Kohler PW 9000DPA User Manual

User Manual

Pioneering solutions for
total power protection

Kohler
PW 9000DPA

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

Document Control

ISSUE DATE REVISION SUMMARY

1.0 01-06-10 Initial issue.

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

Kohler Uninterruptible Power Ltd has taken every precaution to

produce an accurate, complete and easy to understand manual and

will therefore assume no responsibility nor liability for direct,

indirect or accidental personal or material damage due to any

misinterpretation of or accidental mistakes in this manual.

© 2010 Kohler Uninterruptible Power

This manual may not be copied nor reproduced without written

permission of Kohler Uninterruptible Power.

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 i

Table of Contents

1 Safety

1.1 Description of symbols used in this manual 1-1

1.2 User precautions 1-1

2 Description

2.1 Reliability and Quality Standards 2-1

2.2 PowerWAVE 9000 DPA System 2-1

2.3 System Configuration 2-1

2.3.1 Single/Parallel module configurations 2-1

2.3.2 Single/Multi cabinet configurations 2-2

2.3.3 ‘Redundant-module’ versus ‘Capacity’ system 2-2

2.3.4 PowerWAVE 9000DPA MD Frames 2-3

2.3.5 PowerWAVE 9000DPA MX Frames 2-4

2.4 Advanced Design Features 2-4

2.4.1 Hot-swappable modules 2-4

2.4.2 Advanced booster technology 2-4

2.4.3 Flexible battery management (FBM) 2-5

2.4.4 Decentralized Parallel Architecture (DPA) 2-5

2.5 Warranty 2-6

2.6 Extended Warranty 2-6

2.7 Additional Service/Maintenance Support 2-6

3 Installation

3.1 Introduction 3-1

3.2 Receipt of the UPS 3-1

3.2.1 Site transportation 3-1

3.3 Unpacking 3-2

3.3.1 Nameplate 3-2

3.4 Batteries 3-2

3.5 Storage 3-3

3.5.1 UPS 3-3

3.5.2 Battery 3-3

3.6 Positioning 3-3

3.6.1 Planning the installation 3-3

3.7 UPS Power Cabling (preparation and planning) 3-4

3.7.1 General requirements 3-4

3.7.2 Multi-cabinet installation cabling considerations 3-6

3.8 Connecting the UPS input supply 3-7

3.8.1 Safety notes 3-7

3.8.2 Preparing the input cabling 3-7

3.8.3 Connecting the UPS input power cables 3-7

3.9 Connecting the UPS output 3-8

3.9.1 Safety notes 3-8

3.9.2 Preparation for the output cabling 3-8

3.9.3 Connecting the UPS output cables 3-9

ii UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

3.9.4 Connection Terminal Details 3-10

3.10 Connecting the batteries 3-19

3.10.1 Safety Notes 3-19

3.10.2 Battery cabling 3-19

3.10.3 Connecting the battery cables 3-21

3.11 Internal Battery Systems 3-21

3.11.1 DPA-25 3-21

3.11.2 DPA-75 3-22

3.11.3 DPA-50 3-22

3.11.4 DPA-150 3-23

3.12 External Battery Cabinets and Battery Connections 3-23

3.13 Multi-cabinet Parallel Communication Cables (Bus-lines) 3-24

3.14 Interfacing Facilities 3-26

3.14.1 Interface Board 3-26

3.14.2 Smart Port (Serial RS 232) 3-27

3.14.3 Dry Port (volt-free contacts) 3-27

3.14.4 JD11/RS232 Computer Interface 3-28

3.14.5 JD12/RS232 Interface for Multidrop 3-28

3.14.6 USB/2 Computer Interface 3-28

4 Operation

4.1 Commissioning 4-1

4.2 Control Panel 4-1

4.2.1 Power Management Display (PMD) 4-1

4.2.2 Mimic LED indicators 4-2

4.2.3 Operator keys 4-2

4.3 Description of the LCD 4-3

4.3.1 Status screens 4-3

4.3.2 Main menu screen 4-4

4.3.3 Event log menu screen 4-4

4.3.4 Measurements menu screen 4-4

4.3.5 Commands menu screen 4-5

4.3.6 UPS Data menu screen 4-5

4.3.7 Set-up User menu screen 4-6

4.3.8 Set-Up Service menu screen 4-6

4.4 Operating Modes 4-7

4.4.1 On-Line (Inverter) mode 4-7

4.4.2 OFF-Line (also known as ECO or Bypass) mode 4-7

4.4.3 Maintenance Bypass mode 4-8

4.4.4 Parallel Isolator switch(IA2) 4-8

4.5 Operating Instructions 4-9

4.5.1 Transfer to Maintenance Bypass Mode 4-9

4.5.2 Starting the UPS system from the Maintenance Bypass 4-11

4.5.3 Complete system shutdown 4-13

4.5.4 Individual module start/stop procedure 4-14

4.6 Replacement of the UPS Module in a Single Module System 4-15

4.6.1 Removing a UPS Module 4-15

4.6.2 Refitting the UPS Module 4-16

4.7 Replacing a UPS Module in a REDUNDANT Multi-Module System 4-17

4.7.1 Removing the UPS Module 4-17

4.7.2 Inserting a UPS Module 4-18

4.8 Replacing a Module In a CAPACITY Multi-Module System 4-18

4.8.1 Removing a Module 4-18

4.8.2 Refitting a Module in a Capacity Multi-Module System 4-19

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 iii

5 Maintenance

5.1 Introduction 5-1

5.2 System calibration 5-1

5.3 User responsibilities 5-1

5.4 Routine maintenance 5-1

5.5 Battery Testing 5-2

5.6 Battery Maintenance 5-2

5.7 Battery Disposal and Recycling 5-2

6 Troubleshooting

6.1 Alarms 6-1

6.2 Menu, Commands, Event Log, Measurements, 6-1

6.3 Fault Identification and Rectification Messages and Alarms 6-2

6.4 Contacting Service 6-2

7 Options

7.1 Introduction. 7-1

7.2 Remote Emergency Stop Facilities 7-1

7.3 Generator ON Facilities 7-2

7.4 WAVEMON Shutdown and Management Software 7-2

7.4.1 Why is UPS Management important? 7-2

7.4.2 Wavemon Shutdown and Monitoring Software 7-3

7.5 SNMP CARD/ADAPTER For Network Management /Remote Monitoring 7-4

8 Specifications

8.1 Mechanical Characteristics 8-1

8.2 Input Characteristics 8-3

8.3 Battery 8-3

8.4 Output 8-4

8.5 Environmental 8-5

8.6 Packed weights 8-6

8.7 Cable and fuse sizing (Single feed input) 8-7

8.8 Cable and fuse sizing (Dual feed input) 8-8

iv UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 1-1

1

Safety

1.1 Description of symbols used in this manual

1.2 User precautions

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.

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: All servicing must be performed by q ualified personnel. Do not attempt to service
the UPS yourself.
You run risk of exposure to dangerous voltages by opening or removing the UPS-covers!
Kohler Uninterruptible Power will assume no responsibility nor liability due to incorrect
operation or manipulation of the UPS.

WARNING: Th e PowerWAVE 9000 DPA is a Class A UPS product (according to EN 50091-

2). In a domestic environment the UPS may cause radio interference. In such an environment
the user may be required to undertake additional measures.

1: Safety

1-2 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 2-1

2

Description

2.1 Reliability and Quality Standards

Congratulations on your purchase of the PowerWAVE 9000 DPA UPS.
By using a unique modular construction and incorporating the latest technological developments in power

engineering, the PowerWAVE 9000 DPA represents a compl etely new generation of transformer-les s 3
phase UPS-System. High reliability, upgrade ability, low operating cost and excellent electrical performance
are just some of the highlights of this innovative UPS solution.

Kohler Uninterruptible Power specialises in the design, building, installation and maintenance of
Uninterruptible Power Systems. This compact and powerful UPS is just one example of our wide range of
state of the art power protection devices and will provide your critical equipment with a steady and reliable
power supply for many years.

The criteria and methods which are used in the design, manufacture, and maintenance of Uninterruptible
Power Supply systems are certified to International Standard ISO 9001/EN 29001. A full UPS Specification is
given in Chapter 8 of this manual.

2.2 PowerWAVE 9000 DPA System

PowerWAVE 9000 DPA is a truly modular system based on a range of 10kVA to 45kVA UPS power modules
that can be connected in parallel to form a redundant-module system. Th e UPS module s are hou sed in free­standing cabinets which are purpose designed to contain up to one, three or five modules. Two cabinet
ranges are available as standard – the ‘MD’ cabinet range is designed for use with 10kVA-25kVA modules
(see Figure 2.2), whereas ‘MX’ cabinets are used with modules from 30kVA to 45kVA (see Figure 2.3).

Cabinets designed for three (or fewer) modules also contain the UPS batteries; however an additional,
external battery cabinet can be used to extended the battery autonomy time if required. An external battery
cabinet is always required for cabinets designed for 5 UPS modules. A range of battery cabinets of matching
style and colour is available to sit alongside the UPS cabinets to provide a matching suite.

2.3 System Configuration

The PowerWAVE 9000 DPA system configurations are described below.

2.3.1 Single/Parallel module configurations

Within the UPS cabinet, the power modules can be configured in one of two ways:

Single-module system

As its name suggests, a ‘single-module’ system comprises a cabinet fitted with just one UPS module, even if
the cabinet is designed to house several modules – for example a TRIPLE DPA-75 or -150, UPGRADE DPA­125 or -250 fitted with a single module is still considered as a ‘single’ module system.

Parallel-module system

A ‘parallel-module’ system employs several modules (of the same rating) operating in parallel within the
same cabinet (e.g. TRIPLE DPA-75) using the DPA technology (see paragraph 2.4.4).

Key Point: All the modules fitted within a cabinet must be of the same rating – i.e . it is no t possible
to mix 10kVA and 20kVA modules in the same parallel system.

2: Description

2-2 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

2.3.2 Single/Multi cabinet configurations

Single cabinet system

A single-cabinet system comprises a stand-alone cabinet containing one or more UPS power module(s)
operating as a single-module or module-module system (as defined in paragraph 2.3.1).

Multi-cabinet system

To further increase the overall system capacity it is possible to connect up to 10 standard cabinets in parallel.
Depending on the model type, each cabinet ca n contain up to 5 UPS power modu les, thereby potentiall y
resulting in a system comprising up to 50 parallel modules if 10x UPGRADE DPA-125 or 10x UPGRADE
DPA-250 cabinets are employed. Although, in practice, a typical multi-cabinet system will be made up of
fewer than 10 cabinets.

Every standard PowerWAVE 9000 DPA cabinet is provided with the parallel option, eliminating any need fo r
time-consuming or expensive upgrading on site.

Figure 2.1 PowerWAVE 9000 DPA UPS Multi-Cabinet Chain.

The multi-cabinet configuration is based on a Decentralised Bypass Architecture (DPA) – i.e. every UPS is
provided with its own static bypass. In a parallel system there is always one master module and the other
modules are slaves. If at any time the master goes faulty the next UPS (former slave) will immediately take
over the master function and the former master will switch off.

2.3.3 ‘Redundant-module’ versus ‘Capacity’ system

The difference between a ‘redundant-module’ system and a ‘capacity’ system is that a ‘capacity’ system is
rated such that ALL the UPS power modules are required to provide the necessary output load power. This is
not the case for a ‘redundant-module’ system, whereby the overall system is designed with one (or more)
modules 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 affecting the load supply.

Every UPS power module in a parallel configuration is provided with an output parallel Isolator (IA2) which,
when opened, isolates the corresponding module from the parallel system and the module no longer
contributes to the system’s power output. In a ‘capacity’ system opening this isolator this will cause the load
to transfer to the (unprotected) bypass supply. but in a ‘redundant-module’ system the load will continue to
receive protected power until the number of off-line modules exceeds the inb uilt system redun dancy.

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UPS 1 UPS 2 UPS n

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 2-3

2: Description

2.3.4 PowerWAVE 9000DPA MD Frames

Figure 2.2 PowerWAVE 9000DPA MD Frames

PowerWAVE DPA
MD Frames

CLASSIC

DPA-25

TRIPLE
DPA-75

UPGRADE

DPA-125

Capacity Max. 1 module (10-25kVA)

200 x 7/9Ah batteries

3 modules (10-25kVA)

180 x 7/9Ah batteries

5 modules (10-25kVA)

External batteries
Max. Power connection kVA 25 75 125
Dimensions (WxHxD) mm 550x1650x780 550x1975x780 550x1975x780
Weight of Empty Frame kg 200 220 160
Weight of Frame with modules and

no batteries

kg 224 - 233

(with 1 Module)

292 - 319

(with 3 Modules)

280 - 325

(with 5 Modules)

Colours Front: RAL 9007 + black (inlets). Side walls: Graffito grey

PowerWAVE DPA
Modules

DPA 10 DPA 15 DPA 20 DPA 25

Output Apparent Power KVA 10 15 20 25
Output Active Power KW 8 12 16 20
Output Power (PF=1) KVA/KW 8 / 8 12 / 12 16 /16 20 /20
Variable Number of 12V Battery

Blocks

No. 30 – 50 30 – 50 30 – 50 40-50

Dimensions (WxHxD) mm 483 x 225 x 700
Weight UPS Module kg 24 33
Colours Front: RAL 9007

2: Description

2-4 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

2.3.5 PowerWAVE 9000DPA MX Frames

Figure 2.3 PowerWAVE 9000DPA MX Frames

2.4 Advanced Design Features

2.4.1 Hot-swappable modules

In a redundant module system (see paragraph 2.4.4) the unique Hot-Swappable feature enables a UPS
module to be inserted or removed from the larger cabin et assembly whilst it is still powere d (hot) without
affecting the supply to the load, and without having to transfer to bypass.

Note: In a non-redundant configuration the load will unavoidable have to be transferred to bypass while a

module is removed from the system.

2.4.2 Advanced booster technology

The UPS module’s inbuilt advanced booster technology results in a perfect sinusoidal in put power quality at

0.99 input power factor with a harmonic content of less than 3% THD(i). This leads to a more re liable total
system operation and savings in generator and transformer sizing as winding losses are minimised. It also
means that traditional harmonic filters are no longer required.

PowerWAVE DPA
MX Frames

CLASSIC

DPA-50

TRIPLE

DPA-150

UPGRADE

DPA-250

Capacity Max. 1 module (30-45kVA)

280 x 7/9Ah batteries

3 modules (30-45kVA)

240x 7/9Ah batteries

5 modules (30-45kVA)

External batteries

Max. Power connection kVA 50 150 250
Dimensions (WxHxD) mm 730x1650x800 730x1975x800 730x1975x800
Weight of Empty Frame kg 250 270 190
Weight of Frame with modules and

no batteries

kg 300 - 310

(with 1 Module)

420 - 450

(with 3 Modules)

440 - 490

(with 5 Modules)

Colours Front: RAL 9007 + black (inlets). Sidewalls: Graffito grey

PowerWAVE DPA
MODULES

DPA 30 DPA 40 DPA 50

Output Apparent Power KVA 30 40 45*
Output Active Power KW 24 32 40
Output Power (PF=1) KVA / KW 24 / 24 32 / 32 40 /40
Number of 12V Battery Blocks No. 40-50 40-50 40-50
Dimensions (WxHxD) mm 663 x 225 x 720
Weight UPS Module kg 50 57 60
Colours Front: RAL 9007

* On Inverter mode 50 KVA/40kW on Bypass mode 45 KVA/40kW

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 2-5

2: Description

The high power factor presented by the UPS on the incoming mains supply minimises cabling and fusing
costs due to the resulting lack of reactive power consumption. This, together with the accompanying low
harmonic currents, provide the following benefits:

• No additional losses in wires and cables.

• No extra heating of transformers and generators.

• No over sizing of generators.

• No false circuit breaker tripping and malfunction.

• No erratic operation of computers, telecommunication, monitors, electronic test equipment etc.

• No resonance with power factor correction capacitors.

2.4.3 Flexible battery management (FBM)

This equipment employs a flexible battery management which avoids premature deterioration of battery life
by advanced management of battery charging and preventive failure diagnostics.

The major benefits are:

• AC-ripple free battery charging due to a dc-dc charger separated from the rectifier and inverter.

• Wide range of number of battery blocks (30-50 blocks of 12V; depending autonomy times).

• UPS's wide input voltage operating window extends the battery life due to fewer discharge cycles.

• Battery discharge protection caused by load jumps.

• Proactive battery protection from false manipulations and inadequate charging voltages.

• Proactive battery failure detection thanks to Advanced Battery Diagnosis (ABD) - Algorithm.

• User selectable battery tests.

• Optional temperature compensated charging to enhance battery life.

2.4.4 Decentralized Parallel Architecture (DPA)

In a ‘redundant’ parallel UPS system the UPS modules are linked together in parallel so that in the event that
one module fails the others can automatically sustain the load supply.

A ‘parallel redundancy’ configuration i s achieved by having a rand om or fixed master-slave relationsh ip
among the UPS modules whereby the master logic gives out individual commands to all the slave units.
Unfortunately, in some designs this can lead to a single-point-of-failure for the entire system if the master
logic or communication to the slaves fails.

The PowerWAVE 9000 DPA system features DPA paralleling technology that provides n+x redundancy
without introducing a single-point-of-failure. The modules utilizing the DPA technology are completely
autonomous by means of individual power units, bypasses, CPUs, control panels and separate battery
configuration.

DPA technology uses multi-master logic with separated independent regulation and logic buses to maintain
the highest system availability.

This unique decentralized design:

• enables a parallel redundant system providing 100% conditioned power at all times.

• eliminates the system-level single point of failure inherent in traditional parallel UPS

• exponentially increases the reliability of the overall system.

• allows up to ten UPS cabinets to supply the same load in parallel and redundant configuration.

2: Description

2-6 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

2.5 Warranty

The PowerWAVE 9000 DPA 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. Th is warranty is
the only warranty given and no other warranty, express or implied, is provided.

This warranty is invalidated if the UPS is put into use without having been commissioned by a fully trained
and authorised person. This warranty does not apply to any losses or damages caused b y 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 Kohler Uninterruptible Power will, at
its sole option, repair or replace the UPS. All repaired or replaced parts will remain the property of Kohler
Uninterruptible Power.

As a general policy, Kohler Uninterruptible Power 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. Kohler Uninterruptible Power
does not recommend the use of any of its products in direct patient care. Kohler Uninterruptible Power will not
knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to
Kohler Uninterruptible Power that the risks of injury or damage have been minimized, the customer assumes
all such risks and the liability of Kohler Uninterruptible Power is adequately protected under the
circumstances

THE UPS SYSTEM MAY CONTAIN BATTERIES WHICH MUST BE RE-CHARGED FOR A MINIMUM OF
24 HOURS EVERY SIX MONTHS TO PREVENT DEEP-DISCHARGING. BATTERIES THAT HAVE BEEN,
FOR WHATEVER REASON, DEEP-DISCHARGED ARE NOT COVERED BY THE WARRANTY.

2.6 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 [phone] for further details.

2.7 Additional Service/Maintenance Support

In addition to providing support for the PowerWAVE 9000 DPA, Kohler Uninterruptible Power can provide
maintenance and support of a wide range of different UPS products.

If you are interested in an extended warranty for your PowerWAVE 9000 DPA, or any other UPS you may
have, please complete the enquiry form shown opposite and return or FAX to:

Kohler Uninterruptible Power.
7 Jurong Pier
Singapore 619159

Tel: [phone]
Fax: [phone]
Email: [e-mail]

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 2-7

2: Description

Thank you for your enquiry, which will receive our prompt attention.

If you need to contact us immediately on [phone] ,

or E-mail us on [e-mail]

www.kohlerups.sg

Kohler Uninterruptible Power
7 Jurong Pier
Singapore 619159

Tel: [phone]

Name: ............................................................................................

Job Title: ................................. .. ..................................... ... .................

Company: ............................................................................................

Address: ............................................................................................

............................................................................................

............................................................................................

............................................................................................

Post Code .......................................................... ..................................

Tel. ............................................................................................

Fax. ............................................................................................

E-mail ............................................................................................

Please contact me to discuss:

Extended Warranty options for my PowerWAVE 9000 DPA UPS

Extended warranty options for my UPS System as below:

Manufacturer:...................................................................

Model Nº:..........................................................................

Rating kVA:.......................................................................

Replacement Batteries......................................................................

Other ............. ... ... ...............................................(please specify)

Fax to: [phone]

www.kohlerupu.sg

2: Description

2-8 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 3-1

3

Installation

3.1 Introduction

This chapter contains all the information necessary for the correct unpacking, positioning, cabling a nd
installation of the PowerWAVE 9000 DPA.

3.2 Receipt of the UPS

The UPS and accessories are delivered on a specifically designed pallet that is easy to move with a forklift or
a pallet jack.

The packing container protects the UPS from mechanical and environmental damage. This protection is
further increased by wrapping the PowerWAVE 9000 DPA UPS with a plastic sheet.

Upon receiving the UPS, carefully examine the packing container and the UPS for any sign of physical
damage. The outside 'Tip&Tel' (“FRAGILE” and “ARROW”) indicator should be intact if the equipment has
been transported in an upright position. In case of rupture (or if they are suspect) inform the carrier and
Kohler Uninterruptible Power immediately.

Ensure that the received UPS corresponds to the descripti o n i ndi ca te d in the delivery note.

3.2.1 Site transportation

If you transport the UPS equipment after it has been off-loaded (for example, for storage or moving to a
different installation location) please observe the following precautions.

WARNING: All the operations described in this section must be performed by authorised
electricians or suitably qualified personnel.
Kohler Uninterruptible Power will take no responsibility for any persona l or material damage
caused by incorrect cabling or operations, or activities which are not carried out in strict
accordance with the instructions contained in this manual.

CAUTION: When off loading the UPS always keep it in an upright position.
Do not drop the equipment.
Do not stack the pallets due to the high-energy batteries involved and the heavy weight.

CAUTION: Visible transport damages must be claimed to the carrier immediately after receipt!
Other claims for shipping damage must also be filed immediately and the carrier must be
informed within 7 days of receipt of the equipment.
Packing materials should be stored for further investigation.

CAUTION: Transportation:
To avoid the UPS cabinets and/or battery cabinet falling over, use the shipping brackets on the
rear and front to secure the cabinets.
– Do not tilt the cabinets more than 10° from vertical.

CAUTION: Potential dangers:
– If the cabinet has been tilted it might damage the equipment and it should not therefore be
connected to the mains electricity supply.
– The weight of the UPS system could cause serious injuries to persons or anything in the
surrounding area.

3: Installation

3-2 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

3.3 Unpacking

If the packages are received in good order (i.e. the ‘tip & tell’ “FRAGILE” and “ARROW” indications on the
packing container are intact) then perform the following steps to unpack the UPS:

1. If the cabinet is shipped inside a wooden case, remove the screws at the base and sides of the case then
carefully remove the case from the equipment.

2. Cut the wrappers and remove the packing container by pulling it upwards.

3. Remove the plastic sheeting covering the UPS.

4. Remove the UPS from the pallet.

5. Retain the packaging materials for future shipment of the UPS.

6. Examine the UPS for any sign of damage.
Notify your supplier immediately if damage is apparent.

7. Open the cabinet door and ensure that all the UPS modules are correctly and securely fitted in their
compartments. Ensure that a pr otection cover is fitted to the front of any empty UPS compar t me nts.

3.3.1 Nameplate

The technical specifications of the PowerWAVE 9000 DPA are provided on the nameplate which is situated
at the front (internal door) of the UPS.

Check that the details on the nameplate corresponds to the purchased material detailed on the delivery note.

3.4 Batteries

The standard batteries connected to the UPS are sealed, maintenance-free batteries which will be mounted
either within the UPS cabinet or an external battery cabinet. The b attery will usually be con nected when the
UPS is commissioned.

Battery life depends very much on the ambient temperature, and optimum battery life will be obtained if the
batteries are operated at a temperature of 20°C.

If the UPS is delivered without batteries, Kohler Uninterruptible Power is not responsible for any damage or
malfunctioning caused to the UPS by the incorrect storage, installation or connection of batteries by third
parties.

CAUTION: Storage:
– The UPS should be stored in the original packing and shipping carton.
– The recommended storing temperature for the UPS system and batteries is between +5 °C
and +40°C.
– The UPS system and the battery sets must be protected from humidity
< 90% RF (non-condensing).

WARNING: T he UPS system, the battery cabinet (option) and the batteries are heavy and
may tip during transportation causing serious injury if the unpacking instructions are not
followed closely.

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3: Installation

3.5 Storage

3.5.1 UPS

If you plan to store the UPS prior to use, store it in a clean dry environment with a temperature between 5°C
to +40°C and RH of less than 90%. If the packing container is removed, you must protect the UPS from dust.

3.5.2 Battery

The UPS utilizes sealed, maintenance-free batteries, whose storage capability depends on ambient
temperature. It is therefore important not to store the UPS for longer than 6 months at 20°C, 3 months at
30°C or 2 months at 35°C storage temperature without recharging the batteries. For longer term storage the
battery should be fully recharged every 6 months @20°C.

3.6 Positioning

3.6.1 Planning the installation

A certain amount of pre-planning will help ensure smooth, trouble-free equipment installation. The following
guidelines should be taken into account when planning a suitable UPS location and environment.

1. The equipment must be installed and transported in a upright position.

2. The floor at the installed location 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.

3. The UPS cabinet requires space to bottom/front and back to enable cooling airflow. Suitable ventilation
airflow must also be provided (See Figure 3.1). Allo w a 200mm minimum clearance at the back of the
cabinet.

4. All parts of the UPS required for maintenance, servicing and user operation are accessible from the front.
Reserve a minimum of 1000mm space at the front of the UPS cabinet.

5. An ambient temperature of 20°C is recommended to achieve a long battery life. T he cooling a ir entering
the UPS must not exceed +40°C.

6. Avoid high ambient temperature, moisture and humidity. The floor material should be non-flammable and
strong enough to support the heavy load.

7. In summary, the UPS should be located where:
a) Humidity (< 90% non-condensing) and temperature (+15°C to 25°C) are within prescribed limits.

b) Fire protection standards are respected.
c) Cabling can be performed easily.
d) A minimum 900mm front accessibility is available for service or periodic maintenance.
e) Requested air cooling flow is available.
f) The air conditioning system can provide a sufficient amount of air cooling to keep the room at, or

below, the maximum desired temperature.
g) No dust or corrosive/explosive ga ses are present.
h) The location is vibration free.
i) If the UPS will be installed in bayed enclosures, partition walls have to be installed.

CAUTION: Sealed batteries must never be stored in a discharged or partially discharged state.
Extreme temperature, under-charge, overcharge or over-discharge will destroy batteries!

Key Point: Note the following:

• Charge the battery both before and after storing.

• Always store the batteries in a dry, clean, cool environment in their original packaging.

• If the packaging is removed protect the batteries from dust and humidity.

3: Installation

3-4 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

Figure 3.1 UPS & Battery Cabinet Space Requirements

3.7 UPS Power Cabling (preparation and planning)

3.7.1 General requirements

It is the customer’s responsibility to provide all external fuses, isolators and cables used to connect the UPS
input and output power supplies. The information in this section should assist in the planning and preparation
of the UPS power cabling.

The UPS input supply and bypass supply should be connected to the utility mains through a LV-Distribution
board and protected by a circuit breaker or fuse. This provides overload protection and also a means of
isolating the UPS from the mains supply when required. Similarly, the UPS output supply should be
connected to the load equipment via a suitably fused output distribution panel.

The UPS can be wired with a ‘single feed’ input (standard), whereby the UPS input supply is connected
internally to the UPS bypass circuit (see Figure 3.5); or it can be wired with a ‘dual feed’ input, whereby the
UPS bypass circuit is connected to a dedicated ‘bypass’ supply (see Figure 3.6). These diagrams identify the
UPS input/output cabling requirements and provides information regarding fuse ratings, cable ratings and
cable sizing.

Figure 3.4 outlines of the power terminal connections withing the various UPS cabinets including connection
sizes. Detailed connection diagrams can be found in:

• Figure 3.7 (DPA-25 Input/Output Terminal Block, Front View)

• Figure 3.8 (DPA-75 Input/Output Terminal Block, Front View)

• Figure 3.9 (DPA-125 Input/Output Terminal Block, Front View)

• Figure 3.10 (DPA-50 Input/Output Terminal Block, Front View)

• Figure 3.11 (DPA-150 Input/Output Terminal Block, Front View)

• Figure 3.12 (DPA-250 Input/Output Terminal Block, Front View)

Key Point: This information is given for guidance only. All fuses, isolators and power cables must
be rated and installed in accordance with the prescribed IEC standards or local regulation.

UPS

UPS

Battery

Cabinet

XX

Y

Y

ZZ

Front

Front

Clearance (mm) X Y Z

Minimum 200* 200 1000

*Rear access is essential for maintenance.

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3: Installation

These illustrations show that the UPS cabinet requires the following power cables:

Rectifier (In):

• three-phase (1L1, 1L2, 1L3)

• neutral (1N)

• protective earth (PE) connection for the rectifier input

Bypass (In):

• three-phase (2L1, 2L2, 2L3)

• neutral (2N)

• protective earth (PE) connection for the bypass if used as ‘Dual Feed’ input

Load (Out):

• three-phase (3L1, 3L2, 3L3)

• neutral (3N)

• protective earth (PE) connection for the load output

(External) Battery:

• Plus (+)

• Common (N)

• Minus (-)

• protective earth (PE) connection for the external batteries

Input neutral grounding

Figure 3.2 Input neutral grounding

Key Point: Input neutral is required to operate the rectifier.

In TN-S systems, no 4-pole input switches or circuit breakers should be used.
During battery operation the neutral must always be grounded.

0V

230V

UPS

3: Installation

3-6 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

3.7.2 Multi-cabinet installation cabling considerations

In order to achieve equal load sharing between the U PS cabinets in a multi-cabinet instal lation, the input
cables from the input distribution board to each UPS cabinet should be of equal length. Similarly the UPS
output cables to the output distribution board should be of equal length (See Figure 3.3).

.

Figure 3.3 Cable Lengths for Multi Cabinet Configurations (assuming a 2 cable input)

UPS 1 UPS 2 UPS 3 UPS 4

UPS 1 UPS 2 UPS 3 UPS 4

Recommended cable configurations

The cable configuration below is not recommended

Bypass Feed

Rectifier Feed

To Load

To Load

Bypass Feed

Rectifier Feed

UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010 3-7

3: Installation

3.8 Connecting the UPS input supply

3.8.1 Safety notes

Please ensure you read and understand the following safety notes before you begin the UPS electrical
installation.

1. All operations detailed in this section must be performed by an authorised electrician or qualified/
approved personnel.

2. Once the electrical installation is completed the initial UPS start-up and commissioning must be
performed by qualified personnel authorised by the manufacturer.

3. Do not operate the UPS if there is water or moisture present.

4. When carrying out any work on the UPS input power cables you must ensure that the UPS supplies are
isolated at the supply distribution panel and, where possible, locked out. Warning notices should be
posted where applicable to prevent inadvertent operation of the input supply isolators.

3.8.2 Preparing the input cabling

Before you start connecting the UPS input cables:

• Ensure that the provided fuses and cables satisfy the ratings shown in Figures 3.5 and 3.6, and are in

accordance with the prescribed IEC Standards or local regulations.

• Do not commence this procedure until the UPS is properly installed at its intended final location.

3.8.3 Connecting the UPS input power cables

1. To protect personnel durin g the UPS installation ensure that the connections are performed under the
following conditions:

a) No mains voltage is present.
b) Loads are shut down and disconnected.
c) The UPS is shut down and voltage-free.
d) The UPS Maintenance Bypass Isolator IA1 is OFF.

2. Gain internal access to the UPS cabinet and remove the UPS power terminal cover.

3. Connect the earth cable from the LV-Distribution Board to the protective earth (PE) terminal in the UPS.

4. The PowerWAVE 9000 DPA input supply can be wired for ‘single feed’ (standard) or ‘dual feed’
operation. Connect the input power cable coming from the LV-Distribution Board to the UPS input
terminals following the appropriate instructions (single feed) or (dual feed) below.

Single Input Feed

Refer to the schematic drawing and connection table shown in Figure 3.5.

1. Connect the UPS input supply cables to terminals 1L1, 1L2, 1L3 and 1N on the UPS main terminal block
(See Figure 3.4). Ensure correct (clockwise) phase rotation.

2. Secure the cables to the fixing rail located under the UPS connection terminals.

WARNING: Opening or removing the UPS enclosure covers will create the risk of exposure to
dangerous voltages if power is connected to the UPS.

CAUTION: The input Neutral cable must ALWAYS be connected.

3: Installation

3-8 UPS306-01-00 PowerWAVE 9000 DPA User Manual Dated 01-06-2010

Dual Input Feed

Refer to the schematic drawing and connection table in Figure 3.6.

1. The UPS is supplied (as standard) with facilities for a single cable feed for the rectifier and bypass
supplies. For a dual feed configuration remove the links between 1L1 - 2L1; 1L2 - 2L2; 1L3 - 2L3 and 1N

- 2N, on the input terminal block.

2. Connect the UPS input supply cables to terminals 1L1, 1L2, 1L3 and 1N on the UPS main terminal block.
Ensure correct (clockwise) phase rotation.

3. Connect the UPS bypass supply cables to terminals 2L1, 2L2, 2L3 and 2N on the UPS main te rminal
block. Ensure correct (clockwise) phase rotation.

4. Secure the cables to the fixing rail located under the UPS connection terminals.

Note: The UPS commissioning engineer will configure the UPS system for a dua l i nput opera tion at the time

of commissioning.

3.9 Connecting the UPS output

3.9.1 Safety notes

Ensure you read and understand the following safety notes before you begin the UPS electrical installation.

1. All operations detailed in this section must be performed by an authorised electrician or qualified/
approved personnel.

2. Once the electrical installation is completed the initial UPS start-up and commissioning must be
performed by qualified personnel authorised by the manufacturer.

3. Do not operate the UPS if there is water or moisture present.

4. When carrying out any work on the UPS output power cables you must ensure that the UPS supplies are
isolated at the supply distribution panel and, where possible, locked out. Warning notices should be
posted where applicable to prevent inadvertent operation of the input supply isolators.

3.9.2 Preparation for the output cabling

Circuit breakers (or equivalent protection) must be fitted between the UPS output and load equipment to
provide additional protection to the UPS in the event of an overload or short circuit, and also provide a means
of isolating individual loads if required.

Before you start connecting the UPS output cables to the load distribution panel:

• Ensure that the potential load does not exceed the UPS model output power rating (OUTPUT

POWER) on the nameplate.

• Ensure the output circuit breakers are correctly sized with respect to the load rating and associated

cabling.

• The maximum total load rating and maximum load rating of the individual load sockets sh ould be

indicated on the output distribution board.

• The circuit breakers must comply with the prescribed IEC Standards. It is recommended that a

separate output distribution board is provided for the load.

CAUTION: The input Neutral cable must ALWAYS be connected.

CAUTION: The bypass Neutral cable must ALWAYS be connected.

WARNING: Opening or removing the UPS enclosure covers will create the risk of exposure to
dangerous voltages if power is connected to the UPS.