Kohler PW 5000/TP User Manual
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Kohler PW 5000/TP User Manual

Kohler PW 5000/TP User Manual

Three-phase uninterruptible power supply 10-50 kva parallelable up to 400 kva/360 kw
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PW
KOHLER
5000/TP
Three-phase uninterruptible power supply
(10–50 kVA)
Parallelable up to 400 kVA / 360 kW
User Manual

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Summary of Contents for Kohler PW 5000/TP

  • Page 1 KOHLER 5000/TP Three-phase uninterruptible power supply (10–50 kVA) Parallelable up to 400 kVA / 360 kW User Manual...

  • Page 2: Document Control

    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 1: Safety 1.1 Description of symbols used in this manual 1.2 User precautions 2: General Description 2.1 Reliability and Quality Standards 2.2 Kohler PW5000/TP Model Range 2.2.1 Single/Multi-cabinet configurations 2.3 Advanced Design Features 2.3.1 Input booster technology 2.3.2 Flexible battery management 2.3.3 Decentralized Parallel Architecture (DPA)
  • Page 4 4.3.3 Event log menu screen 4.3.4 Measurements menu screen 4.3.5 Commands menu screen 4.3.6 UPS Data menu screen 4.3.7 Set-up User menu screen 4.3.8 Set-Up Service menu screen 4.4 Operating Modes 4.4.1 On-Line (Inverter) mode 4.4.2 Bypass (Line-Interactive) mode 4.4.3 Maintenance Bypass Mode 4.4.4 Multi-module configuration concept 4.5 Operating Instructions 4.5.1 Transfer to Maintenance Bypass Mode...

  • Page 5: Description Of Symbols Used In This Manual

    Power will assume no responsibility nor liability due to incorrect operation or manipulation of the UPS. WARNING: The Kohler PW5000/TP is a Class A UPS product (according to BS EN 62040-2:2006). In a domestic environment the UPS may cause radio interference. In such an environment the user may be required to undertake additional measures.

  • Page 6: General Description

    International Standard ISO 9001/EN 29001 and ISO 14001. A full UPS Specification is given in Chapter 8 this manual. Kohler PW5000/TP Model Range The Kohler PW5000/TP UPS range covers 10, 15, 20, 25, 30, 40 and 50kVA models, in three different sized cabinets, that can be employed in a Single or Multi-Module configuration.

  • Page 7: Single/Multi-Cabinet Configurations

    Single/Multi-cabinet configurations The Kohler PW5000/TP UPS may be configured to operate as a single cabinet or several (up to 20) cabinets can be connected in parallel to operate as a multi-module UPS system. A multi-module configuration is selected either to increase the system’s total power capacity or to provide module redundancy.

  • Page 8: Extended 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 9: Additional Service/Maintenance Support

    Additional Service/Maintenance Support If you are interested in obtaining an extended warranty for your Kohler PW5000/TP, or require service/maintenance support for any other UPS you may have, please contact Kohler Uninterruptible Power at the following address: www.kohler-ups.co.uk Kohler Uninterruptible Power web site ukservice.ups@kohler.com...

  • Page 10: Installation

    'Tip&Tel' (“FRAGILE” and “ARROW”) indicator should be intact if the equipment has been transported in an upright position. In case of rupture (or if they are suspect) inform the carrier and Kohler Uninterruptible Power immediately. CAUTION: Visible transport damages must be notified to the carrier immediately after receipt! Other claims for shipping damage must also be filed immediately and the carrier must be informed within 7 days of receipt of the equipment.

  • Page 11: Unpacking The Ups

    UPS. The batteries are usually shipped separately and fitted by a manufacturer-approved engineer when the UPS is commissioned. If the UPS is delivered without batteries, Kohler Uninterruptible Power is not responsible for any damage or malfunctioning caused to the UPS by the incorrect supply, storage, installation or connection of batteries by third parties.

  • Page 12: Planning The Installation

    The air conditioning system can provide a sufficient amount of air cooling to keep the room at, or below, the maximum desired temperature. g) No dust or corrosive/explosive gases are present. h) The location is vibration free. If the UPS is to be installed in bayed enclosures, partition walls have to be installed. © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 13 Top, rear, front, left and right side Top, front, left and right side Positioning Min. 200mm rear space required for ventilation Input and Output Power Cabling From the bottom at the rear. From the bottom at the front © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 14 • protective earth (PE) connection for the external batteries • the UPS internal batteries must be disconnected if external batteries are used. Under no circumstances should external and internal batteries be connected together in parallel. © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 15 I n T N - S s y s t e m s , n o 4 - p o l e i n p u t s w i t c h e s o r c i r c u i t b r e a k e r s s h o u l d b e u s e d . During battery operation the neutral must always be grounded. 230V Figure 3.3 Input neutral grounding © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 16 2. The fuse and cable rating details in the above tables are a recommendation only. 3. The UPS must be installed to prescribed IEC or local regulations (e.g. BS7671). 4. External DC Cables and Battery fuses are bespoke to the installation. Figure 3.4 Kohler PW5000/TP fuse & cable rating © 2023 Kohler Uninterruptible Power...
  • Page 17 Load The cable configuration below is not recommended Bypass Feed Rectifier Feed UPS 1 UPS 2 UPS 3 UPS 4 Load Figure 3.5 Cable lengths for multi cabinet configurations (assuming a dual input supply) © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 18 2. The fuse and cable rating details in the above tables are a recommendation only. 3. The UPS must be installed to prescribed IEC or local regulations (e.g. BS7671) Figure 3.6 10-25kVA Connection details © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 19 2. The fuse and cable rating details in the above tables are a recommendation only. 3. The UPS must be installed to prescribed IEC or local regulations (e.g. BS7671) Figure 3.7 30-50kVA Connection details © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 20: Ups Cabinet

    3. The UPS must be installed to prescribed IEC or local regulations (e.g. BS7671). 4. External DC Cables and Battery fuses are bespoke to the installation. Figure 3.8 Single input feed - power connection diagram © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 21 3. The UPS must be installed to prescribed IEC or local regulations (e.g. BS7671). 4. External DC Cables and Battery fuses are bespoke to the installation. Figure 3.9 Dual input feed - power connection diagram © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 22: Connecting The Ups Input Supply

    Figures 3.10, 3.11 and 3.12. The Kohler PW5000/TP input supply can be wired for ‘single feed’ (standard) or ‘dual feed’ operation. Connect the input power cable coming from the LV-Distribution Board to the UPS input terminals following the ‘single input feed’ or ‘dual input feed’...

  • Page 23: Connecting The Ups Output

    • The maximum total load rating and maximum load rating of the individual load sockets should be indicated on the output distribution board. • The circuit breakers must comply with the prescribed IEC Standards (e.g. BS7671). It is recommended that a separate output distribution board is provided for the load. © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 24: Connecting The Ups Output Cables

    CAUTION: The output Neutral cable must ALWAYS be connected. Secure the cables to the fixing rail located below the UPS connection terminals. Ensure the output cables are connected to the correct power terminals on the load distribution panel. © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 25 IA2: Output (parallel) isolator switch FA2 I A1 I A2 IA1: Maintenance Bypass isolator switch Power terminals: Ext. Battery, Rectifier (input), Bypass, Output terminals Figure 3.10 10 kVA–15 kVA Cabinet A connector details (rear view) © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 26 IA2: Output (parallel) isolator switch I A1 I A2 IA1: Maintenance Bypass isolator switch Power terminals: Ext. Battery, Rectifier (input), Bypass, Output terminals Figure 3.11 10 kVA - 25 kVA Cabinet B connector details (rear view) © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 27 IA2: Output (parallel) isolator switch I A1 I A2 IA1: Maintenance Bypass isolator switch Power terminals: Ext. Battery, Rectifier (input), Bypass, Output terminals Figure 3.12 25 kVA - 50 kVA Cabinet C connector details (front view) © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 28: Battery Connections

    A range of matching battery enclosures are available, designed to suit individual site requirements. In each case the battery enclosure is fitted with a suitably rated fused isolator which is connected to the battery connection terminals inside the Kohler PW5000/TP as shown in Figures 3.6 and 3.7. Note: DC fuses and cables are bespoke to the installation.
  • Page 29 Note: To remove the front cover to gain access to the switches, firmly pull the 2 handles away from the front of the UPS. The cover is held in place by 4 pin clips. Figure 3.13 Internal battery locations © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 30: Multi-Module Control Cabling And Configuration

    Output Input Output Input Output Input Parallel Adaptor Master-Slave Master-Slave SW2-2 Input Output SW2-2 Configuration First Unit Middle Unit Last Unit Single Unit SW 1 SW 2 Figure 3.14 Bus-lines connections (3 Modules shown) © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 31: Module Interfacing Facilities

    UPS-status continuously and display a message in the event of any UPS system changes. Figure 3.15 and show the connection to a PC from the UPS for PC’s with a 9 pin serial port and 25 pin serial port respectively. © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 32 The Computer Interface JR1 located on the distribution part is an intelligent RS485 serial port that allows system information to be gained from all modules which are connected in parallel using the Multidrop connection kit. (For details see user manual Multidrop kit). The connector JR1 is a standard RJ45 port. © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 33: X2 Dry Port - Optional Output Interfaces Terminal Block (X2)

    Load on Mains (BYPASS MODE) Common Alarm BATT_LOW Battery Low Battery OK Common Message LOAD_ON_MAINS Load On Mains (BYPASS-MODE) Load on Inverter Common Alarm COMMON_ALARM Common Alarm No Alarm Condition Common Figure 3.16 Dry Port (X2) Connections © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 34: Operation

    Operation Commissioning The Kohler PW5000/TP UPS is a high quality electronic machine that must be commissioned by a fully trained and authorised Kohler Uninterruptible Power field service engineer before being put into use. Commissioning the UPS involves connecting the UPS battery, checking the electrical installation and operating environment of the UPS, performing a controlled start-up and testing of the UPS system, and customer training.
  • Page 35 Note: When the UPS is under normal operation, pressing the two ON/OFF buttons simultaneously will immediately shut down the UPS. In a single module installation this will disconnect the UPS from the load. In a parallel module system the © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 36: Description Of The Lcd Display

    If a UP S is o perating as a S ingle m odu le then it is se en as th e First an d Las t in an im agina ry chain . © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 37 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 © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 38 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 (%) © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 39 1. These general UPS Data are installed at the manufacturing plant. UPS SERIAL NUMBER nn-nnnnn 2. Manufacturing date DATE OF MANUFACTURE 15-03-11 3. EPROM Version EPROM VERSION V-000 4. Actual Date and Time DATE TIME dd-mm-yyyy hh:mm:ss © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 40 From within the Set-up Service menu a service engineer can adjust the UPS voltages, frequencies, currents, power and autonomies, together with setting up: • 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%) © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 41: Operating Modes

    3 to 5 ms – which is the transfer time taken to change from Bypass mode to On-Line mode. WARNING: The On-Line mode must always be used to provide maximum load protection. © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 42: Maintenance Bypass Mode

    In this type of system the maintenance bypass circuit is provided by a single external circuit breaker that wraps around the entire UPS system. For reasons of safety, and sustaining the load © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 43: Multi-Module Configuration Concept

    4.4.4 Multi-module configuration concept Up to 20 Kohler PW5000/TP UPS modules can be connected in parallel to provide increased power capacity or redundancy operation. Note: Although the UPS single/multi configuration can be modified in the field it is generally specified on ordering so that the module can be configured and fully tested in the factory prior to despatch.

  • Page 44: Transfer To Maintenance Bypass Mode

    The UPS system will transfer the load to static bypass. On all modules in a multi module system check and confirm that: a) The INVERTER LED has extinguished. b) The BYPASS LED is green. The LCD displays LOAD NOT PROTECTED. © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 45 If using external batteries open the battery fuses/isolator on the associated battery cabinet/rack. On the UPS module open the module’s Parallel Isolator (IA2). LINE 2 BY PASS Colour LINE 1 Green LOAD LINE 1 INVERTER LINE 2 BY PASS INVERTER BATTERY BATTERY Green Flashing © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 46: Starting The Ups System From The Maintenance Bypass

    Initially LINE 2 LED will be red, then change to green. a) At this stage the LCD display will indicate LOAD NOT PROTECTED and the module mimic LED indications should be as follows: © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 47 10. The UPS system will transfer the load to Inverter (on all modules in a multi-module system). a) The LCD display(s) will now indicate LOAD PROTECTED. b) Check and confirm that the LED display(s) are as shown below: © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 48: Complete System Shutdown

    Open the UPS Input and Bypass supply fused isolators (or breakers) in the building power 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. © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 49: Individual Module Start/Stop Procedure

    LINE 2 BY PASS Colour LOAD LINE 1 Green LINE 1 INVERTER LINE 2 Green BY PASS INVERTER Green BATTERY BATTERY Green The UPS module is now On Line and connected to the parallel system. © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 50: Module Shut-Down

    If using external batteries open the battery fuses/isolator on the associated battery cabinet/rack. Open the UPS input supply isolator and UPS output isolator on the LV Switchboard. The UPS module is now totally shut-down. © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 51: System Calibration

    UPS. Preventative maintenance inspections involve working inside the UPS which contains hazardous AC and DC voltages. WARNING: Only Kohler Uninterruptible Power trained and authorised field service engineers are fully aware of all of the hazardous areas within the UPS.

  • Page 52: Battery Testing

    • The battery is fully charged The battery test procedure can be performed from the UPS front panel and can be carried out independently of the operating mode (Off-line or On-line) and whether or not the load is connected. © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 53: Troubleshooting

    Silence the audible alarm by pressing the RESET button. Identify the cause of the alarm condition by viewing the events register in the main menu (See paragraph 4.3.3). In case of doubt please contact Kohler Uninterruptible Power Fault identification and rectification information is given on the following pages.

  • Page 54: Menu, Commands, Event Log, Measurements

    BATTERY IN DISCHARGE UPS switches itself off to protect its batteries Maintenance Bypass closed. Load supplied by This alarm is only displayed if the UPS is on MANUAL BYP IS CLOSED mains Maintenance Bypass © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 55: 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. We recommend that your UPS is protected by an Extended Warranty Agreement. These agreements assist us in caring for your UPS correctly, ensuring that it is well maintained and attended to promptly should any problems occur.

  • Page 56: Remote Emergency Stop Facilities

    Options Introduction The Kohler PW5000/TP UPS has the following available options: • Remote Emergency Stop facilities • Generator On facilities • Temperature sensor for temperature-dependant battery charging • Software for automatic shutdown and monitoring • SNMP Card for network management and remote monitoring •...

  • Page 57: Generator On Facilities

    Use a screened cable with 1 pair (section of wires 0.6 mm ) and maximum length of 100 m. Connect the cable as shown in Figure 7.2. Generator Alarm Panel UPS Generator Port X1/1 X1/2 Figure 7.2 Generator ON Connection © 2023 Kohler Uninterruptible Power 29/11/23...
  • Page 58 7: Options Temperature sensor for temperature-dependent battery charging A temperature sensor can be used to vary the battery charging voltage depending upon the battery temperature. Temp. Sensor Battery Temperature Port X1/5 X1/6 © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 59: Ups Monitoring And Automated Control Software

    Kohler Uninterruptible Power considers it important to have a complete solution for its UPS systems and offers its customers a number of remote control and monitoring tools to provide optimum protection.

  • Page 60: Powerreporter™ Management Software

    The main features and benefits offered by PowerREPORTER are: • real time alarm or critical event email notification sent directly to Kohler Uninterruptible Power service centre • acquisition of key performance data and productivity information to allow a better understanding of the UPS system performance and quickly troubleshoot downtime events •...

  • Page 61: Functional Description

    PowerREPORTER communicates constantly with your UPS system to automatically detect any error or alarm messages. If it encounters an incident, PowerREPORTER will automatically transmit a status message, via email, to the Kohler Uninterruptible Power service centre providing details relating to the identified fault, a snapshot of the UPS performance parameters and a device identification string.

  • Page 62: Specifications

    440 x 1420 x 910 Dimensions (WxHxD) Weight (without battery) (9Ah/ (9Ah/28Ah) (9Ah/ (9Ah/28Ah) 28Ah) 160/145 28Ah) 170/155 151/135 165/150 Weight (with 144x7/9Ah battery) Weight (with 48x28Ah battery) Weight (with standard packaging) Colour Black (RAL 9005) © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 63: Input Characteristics

    At p.f. 0.8 125% load 10 min. At p.f. 0.8 150% load 1 min. Output short capability (RMS) Inverter: up to 3 x In during 40 ms Bypass: 10 x In during 10 ms Crest - Factor 3: 1 © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 64: Battery Characteristics

    25kVA – 40kVA in type C cabinets are cabled at the rear Efficiency AC-AC up to (at pf=1.0) Load: 100% 75% 50% 25% (depending on UPS power) Efficiency: 95.5% 95.5% 95% 94.5% Eco-Mode efficiency at 100% load © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 65: Heat Dissipation With Non-Linear Loads

    Customer Interfaces: Outputs (DRY PORTS) Load on Bypass Battery Low Load on Inverter Mains Failure RS232 on USB Port For remote signalling and automatic computer shutdown SNMP Card (slot already included) For monitoring and integration in network management © 2023 Kohler Uninterruptible Power 29/11/23...

  • Page 66: Fuses & Cables Quick Reference

    2. The fuse and cable rating details in the above tables are a recommendation only. 3. The UPS must be installed to prescribed IEC or local regulations (e.g. BS7671). 4. External DC Cables and Battery fuses are bespoke to the installation. © 2023 Kohler Uninterruptible Power 29/11/23...

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