Kohler PW 6000 User Manual
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Kohler PW 6000 User Manual

Kohler PW 6000 User Manual

Medium to high power three-phase uninterruptible power supply
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PW
KOHLER
6000
Medium to high power three-phase uninterruptible power supply
(400-500 kVA)
User Manual

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Summary of Contents for Kohler PW 6000

  • Page 1 KOHLER 6000 Medium to high power three-phase uninterruptible power supply (400-500 kVA) User Manual...
  • Page 2 All product, product specifications and data are subject to change without notice to improve reliability, function, design or otherwise. Kohler Uninterruptible Power has taken every precaution to produce an accurate, complete and easy to understand specification document and will assume no responsibility nor liability for direct, indirect or accidental personal or material damage due to any misinterpretation of, or accidental errors, in this manual.

  • Page 3: Table Of Contents

    1.2 User precautions 2: General Description 2.1 Introduction 2.1.1 Reliability and quality standards 2.1.2 Key features 2.2 KOHLER PW 6000 (400-500kVA) model range 2.3 UPS module functional description 2.3.1 UPS module block diagram 2.3.2 UPS internal operating modes 2.3.3 System operating modes 2.4 Multi-module parallel system...
  • Page 4 8.3 RS485 Interface for multidrop – JR2 8.4 Dry ports customer interface (X1, X2, X3) 8.4.1 Dry port connections 8.4.2 Remote Emergency Power Off (EPO) option 8.4.3 Generator ON facilities 8.5 SNMP Card slots © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 5 9: Specification © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 6: Useful Contacts

    Powerwill assume no responsibility nor liability due to incorrect operation or manipulation of the UPS. WARNING: The Kohler PW 6000 (400-500kVA) 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 7: 2: General Description

    2.1.1 Reliability and quality standards The KOHLER PW 6000 (400-500kVA) UPS is available over a model range of 400kVA to 500kVA and incorporates the latest technological developments in power engineering. Representing a completely new generation of high power three phase UPS systems, 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.

  • Page 8: Kohler Pw 6000 (400-500Kva) Model Range

    The safety panel panels should be removed only by an Kohler Uninterruptible Powertrained engineer. The KOHLER PW 6000 (400-500kVA) UPS can be used as a single, stand-alone UPS module or up to ten modules can be configured to operate as a parallel UPS system. A multi-module system is designed to increase the UPS system’s output capacity and enhance the system’s reliability by providing module redundancy.

  • Page 9: Ups Module Functional Description

    2: General Description UPS module functional description Figure 2.2 KOHLER PW 6000 (400-500kVA) UPS module block diagram 2.3.1 UPS module block diagram Figure 2.2 shows the major power blocks contained within the UPS system. UPS Input supplies (1), (2) The UPS is connected to two, 3-phase supplies, the ‘input mains supply’ and ‘bypass mains supply’. The input supply cables must be protected by an external isolation device (fuse/circuit breaker) to provide a means of disconnecting the mains supplies to the UPS.

  • Page 10: Ups Internal Operating Modes

    The UPS batteries are either installed in a dedicated battery cabinet or on a purpose-designed battery rack. The battery installation is bespoke but it must include a fuse located near the battery source to enable the batteries to be disconnected from the UPS. A range of external battery cabinets is available from Kohler Uninterruptible Power on request. 2.3.2 UPS internal operating modes The following simplified block diagrams illustrate various UPS operating modes.
  • Page 11 Similarly, the inverter can also remain in an operating (standby) state ready to be brought back into use. Note: This is the normal operating mode when using the UPS in ECO mode. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 12: System Operating Modes

    UPS system. The KOHLER PW 6000 (400-500kVA) can be operated in all three of the above categories. On-line operation When used as an ‘on-line’ UPS the KOHLER PW 6000 (400-500kVA) module is configured to normally operate in the ON INVERTER mode.

  • Page 13: Multi-Module Parallel System

    2.4.1 Parallel system concept The outputs from up to ten KOHLER PW 6000 (400-500kVA) UPS modules can be connected together to form a parallel UPS system – an example of a three module parallel system is shown in Figure 2.7.
  • Page 14 2: General Description Figure 2.7 KOHLER PW 6000 (400-500kVA) UPS Parallel system © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 15: Common Battery

    We highly recommend the use of individual batteries for each module. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 16: Module Control Panel (Standard Lcd)

    Module Control Panel (standard LCD) The standard KOHLER PW 6000 (400-500kVA) module is controlled and monitored through an LCD-based module control panel located on the front of the cabinet. An alternative TFT touch screen, described in paragraph 2.6, is available.

  • Page 17: Operator Buttons

    – i.e. if there are a sufficient number of modules remaining to support the system load then the load will not be transferred. To shut down all the modules in a parallel system you must press both ON/OFF buttons on every module. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 18: Power Management Display (Pmd)

    – [SET GENERATOR OP.].[BATT CHARGE LOCK] turns off the battery charger when the UPS is operating on generator. – [SET GENERATOR OP.].[BYPASS LOCK] inhibits load transfer to bypass when the UPS is operating on generator. © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 19 2: General Description Figure 2.10 Module control panel menus © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 20: Tft Module Control Panel

    UPS number In a single module installation this would indicate S01. Load Status Indicates whether or not the load is protected, when the user is in the module navigation level. Figure 2.12 Display header bar © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 21: Mimic Diagram Screen

    Three meters are included on the mimic display screen to indicate the rectifier, inverter, bypass and load operating parameters. The displayed battery parameters include the battery temperature and remaining autonomy time. The meter display source is selected by touching the associated interactive block on the mimic display. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 22: Home Screen

    Enables the user to adjust of data such as date and time, automatic battery test, etc. This password protect area enables the service technician to adjust several UPS parameters and is not Service accessible to the UPS Operator. Figure 2.14 Home display screen © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 23 2: General Description Figure 2.15 TFT Home Screen menus © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 24: Warranty

    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...

  • Page 25: 3: Installation

    This chapter contains essential information concerning the unpacking, positioning, installing and cabling of the KOHLER PW 6000 (400-500kVA) UPS. Key Point: If you are installing an external battery cabinet supplied by Kohler Uninterruptible Power you should refer to the manual that is provided with the cabinet for installation instructions.

  • Page 26: Local Transportation

    The floor at the proposed installation site and en-route from the off-loading point must be able to safely support the weight of the UPS and battery equipment, plus fork lift or trolley jack during transit. The minimum clearances required around the UPS for cooling air flow and service access is shown in Kohler Uninterruptible Power A temperature of 20°C is necessary to achieve the optimum battery life span.

  • Page 27: Ups Cabinet Installation

    The enclosure is delivered on a specifically designed pallet that can be moved easily using a forklift or a pallet jack. The accessories pack is shipped inside the enclosure and the cable set is delivered in a separate package. © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 28 Attach the base of the TCE enclosure to the two U shaped brackets using 2x M5 screws to secure each bracket – affix the screws through the base of the enclosure into the brackets. Using 6x M5 screws, secure the tops of the cabinets together by fitting three tie bars, as shown in Figure 3.4. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 29: Battery Installation

    If the batteries are to be mounted on external battery racks, rather than in a cabinet, the battery cables must be sized to take into account the DC voltage drop between the battery installation and UPS. Contact Kohler Uninterruptible Power for installation advice and support if necessary.

  • Page 30: Parallel Cabinet Cabling Recommendations

    Similarly, the UPS output should be connected to the load equipment via a suitably rated UPS output device. The battery installation requires fuses fitted in the battery positive, negative, and mid-point (neutral) feeds, as shown in Figure 3.5. Kohler Uninterruptible Power can supply a range of matching battery cabinets containing the necessary fuses and switchgear on request.

  • Page 31: External Maintenance Bypass Switch

    The switches may be installed in a dedicated external Maintenance Bypass switch cabinet or included in an existing (or dedicated) switchgear panel. Kohler Uninterruptible Power can supply a range of external maintenance bypass solutions to suit all of its UPS systems.

  • Page 32: Cable Sizing

    3x (5 x M12) 3x (4 x M12) Current ratings shown for 400V, 100% Linear load and maximum battery charging. All terminals should be tightened to a torque of 84 Nm Figure 3.9 Cable sizing © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 33: Electrical Installation (Cabling Procedures)

    All the operations detailed in this section must be supervised by an authorised electrician. After the electrical installation is completed, the initial UPS start-up must be performed by qualified commissioning engineer authorised by Kohler Uninterruptible Power WARNING: Do not apply electrical power to the UPS before it has been commissioned and handed over.

  • Page 34: Bottom Entry Cabling Procedure

    The kit contains several cabinet-wide support bars that are fitted behind of each row of cables and must be installed progressively as the power cables are connected, as described below. A cable support kit, containing all the necessary fittings and securing hardware, is shipped separate to the UPS cabinet. © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 35 Note: For reasons of clarity the cables connected to the rear holes are not shown in Figure 3.15. Figure 3.15 10. Once the middle cables are connected, secure them to the middle cable securing bars just fitted. © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 36 19. This completes the module bottom entry power cabling. WARNING: The UPS must be commissioned by an Kohler Uninterruptible Power approved engineer. DO NOT APPLY POWER TO THE UPS BEFORE IT HAS BEEN FULLY COMMISSIONED.

  • Page 37: Top Entry Cabling Procedure

    The connections at each end of the Figure 3.19 busbars therefore have two, offset M12 holes through which the cable can be attached. Figure 3.19 shows the recommended method of connecting three parallel cables. © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 38 11. Next connect the 2L2, 2L1 and 2N cables in turn placing each set of cables on the ones below. The completed output cabling should appear similar to that shown in the diagram alongside. © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 39 Note that this illustration is provided for guidance only and does not specify the exact positioning of required gland holes. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 40: Connecting The Battery

    IMPORTANT NOTE High voltage battery strings can be extremely dangerous and should not be installed by the customer’s installation team. The batteries must be installed and connected to the UPS by an Kohler Uninterruptible Power service engineer. It is the customer’s responsibility to provide appropriate containment for the DC power cables between the UPS cabinet and battery cabinet where necessary –...

  • Page 41: Single/Dual Feed Conversion

    Note: Use the above procedure in reverse order if it is necessary to convert the UPS from a dual feed to single feed input. WARNING: The UPS must be commissioned by an Kohler Uninterruptible Power approved engineer. DO NOT APPLY POWER TO THE UPS BEFORE IT HAS BEEN FULLY COMMISSIONED.

  • Page 42: Installation Of Remote Monitoring And Control Facilities

    (JD8). This must be installed and configured by the commissioning engineer; however, depending on the modules’ positioning, it may be necessary for the customer to provide any necessary containment. Contact Kohler Uninterruptible Power for further installation advice if required. IDENT...

  • Page 43: 4: Operating Instructions (Lcd)

    Introduction 4.1.1 Commissioning The KOHLER PW 6000 (400-500kVA) UPS is a high quality, complex electronic system which must be commissioned by an authorised Kohler Uninterruptible Power engineer before it is put into use. The commissioning engineer will: • check the UPS electrical and mechanical installation, and operating environment •...

  • Page 44: General Warnings And Precautions

    The LCD displays LOAD OFF, SUPPLY FAILURE. If necessary press the RESET button to obtain this display. Close the external UPS system output isolation device. Close the UPS maintenance bypass switch. Turn on the load equipment. © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 45 17. Scroll through the measurements menu and check that the module’s input and output supply indications are correct. Key Point: The UPS system is now operating in its ‘on-inverter’ mode and the load is fully protected. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 46: How To Start The Ups System From The Maintenance Bypass

    The UPS system is operating normally, on-inverter– continue with step 3: The UPS system is operating with the load on bypass due to a system fault, severe overload, loss of redundancy or operating in ‘ECO’ mode – continue with step 7: © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 47: How To Shut Down The Complete Ups System

    Turn OFF the UPS input mains and bypass mains supplies. Where used, refer to the operating instructions for the bespoke external maintenance bypass facility for additional details of how to isolate the UPS mains supply if necessary. The UPS cabinet is now voltage free. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 48: Operating In Bypass (Eco) Mode

    Use the UP/DOWN keys to move the cursor so that it is adjacent to LOAD TO INVERTER and then press the ENTER key. d) The UPS module output should transfer to inverter and the module control panel mimic indications should be as shown here. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 49: 5: Operating Instructions (Tft)

    Introduction 5.1.1 Commissioning The KOHLER PW 6000 (400-500kVA) UPS is a high quality, complex electronic system which must be commissioned by an authorised Kohler Uninterruptible Power engineer before it is put into use. The commissioning engineer will: • check the UPS electrical and mechanical installation, and operating environment •...

  • Page 50: General Warnings And Precautions

    WARNING triangle in the TFT Header bar and, in some cases, accompanied by an audible alarm. When this occurs you can cancel the audible warning by pressing the triangular warning symbol.The TFT Control Panel is described in paragraph 2.6. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 51: How To Turn On The Ups System From A Fully Powered-Down Condition

    The mimic screen indicates the rectifier and static bypass are operating (green). The inverter is OFF (white) d) IA2 is open – so there is no power connected to the UPS output. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 52: Transfer The Load To The Static Bypass Line

    14. On the TFT control panel, verify that: a) The parallel isolator switch icon is shown closed and changed to green. WARNING: For a parallel-module system, do not proceed if the TFT mimic indication on any module is not as shown. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 53: Transfer The Load To Inverter

    21. Scroll through the measurements menu and check that the module’s input and output supply indications are correct. Key Point: The UPS system is now operating in its ‘on-inverter’ mode and the load is fully protected. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 54: How To Start The Ups System From The Maintenance Bypass

    The battery line and the battery charge indicator arrowhead changes to green. load rectifier inverter b) The parallel isolator switch icon is shown closed and changes to green. Repeat step 1 to 6 for each module in a parallel- module system. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 55: Transfer The Load To The Static Bypass Line

    The load can be transferred to the maintenance bypass supply, and the UPS module turned off, when troubleshooting a ‘system level’ fault or if the UPS processed power is not required for a period of time. This procedure is normally carried © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 56: Transfer The Load To The Static Bypass

    The static bypass is turned ON (green) b) The inverter is turned OFF (green). load rectifier inverter The battery is being charged. d) LOAD NOT PROTECTED status is displayed in the header bar. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 57: Transfer The Load To The Maintenance Bypass

    Turn OFF the UPS input mains and bypass mains supplies. Where used, refer to the operating instructions for the bespoke external maintenance bypass facility for additional details of how to isolate the UPS mains supply completely if necessary. The UPS cabinet is now voltage free. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 58: Operating In Bypass (Eco) Mode

    The static bypass is turned ON (green) b) The inverter is turned OFF (green). load rectifier inverter The battery is being charged. d) LOAD NOT PROTECTED status is displayed in the header bar. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 59: 6: Maintenance

    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 page 1. A preventative maintenance inspection of the following: •...

  • Page 60: 7: Troubleshooting

    Pressing the Home screen icon on the display header bar then selecting Measures. This will open the metering screens from which you can observe and note the value of the UPS input/output/battery parameters etc. Refer to the troubleshooting table below for possible fault resolutions and seek advice if necessary. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 61: Troubleshooting Table

    CLOSED 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. www.kohler-ups.co.uk Kohler Uninterruptible Power web site ukservice.ups@kohler.com...

  • Page 62: Introduction

    • RS232 Computer serial interface – USB & JD1 (see paragraph 8.2) • RS485 Interface for multidrop – JR1 (see paragraph 8.3) • Dry port customer interface – X2, X3 (see paragraph 8.4) • SNMP/ Modem slots for remote monitoring/control – (see paragraph 8.5) © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 63: 8: Options

    If this feature is requested, the commissioning engineer will install the required kit of parts and test the system to ensure it is fully functional as part of the UPS commissioning procedure. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 64: Dry Ports Customer Interface (X1, X2, X3)

    Load on Inverter active X2/3 Alarm MAINS OK Common X2/2 Mains not present X2/1 Mains Present X1/2 230Vac – EXT MAN BYP Castell Interlock Function External Manual Bypass closed (230 Vac 2AT) X1/1 – © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 65: Remote Emergency Power Off (Epo) Option

    UPS input power. Use a screened cable with 1 pair (section of wires 0.6 mm ) and maximum length of 100 m. Figure 8.4 Generator ON Connection Connect the cable as shown in Figure 8.4. © 2023 Kohler Uninterruptible Power 12/9/23...

  • Page 66: Snmp Card Slots

    The KOHLER PW 6000 (400-500kVA) 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 67 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 fully 25%load 50% load 75% load 100% load charged battery and linear load (PF = 1) 95.2% 96.0% 95.8% 95.6% © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 68 At PF=1.0 110% load for 10 minutes At PF=1.0 135% load for 1 minute At PF=0.9 125% load for 10 minutes At PF=0.9 150% load for 1 minute Inverter short circuit capability 2.0x (x rated output for 40ms) © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 69 (option) Slot for SNMP Card Modem card for GSM remote monitoring (option) Customer Interfaces: (Dry Ports) LCD display and mimic diagram showing UPS operational status (Optional 7” TFT touch-screen display standard on 400/500kVA model) © 2023 Kohler Uninterruptible Power 12/9/23...
  • Page 70 9: Specification OUTPUT POWER VERSUS COS ø Inductive (lagging COS ø) Unity Capacitive (leading COS ø) Module 0.65 0.75 0.85 0.95 0.95 0.85 Vout=230Vac (L-N), 50 Hz, with minimum of 44 battery blocks © 2023 Kohler Uninterruptible Power 12/9/23...

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