD and navigated using the control panel keys shown in Table 2 5 Key Point In the following description of the menu navigation system the keys will be described as ON OFF UP DOWN and SELECT From the default screen you can cycle through the Alarm Battery and Status Running Time monitoring screens by Mains Output pressing the UP and DOWN keys for less than one second 220 v Tw 220 v as shown in Figure 2 10 220 50Hz To return to the default screen you must press the 220 100 9000 w SELECT key for less than one second 502 To access the Main Menu from the default screen you must press the DOWN key for longer than one second This presents the Main Menu options in the order shown in Figure 2 10 and described individually below 2 6 1 Event Log The Event Log displays a date time stamped list of the most recent 50 warning and fault events Fault events are indicated by a corresponding event code running time To access the Event Log you must highlight the Event Log option in the Main Menu then press the SELECT key for longer than one second This offers two further sub menu options from which you can choose to view either Warnings or Fault events Once accessed using the SELECT key you can scroll through the log entries using the UP DOWN keys To exit the Event Log screen y
86. ueries 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 Section 2 for details These agreements assist us in caring for your UPS correctly ensuring that it is well maintained and attended to promptly should any problems occur 6 2 Fault identification and rectification Alarm and events identify warning situations and notify errors or potential failures of the system The output of the UPS is not necessarily affected in case of an alarm but taking the correct actions may prevent loss of power to the load If the UPS system does not operate correctly attempt to solve the problem using the table below Please collect the following information before calling the After Sales Service Department Model number serial number Date on which the problem occurred LCD LED display information buzzer alarm status Mains power condition load type and capacity environment temperature ventilation condition Information on external batteries battery capacity quantity UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 49 Uninterruptible Power Supplies Ltd 6 Troubleshooting KOHLER COMPANY 6 2 1 Troubleshooting without an err
87. ule UPS system from a completely powered down condition 1 2 3 Check that all the loads connected to the UPS are turned off Close the external UPS Input bypass Isolators as required to connect power to the UPS If an external battery cabinet is used close the fused isolator on the back of the battery cabinet together with any circuit breaker connected in the battery line On the back of the UPS cabinet close the input breakers M1 and M2 position ON a The fans will start running b The UPS will perform a self test and will then display the default status menu on the LCD On the UPS Operator Control Panel press the POWER ON key for more than one second a The alarm buzzer will sound and the UPS will start b After a few seconds the UPS will switch to its on line mode Check that the LCD indicates the on line status and no warning alarms are present The UPS is now fully operational and providing protected output power You can now switch on the loads If possible turn on the loads sequentially to prevent a UPS overload occurring due to combined inrush currents 4 3 Single module start up without mains supply If there is no mains supply present you can use this procedure to start a single module UPS system using battery power also described as a cold start to sustain power to the load it is important that the mains supply is restored before the UPS shuts down due to the battery reaching its end of dis
88. upply CAUTION This mode is normally used only by fully trained UPS service engineers when gaining internal access to the UPS It is not required during normal UPS operation or use Transferring the load from UPS to the internal Maintenance bypass 1 Checkthe SETTINGS menu to ensure that the Auto Bypass is enabled see paragraph 2 6 5 2 Ifthe UPS is operating in the on line mode press the POWER ON key on the Operator Control Panel continuously for more than three seconds a The alarm buzzer will sound b The UPS will transfer to on bypass mode and its output will remain live through the bypass supply e Remove the Maintenance Switch cover plate on the back of the UPS Switch the Maintenance Switch from UPS to BPS a The load is now powered from the unprotected UPS bypass supply via the Maintenance Switch b The UPS can now be powered down e g for repair by opening the input breakers M1 and M2 position OFF on the back of the UPS together with the external battery cabinet fuses isolator where used B WARNING With the UPS shut down allow at least 5 minutes for the UPS DC capacitors to discharge before gaining internal access WARNING Even with the UPS input breakers M1 and M2 open potentially lethal voltages are still present within the unit Transferring the load from the internal Maintenance bypass to the UPS 1 If an external battery cabinet is used check that the fuses isolator on the back of the
89. y DC An automatic changeover switch ensures that the two sources are never connected to the Rectifier DC Converter simultaneously with the UPS Mains input always being accepted as the preferred source provided it remains within specified limits Power Inverter The single phase Inverter converts its DC input from the Rectifier DC Converter into the required UPS output AC supply The output voltage is tightly regulated using advanced PWM techniques and the output frequency is similarly controlled Usually the inverter operates at the same frequency as the UPS input bypass supply however the UPS can be operated in a frequency changing mode whereby the input and output frequencies are different e g 50HZ 60Hz input output Note that when used as a frequency changer the UPS bypass circuit is inhibited Static switch The static switch which is controlled by the UPS microprocessor control logic contains two solid state switches whose operation is mutually exclusive One side connects the UPS AC Output to the inverter and the other connects it to the static bypass line The microprocessor system automatically transfers the load between inverter bypass sources as dictated by local conditions e g overload it also provides a means of effecting manual load transfer Maintenance bypass switch The Maintenance Bypass Switch connects the UPS AC Output terminals directly to the Bypass Input and provides a means of temporarily supplying the lo
90. y depending on the type of UPS input bypass configuration and shown in detail in Figure 3 7 to Figure 3 10 UPS Output These are the UPS AC output terminals that are connected to the load distribution panel Parallel JP f the UPS is used as a stand alone unit single module the JP1 and JP2 terminals must be connected together If the UPS is connected to a parallel system the link between JP1 JP must be removed The unit is shipped with the link installed Battery The battery terminals are used to connect the UPS cabinet to an external battery cabinet where used A CAUTION The UPS is usually shipped with its internal batteries already connected UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 29 Uninterruptible Supplies Ltd ta 3 Installation A KOHLER COMPANY 10kVA 20kVA Fuse A 3x 25A 3x 40A UPS Mains Supply UPS Bypass Supply 3 x 380 400 415V 1x 220 230 240V Cable A 5x 6 0 mm 5x 10 mm Fuse C 1x 50A 1x 100A Cable C 3x 10 mm 3x 35 mm Cable D 3x 10 mm 3x 35 mm lt U EY 2 Cable E Bespoke Bespoke S 8 Note Cable ratings are indicative based on clipped LT HLZ Jf C3 HN HEND MHN HSND direct or in free air perforated cable tray and must be TE HTS H E Z L He checked by the circuit designer against local regulations WIRING NOTES 1 Connect the neutral cable to the bypass neutral terminal Main 2 which is connected
91. ypass Breaker 3 Open the System Output Breaker 4 Theload is now powered entirely through the unprotected external maintenance bypass supply To shutdown the UPS modules 5 Open the individual modules Output Breakers 6 On the back of each UPS cabinet in turn open the input breakers M1 and M2 position OFF a Power will be removed from the UPS output terminals b The fans will stop c After a few seconds the UPS LCD display will power down 7 To totally isolate the modules open the UPS Input bypass Isolators and where used open the external battery cabinet fuses isolator Transferring the load from the external bypass to the UPS On each module in turn 1 Close the external mains bypass power Input Isolators as required to connect power to the UPS 2 If an external battery cabinet is used close the fused isolator on the back of the battery cabinet together with any circuit breaker connected in the battery line 3 On the back of the UPS cabinet close the input breakers M1 and M2 position ON a The fans will start running b The UPS will perform a self test and will then display the default status menu on the LCD 4 Checkthat no abnormal conditions are shown on any of the modules LCD panel System start up 5 Onthe UPS operator control panel of ANY module press the POWER ON key for more than one second a The alarm buzzer will sound and ALL the UPS modules will start b After a few seconds ALL the UPS modu
92. z gt ECO mode frequency high limit lt 5 52 5Hz gt Battery remaining time lt enabled gt Set running time Day 0001 Time 00 00 00 access the remaining menu options Enter the password using the UP DOWN and SELECT keys P Key Point Once the Language is selected you must enter a password if the User Password is enabled to 18 UPS463 01 02 PowerWave PW3000 TP User Manual UK Dated 25 09 14 Uninterruptible Power Supplies Ltd KOHLER company 2 General Description Sub menu Item Description Values Default Language Select menu language English Chinese English User password Protects against unapproved access Enabled Disabled Disabled Audio alarm Enable disable alarm sounds Enabled Disabled Enabled Output voltage Define local output voltage 200 208 220 230 240V 230V Output frequency Define local output frequency Autosensing Autosensing UPS detects the frequency in autosensing 50Hz 60Hz Power strategy Define the operating mode Normal ECO mode Normal Frequency converter DC start Cold start Start the UPS from batteries without mains power Enabled Disabled Enabled Automatic battery test period Define the frequency of the battery tests 0 31 days 7 days Auto restart After power outage the load restart automatically Enabled Disabled Enabled when mains power is recovered Automatic overload restart The UPS automatically restarts if it shuts down Enabled Disabled En

463-01-02 PW3000TP User Manual.book

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