Kohler PowerWAVE 6000 User Manual Download

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Summary of Contents for PowerWAVE 6000

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Page 2: ...TS_610_01 PowerWAVE 6000 S3 60 120kVA User Manual 21 10 19 ...

Page 3: ...indirect or accidental personal or material damage due to any misinterpretation of or accidental errors in this manual 2019 Kohler Uninterruptible Power Ltd This manual may not be copied or reproduced without written permission of Kohler Uninterruptible Power Ltd PDF ISSUE DATE REVISION SUMMARY TS_610_01 21 10 2019 First Issue www kohler ups co uk Kohler Uninterruptible Power Ltd web site ukservic...

Page 4: ...TS_610_01 PowerWAVE 6000 S3 60 120kVA User Manual 21 10 19 ...

Page 5: ...ible Power Ltd will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to KKohler Uninterruptible Power Ltd that the risks of injury or damage have been minimized the customer assumes all such risks and the liability of Kohler Uninterruptible Power Ltd is adequately protected under the circumstances Extended Warranty The Standard Warr...

Page 6: ...TS_610_01 PowerWAVE 6000 S3 60 120kVA User Manual 21 10 19 ...

Page 7: ...ion 10 2 4 3 Common battery 11 2 5 PowerWAVE 6000 S3 60 120 kVA User Controls 11 2 5 1 Power isolators 11 2 5 2 UPS Control panel 12 2 6 LCD Control Panel 12 2 6 1 Module mimic LED indicators 12 2 6 2 Operator buttons 13 2 6 3 Power Management Display PMD 14 2 7 UPS Communication interface 16 Installation Planning 17 3 1 Introduction 17 3 2 Environmental and mechanical planning 17 3 2 1 Environmen...

Page 8: ...rating in ECO on bypass mode 40 5 6 1 How to Turn ON the UPS system and operate in on bypass ECO mode 40 5 6 2 How to Turn OFF the UPS system when operating in on bypass ECO mode 40 5 6 3 How to transfer between ECO on bypass and on inverter mode 40 5 7 Individual module stop start procedure redundant parallel system 41 Maintenance 43 6 1 Introduction 43 6 2 User responsibilities 43 6 3 Battery te...

Page 9: ... Planning and Chapter 4 Installation Procedure of this manual WARNING High leakage current Ensure that the UPS has been correctly earthed before you connect the mains power cables WARNING Do not apply electrical power AC or DC to the UPS before it has been commissioned by a fully trained engineer authorised by Kohler Uninterruptible Power Ltd WARNING All servicing must be performed by a Kohler Uni...

Page 10: ... 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 2011 65 EU Restriction of the use of certain hazardous substances RoHS DIRECTIVE The suppl...

Page 11: ... with IEC 62040 3 VFI SS 111 standards Kohler Uninterruptible Power Ltd specialises in the installation and maintenance of Uninterruptible Power Systems and this powerful UPS is just one example of our wide range of state of the art power protection devices that can provide your critical equipment with a steady and reliable power supply for many years 2 1 2 Key features High reliability upgrade ab...

Page 12: ...ons The PW6000 S3 UPS can be installed as a standalone UPS or as a multi module parallel UPS system comprising up to ten UPS cabinets In a multi module UPS system additional modules can be added to the system to a total of ten parallel modules to increase the UPS system capacity when necessary i e the UPS system can grow to suit an expanding connected load It can also enhance the overall system re...

Page 13: ...vidual cabinet s load so where two or more cabinets are connected together to form a parallel UPS system the internal maintenance bypass switch IA1 should not be used In a parallel system an external maintenance bypass facility must be incorporated into the system design which includes a system rated maintenance bypass switch a typical external maintenance bypass installation is shown on page 24 R...

Page 14: ... to isolate the UPS from the parallel system in the event of an inverter fault Static switch 8 The static switch is an electronically controlled solid state switch connected in the static bypass line As described above it operates in conjunction with the output contactor 7 to transfer the load between the inverter and static bypass line when necessary The static switch control logic transfers the ...

Page 15: ...rom battery power the inverter frequency is controlled by a free running oscillator that maintains the output frequency at a constant 50 60 Hz An alarm is activated to warn the operator that the UPS is operating on battery power and a further alarm is triggered if the battery discharges to a preset low battery level The low battery alarm is generated sufficiently early to enable the operator to sh...

Page 16: ...ficant load supply break Load on maintenance bypass In this mode of operation the manually closed maintenance bypass switch IA1 connects the UPS output directly to the bypass mains supply This mode is generally only used to keep the load supplied albeit without any power protection whilst allowing the remainder of the UPS to be shut down for service repair Note that when operating in the maintenan...

Page 17: ...ack to the static bypass line when the bypass mains supply is restored If the input mains supply is unavailable when the load transfer to inverter takes place the rectifier is shut down and the inverter will operate from battery power and support the load only until the battery is fully discharged whereupon the UPS will completely shut down resulting in the loss of load power The off line mode of ...

Page 18: ... of operation at all times i e it is not permissible for one module to operate in the load on inverter mode while the remaining modules are in the load on bypass mode such a situation would almost inevitably result in damage to the modules inverter In a parallel system therefore if you activate the LOAD TO BYPASS command on any one module then all the modules will simultaneously switch to the load...

Page 19: ...dule 2 5 PowerWAVE 6000 S3 60 120 kVA User Controls 2 5 1 Power isolators The PW6000 S3 power isolators shown in Figure 2 7 are used by the operator when starting and shutting down the UPS in accordance with the operating procedures provided in this manual Figure 2 7 PowerWAVE 6000 S3 60 120 kVA power isolators WARNING When the UPS module is shut down its output terminals will be live even if the ...

Page 20: ...e module mimic LEDs change colour between GREEN RED and OFF to indicate the operational status of key UPS stages and thereby serve to show the active power path through the UPS LINE 1 rectifier and LINE 2 bypass LEDs indicate the availability of the input mains and bypass mains supplies respectively INVERTER and BYPASS LEDs illuminate green to indicate which of the two sources is providing the UPS...

Page 21: ...red To shut down all the modules in a parallel system you must press both ON OFF buttons on every module INDICATOR STATUS INTERPRETATION LINE 1 GREEN RED Input Mains available Input Mains not available Normal display during an input mains power failure LINE 2 GREEN RED Bypass Mains OK Bypass Mains not OK Bypass not present or bypass voltage frequency error ALARM OFF RED buzzer RED No alarm conditi...

Page 22: ...ttery voltage for 1 min then transfers the load to battery for a further 1 min PERFORM DEEP BATT TEST Performs as above but runs with battery on load until the low voltage alarm activates SET UP DATA This is a read only menu and shows the UPS details input by the manufacturer commissioning engineer DYNAMIC PASSWORD is normally set to NO SET UP USER This sub menu allows the user to select the LCD d...

Page 23: ...ON V V CCCC ENGLISH FRANCAIS DEUTCH SPANISH POLISH PORTUGUESE DD MM YYYY HH MM SS DAY OF MONTH 1 31 HOUR OF DAY 0 23 REPETITIVE Y N BATT CHARGE LOCK Y N BYPASS LOCK Y N SET LANGUAGE SET UP DATEAND TIME SET UP BATT TEST SET GENERATOR OP BATT RUN TIME MIN 00h 00m OUTPUT FREQUENCY HZ 50 00 BATTERY VOLTAGE V 0 0 0 0 BATT CHARGE CUR A 0 0 0 0 DISCHARGE CURRENT A 00 00 RECTIFIER VOLTAGE V 000 000 000 BY...

Page 24: ...d This board is used only in a parallel system and plugs into JD8 on the Communication Interface Board It is secured in place by 2 screws as shown A SLOT 2 for optional USB and Relay card Provides customer outputs B JD6 Parallel Adapter Board output cable to the next module in the parallel chain C SW2 2 Parallel configuration DIP switch located on Parallel Adapter Board set by the commissioning en...

Page 25: ... fork lift during transit 3 Locations with high ambient temperature moisture or humidity must be avoided a The installation site humidity should be 95 non condensing b The prescribed equipment ambient temperature is 0 C to 40 C c A battery temperature of 20 C to 25 C is recommended to achieve a long battery life d The air conditioning system must be able to provide a sufficient amount of cooling a...

Page 26: ...attery trays When installing a UPS suite with the UPS cabinets aligned with the front of the CBAT 150T this front clearance A also applies to the UPS cabinets If the battery is installed in a remote enclosure the UPS cabinet front clearance can be reduced to 1000 mm B Note These are the specified minimum clearances Where possible these clearances should be ideally increased to allow safe passage i...

Page 27: ...the doors have been designed to be easily removable to aid internal access when needed Battery installation Although a CBAT 150T battery cabinet is shown in Figure 3 1 the design of the battery installation is bespoke to the individual site However we recommend that where possible the battery is contained in a purpose designed cabinet installed immediately adjacent to the UPS cabinet It can be pos...

Page 28: ...S output cables It is left to the customer to select and provide suitable cables and protective devices in accordance with national and local regulations Battery fuses and cables Figures 3 3 and 3 4 do not show battery fuse and cable sizing details as these are bespoke to the installation The DC cables and fuses will be provided by Kohler Uninterruptible Power Ltd but it is the customer s responsi...

Page 29: ...A 100 kVA 167A 145A 120 kVA 201A 174A Cable E Fuse E Rectifier Inverter Static Switch IA2 Fuse A Cable D Cable A Mains Supply 3x380 400 415 IA1 Maint Bypass 1L3 1N PE 1L1 1L2 2L3 2N PE 2L1 2L2 3L3 3N PE 3L1 3L2 L3 N PE L1 L2 UPS CABINET MAINS DISTRIBUTION BOARD UPS MAINS SUPPLY BATTERY CAB LOAD DISTRIBUTION BOARD L3 N PE L1 L2 Static Bypass Line IA4 IA3 Single Feed Link Cables The customer must pr...

Page 30: ...2L2 3L3 3N PE 3L1 3L2 L3 N PE L1 L2 UPS CABINET MAINS DISTRIBUTION BOARD UPS MAINS SUPPLY BATTERY CAB LOAD DISTRIBUTION BOARD L3 N PE L1 L2 Fuse C Cable C Mains Supply 3x380 400 415 L3 N PE L1 L2 UPS BYPASS SUPPLY Static Bypass Line IA4 IA3 UPS Rating Max Input Demand Cable B Max Bypass Demand Cable C Max Output Demand Cable D 60 kVA 101A 87A 87A 80 kVA 134A 116A 116A 100 kVA 167A 145A 145A 120 kV...

Page 31: ...installation the input cables from the mains distribution board to each UPS cabinet should be of equal length Similarly the length of the UPS output cables to the load distribution board should be of equal lengths see Figure 3 5 Figure 3 5 Cable lengths for multi cabinet configurations Mains distribution board Load distribution board Mains distribution board Load distribution board CORRECT INCORRE...

Page 32: ...nstallation it is not possible to fully power down the UPS for test or repair when the internal maintenance bypass switch IA1 is closed because the UPS bypass mains supply is required to power the maintenance bypass circuit This situation can be overcome by adding an external maintenance bypass MBP facility similar to that shown in Figure 3 6 which can supply the load through the external BYPASS s...

Page 33: ...ier and Kohler Uninterruptible Power Ltd immediately Key Point If you are installing an external battery cabinet supplied by Kohler Uninterruptible Power Ltd you should refer to the manual that is provided with the cabinet for installation instructions WARNING All cabling operations must be supervised by an authorised electrician or other suitably qualified person All installation procedures must ...

Page 34: ...by cutting it on a corner where there is a cardboard fillet underneath A 2 Carefully remove the 4 cardboard corner edge protectors B while taking care that the accessory package C placed on top of the UPS does not fall off 3 Carefully retrieve the accessories package C which should contain a user manual 2 painted kick plates with screws 4 feet and a set of door keys 4 Remove the bubble wrap and se...

Page 35: ...TS_610_01 PowerWAVE 6000 S3 60 120kVA User Manual 21 10 19 27 4 Installation Procedure Figure 4 2 Unpacking the UPS cabinet standard packaging J I A B C D E F H G K L ...

Page 36: ... package which should contain a user manual 2 painted kick plates with screws 4 feet and a set of door keys from its shipping location beneath the cabinet 4 Using the keys from the accessories package open the door of the UPS then remove the humidity absorbent strip inside the front of the cabinet D by tearing it away 5 Similarly remove the humidity absorbent strip from the back of the UPS cabinet...

Page 37: ...pass output power terminal identifications are etched on a transparent safety panel that is fitted over the front of the connections The table below details the maximum size of the cable terminations and the correct torque that should be applied to the termination bolts Input Rectifier Bypass Input UPS Output Neutral Battery ve Battery ve Earth Terminal Identification 1 L1 1 L2 1 L3 2 L1 2 L2 2 L3...

Page 38: ...and locked out at their respective distribution boards Warning notices should be posted to prevent any inadvertent operation of the UPS external supply isolators 5 Before you connect the UPS power cables ensure that the fuses and cables provided by the customer are suitably rated in accordance with the prescribed IEC standards or local regulations for example BS7671 6 Once the electrical installat...

Page 39: ...s supply cables to terminals 2 L1 2 L2 2 L3 Ensure correct clockwise phase rotation 11 Connect the bypass neutral to the Neutral busbar Note The UPS commissioning engineer will re configure the UPS electronics to operate with a dual feed input at the time of commissioning 4 4 4 Connecting the UPS output cables We recommend that a dedicated load distribution board is connected between the UPS outpu...

Page 40: ...t is the customer s responsibility to install appropriate cable containment facilities between the UPS cabinet and battery cabinet where necessary e g cable trays or trunking Contact Kohler Uninterruptible Power Ltd for further installation advice if required SLOT 1 Can be used for optional USB and Relay Card customer outputs SLOT 2 Can be used for optional SNMP card JD1 RS232 Can be used for seri...

Page 41: ...ided no external power is applied to the circuits until they have been properly commissioned Details of the interface facilities and other options are provided in Chapter 8 Key Point In a parallel system UPS cabinet a parallel adapter board is fitted to the JD1 Parallel Bus connector which is in turn connected to the parallel control bus cables that pass between every module Similarly an inter mod...

Page 42: ...transfer to the static bypass and thereby connected to the unprotected bypass mains power supply A parallel module PW6000 S3 installation requires an external maintenance bypass facility which wraps around the entire UPS system this is optional in a standalone UPS cabinet installation The external maintenance bypass is bespoke to the installation and can be installed in a separate cabinet or switc...

Page 43: ...NTENANCE BYPASS SWITCH the load supply is unprotected if the bypass mains supply fails It is essential that the load user is informed of this possibility before you intentionally select these operating modes WARNING When the UPS is shut down power is still applied to the UPS input bypass terminals unless the mains supplies are isolated at the incoming switchgear panel In a standalone cabinet insta...

Page 44: ...a The BATTERY LED should change to a flashing green then to a solid green within 5 minutes 13 On the module control panel verify that a The LCD displays PARALLEL SW CLOSED 14 Before you continue ensure that the indications on the module control panels of ALL modules in a parallel module system are identical and as described above Transfer the load to inverter 15 Only proceed if the module control ...

Page 45: ...aintenance bypass Initial conditions This procedure assumes the following initial conditions The UPS input and bypass mains supplies are turned ON at the switchgear panel The load equipment is turned on and receiving power through the UPS maintenance bypass Powering up the UPS system If the UPS system is operating on maintenance bypass it can be powered up using the procedure described in paragrap...

Page 46: ...ECO mode In which case continue with step 7 below Transfer the load to the UPS static bypass 3 On the UPS control panel on any module in a parallel module system press the ENTER key once to access the menu system 4 Using the UP DOWN keys move the cursor so that it is adjacent to COMMANDS and then press the ENTER key 5 Using the UP DOWN keys move the cursor so that it is adjacent to LOAD TO BYPASS ...

Page 47: ...except for LINE 1 and BATTERY flashing green 12 Open the module s parallel isolator IA2 13 Open the external battery fuse s a The BATTERY LED will flash red Key Point The UPS System single or multi module is operating on maintenance bypass and the load is unprotected WARNING In a standalone single unit installation using the internal maintenance bypass switch IA1 the UPS bypass mains supply must b...

Page 48: ...mode 1 Follow the standard UPS system start up operating instructions in paragraph 5 2 but do not perform the Transfer the load to inverter stage step 15 onwards 5 6 2 How to Turn OFF the UPS system when operating in on bypass ECO mode 1 Follow the standard UPS system shut down operating instructions in paragraph 5 4 beginning at step 10 as the load is already operating on bypass 5 6 3 How to tran...

Page 49: ...LOAD PROTECTED 5 7 Individual module stop start procedure redundant parallel system As described earlier in this manual if a parallel module UPS system includes module redundancy an individual UPS module can be shut down without affecting the overall system operation The situations where this might be put into effect are usually managed by a qualified service engineer when undertaking service repa...

Page 50: ...ch IA2 3 Close the battery fuses breaker located in the external battery cabinet rack a The module control panel will display LOAD OFF SUPPLY FAILURE b The BATTERY led on the module control panel mimic should change from flashing to permanent green c The module control panel mimic indications should be as shown here 4 Turn ON the UPS module by simultaneously pressing both ON OFF buttons then relea...

Page 51: ...ions form an integral part of all Extended Warranty Agreements maintenance contracts offered by Kohler Uninterruptible Power Ltd For further details on Extended Warranty Agreements see the warranty information at the front of this manual A preventative maintenance inspection includes the following Site environment conditions Integrity of electrical installation Cooling airflow Rectifier booster op...

Page 52: ... the alarm by making a note of the EVENT LOG which is accessed from the MAIN MENU this will present a list of time stamped events that took place preceding the detected alarm The module control panel menu map is shown in Figure 2 10 on page 15 3 Access the MEASURMENTS screen from the MAIN MENU and make a note of the UPS input output battery parameters etc 4 Refer to the following troubleshooting t...

Page 53: ...a connected load Check all output connections and protective devices OVERLOAD Load exceeds the UPS rated power Identify which piece of equipment is causing the overload and disconnect it from the UPS TEMPERATURE HIGH UPS temperature has exceeded the allowed value Check the ambient temperature of the UPS is 40 C If the ambient temperature is normal call the authorised service centre for assistance ...

Page 54: ...e system flashing twice sec interface is master 1st cabinet flashing once sec Interface is slave 2nd 10th cabinet The red led signifies a board malfunction and possibly needs replacing Figure 8 1 UPS Communications interface board connectors 2 3 4 6 7 1 1 SLOT 2 for optional USB and Relay card Relay card provides UPS MAINS status via volt free relay switching USB provides an alternative RS232 outp...

Page 55: ...g process If you wish to activate this feature after the system has been commissioned please contact Kohler Uninterruptible Power Ltd service department for advice 1 Use a screened cable with 1 pair section of wires 0 5 mm2 1 5 mm2 and maximum length of 100m 2 Connect the cable as shown in Figure 8 2 Terminal Contact Signal Function X1 X1 10 Gnd Gnd 12Vdc Power source max 200mA X1 9 In 12Vdc X1 8 ...

Page 56: ...unications interface board The relay card contains 5 relay switched volt free outputs that can by connected to the external site monitoring BMS facilities The relays are rated at 60VAC and 500mA and the connections are made to Phoenix spring terminals using wires of up to 1 5mm Terminal Contact Signal Display Function X1 X2 15 Com ALARM COMMON_ALARM Common X2 14 N C No Alarm Condition X2 13 N O Co...

Page 57: ...gure 8 4 shows the connector pin out Note that the maximum length for the interconnecting RS232 cable is 15m Figure 8 4 Connector Cable PC Serial Port 8 5 RS485 Interface for multidrop Multidrop cables are connected between the modules in a parallel module system to enable the system to be remotely monitored over Ethernet The cables supplied are terminated with RJ45 plug connectors that fit into t...

Page 58: ...over IP An optional card enables Modbus comms over RS485 Figure 8 6 SNMP Internal and external adapters 8 7 UPS Monitoring and automated control software 8 7 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 sy...

Page 59: ...es on request Double conversion AC AC efficiency With fully charged battery and linear load PF 1 Tolerance of 0 2 Load 60 80 100 120 100 95 5 95 5 95 7 95 7 75 95 8 95 8 96 0 96 0 50 96 0 96 0 96 0 96 0 25 95 0 95 0 95 0 95 0 Eco mode efficiency 99 0 INPUT CHARACTERISTICS 60 80 100 120 Input voltage V 3x 380 220V N 3x 400 230V N 3x 415 240V N Input voltage tolerance ref to 3x400 230V for Loads in ...

Page 60: ...battery capacity Battery test Automatic and periodic adjustable OUTPUT CHARACTERISTICS 60 80 100 120 Output rated power min 42 battery blocks kVA kW 60 60 80 80 100 100 120 120 Load power factor rated 1 0 Output current In PF 1 0 min 42 battery blocks A 87 116 145 174 Output rated voltage V 3x 380 220 or 3x 400 230 or 3x 415 250 Output waveform Sinewave with 0deg phase imbalance 100 unbalanced loa...

Page 61: ...100 linear load W 2850 3800 4750 5700 BTU h 9730 12970 16220 19460 Heat dissipation without load W 410 530 640 640 Relative air humidity 95 non condensing Max altitude above sea level without derating 1000m 3300ft without derating De rating factor for use at altitudes above 1000m sea level according IEC 62040 3 Height above sea level m ft 1500 4850 2000 6600 2500 8250 3000 9900 STANDARDS Safety IE...

Page 62: ...RJ45 port Remote monitoring system with graphical display option RS485 on RJ45 port For multidrop purposes option Slot for SNMP Card Ethernet card for monitoring and integration in network management option Slot for SNMP Card USB Port and relay card Customer outputs COMMUNICATION OPTIONS ...

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