Kohler powerwave 8000dpa S2 ST-60 User manual

PowerWAVE 8000DPA
User Manual
S2 (10-200 kW)

TS_616_03 PW8000DPA ST S2 User Manual 4/4/18

TS_616_03 PW8000DPA ST S2 User Manual 4/4/18
Document Control
PDF 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 ST120 terminal details
TS_616_03 04/04/18 Added external MBP interlocking details to Chapter 7, and corrected spelling

TS_616_03 PW8000DPA ST S2 User Manual 4/4/18
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.
© 2016 Uninterruptible Power Supplies Ltd
This manual may not be copied or reproduced without written permission
of Uninterruptible Power Supplies Ltd.
USEFUL CONTACTS
www.upspower.co.uk UPS Limited web site
[email protected] Service department – booking service, fault reporting etc.
[email protected] Technical queries
[email protected] Hardware sales
[email protected] Extended warranty agreements etc

TS_616_03 PW8000DPA ST S2 User Manual 4/4/18 I
Table of Contents
Safety 1
1.1 Description of symbols used in this manual 1-1
1.2 User precautions 1-1
General Description 2
2.1 General introduction 2-2
2.1.1 Reliability and quality standards 2-2
2.1.2 Advanced design features 2-2
2.1.3 Model range 2-3
2.2 Functional description of operation 2-4
2.2.1 UPS Power module internal operation 2-4
2.2.2 UPS Power module operational states 2-5
2.2.3 UPS system operation 2-6
2.2.4 Parallel system operation 2-7
2.3 Module component identification 2-9
2.4 UPS Interface boards 2-14
2.4.1 Customer Interface Board 2-14
2.4.2 Parallel Interface Board 2-14
2.5 Module control panel 2-16
2.5.1 Power Management Display (PMD) 2-16
2.5.2 Mimic LED indicators 2-16
2.5.3 Operator keys 2-17
2.6 Description of the LCD display 2-18
2.6.1 Status screens 2-18
2.6.2 Main menu screen 2-18
2.6.3 Event log menu screen 2-18
2.6.4 Measurements menu screen 2-19
2.6.5 Commands menu screen 2-20
2.6.6 UPS Data menu screen 2-20
2.6.7 Set-up User menu screen 2-21
2.6.8 Set-Up Service menu screen 2-21
2.7 Optional system control panel 2-22
2.7.1 Display header bar 2-23
2.7.2 Mimic diagram – system level 2-24
2.7.3 Module selection screen 2-25
2.7.4 Home screen 2-27
2.8 Warranty 2-29
2.8.1 Extended warranty 2-29
2.8.2 Additional service/maintenance support 2-29
Installation 30
3.1 Introduction 3-30
3.2 Taking receipt of the UPS 3-30

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II TS_616_03 PW8000DPA ST S2 User Manual 4/4/18
3.2.1 Reporting transpiration damage 3-30
3.2.2 Local site transportation 3-31
3.2.3 Storage 3-31
3.2.4 Unpacking 3-31
3.2.5 Batteries 3-32
3.3 Positioning 3-32
3.3.1 Planning the installation 3-32
3.3.2 Clearances 3-32
3.4 UPS Power Cabling (preparation and planning) 3-35
3.4.1 General requirements 3-35
3.4.2 Cable sizing 3-35
3.4.3 Parallel cabinet cabling recommendations 3-39
3.4.4 External maintenance bypass 3-40
3.5 Connecting the UPS AC power cables 3-41
3.5.1 Safety notes 3-41
3.5.2 Preparing the UPS power cabling 3-41
3.5.3 Connecting the UPS input power cables 3-41
3.5.4 Preparing the output power cabling 3-42
3.5.5 Connecting the UPS output cables 3-42
3.6 Battery configuration 3-44
3.6.1 Battery configuration options 3-44
3.6.2 Battery cabling 3-44
3.6.3 Internal battery configuration for ST-40 and ST-60 cabinets 3-45
3.7 Customer Interface Board 3-47
3.8 Parallel-cabinet control and configuration 3-48
Operation 50
4.1 Introduction 4-50
4.1.1 Commissioning 4-50
4.1.2 Operating procedure summary 4-50
4.1.3 General warnings 4-51
4.2 Operating instructions 4-51
4.3 How to start the UPS system from a fully powered-down condition 4-51
4.4 How to start the UPS system from the maintenance bypass 4-53
4.5 How to transfer load to maintenance bypass then shut down the UPS system 4-54
4.6 How to shut down the complete UPS system 4-55
Maintenance 56
5.1 Introduction 5-56
5.2 User responsibilities 5-56
5.3 Scheduled maintenance 5-56
5.3.1 Preventative maintenance inspection 5-56
5.3.2 System calibration 5-56
5.3.3 Battery maintenance and testing 5-57
Troubleshooting 58
6.1 Alarms 6-58
6.2 Menu, Commands, Event Log, Measurements, 6-58
6.3 Fault identification, rectification messages and alarms 6-58
6.4 Contacting service 6-59

TS_616_03 PW8000DPA ST S2 User Manual 4/4/18 III
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Options 60
7.1 Introduction 7-60
7.2 Remote shut down 7-60
7.3 Generator ON facilities 7-61
7.4 UPS Monitoring and automated control software 7-61
7.4.1 SNMP Card slots 7-61
7.5 Remote interlock (for external maintenance bypass only) 7-62
Specification 63
8.1 Mechanical characteristics – UPS Cabinet 8-63
8.2 System data 8-64
8.3 UPS Power module data 8-66
8.4 Battery data 8-66
8.5 Standards 8-67
8.6 Options 8-67

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IV TS_616_03 PW8000DPA ST S2 User Manual 4/4/18

TS_616_03 PW8000DPA ST S2 User Manual 4/4/18 1
1Safety
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 qualified personnel. Do not attempt to service the UPS yourself.
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 PW8000DPA ST S2 is a Class A UPS product (according to BS EN 62040). In a domestic
environment the UPS may cause radio interference. In such an environment the user may be required to
undertake additional measures.

2TS_616_03 PW8000DPA ST S2 User Manual 4/4/18
2General Description
2.1 General introduction
Congratulations on your purchase of the PW8000DPA ST S2 Uninterruptible Power Supply system.
2.1.1 Reliability and quality standards
Using a unique modular construction, the PW8000DPA ST S2 represents a completely new generation of medium power,
3 phase UPS-Systems, incorporating the latest technological developments in power engineering. High reliability, upgrade
ability, low operating costs and excellent electrical performance are only some of the highlights of this innovative UPS
solution.
Uninterruptible Power Supplies Ltd. 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 we use in the design, manufacture, and maintenance of Uninterruptible Power Supply systems
are certified to International Standard ISO 9001/EN 29001 and ISO 14001. A full UPS Specification is provided in Chapter
8 of this manual.
2.1.2 Advanced design features
Input booster technology
The UPS 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 <4.5% THD(i) (10KW module) and <3% THD(i) (20KW module). This leads to a
more reliable overall 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.
The high power factor presented by the UPS on the incoming mains supply minimises cabling and fusing costs due to the
minimised 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
Decentralized Parallel Architecture (DPA)
The PW8000DPA ST S2 system features Decentralized Parallel Architecture (DPA) paralleling technology that provides
n+x redundancy without introducing a single-point-of-failure. Each power module is a fully functional, self-contained UPS
that includes an individual battery charger, power inverter, bypass, CPU, control panel and separate battery configuration;
making it a completely autonomous operating unit.
Flexible battery management
This equipment employs flexible battery charging management which avoids premature deterioration of battery life and
provides 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).