Kohler PW 5000/TP User Manual
  1. Manuals
  2. Brands
  3. Kohler Manuals
  4. UPS
  5. PW 5000/TP
  6. User manual
Kohler PW 5000/TP User Manual

Kohler PW 5000/TP User Manual

Hide thumbs Also See for PW 5000/TP:
Table of Contents

Advertisement

Quick Links

Download this manual

User Manual

Kohler
PW 5000/TP
Pioneering solutions for
total power protection

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PW 5000/TP and is the answer not in the manual?

Questions and answers

Related Manuals for Kohler PW 5000/TP

Summary of Contents for Kohler PW 5000/TP

  • Page 1: User Manual

    User Manual Kohler PW 5000/TP Pioneering solutions for total power protection...
  • Page 3 Initial issue 14-09-11 Major changes to Chapter 3 plus other general book-wide updates 31-10-11 General corrections and layout update prior to initial issue. 17-11-11 Update model nomenclature and general typographical error corrections UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 4 © 2011 Kohler Uninterruptible Power This manual may not be copied nor reproduced without written permission of Kohler Uninterruptible Power. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 5: Table Of Contents

    3.8.1 Remote battery enclosures 3-19 3.8.2 Connecting the external battery enclosure 3-19 3.9 Multi-module control cabling and configuration 3-21 3.9.1 Connecting the parallel communication cables (Bus-lines) 3-21 3.9.2 Configuration DIP Switch selection 3-22 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 6 5.3 User responsibilities 5.4 Routine maintenance 5.5 Battery Testing Troubleshooting 6.1 Alarms 6.2 Menu, Commands, Event Log, Measurements, 6.2.1 Event Log Screen 6.2.2 Fault Identification and Rectification Messages and Alarms 6.3 Contacting Service UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 7 7.7 Modem/Ethernet card / PowerREPORTER™ management software Specifications 8.1 Mechanical 8.2 Input Characteristics 8.3 Output Characteristics 8.4 Battery Characteristics 8.5 Environmental 8.6 Heat Dissipation With Non-Linear Loads 8.7 Standards 8.8 Communication Options 8.9 Fuses & Cables Quick Reference UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 8 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 9: Safety

    Kohler Uninterruptible Power will assume no responsibility nor liability due to incorrect operation or manipulation of the UPS. WARNING: The Kohler PW 5000/TP is a Class A UPS product. In a domestic environment the UPS may cause radio interference. In such an environment the user may be required to undertake additional measures.
  • Page 10 1: Safety UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 11: Description

    Specification is given in Chapter 8 of this manual. Kohler PW 5000/TP Model Range The Kohler PW 5000/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 12: Single/Multi-Cabinet Configurations

    2: Description 2.2.1 Single/Multi-cabinet configurations The Kohler PW 5000/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 generally used either to increase the system’s total power capacity, or to provide module redundancy.

  • Page 13: Extended Warranty

    UPS products. If you are interested in an extended warranty for your Kohler PW 5000/TP UPS, or any other UPS you may have, please complete the enquiry form shown opposite and return or FAX to: Regional Office (South East Asia) Kohler Uninterruptible Power.
  • Page 14 .................... Tel..................... Fax..................... E-mail .................... Please contact me to discuss: Extended Warranty options for my Kohler PW 5000/TP UPS Extended warranty options for my UPS System as below: Manufacturer:..............Model Nº:................Rating kVA:............... Replacement Batteries..............Other ..............(please specify) Thank you for your enquiry, which will receive our prompt attention.

  • Page 15: Installation

    The packing container protects the UPS from mechanical and environmental damage. This protection is further increased by wrapping the Kohler PW 5000/TP UPS with a plastic sheet. Upon receiving the UPS, carefully examine the packing container and the UPS for any sign of physical damage.

  • Page 16: Unpacking The Ups

    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 17: Storage

    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. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 18: Battery Cabinet

    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 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 19: Ups Power Cabling

    • 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. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 20 Key Point: Input neutral is required to operate the rectifier. In TN-S systems, no 4-pole input switches or circuit breakers should be used. During battery operation the neutral must always be grounded. 230V Figure 3.3 Input neutral grounding UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 21 The fuse and cable rating details in the above tables are a recommendation only. The UPS must be installed to prescribed IEC or local regulations. External DC Cables and Battery fuses are bespoke to the installation. Figure 3.4 Kohler PW 5000/TP fuse & cable rating UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 22 The cable configuration below is not recommended Bypass Feed Rectifier Feed UPS 1 UPS 2 UPS 3 UPS 4 To Load Figure 3.5 Cable lengths for multi cabinet configurations (assuming a dual input supply) UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 23 Fuse and Cable recommendations to IEC 60950-1:2001. The fuse and cable rating details in the above tables are a recommendation only. The UPS must be installed to prescribed IEC or local regulations. Figure 3.6 15-25kVA Connection details UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 24 Fuse and Cable recommendations to IEC 60950-1:2001. The fuse and cable rating details in the above tables are a recommendation only. The UPS must be installed to prescribed IEC or local regulations. Figure 3.7 30-50kVA Connection details 3-10 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 25 The UPS must be installed to prescribed IEC or local regulations. External DC Cables and Battery fuses are bespoke to the installation. Figure 3.8 Single input feed - power connection diagram 3-11 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 26 The UPS must be installed to prescribed IEC or local regulations. External DC Cables and Battery fuses are bespoke to the installation. Figure 3.9 Dual input feed - power connection diagram 3-12 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 27: Connecting The Ups Input Supply

    Figures 3.10, 3.11, 3.12. The Kohler PW 5000/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’...

  • Page 28: Connecting The Ups Output

    Before you start connecting the UPS output cables to the load distribution panel: • Ensure that the potential (maximum) load does not exceed the UPS model output power rating (OUTPUT POWER) on the nameplate. 3-14 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 29: 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. 3-15 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 30 IA2: Output (parallel) isolator switch FA2 IA1 IA2 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) 3-16 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 31 IA2: Output (parallel) isolator switch IA1 IA2 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) 3-17 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 32 IA2: Output (parallel) isolator switch IA1: Maintenance Bypass isolator switch Power terminals: Ext. Battery, Rectifier (input), Bypass, Output terminals Figure 3.12 30 kVA - 50 kVA Cabinet C connector details (front view) 3-18 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 33: 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 PW 5000/TP as shown in (See Figures 3.6 /3.7). Note: DC fuses and cables are bespoke to the installation.
  • Page 34 • 48 x 28Ah blocks • 96 x 9Ah blocks • 144 x 9Ah blocks Note: All installations must use an even number of battery blocks. Batt. Location Figure 3.13 Internal battery locations 3-20 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 35: Multi-Module Control Cabling And Configuration

    Output Output Output Parallel Adaptor Master-Slave Master-Slave SW2-2 Input Output SW2-2 Configuration Single Unit First Unit Middle Unit Last Unit SW 1 SW 2 Figure 3.14 Bus-lines connections (3 Modules shown) 3-21 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 36: Configuration Dip Switch Selection

    Customer output interface on Phoenix terminals (Potential free contacts): Common Alarm Load On Bypass Battery Low Load on Inverter Mains Failure SNMP Slot for optional SNMP card ONLY For monitoring and integration in network management. 3-22 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 37: Jd1 Smart Port - Serial Rs 232 And Usb Port

    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. Interface Cable Interface Cable UPS end Computer end 9-Pin D-Type 9-Pin D-Type (Male) (Female) 9-Pin D-Type 25-Pin D-Type (Male) (Female) Figure 3.15 Connector Cable - PC Serial Port 3-23 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 38: X1 Dry Port (Volt-Free Contacts)

    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 3-24 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 39: Operation

    Operation Commissioning The Kohler PW 5000/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 40: Mimic Led Indicators

    Scroll downwards through a displayed menu. DOWN ALARM RESET Cancels the audible alarm. If the alarm condition was transient the will also extinguish, otherwise it will remain (red). ENTER Confirms (selects) a chosen menu item. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 41: Description Of The Lcd Display

    – UPS module is last in the parallel configuration chain. If a UPS is operating as a Single module then it is seen as the First and Last in an imaginary chain. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • 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) UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 43: Commands Menu Screen

    UPS SERIAL NUMBER These general UPS Data are installed at the manufacturing plant. nn-nnnnn DATE OF MANUFACTURE Manufacturing date 15-03-11 EPROM VERSION EPROM Version V-000 DATE TIME Actual Date and Time dd-mm-yyyy hh:mm:ss UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • 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%) UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 45: 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. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 46: Maintenance Bypass Mode

    UPS input mains supply circuit breaker at the mains distribution panel. WARNING: DO NOT CLOSE THE MAINTENANCE BYPASS SWITCH (IA1) ON A UPS MODULE IN A MULTI-MODULE PARALLEL SYSTEM. DOING SO COULD CAUSE PERSONAL INJURY, EQUIPMENT DAMAGE OR INTERRUPT THE LOAD SUPPLY. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 47: Multi-Module Configuration Concept

    4: Operation 4.4.4 Multi-module configuration concept Up to 20 Kohler PW 5000/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 48: Operating Instructions

    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. 4-10 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 49 On the UPS module open the module’s Parallel Isolator (IA2). LINE 2 BY PASS Colour LOAD LINE 1 Green LINE 1 INVERTER LINE 2 BY PASS INVERTER BATTERY BATTERY Green Flashing 4-11 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 50: 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: 4-12 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 51 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: 4-13 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 52: Complete System Shutdown

    Open the Bypass Line fuse holder FA2 and the Rectifier Line fuse holder FA1. Open the UPS Input and Bypass supply fused isolators (or breakers) in the building power distribution panel. 4-14 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 53: Individual Module Start/Stop Procedure

    Colour LOAD LINE 1 Green LINE 1 INVERTER LINE 2 Green BY PASS BATTERY INVERTER Green BATTERY Green The UPS module is now On Line and connected to the parallel system. 4-15 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 54 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. 4-16 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 55: Maintenance

    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. During a preventative maintenance inspection the field service engineer will carry out the following checks: •...

  • Page 56: Battery Testing

    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. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 57: Troubleshooting

    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 on +65 6302 0708. Fault identification and rectification information is given on the following pages.

  • Page 58: Fault Identification And Rectification Messages And Alarms

    Maintenance Bypass 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 59: Options

    Options Introduction The Kohler PW 5000/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 60: 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 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 61: Temperature Sensor For Temperature-Dependant Battery Charging

    7: Options Temperature sensor for temperature-dependant 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 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 62: Wavemon Shutdown And Management Software

    A prolonged mains failure may outlast the battery autonomy of the UPS system. If this situation occurs the UPS management software will initiate an automatic, ‘controlled’ shutdown of the operating system, and so protect valuable data. Kohler Uninterruptible Power offer a wide range of local and remote monitoring and control systems, affording maximum protection for computer systems.

  • Page 63: Snmp Card/Adaptor For Network Management/Remote Monitoring

    • Maintenance on a redundant unit may be executed without affecting the management system (supervisor). The Kohler PW 5000/TP can be integrated in a network in two ways: By means of the server which is being powered by the UPS and is integrated in the network. In most of the cases the server is used as sub-agent and you only need the PMC-Software without any SNMP Adapter.
  • Page 64 UPSMAN. This makes a shutdown call possible in any LAN and WAN, regardless of the network type or operating system. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 65: Modem/Ethernet Card / Powerreporter™ Management Software

    Interface (PLC’s) Optional Interface Card 1 ….10 D DE Call back Co mmunication Modem GSM Interface (PLC’s) Alarm Situation Problem in Modem the System Network interface PowerREPORTER (ethernet) Figure 7.5 PowerREPORTER™ management software UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 66 7: Options UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 67: Specifications

    440 x 1420 x 910 Dimensions (WxHxD) Weight (without battery) (9Ah/28Ah) (9Ah/28Ah) (9Ah/28Ah) (9Ah/28Ah) 151/135 160/145 165/150 170/155 Weight (with 144x7/9Ah battery) Weight (with 48x28Ah battery) Weight (with standard packaging) Colour Graphite grey (RAL 7024) UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 68: 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 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 69: Battery Characteristics

    Heat Dissipation with 100% Non-linear Load per BTU/h 2048 3072 3754 4778 5802 7850 9898 range (EN 62040-3) Airflow (25°C - 30°C) with 100% Non-linear Load per m³/h range (EN 62040-3) Heat Dissipation without load UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 70: Standards

    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 UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

  • Page 71: Fuses & Cables Quick Reference

    The fuse and cable rating details in the above tables are a recommendation only. The UPS must be installed to prescribed IEC or local regulations. External DC Cables and Battery fuses are bespoke to the installation. UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...
  • Page 72 8: Specifications UPS412-01-01 Kohler PW 5000/TP User Manual Dated 17-11-11...

Table of Contents