Uninterruptible Power Supplies PowerWAVE 9000DPA User Manual

User Manual

Pioneering solutions for
total power protection

PowerWAVE
9000DPA

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

Document Control

ISSUE DATE REVISION SUMMARY

471-02-00 06/08/2014 Manual revised and published as 471-02-00

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

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.

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 i

Table of Contents

Safety 1

1.1 Description of symbols used in this manual 1

1.2 User precautions 1

General Description 2

2.1 Introduction 2

2.2 PowerWave 9000 Model range 3

2.2.1 Advanced design features 4

2.3 Functional description of operation 5

2.3.1 PowerWave 9000 Module block diagram 5

2.3.2 UPS Module operating modes 6

2.3.3 UPS System operating modes 8

2.3.4 Multi-module parallel system operation 9

2.4 PowerWave 9000 User controls 11

2.5 UPS Module control panel 13

2.5.1 UPS Module control panel keys 14

2.5.2 Module mimic leds 15

2.5.3 Power Management Display (PMD) 15

2.6 Warranty 20

2.7 Extended Warranty 20

2.8 Additional Service/Maintenance Support 20

Installation 22

3.1 Introduction 22

3.2 Taking receipt of the UPS 22

3.2.1 Site transportation 22

3.3 Unpacking 23

3.4 Storage 23

3.5 Planning the installation (site considerations) 24

3.5.1 Clearances 24

3.6 Planning the installation (cabling considerations) 25

3.6.1 General requirements 25

3.6.2 UPS Cable and fuse sizing 25

3.6.3 UPS Power cable termination sizes 28

3.6.4 UPS Power connection details 28

3.6.5 Power cabling in a multi-cabinet installation 30

3.6.6 Battery cabling considerations 31

3.7 UPS Cabling procedure 35

3.7.1 Connecting the input cables 35

3.7.2 Connecting the UPS output cables 36

3.8 Battery cabling procedure 40

3.8.1 Connecting the battery cables 40

3.9 Multi-cabinet configuration and paralleling cables 41

3.10 Optional remote monitoring and control facilities 42

:

ii UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

Operation 43

4.1 Introduction 43

4.1.1 Operating procedure summary 43

4.2 Operating Instructions 43

4.2.1 Starting the UPS system from the maintenance bypass 44

4.2.2 Individual module start/stop procedure in a parallel system 45

4.2.3 Transfer the load from UPS to maintenance bypass mode 47

4.2.4 Complete system shutdown 49

4.3 Replacement of the UPS module in a single module system 50

4.3.1 Removing a UPS Module in a single module system (e.g. DPA-50) 50

4.3.2 Refitting the UPS module 51

4.4 Replacing a module in a REDUNDANT multi-module system 51

4.4.1 Removing the UPS module 51

4.4.2 Inserting a UPS module 52

4.5 Replacing a module in a CAPACITY multi-module system 52

4.5.1 Removing a module 53

4.5.2 Refitting a module in a capacity multi-module system 54

Maintenance 55

5.1 Introduction 55

5.2 System calibration 55

5.3 User responsibilities 55

5.4 Routine maintenance 55

5.5 Battery testing 56

5.6 Battery maintenance 56

5.7 Battery disposal and recycling 56

Troubleshooting 57

6.1 Alarms 57

6.2 Menu, Commands, Event Log, Measurements, 57

6.3 Fault Identification and Rectification Messages and Alarms 58

6.4 Contacting Service 58

Options 59

7.1 Introduction 59

7.2 Dry port (volt-free contacts) 60

7.2.1 Input interfaces terminal block X1 60

7.2.2 Output interfaces terminal blocks X2, X3, X4 61

7.3 RS232 Computer serial interface – USB & JD11 62

7.4 RS232 Interface for multidrop – JD12 62

7.5 SNMP/ Modem slots for remote monitoring/control 63

7.6 UPS Monitoring and automated control software 63

7.6.1 The importance of UPS management 63

7.6.2 WAVEMON Shutdown and Management Software 64

7.6.3 PowerREPORTER™ management software 65

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 iii

:

Specifications 68

8.1 Mechanical Characteristics 68

8.2 Input Characteristics 69

8.3 Battery 69

8.4 Output 70

8.5 Environmental 70

8.6 Packed weights 71

8.7 Cable and fuse sizing (Single feed input) 72

8.8 Cable and fuse sizing (Dual feed input) 73

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iv UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 1

1: Safety

1.1 Description of symbols used in this manual

1.2 User precautions

1

Safety

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: This UPS must be serviced by qualified personnel.
You run risk of exposure to dangerous voltages 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 9000 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.

2: General Description

2 UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

2.1 Introduction

Congratulations on your purchase of the PowerWave 9000 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 9000 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 standards

By using a unique modular construction and incorporating the latest technological developments in power engineering, the
PowerWave 9000 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.

• Decentralised Parallel Architecture (DPA) – Highest availability, with near zero down time. Each UPS module

contains its own bypass circuit, which greatly improves the overall system reliability by removing a common point of
failure that is often present in more traditional UPS systems.

• Truly modular design – The PowerWave 9000 is designed around multiple 30kVA, 40kVA,or 50kVA UPS modules.

• Hot-swappable modules – Enables system expansion and module replacement to be carried out without disturbing

the connected load.

• Compact size, small foot print – Up to 342kW/m² saving on expensive floor space.

• Flexible battery management – Advanced management of battery charging and preventive failure diagnostics

avoids premature deterioration of battery life.

• High ac-ac efficiency (up to 95.7%) even with partial loads – Results in energy and operational cost savings (TCO)

• Full power available from 0.9 lead to 0.8 lag – Blade-server-friendly power; No de-rating required with leading

power factor loads

• Very low input current distortion – THDi = < 3-4% @ 100-25% load leads to savings in generator-set power and

installation costs.

2

General Description

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 3

2: General Description

2.2 PowerWave 9000 Model range

The PowerWave 9000 UPS is based on a range of 30kVA to 50kVA plug-in power modules fitted into one of three
purpose-designed cabinets. Each power module is a self-contained UPS comprising a rectifier, battery charger, inverter
and static switch; and when two or more modules are fitted into a cabinet they effectively operate as a parallel UPS
system. The available cabinets can contain up to one, three or five power modules as shown below in Figure 2.1.

The PowerWave 9000 cabinets are identified as CLASSIC DPA-50, TRIPLE DPA-150 and UPGRADE DPA-250 – where
the model number represents the maximum kVA output available when the cabinet is fully populated with 50 kVA power
modules. Figure 2.1 shows that the DPA-50 and DPA-150 cabinets include shelves for housing the UPS batteries;
however the DPA-250 cabinet has no internal battery mounting facilities and requires an external battery cabinet. A range
of matching battery cabinets is available which are installed adjacent to the UPS cabinet in the majority of installations. An
additional (external) battery cabinet can also be connected to the DPA-50 and DPA-150 models to extended the overall
system autonomy time if desired.

Figure 2.1 PowerWave 9000 Cabinets (frames)

Figure 2.2 PowerWave 9000 UPS Power Modules

Key Point: All the modules fitted within a cabinet must be of the same rating – for example, it is not possible to

mix 30kVA and 50kVA modules in the same cabinet.

CLASSIC

DPA-50

TRIPLE

DPA-150

UPGRADE

DPA-250

Power module capacity

Max. 1 module (30-50kVA)

280 x 7/9Ah batteries

3 modules (30-50kVA)

240x 7/9Ah batteries

5 modules (30-50kVA)

External batteries

Maximum power connection

kVA 50 150 250

Dimensions (WxHxD)

mm 730x1650x800 730x1975x800 730x1975x800

Weight of empty frame

kg 262 239 205

Weight of frame with modules fitted
(but without batteries)

kg 305 - 309

(with 1 Module)

368 - 379

(with 3 Modules)

420 - 439

(with 5 Modules)

Colours

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

DPA 30 Module DPA 40 Module DPA 50 Module

Output Apparent Power

KVA 30 40 50*

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 43.1 45.3 46.8

Colours

Front: Graphite grey

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

2: General Description

4 UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

2.2.1 Advanced design features

Hot-swappable modules

In a redundant module system the unique ‘hot-swappable’ feature enables a UPS power module to be inserted or

removed from its cabinet whilst it is still powered (hot) without having to shut down the load or transfer it to the bypass

supply.

Note: In a non-redundant system the load will unavoidably have to be transferred to the bypass supply wh ile a mo dule i s

shut down or removed from the system.

Advanced booster technology

The UPS power module’s inbuilt advanced booster technology results in a perfect sinusoidal input power quality at 0.99
input power factor with a harmonic content of less than 3% THD(i). This leads to a more reliable system operation together
with savings in generator and transformer sizing due to reduced winding losses; and also means that traditional input
harmonic filters (still used by some systems) are not required.

The high power factor presented by the UPS on the incoming mains supply minimises cabling and fusing costs due to the
reduced reactive power consumption which, together with the accompanying low harmonic currents, provides 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, telecommunications, monitors, electronic test equipment etc.

• No resonance with power factor correction capacitors

Flexible battery management (FBM)

Premature battery deterioration is avoided by the advanced management of battery charging and preventive failure
diagnostics. The major benefits are:

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

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

• Wide UPS 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 the Advanced Battery Diagnosis (ABD) algorithm

• User-selectable battery tests to ascertain the battery state

• Optional temperature compensated charging regime to enhance battery life

Decentralised Parallel Architecture (DPA)

In a ‘redundant’ parallel UPS system the power modules’ outputs are connected in parallel so that if one module fails the
remaining modules can sustain the load supply. Such operation requires a certain amount of inter-module communication

to control frequency synchronisation, load sharing, load transfer etc. This is achieved by having a master-slav e
relationship among the power modules whereby the master logic gives out individual commands to all the slave units to

keep them in step.

In some designs this can unfortunately lead to a single-point-of-failure for the entire system if the master logic or

communication with the slaves fails; however, the PowerWave 9000 technology uses multi-master logic with separated
independent regulation and control logic busses which enables any of the connected power modules to adopt the master

role if called upon. This control philosophy maintains the high

est possible system availability.

This unique decentralized design:

• Enables a parallel redundant system providing 100% conditioned power at all time

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

• Exponentially increases the reliability of the overall system

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 5

2: General Description

2.3 Functional description of operation

This section describes:

• The internal operation of an individual UPS power module at block-diagram level (see paragraph 2.3.1)

• The various operational modes of an individual UPS power module (see paragraph 2.3.2)

• UPS system operational modes – ‘On-line’ versus ‘Off-line’ system operation (see paragraph 2.3.3)

• Multi-module system operation and paralleling considerations (see paragraph 2.3.4)

2.3.1 PowerWave 9000 Module block diagram

Figure 2.3 shows a functional block diagram of a PowerWave 9000 cabinet containing two power modules.

UPS Input supplies

The mains supply (1) is a standard 3ph+N supply which is connected to the rectifier section of each power module. During
normal operation this supply is rectified to provide a DC input to the inverter and also powers the battery charger.

A 3ph+N bypass supply (2) is shown connected via a fused isolator (F2) to the static switch within each power module. It
is also to the cabinet’s maintenance bypass switch (IA1). In a standard installation the bypass supply terminals (2) are
usually linked to the mains supply terminals (1) within the cabinet so only one mains supply feed is required. (See
paragraph 3.6.3 for details concerning ‘Single Feed’ & ‘Dual Feed’ input supply configurations.)

Figure 2.3 PowerWave 9000 UPS block diagram (2 modules fitted)

Each power module is wired to individual battery connections on the cabinet’s main terminal block (3). This terminal block
is then connected to internal batteries in the case of the DPA 50 and DPA 150 cabinets, or to an external battery cabinet in
the case of the DPA 250.

If required, two or more power modules can be connected to a common battery by linking together the modules’ battery
terminal block connections (3), as described in paragraph 3.8. However, by employing a separate battery bank for each
module it again avoids a potential single point of failure and effectively extends the system redundancy to include the
batteries – which is highly recommended.

PowerModule2

MAINTENANCEBYPASSLINE

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2‐1

PowerModule1

RECTIFIER INVERTER

STATIC

SWITCH

Booster/

Charger

STATICBYPASSLINE

Battery

PW9000DPACABINET

IA2‐2

STATIC

SWITCH

STATICBYPASSLINE

Battery

F2‐1

F1

RECTIFIER INVERTER

Booster/

Charger

F1

F2‐2

F4‐1

F4‐2

3

4

5

1

2

3

6

4

5

2: General Description

6 UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

UPS Output (load) supply

Figure 2.3 shows that the UPS output (Load Supply) can be provided through one of three power paths depending on the
UPS operating mode:

• From the inverter (4), via the static switch and isolator IA2

• From the static bypass line (5) via the static switch and isolator IA2

• From the maintenance bypass line (6) via the maintenance bypass isolator IA1

The criteria for operating under each of these UPS modes is described below.

2.3.2 UPS Module operating modes

The diagrams in this section illustrate cabinet fitted with a single power module. Where two or more power modules are
fitted they will always adopt the same operating mode due to the parallel control logic signals.

Load on Inverter

Figure 2.4 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 DC by the rectifier which then charges the battery and provides
operating power for the inverter; which converts the rectifier output back to AC suitable for powering the load.

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 50/60Hz UPS output.

Load on Battery

Figure 2.5 Load on battery

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

INVERTER

STATIC

SWITCH

RECTIFIER

STATICBYPASSLINE

PW9000DPACabinet

Charger

LINE 1

LINE 2 BY PASS

INVERTER

BATTERY

LOAD

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

INVERTER

STATIC

SWITCH

RECTIFIER

STATICBYPASSLINE

PW9000DPACabinet

Charger

LINE 1

LINE 2 BY PASS

INVERTER

BATTERY

LOAD

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 7

2: General Description

If the mains supply fails, the LINE 1 led will extinguish and the rectifier will shut down. The battery now provides an
alternative DC power source for the inverter via the charger/booster and the BATTERY led will flash green to indicate that
it is on load.

Larger installations often include a standby generator which is designed to start-up and connect to the UPS 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, which results in very short battery discharge periods.

In the case of a dual feed input – if the bypass supply remains live, the LINE 2 led will stay illuminated and 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 the LINE 2 led will

extinguish along with the LINE 1 led. Under these circumstances inverter frequency will revert to a free-running oscillator
that will produce a constant 50/60Hz UPS output.

Battery discharge operation

Various alarms are generated at preset levels as the battery discharges. This allows the operator observe the remaining
autonomy and, if required, shut-down the load in an orderly manner (e.g. to save data) before the battery reaches its final
end-of-discharge voltage. Various options are available to automate the load shut-down process, as described in Chapter
8 of this manual (Options).

When the battery is initially put on load the BATTERY led will flash green, as shown in Figure 2.5. This will continue until
the remaining autonomy time falls to 3 minutes whereupon the led will begin flashing red 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 BATTERY led will change to solid red and the UPS will attempt to
transfer the load to the bypass supply if it is present.

Load on Bypass

Figure 2.6 Load on bypass

In the ‘load on bypass’ mode the load supply is connected to the unprocessed static bypass line via the static switch.

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/charger section can be turned off entirely or remain running, and continue to provide
battery charging (as shown above). Similarly, the inverter may have been manually turned OFF or shutdown due to a fault,
and the INVERTER led may be OFF or solid RED.

Static switch operation

The static switch is a solid state switch contained in each power module and operated by the module’s microprocessor
control logic which ensures that the static switch of all the power modules connected to the load (through IA2) are always
in the same operational state. It is not permissible for one module to be operating with ‘load on inverter’ while the
remaining modules are in the ‘load on bypass’ mode as such a situation would cause damage to the modules.

During normal operation the load is transferred from the inverter to the static bypass line in the event of an overload or loss
of system redundancy due to a failed power module. Load transfer can also be initiated manually via the UPS operator

control panel located on the front cabinet door (see paragraph 2.3.3).

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

STATIC

SWITCH

PW9000DPACabinet

STATICBYPASSLINE

Charger

INVERTERRECTIFIER

LINE 1

LINE 2 BY PASS

INVERTER

BATTERY

LOAD

2: General Description

8 UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

Load on Maintenance Bypass

Figure 2.7 Load on maintenance bypass

In this mode of operation the manually closed maintenance bypass switch (IA1) 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 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.

2.3.3 UPS System operating modes

The previous section described the operating modes of the UPS power 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 9000 can be operated in all three of the above categories.

On-line operation

When used as an ‘on-line’ UPS system, the PowerWave 9000 UPS modules normally operate in their ‘load on inverter’
mode and will switch over to ‘load on bypass’ in the event of an inverter fault or overload which exceeds the system
redundancy. This will transfer the load to the static bypass without interruption (transfer time = 0).

If the transfer is due to an overload the UPS modules will 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 brief supply interruption.

Off-line / line interactive operation

When the PowerWave 9000 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 and battery charger are
still powered up to maintain battery charging, and the inverter section is enabled and operating on standby.

In 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 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 function.

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 it is sometimes referred to as the “ECO” mode. However this mode is recommended
only if the connected load equipment can tolerate power interruptions of up to 3 to 5 ms during the transfer period.

WARNING: always follow the operating instructions in this manual when starting or shutting down the UPS.

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA2

Charger

INVERTER

STATIC

SWITCH

RECTIFIER

IA1

STATICBYPASSLINE

PW9000DPACabinet

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 9

2: General Description

2.3.4 Multi-module parallel system operation

As described above, the PowerWave 9000 cabinets are designed to
accommodate between one and five UPS power modules. Each module
has an individual output power isolator (IA2) which connects the module's
output to the cabinet’s output power terminals. This enables an individual
module to be disconnected from the load supply for maintenance or
repair purposes.

Under normal conditions all the modules within the cabinet are turned on
and operating in parallel to provide the cabinet’s rated output.

‘Capacity’ versus ‘redundant module’ system

The paralleled UPS modules can be 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 power modules are required to furnish the specified full load
power, whereas a ‘redundant-module’ 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) power module without disrupting the load, whereas this is not the
case in a capacity system where the loss of one power module would
automatically transfer the load to the bypass supply.

Parallel control bus

All the UPS power modules within a cabinet 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 power 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.

The module control logic always observes one of the power modules as being the ‘master’ and the others as ‘slaves’.
However if the ‘master’ module goes faulty at any time the next module in the chain (a former ‘slave’) will immediately take
over the role of master and the former master module will turn off.

Multi-cabinet parallel system

To further expand the overall UPS system capacity, several (up to ten) PowerWave 9000 cabinets can be connected
together to operate as a ‘multi-cabinet’ parallel 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 that is connected to every power module in the system – see Figure 2.9.

Taken to its limit, a system comprising ten fully populated DPA-250 cabinets would result in a UPS system rating of
2500kW; however, such large systems are rare and a typical multi-cabinet installation will contain far fewer than the
maximum ten cabinets.

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 condition is easily managed by a PowerWave 9000 system which, due to its ‘hot-swappable’ design, makes it
possible to fit an additional power module to a DPA-150 or DPA-250 cabinet if it is not already fully populated, or add a
further cabinet to an existing UPS system without disrupting the load supply.

Note: Every standard PowerWave 9000 cabinet is supplied with all the features required for parallel operation to eliminate

any need for time-consuming or expensive upgrading on site.

WARNING: The on-line mode must always be used for critical load protection.

Figure 2.8 Single cabinet with five

parallel power modules

Parallel Control Bus

Fully populated cabinet

with 5 parallel power

modules connected to a

parallel control bus.

Operator Control Panel (for each Module)

2: General Description

10 UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

Figure 2.9 PowerWave 9000 UPS Parallel cabinet system

Inter-cabinet
Parallel Control Bus

Three-cabinet parallel

system with interconnected

Parallel Control Bus

Cabinet 1 Cabinet 2

CABINET2

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

POWERMODULE1‐5

INVERTER

STATIC

SWITCH

RECTIFIER

Charger

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

IA1

IA2

INVERTER

STATIC

SWITCH

RECTIFIER

Charger

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

IA1

IA2

INVERTER

STATIC

SWITCH

RECTIFIER

Charger

Load
Supply

LoadDist.Panel

Control

Logic

Control

Logic

Control

Logic

ParallelControlBus ParallelControlBus

STATICBYPASSLINE

STATICBYPASSLINE

STATICBYPASSLINE

CABINET1

POWERMODULE1‐5

CABINET3

POWERMODULE1‐5

Cabinet ‘n’

5x Power Modules
in each cabinet

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 11

2: General Description

2.4 PowerWave 9000 User controls

The following illustrations show the location of the PowerWave 9000 power switches and fused isolators that are used
when operating the equipment. Note that the input mains fuse (F1) is located within the module and is not accessible with
the module in-situ. The Operator Control Panel (one per UPS module) is described in paragraph 2.5

DPA-50 Component identification

Figure 2.10 DPA-50 Cabinet details

[F2] Module bypass supply fuse

Battery trays

UPS Customer Interface connections
(described in the Options chapter).

[F4] Battery fuse

[IA2] Parallel Isolator

[IA1] Maintenance Bypass Isolator

UPS Power Module

MAINTENANCEBYPASSLINE

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

PowerModule

RECTIFIER INVERTER

STATIC

SWITCH

Booster/

Charger

STATICBYPASSLINE

Battery

PW9000DPACABINET

F2

F1

F4

2: General Description

12 UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

DPA-150 Component identification

The DPA-150 can be fitted with up to three UPS power modules, with the uppermost module identified as module 1.

The battery fuses (F4) are identified with their associated power module on the panel silk-screen – e.g. F4-2 is the battery
fuse associated with module 2. The module parallel isolator switches (IA2) are similarly identified – e.g. IA2-2 pertains to
power module 2.

Note that the module input mains fuses (F1) are located within the modules and are not accessible with the module in-situ.

Figure 2.11 DPA-150 Cabinet details

[F2-2] Module 2 bypass supply fuse

Battery trays

UPS Customer Interface connections
(described in the Options chapter).

Parallel Isolator (1 per power module)

[IA1] Maintenance Bypass Isolator

UPS Power Module 1

[F2-1] Module 1 bypass supply fuse

[F2-3] Module 3 bypass supply fuse

UPS Power Module 2

UPS Power Module 3

[IA2-1] [IA2-2] [IA2-3]

Battery fuse (1 per power module)

[F4-1] [F4-2] [F4-3]

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 13

2: General Description

DPA-250 Component identification

The DPA-250 contains no batteries and can be fitted with up to five UPS power modules, with the uppermost module
identified as module 1.

The module parallel isolator switches (IA2) are identified with their associated power module on the panel silk-screen –
e.g. IA2-2 pertains to power module 2.

Note that the module input mains fuses (F1) are located within the modules and are not accessible with the module in-situ.

Figure 2.12 DPA-250 Cabinet details

2.5 UPS Module control panel

The UPS module control panel is used to start/stop an individual module as part of the UPS system operating procedures.

It can also be used to configure and test a module’s operating parameters during troubleshooting and commissioning, and
monitor the module’s input/output/battery values during normal operation.

[F2] Module 2 bypass supply fuse

UPS Customer Interface connections
(described in the Options chapter).

Parallel Isolator (1 per power module)

[IA1] Maintenance Bypass Isolator

UPS Power Module 1

[F2] Module 1 bypass supply fuse

[F2] Module 3 bypass supply fuse

UPS Power Module 2

UPS Power Module 3

[IA2-1] [IA2-2] [IA2-3] [IA2-4] [IA2-5]

[F2] Module 4 bypass supply fuse

[F2] Module 5 bypass supply fuse

UPS Power Module4

UPS Power Module 5

2: General Description

14 UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

Figure 2.13 UPS Module control panel

2.5.1 UPS Module control panel keys

The keys on the operator control panel allow the user to:

• Make settings and adjustments via a menu driven LCD display

• Start-up and shut-down the UPS and transfer the load between inverter and bypass

• Monitor and display the UPS operating voltages, currents, frequencies and other values on the LCD display

• Reset/cancel an alarm

Key function summary

ON/OFF Keys

The UPS can be switched ON or OFF by simultaneously pressing both ON/OFF keys on the control panel. The
requirement to press both buttons is to help avoid accidental UPS start-up or shutdown operation.

During normal operation, pressing the two ON/OFF buttons simultaneously will immediately shutdown the UPS module.

• In a single module system (e.g. DPA-50) this will disconnect the UPS from the load unless the load is first
transferred to the maintenance bypass.

• In a parallel module system the power module will shutdown and be disconnected from the load bus. However, the
load may or may-not transfer to the static bypass depending on whether or not the number of remaining live
modules satisfies the system’s redundancy – i.e. if there are a sufficient number of modules remaining to support
the system’s load then the load will not be transferred.

Note: To shut down all the modules in a parallel system you must press both

ON/OFF

buttons on every module.

KEYS FUNCTION

ON/OFF
ON/OFF

Used to switch-on or switch-off the UPS

UP

 )

Scroll upwards through a displayed menu

DOWN

()

Scroll downwards through a displayed menu.

ENTER Confirms (selects) a chosen menu item.

RESET Cancels an audible alarm. If the alarm condition was transient the

ALARM LED will also extinguish, otherwise it will remain ON (red).

Power Management Display (PMD)Mimic LED Indicators

Menu navigation & Alarm & Reset

selection keys

Module ON/OFF
control keys

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 15

2: General Description

2.5.2 Module mimic leds

The mimic diagram leds indicate the status of the general UPS power flow and change colour between Green and Red
(and OFF) to indicate the present UPS operating conditions.

LED Indication summary

* The

ALARM

LED is a visual indication of an internal or external alarm condition. When activated, it is accompanied by an

audible alarm which can be cancelled by pressing the

RESET

key.

2.5.3 Power Management Display (PMD)

The 2 x 20 character LCD Power Management Display (PMD) simplifies communication with the UPS power module and
also provides monitoring information.

The menu driven LCD enables the access to:

• Access the ‘Event register’.

• Monitoring the input and output voltage, current, frequency & power.

• Monitoring battery run time.

• Perform commands such as module START and STOP, Load transfer between INVERTER to BYPASS.

• Access the module’s Diagnostics (service mode).

• Carry out module adjustments and testing (service mode).

Status screens

Note: The ‘Unit’ number on the right hand side of the LCD indicates the cabinet number (in a multi-cabinet system)

together with the UPS power module (slot) number within the cabinet. The maximum number of Module units is 10 and the
module slot number can vary from 1 to 5. The definition of a Module’s position is achieved in the menu Service Set-Up.
For example: Unit:05/3 indicates power module number 3 in system Cabinet number 5.

Indicator Indicator Status Interpretation

LINE 1 GREEN

RED

Input mains available
Input mains not available

LINE 2 GREEN

RED

Bypass mains bypass OK
Bypass mains bypass not OK or not present

ALARM* OFF

Flashing RED + buzzer
RED

No alarm condition
Alarm condition
Alarm condition present (audio has been reset)

INVERTER GREEN

RED
OFF

Load on inverter
Inverter fault
Inverter not operating

BY-PASS GREEN

OFF

Load on bypass
Bypass not operating

BATTERY GREEN

RED
Flashing RED
Flashing GREEN

Battery OK
Battery faulty or discharged
Battery fuses blown
On Battery

DESCRIPTION LCD-DISPLAY

1. Load is protected by UPS power Load is supplied by inverter (Normal
Operation).

LOAD
PROTECTED

Unit:01/1

2. Load is not protected by UPS
Load is supplied by mains power (load on bypass).

LOAD
NOT PROTECTED

Unit:01/1

3. Load supply completely interrupted. UPS has been switched off by “ON/
OFF” buttons.

LOAD OFF
SUPPLY FAILURE

Unit:01/1

4. UPS/module is not supplying load. The output switch is open

LOAD DISCONNECTED
PARALLEL SWITCH OPEN

Unit:01/1

2: General Description

16 UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14

Main menu screen

Event log menu screen

DESCRIPTION LCD-DISPLAY

1. Single Systems.

SYSTEM CONFIGURATION
SINGLE

Unit:01/1

2. Parallel System e.g. First Cabinet/Master Modules no 2 in slot 2.

SYSTEM CONFIGURATION
PARALLEL

Unit:02/2

3. Parallel System e.g. Second Cabinet/Slave Modules no 5 in slot 3.

LOAD OFF
SUPPLY FAILURE

Unit:05/3

4. Parallel System e.g. Second Cabinet/Slave Modules no 6 in slot 2.

LOAD DISCONNECTED
PARALLEL SWITCH OPEN

Unit:06/4

DESCRIPTION LCD-DISPLAY

1. A log of the last 64 events is stored in the Power Management Display.

 EVENT LOG

MEASUREMENTS

2. Allows monitoring of voltages, power, frequencies, currents, autonomy etc.

 MEASUREMENTS

COMMANDS

3. Enables the commands “Load to inverter”, “Load to bypass” and battery test to be
executed.

 COMMANDS

SET-UP DATA

4. Allows the UPS personalized information (such as serial number) to be entered.

 SET-UP DATA

SET-UP USER

5. Allows user to set up Date/Time, automatic battery test, etc.

 SET-UP USER

SET-UP SERVICE

6. Password-protected area for service engineer use only.

 SET-UP SERVICE

DESCRIPTION LCD-DISPLAY

1. Logging Control; a log of the last 64 events is stored in the Power Management Display.

01 05-10-08 14-38-56

LOAD TO INV.

2. Every stored event is identified with a sequential number and time stamp.

02 05-10-08 14-38-59

LOAD TO BYP.

3. By pressing ENTER the code of the event will be displayed.

03 05-10-08 14-39-14

LOAD OFF

UPS471-02-00 PW9000DPA User Manual UK Dated 06/08/14 17

2: General Description

Measurements menu screen

Commands menu screen

DESCRIPTION LCD-DISPLAY

1. Battery Runtime

BATT. RUN TIME (MIN)

00h 00mm

2. UPS-Output Frequency

OUTPUT FREQUENCY (HZ)

50.00

3. Bypass Frequency.

BYPASS FREQUENCY (HZ)

50.00

4. Battery Voltage

BATTERY VOLTAGE (V)

+0.0 - 0.0

5. Battery Charger Current

BATT. CHARGE CUR. (A)

+ 0.0 - 0.0

6. Battery Discharge Current.

DISCHARGE CURRENT (A)

00.00

7. Rectifier Input Voltage (all three phases)

RECTIFIER VOLTAGE (V)

00.00 00.00 00.00

8. Bypass Input Voltage (all three phases)

BYPASS VOLTAGE (V)

00.00 00.00 00.00

9. Output Voltage (all three phases)

OUTPUT VOLTAGE (V)0

0.00 00.00 00.00

10.Output Current (all three phases)

OUTPUT CURRENT (A)0

0.00 00.00 00.00

11.Active Output Power (all three phases)

ACTIVE POWER (KW)

00.00 00.00 00.00

12.Reactive Output Power (all three phases)

REACTIVE POWER (kVAr)

00.00 00.00 00.00

13.Apparent Output Power (all three phases)

APPARENT POWER (KVA)

00.00 00.00 00.00

14.Output Power (all three phases)

OUTPUT POWER (%)

00.00 00.00 00.00

15.Battery capacity

BATT. CAPACITY (%)

00.00

DESCRIPTION LCD-DISPLAY

1. Transfer Load to inverter

 LOAD TO INVERTER

LOAD TO BYPASS

2. Transfer Load to bypass.

 LOAD TO BYPASS

PERFORM BATT.TEST

3. Battery Test

 PERFORM BATT.TEST