Kohler PW 6000 User Manual
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Kohler PW 6000 User Manual

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User Manual

Kohler PW 6000
Pioneering solutions for
total power protection

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Summary of Contents for Kohler PW 6000

  • Page 1: User Manual

    User Manual Kohler PW 6000 Pioneering solutions for total power protection...
  • Page 3 Document Control ISSUE DATE REVISION SUMMARY 02-05-12 Initial issue of 60-500kVA Manual 08-05-12 Minor typographic errors corrected 25-06-12 Minor typographic errors corrected and new Lexan inserted in Ch-4 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 4 © 2010 Kohler Uninterruptible Power This manual may not be copied nor reproduced without written permission of Kohler Uninterruptible Power. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 5: Table Of Contents

    3.8.3 Connecting the batteries 3-18 3.9 Multi-module control cabling and configuration 3-18 3.9.1 Connecting the parallel communication bus cables 3-18 3.9.2 Configuration DIP switch selection 3-19 3.9.3 Module communications interface facilities 3-20 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 6 7.5.1 SNMP monitoring software 7.5.2 WAVEMON UPS monitoring and control software 7.5.3 PowerREPORTER™ management software Specifications 8.1 General specifications 8.2 60-300kVA Fuses & cables quick reference 8.3 400-500kVA Fuses & cables quick reference UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 7: Safety

    Uninterruptible Power Supplies Ltd will assume no responsibility nor liability due to incorrect operation or manipulation of the UPS. WARNING: The Kohler PW 6000 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.
  • Page 8 1: Safety UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 9: Description

    2.1.1 Reliability and quality standards The Kohler PW 6000 UPS is available over a model range of 60kVA to 500kVA and incorporates the latest technological developments in power engineering. Representing a completely new generation of high power...

  • Page 10: Kohler Pw 6000 Model Range

    2.2.1 Single/Parallel system configurations The Kohler PW 6000 UPS can be configured to operate as a single, stand-alone UPS or several (up to 10) UPS cabinets can be connected in parallel to operate as a multi-module UPS system. A multi-module configuration is generally chosen either to increase a system’s total power capacity or to increase the...

  • Page 11: Kohler Pw 6000 Block Diagram

    2: Description 2.3.1 Kohler PW 6000 block diagram Figure 2.1 shows the power blocks contained within the Kohler PW 6000 UPS. UPS Input supplies The Mains supply (1) is a three phase supply which is connected to the UPS rectifier. During normal operation this supply is rectified to provide a DC input to the inverter and also charges the battery.
  • Page 12 (‘load on bypass’) before the maintenance bypass switch is closed – always follow the operating instructions in Chapter 4 of this manual when starting or shutting down the UPS. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 13: System Operating Modes

    A parallel system comprising 3 UPS cabinets is shown in figure 2.5. Note: If a Kohler PW 6000 is purchased as a stand-alone UPS it will require a field upgrade in order to be connected to a parallel system.
  • Page 14 Master/slave configuration is achieved through selector switches located in each cabinet and is set-up during commissioning (See paragraph 3.9.2). UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 15: Warranty

    It is possible to connect two or more Kohler PW 6000 UPS modules to a common battery and allow them to share the battery charging. However by employing a separate battery bank for each module, as illustrated in figure 2.5, it again avoids a potential single point of failure and effectively extends the system redundancy to...

  • Page 16: Extended Warranty

    UPS products. If you are interested in an extended warranty for your Kohler PW 6000 UPS, or any other UPS you may have, please complete the enquiry form shown opposite and return or FAX to:...
  • Page 17 ..............(please specify) Thank you for your enquiry, which will receive our prompt attention. If you need to contact us immediately call free on +65 6302 0708, or E-mail us on serviceUPS.sg@kohler.com UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 18 2: Description 2-10 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 19: Installation

    The packing container protects the UPS from mechanical and environmental damage during transit. This protection is further increased by wrapping the Kohler PW 6000 UPS with a plastic sheet. Upon receiving the UPS you should carefully examine the packing container for any sign of physical damage.

  • Page 20: Unpacking

    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. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 21: Planning The Installation (Site Considerations)

    Figure 3.1 UPS Cabinet access space recommendations All cables enter the UPS via the bottom of the cabinet therefore no service/installation access is required from the rear or sides of the cabinets. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 22: Planning The Installation (Cabling Considerations)

    Key Point: As the input neutral must be unswitched and connected to the UPS at all times, a 4- pole input switch or isolator must not be used at the LV Distribution board on a TN-S system. 230V Figure 3.2 Input neutral grounding UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 23: Cable And Fuse Sizing

    All external fuses, isolators and power cables must be rated and installed in accordance with the prescribed IEC standards or local regulation – e.g. BS7671:2008. • External DC Cables and battery fuses are bespoke to the installation. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 24 5x (3x95) or 5x (2x185) 3x800 5x (3x150) 5x (3x150) Note: Cable E and Fuse E are bespoke to the installation Figure 3.3 Single feed input fuse and cable ratings UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 25 5x (3x95) or 5x(2x185) 5x(3x95) or 5x(2x185) 3x800 5x (3x150) 3x800 5x50 5x(3x150) Note: Cable E and Fuse E are bespoke to the installation Figure 3.4 Dual feed input fuse and cable ratings UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 26: Power Cable Terminations

    3: Installation 3.6.3 Power cable terminations The table below gives details of the cable termination sizes applicable to the various models across the Kohler PW 6000 range. Figure 3.5 illustrates the terminal block/busbar layouts. Mains Supply Bypass Supply Output Load...
  • Page 27 1/2N Single/dual feed links Battery connections 250kVA- 300kVA Power connections 400kVA - 500kVA Power connections 2L3 3N 3L1 3L2 3L3 Battery connections Figure 3.5 Input, output and battery power terminals UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 28: Power Cabling In A Parallel System

    Not recommended cable configurations Bypass Feed Rectifier Feed UPS 1 UPS 2 UPS 3 UPS 4 To Load Figure 3.6 Cable lengths for multi cabinet configurations (dual feed input supply shown) 3-10 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 29: Ups Cabling Procedure

    Connect the UPS input supply cables to terminals 1L1, 1L2, 1L3 and 1N on the UPS terminal block. Ensure correct (clockwise) phase rotation. CAUTION: The input Neutral cable must be unswitched and ALWAYS connected. Secure the cables to the fixing rail under the connection terminals. 3-11 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 30: Connecting The Ups Output Cables

    Secure the cables to the fixing rail located under the UPS connection terminals. Ensure the output cables are connected to the correct power terminals on the load distribution board. 3-12 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 31 Parallel BUS - Input Connector Parallel BUS - Output Connector SNMP Slot for optional SNMP card ONLY Maintenance Bypass Parallel Isolator Bypass Line Fuse Rectifier Fuse Figure 3.7 60kVA-100 kVA Module details 3-13 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 32 SW1-9 Rect. Fuse Byp. Fuse SNMP Parallel Isolator Byp. Isolator Input/output power connections (See Figure 3.5) Battery Connections (See Figure 3.5) Earth busbar Figure 3.8 120kVA-200 kVA Module details 3-14 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 33 SW1-9 Rect. Fuse Byp. Fuse Parallel Isolator Byp. Isolator SNMP Earth Input/output power connections Battery connections Earth (See Figure 3.5) (See Figure 3.5) Figure 3.9 250kVA-300 kVA Module details 3-15 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 34 Isolator Bypass Isolator (Parallel) Isolator (Optional) Power Reporter SNMP SW1-9 Protective Input/output power connections Battery connections Earth (See Figure 3.5) (See Figure 3.5) busbar Figure 3.10 400kVA-500kVA Module details 3-16 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 35: Battery Connections

    1180x1820x750 Weight w/o trays and w/o batteries (kg) Battery configuration with BAT-ENC A & B Bespoke to installation Note: Only an even number of 12V-battery blocks can be used. 3-17 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 36: Remote Battery Enclosure

    Fit a parallel adaptor board over connector JD8 on the communications interface board in all UPS cabinets (JD8 is identified in Figure 3.13). The parallel adapter board contains a DIP switch (SW2-2) and two ribbon connectors, JD5 & JD6. 3-18 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 37: Configuration Dip Switch Selection

    • Middle cabinet (there may be several ‘middle’ cabinets). • Last cabinet. In each cabinet, set Switch SW1-9 according to the table below: SW1-9 Single Cabinet First Cabinet Middle Cabinet Last Cabinet 3-19 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 38: Module Communications Interface Facilities

    SNMP Slot for optional SNMP card Modem Slot for optional modem/ethernet card only Customer inputs Volt-free switched alarm/status outputs Castell Interlock function Figure 3.13 UPS Communications interface board connectors 3-20 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 39: Operation

    Operation Commissioning The Kohler PW 6000 UPS is a high quality electronic machine that must be commissioned by a fully trained and authorised Uninterruptible Power Supplies Ltd. field service engineer before being put into use. Commissioning the UPS involves connecting the UPS battery, checking the electrical installation and operating environment, performing a controlled start-up and testing of the UPS system together with customer training.

  • Page 40: Mimic Led Indicators

    The UPS may 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. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 41: Description Of The Lcd Display

    The position of a module in a multi-module configuration is set by DIP Switch SW1-9, which is located on the and set by the commissioning engineer. This switch should not be touched by the operator: UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 42: Main Menu Screen

    Battery Charger Current + 0.0 - 0.0 DISCHARGE CURRENT (A) Battery Discharge Current. 00.00 RECTIFIER VOLTAGE (V) Rectifier Input Voltage (all three phases) BYPASS VOLTAGE (V) Bypass Input Voltage (all three phases) UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 43: Commands Menu Screen

    These general UPS Data are installed at the manufacturing plant. nn-nnnnn DATE OF MANUFACTURE Manufacturing date 15-03-09 EPROM VERSION EPROM Version V-000 DATE TIME Actual Date and Time dd-mm-yyyy hh:mm:ss UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 44: Set-Up User Menu Screen

    • UPS Rated Power • Module configuration S, P01, P02… • Single (standard) or Dual input feed • Frequency-converter, 50/60Hz and 60/50Hz • Synchronisation window (2-4%) UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 45: Operating Instructions

    INVERTER LINE 2 BY PASS INVERTER BATTERY BATTERY Green Flashing Close the parallel isolator switch (IA2) and check that the PARALLEL SW CLOSED message is shown on the LCD display. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 46 Use the UP/DOWN keys to move the cursor so that it is adjacent to COMMANDS and then press the ENTER key. Use the UP/DOWN keys move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 47: Individual Module Start/Stop Procedure

    Colour LOAD LINE 1 Green LINE 1 INVERTER LINE 2 Green BY PASS BATTERY INVERTER BATTERY Green The UPS module is now on line and connected to the parallel system. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 48: Transfer To Maintenance Bypass Mode

    (on all UPS modules in a multi-module system): LINE 2 BY PASS Colour LINE 1 Green LOAD LINE 1 INVERTER LINE 2 Green BY PASS INVERTER Green BATTERY BATTERY Green 4-10 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 49 The LCD displays MANUAL BYP IS CLOSED. LINE 2 BY PASS Colour LINE 1 Green LOAD LINE 1 INVERTER LINE 2 Green BY PASS Green INVERTER BATTERY BATTERY Green 4-11 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 50: Complete System Shutdown

    The LCD panel will indicate: LOAD OFF, SUPPLY FAILURE. Identify the battery cabinet/rack associated with the UPS module then open the battery fuses or circuit breaker on the battery cabinet/rack. 4-12 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 51 Open the UPS input and bypass supply isolators (or circuit breakers) on the UPS input supply distribution panel. The UPS is now voltage free. WARNING: Allow 10 minutes for the internal DC capacitors to discharge before touching the UPS internal components. 4-13 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 52 4: Operation 4-14 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 53: Maintenance

    • Operation of all installed options Preventative maintenance inspections form an integral part of all Extended Warranty Agreements (maintenance contracts) offered by Kohler Uninterruptible Power For further details on Extended Warranty Agreements see Chapter 2. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 54: Battery Testing

    The test can be carried out independent of the operating mode (Off-line or On-line) and whether or not the load is connected, but it should be undertaken only if there are no alarm conditions and the battery is fully charged. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 55: Troubleshooting

    Identify the cause of the alarm condition by means of the events register in the main menu (See paragraph 4.3.3). In case of doubt please contact Kohler Uninterruptible Power on +65 6302 0708. Fault identification and rectification information is given on the following pages.

  • Page 56: Fault Identification And Rectification Messages And Alarms

    UPS switches itself off to protect its batteries MANUAL BYP IS CLOSED Maintenance bypass closed. Load This alarm is only displayed if the UPS is supplied by mains on maintenance bypass UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 57: Contacting Service

    6: Troubleshooting Contacting service Kohler Uninterruptible Power has a service department dedicated to providing routine maintenance and emergency service cover for your UPS. If you have any queries regarding your UPS please contact us. Regional Office (South East Asia) Kohler Uninterruptible Power...
  • Page 58 6: Troubleshooting UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 59: Options

    • RS485 Interface for multidrop – JR1 (JR2 for 400-500kVA) (see paragraph 7.3) • Dry port customer interface – X1, X2 (X1, X2, X3 for 400-500kVA) (see paragraph 7.4) • SNMP/ Modem slots for remote monitoring/control – (see paragraph 7.5) UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 60: Serial Rs232 Computer Interface - Usb & Jd1 (Smart Port)

    RS485 serial port that allows a computer to access information from all modules connected in a parallel system. The retrieved data can be used to display the system operating parameters and status. UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 61: Dry Ports Customer Interface (X1, X1, X3)

    Battery Low active X2/6 Status LOAD ON INV Common X2/5 Load not On Inverter X2/4 Load on Inverter active X2/3 Alarm MAINS OK Common X2/2 Mains Failure X2/1 Mains Present UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 62: 400-500Kva Customer Interface Connections

    Load on Inverter active X2/3 Alarm MAINS OK Common X2/2 Mains Failure X2/1 Mains Present X1/2 230Vac – EXT MAN BYP Castell Interlock Function External Manual Bypass closed (230Vac 2AT) X1/1 – UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 63: Remote Emergency Stop Option

    The remote stop facility comprises a normally-closed circuit connected between terminal X1/7 and X1/8 (or X3/3 and X3/4) on the communication card located on the Kohler PW 6000 front frame (see Figure 7.3). It is recommended that a terminal block, with linking facilities, is installed between the UPS and the remote emergency stop button, as shown, in order to allow the removal, maintenance or testing of the remote emergency stop circuit without disturbing the normal UPS operation.

  • Page 64: Generator On Facilities

    The Kohler PW 6000 contains two SNMP slots; one is designed to house a Modem/Ethernet SNMP adapter card and the other a Modem/GSM adapter. Alternatively, SNMP connectivity can also be implemented using an external SNMP adapter connected to the UPS RS232 output.

  • Page 65: Ups Monitoring And Automated Control Software

    Figure 7.5 SNMP Internal and external adapters UPS Monitoring and automated control software Three (optional) monitoring systems are available for use with the Kohler PW 6000 UPS system: • SNMP – can be used for monitoring and controlled UPS shutdown •...

  • Page 66: Powerreporter™ Management Software

    • Priority driven Management (with escalation) Comprehensive management system • Reception and management of alarm calls from Kohler Uninterruptible Power • Storage of UPS data in a database exportable in a CSV-format for easy handling in Excel • Unlimited number of UPS that can be managed •...

  • Page 67: Specifications

    1600 1625 Colour Graphite Grey (RAL 7024) Batteries (Max configuration) 120 x 28Ah Battery blocks mounted on 24 shelves. Input and output power cable entry Bottom Exhaust cooling air Rear UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 68 For added redundancy and/or capacity a parallel system can be extended to up to 10 modules on request Double conversion AC/AC efficiency with Load 100% fully charged battery and linear load (PF = 1) % eff. 95.5% 96.0% 95.5% 95.0% UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 69 3x 380/220 or 3x 400/230 or 3x 415/250 Output voltage stability (Static) < ± 1.0 Output voltage stability (Dynamic) < ±4 (with load step 0-100%, 100-0%) Output voltage distortion with linear < 2 with linear load load UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 70 Inductive (lagging COS ø) Unity Capacitive (leading COS ø) Module 0.65 0.75 0.85 0.95 0.95 0.85 200* Vout=230Vac (L-N), 50 Hz, with minimum of 44 battery blocks (*50 Battery blocks on 200kVA model) UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 71 RS485 on RJ45 port For multidrop purposes (option) Slot for SNMP Card Ethernet card for monitoring and integration in network management (option) Slot for SNMP Card Modem card for GSM remote monitoring (option) UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 72: 60-300Kva Fuses & Cables Quick Reference

    5x240 or 5x(2x95) 3x400 5x240 or 5x(2x95) 5x240 or 5x(2x95) 3x500 5x(2x120) 3x500 5x(2x120) 5x(2x120) Note: Battery cabling (Cable E) and battery fuses (Fuse E) are bespoke to the installation UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

  • Page 73: 400-500Kva Fuses & Cables Quick Reference

    5x(3x95) or 5x(2x185) 3x630 5x (3x95) or 5x(2x185) 5x(3x95) or 5x(2x185) 3x800 5x (3x150) 3x800 5x50 5x(3x150) Note: Battery cabling (Cable E) and battery fuses (Fuse E) are bespoke to the installation UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...
  • Page 74 8: Specifications UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012...

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