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3:  Installation Planning

44

TS_616_08 PW8000DPA ST (S2) User Manual  21/4/22

3.3.4  External maintenance bypass

An external maintenance bypass is a required part of a multi-cabinet 

PW8000DPA ST system but is optional in the case of a single cabinet 

installation.
The external bypass is bespoke to the installation but generally 

comprises three isolators rated to carry the full system load and 

connected in a similar fashion to that shown in Figure 3.11.
Depending on size and location, the isolators may be installed in a 

dedicated Maintenance Bypass cabinet or included in an existing (or 

dedicated) switch-panel.
Kohler Uninterruptible Power Ltd can provide a range of external 

maintenance bypass solutions to suit all of its UPS systems.

Note: When starting the UPS system we advise that the load is initially

turned on while the system is operating on the maintenance bypass in

order to handle any large inrush currents that might occur.

Single UPS cabinet installation

An external maintenance bypass facility is not essential for a single 

cabinet installation as the internal maintenance bypass switch (IA1) is 

fully rated and can be used to connect the load directly to the raw UPS 

bypass mains supply.
However, when the load is powered via IA1 the UPS cabinet’s bypass 

mains terminals must be permanently live in order to supply the load. 

This means that it is not possible to fully isolate the mains supplies 

from the UPS cabinet while the internal maintenance bypass is in use.
This situation can be overcome by the addition of the optional external 

maintenance bypass facility which can supply the load through an 

external BYPASS switch while allowing the UPS input and output 

supplies to be totally isolated by opening the external INPUT and 

OUTPUT switches.

Parallel UPS cabinet installation

If two (or more) UPS cabinets are connected as a parallel system each 

one still contains the internal maintenance bypass switch (IA1). 

However, the switch is only rated for the specified cabinet output and 

is not designed to switch the potential full system load.
An external maintenance bypass facility containing a ‘system rated’ bypass switch is therefore an essential part of a 

parallel cabinet system as it allows the full load to be switched between the system and maintenance bypass. It also 

allows the modules’ mains supplies to be isolated as described above for the single UPS cabinet system.

Key Point: 

When operating a parallel system ALWAYS use the external maintenance bypass facility. Do not 

operate the internal maintenance bypass switch (IA1).

Figure 3.11   External Maintenance Bypass

INPUT

UPS INPUT 

Mains

(3x400/230V)

UPS OUTPUT

(Load)

(3x400/230V)

EXTERNAL MBP PANEL

BYPASS

OUTPUT

Cable C

Cable A/B

UPS

Module

UPS FRAME

MAINT

BYPASS

IA1

Static Switch

Inverter

Rectifier

Содержание PowerWAVE 8000DPA RI (S2) Series

Страница 1: ...User Manual PowerWAVE 8000DPA ST S2 10 20 kVA kW Parallelable up to 400 kVA kW...

Страница 2: ...TS_616_08 PW8000DPA ST S2 UK User Manual 21 4 22...

Страница 3: ...on of Kohler Uninterruptible Power Ltd ISSUE DATE REVISION SUMMARY TS_616_00 11 10 16 New Issue Revision 00 TS_616_01 20 01 17 Updated clearances and battery cabinet details TS_616_02 21 03 17 Updated...

Страница 4: ...TS_616_08 PW8000DPA ST S2 UK User Manual 21 4 22...

Страница 5: ...8000DPA ST S2 Communications 17 2 5 1 Standalone cabinet communication 17 2 5 2 Parallel cabinet communication 18 2 5 3 UPS Interface boards 19 2 6 Module control panel 21 2 6 1 Module mimic LED indic...

Страница 6: ...How to start the UPS system from a fully powered down condition 58 5 3 Operating in ECO on bypass mode 60 5 3 1 How to power up the UPS system and operate in ECO on bypass mode 60 5 3 2 How to transf...

Страница 7: ...nitoring and control software 74 8 2 4 PowerREPORTER management software 75 Specification 77 9 1 Mechanical characteristics UPS Cabinet 77 9 2 UPS Module characteristics 78 9 3 Battery Data 79 9 4 Sta...

Страница 8: ...IV TS_616_08 PW8000DPA ST S2 UK User Manual 21 4 22...

Страница 9: ...ARNING High leakage current Ensure that the UPS has been correctly earthed before you connect the mains power supply WARNING Do not apply electrical power AC or DC to the UPS before it has been commis...

Страница 10: ...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 U...

Страница 11: ...esign building installation and maintenance of Uninterruptible Power Systems This compact and powerful UPS is just one example of our wide range of state of the art power protection devices and will p...

Страница 12: ...chanism is applied on a master slave basis in which one module usually module 1 is set as the master module and the remaining modules as slaves If the master module shuts down the next module in the c...

Страница 13: ...hin the cabinets are effectively paralleled for example a UPS system comprising three fully populated ST 120 cabinets will contain 18 fully paralleled UPS modules offering a system capacity of 360 kW...

Страница 14: ...75kW when full load is applied but if one module fails or is taken off line the remaining 15 modules can sustain the load by each providing their rated 20 kW output Clearly the ability to lose one UP...

Страница 15: ...attery is not called upon during substantial power dips brown outs which in turn maximises the UPS battery life and availability The rectifier uses leading edge switched mode techniques that result in...

Страница 16: ...Line Mode in section 2 3 3 Automatic battery changeover switch If the UPS mains input supply fails or undergoes a sustained dip brownout the automatic battery switch will close to connect the battery...

Страница 17: ...rrences such as a UPS output overload The static switch is turned on to connect the load to the unregulated UPS bypass mains input Depending on whether or not the transfer to bypass was selected or fo...

Страница 18: ...pply failure the UPS changes to its ON BATTERY mode Figure 2 5 without affecting its output supply i e the UPS will continue to provide its rated output running from battery power and the changeover t...

Страница 19: ...y charging and the inverter section is turned on but operating on standby In the event of a bypass supply failure the inverter is immediately brought on line and the load is transferred from the bypas...

Страница 20: ...onent identification Figure 2 8 ST 40 Cabinet front view UPS Module 2 UPS Module 1 Batteries Power Connections see page 51 UPS Interface Connections see page 17 Module Control Panel see page 21 Mainte...

Страница 21: ...binet front view UPS Module 2 UPS Module 1 Batteries Power Connections see page 51 UPS Interface Connections see page 17 Module Control Panel see page 21 Maintenance Bypass Switch IA1 Module 2 Battery...

Страница 22: ...UPS Module 2 UPS Module 1 Power Connections see page 51 UPS Interface Connections see page 17 Module Control Panel see page 21 Maintenance Bypass Switch IA1 Module 2 Battery Isolator F4 2 Module 1 Ba...

Страница 23: ...see page 51 UPS Interface Connections see page 17 Module Control Panel see page 21 Maintenance Bypass Switch IA1 Module 5 Battery Isolator F4 5 Module 4 Battery Isolator F4 4 Module 6 Battery Isolato...

Страница 24: ...10 Power Connections see page 52 UPS Interface Connections see page 17 Maintenance Switch IA1 Bypass Module Control Panel see page 21 Module 1 Battery Isolator F4 1 Module 2 Battery Isolator F4 2 Modu...

Страница 25: ...it system wide command signals such as load transfer requests to all the modules in the system Customer interface facilities As shown the internal parallel bus is also connected to a communications in...

Страница 26: ...a collection UPS Control system UPS Power blocks Battery Input output Supplies Power Switches UPS Module 3 Cabinet internal parallel bus Volt free contacts for remote alarms panel or BMS Server PC Int...

Страница 27: ...ure that enables the customer interface board fitted in the master cabinet to collect data from ALL the slave cabinets It then generates a single data stream combining the data from every cabinet and...

Страница 28: ...een led indicates the board s status and normally flashes twice second when the board is healthy 7 JD1 RS232 Smart port computer interface A Sub D 9 female connector that provides an RS232 interface f...

Страница 29: ...the two sources is providing the UPS output supply BATTERY illuminates green when the battery is being charged and flashes when the battery is discharging e g when the inverter is operating from batte...

Страница 30: ...put mains supply is available and within acceptable parameters Input mains supply is unavailable or not within acceptable parameters this is the normal display during an input mains power failure LINE...

Страница 31: ...ery 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 UPS DATA This...

Страница 32: ...ENCH SPANISH GERMAN POLISH RUSSIAN PORTUGUESE DUTCH 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 DATE AND TIME SET UP...

Страница 33: ...performed from an individual module s control panel By having both control panels in place working at module and system level the UPS offers enhanced user friendliness without compromising on robustne...

Страница 34: ...time indication Set in the user menu and used to time stamp the alarms events log F Module selection Accesses MODULE SELECTION screen from where it is possible to select a particular module and exerc...

Страница 35: ...isplayed battery parameters include the battery temperature and remaining autonomy time The meter display sources are selected by pressing lightly on the touch sensitive area on the mimic display A Re...

Страница 36: ...icates their operating status through the colour coding shown in Figure 2 23 The UPS modules which are identified numerically by the ID number entered into the module s configuration set up during com...

Страница 37: ...live and available Module System ON BYPASS This is the normal mimic indications if the UPS is operating in ECO mode In the case of a standard ON LINE UPS it indicates that either the UPS has a fault...

Страница 38: ...ange the operating mode of the UPS Once the command is executed the user is immediately directed to the mimic diagram where the new status of the UPS is indicated detailed below D Ups Data Gives infor...

Страница 39: ...ervice For the use of trained maintenance personnel only Available commands Load to inverter Load to bypass User password protected UPS Data Serial Number Manufacturing Firmware Version Hardware Versi...

Страница 40: ...s recommended to achieve a long battery life 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 e The air...

Страница 41: ...ances that must be provided around the UPS cabinet Figure 3 1 ST40 ST120 Clearance recommendations ST40 ST120 clearances notes 1 No rear or side access is required for maintenance servicing or user op...

Страница 42: ...e width of 600 mm B1 should be adequate to enable battery breaker access In this situation there is no need to allow any clearance on the left side of the cabinet C1 3 No right side clearance is neces...

Страница 43: ...the rectifier to operate correctly and allow the UPS to function properly The input neutral must also be grounded to ensure correct operation when the UPS is running on battery Figure 3 3 Input neutra...

Страница 44: ...having to shut it down to up rate the input cables For example the cables connected to the PW8000DPA ST 200 cabinet should be rated for the full 200 kW load even if fewer than ten UPS modules are fitt...

Страница 45: ...tallation is shown in Figures 3 6 and 3 8 In this configuration a single external battery which can itself comprise several parallel battery strings is connected to the battery terminals N within the...

Страница 46: ...Cable A Max input current including max battery charging 68A 102A 136A 208A 333A UPS output Cable D nominal current 58A 87A 116A 174A 290A Battery Fuse F Agl CB with common battery only Bespoke to ins...

Страница 47: ...rent including max battery charging 68A 102A 136A 208A 333A UPS output Cable D nominal current 58A 87A 116A 174A 290A Battery Fuse F Agl CB with common battery only Bespoke to installation IA 1 MBP Fu...

Страница 48: ...208A 333A Bypass mains Fuse B Agl CB 3x 80A 3x 125A 3x 160A 3x 224A 3x 350A Bypass mains Cable B max bypass current 58A 87A 116A 174A 290A UPS output Cable D nominal current 58A 87A 116A 174A 290A Ba...

Страница 49: ...ns Fuse B Agl CB 3x 80A 3x 125A 3x 160A 3x 224A 3x 350A Bypass mains Cable B max bypass current 58A 87A 116A 174A 290A UPS output Cable D nominal current 58A 87A 116A 174A 290A Battery Fuse F Agl CB w...

Страница 50: ...T ST 60 3x 35 T 1x 35 N T 1x 50 PE T 3x 35 T 1x 35 N T 3x 35 T 1x 35 N T 1x 50 PE T ST 80 3x 50 T 1x 50 N T 1x 50 PE T 3x 50 T 1x 50 N T 3x 50 T 1x 50 N T 1x 50 PE T 1x 50 T 3x 4x16 T 3x M6 B ST 120...

Страница 51: ...a multi cabinet installation the input cables from the mains switchboard to each UPS cabinet should be of equal length Similarly the UPS output cables to the output load distribution panel should be o...

Страница 52: ...must be permanently live in order to supply the load This means that it is not possible to fully isolate the mains supplies from the UPS cabinet while the internal maintenance bypass is in use This si...

Страница 53: ...ontainment for the DC power cables between the UPS cabinet and battery cabinet so the customer e g cable trays or trunking 3 4 1 Common Individual battery cabling Figure 3 12 Battery connections ST 80...

Страница 54: ...uipment If the equipment is to be stored for longer than seven days before it is installed you should unpack it and inspect it for signs of internal damage before you put it into storage Any optional...

Страница 55: ...C without being fully recharged For longer term storage the batteries should be fully recharged every 6 months 20 C An storage temperature between 20 C to 25 C will help achieve optimum battery life...

Страница 56: ...ing it upwards over the top of the cabinet Note The edges of the cabinet are not protected so if you have to cut the wrapping take care not to scratch or damage the cabinet paintwork 6 Remove the four...

Страница 57: ...e to the bottom of the cabinet legs 7 Open the cabinet door remove any further internal packaging where applicable and inspect for internal damage Report any damage to the shipper immediately 8 If no...

Страница 58: ...supply is isolated and locked out at the UPS output distribution panel 5 Before you connect the UPS power cables ensure that the fuses and cables are suitably rated in accordance with the prescribed...

Страница 59: ...3 1N PE 3L1 3L3 PE 1L1 2L1 2L2 2L3 2N 3L2 3N 1L2 1L3 1N PE 3L1 3L3 PE ST 40 ST 60 1L1 2L1 2L2 2L3 2N 3L2 3N 1L2 1L3 1N PE PE 3L1 3L3 PE External Batt N N 1L1 2L1 2L2 2L3 2N 3L2 3N 1L2 1L3 1N 3L1 3L3 E...

Страница 60: ...2N 3L2 3N 1L2 1L3 1N 3L1 3L3 1 2 3 4 5 1 2 3 4 5 1 N 2 N 3 N 4 N 5 N 2L1 2L2 2L3 2N 1L1 1L2 1L3 1N 3N 3L1 3L2 3L3 External Battery Common battery links Single Dual feed input links Protective earth P...

Страница 61: ...rminals 2 L1 2 L2 2 L3 Ensure correct clockwise phase rotation 8 If the bypass mains supply is obtained from a different mains switchboard to the input mains supply connect the bypass mains neutral to...

Страница 62: ...type of installation is used the common battery links must fitted to the battery terminal block connections as shown in the left hand diagram of Figure 4 8 These links must be removed for individual b...

Страница 63: ...ge 17 with connection details contained in Chapter 8 Although all the connected optional features will be checked by the commissioning engineer they can be connected by the customer installation team...

Страница 64: ...four operational states as shown in Figure 5 1 The procedures contained in this chapter describe transitions between these states as follows How to start the UPS system from a fully powered down cond...

Страница 65: ...MODULE Input Relay Automatic Batt Switch Output Relay MAINTENANCE BYPASS AC DC PFC CONVERTER DC BOOST CONVERTER DC AC INVERTER BATT CHARGER STATIC SWITCH UPS AC Output UPS Bypass Mains UPS Input Main...

Страница 66: ...itch see the IMPORTANT NOTE above 5 Turn on power to the load equipment by closing the individual load isolation devices at the output distribution panel a The load is now powered through the maintena...

Страница 67: ...trained advice if it still fails to light green 13 Open the maintenance bypass switch see the IMPORTANT NOTE above a The module control panel LCD should display MANUAL BYPASS OPEN followed by LOAD NOT...

Страница 68: ...ally switched to ECO on bypass from the on line on inverter mode using the module control panel load transfer menu 1 On the module control panel of any UPS module press the ENTER key once to access th...

Страница 69: ...n press the ENTER key 3 Using the UP DOWN keys move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key a The UPS system will transfer the load to the static bypass on a...

Страница 70: ...ECO mode In which case continue with step 7 below Transfer the load to the UPS static bypass 3 On the UPS control panel of any UPS module press the ENTER key once to access the menu system 4 Using th...

Страница 71: ...urn OFF except for LINE 1 and BATTERY flashing green 12 Open the battery fuses F4 x a The BATTERY LED will now flash red Key Point The UPS system is operating on maintenance bypass and the load is unp...

Страница 72: ...he load isolation devices and UPS system output isolation device on the load distribution panel 3 Open the maintenance bypass switch see the IMPORTANT NOTE above 4 Turn OFF the UPS input mains and byp...

Страница 73: ...ng the manufacturer s service desk Routine maintenance The commissioning engineer will leave a service record book with the UPS which will be used to log the UPS service history To ensure optimum UPS...

Страница 74: ...of the operating mode on inverter or on bypass and whether or not the load is connected should be performed only if there are no existing alarm conditions and the battery is initially fully charged W...

Страница 75: ...te 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 Figu...

Страница 76: ...y fuses circuit breakers etc OUTPUT SHORT There is a short circuit at the output of UPS on the load side Check for a short circuit on a connected load Check all output connections and protective devic...

Страница 77: ...are accessible from the front of the UPS cabinet see Figures 2 8 to 2 12 2 3 4 6 8 9 10 11 12 5 7 1 2 3 4 6 8 9 10 11 12 5 7 1 X1 1 10 Customer Interface Board 1 SLOT 1 Slot for optional Modem Etherne...

Страница 78: ...sh to activate this feature after the system has been commissioned please contact Kohler Uninterruptible Power Ltd service department for advice To fit an external remote shutdown facility 1 Use a scr...

Страница 79: ...attery temperature sensor allows the battery charger to automatically and continuously compensate the battery charging voltage according to the battery temperature The battery sensor is supplies with...

Страница 80: ...the USB cable that is supplied with the UPS between the UPS USB port and the USB port on the computer The USB port is compliant with USB 1 1 protocol JD1 RS232 Port J1 is a standard 9 pin D Type femal...

Страница 81: ...Ethernet adapter card contains an RJ 45 connector which can be connected to the network using a standard CAT 5 cable Once connected the UPS Management software agent which is already installed in the...

Страница 82: ...and for normal operation at least one Ethernet network connection It also requires that the network operating system in use is SNMP compatible 8 2 3 WAVEMON UPS monitoring and control software WAVEMO...

Страница 83: ...must be purchased The license is for the RCCMD client or listening software that resides in each target server 8 2 4 PowerREPORTER management software PowerREPORTER is a remote monitoring and manageme...

Страница 84: ...mmunications chain UPS Server UPS with Reporting software Batteries Email Battery Care System Site manager UPS Email server Alarm Event Data monthly report Servers with Power REPORTER software Consult...

Страница 85: ...60 80 120 200 Dimensions WxHxD mm 550x1135x775 550x1975x775 550x1135x775 550x1975x775 Weight of empty cabinet kg 92 173 82 133 174 Weight with modules and no batteries kg 130 up to 136 with 2 Modules...

Страница 86: ...A 15 2 30 4 Max input power with rated output power and discharged battery per module output cos 1 0 kW 11 5 23 Max input current with rated output power and discharged battery per module output cos 1...

Страница 87: ...Storage temperature C 25 70 Battery storage time at ambient temperature Max 6 months Max altitude above sea level m 1000m 3300ft without de rating De rating factor for use at altitudes above 1000m sea...

Страница 88: ...munication options All systems Module control panel LCD display 1 x LCD display fitted to module control panel of each module RJ45 Plug Not used RJ45 Plug for future options Customer interfaces output...

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