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413-01-00 PW6000 60-500kVA User Manaual (UK).book

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2. IA3 Mains Supply Isolator Bypass Supply Power Reporter SNMP USB JD1 USB SW1 9 JR2 408 x3 2 x1 Maintenance Bypass Isolator Optional Slot for optional Modem Ethernet card ONLY Slot for optional SNMP card ONLY PC Interface RS232 Sub D9 female Interface UPS system to computer PC Interface RS485 on RJ 45 port Remote panel connection Multi Cabinet Configuration Switch RS485 on RJ 45 port Interface for Multidrop connection between several UPS cabinets Parallel BUS connector ONLY For paralleling cabinets Customer Inputs Customer interface on Phoenix Terminals X2 Potential free contacts Castell Interlock option 1 2 Output Parallel Isolator Power Reporter SNMP JD1 USB JR3 SW1 9 n JR2 JD8 x3 2 alu ole X1 Protective Earth busbar Input output power connections See Figure 3 5 Battery connections See Figure 3 5 Figure 3 10 400kVA 500kVA Module details 3 16 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 3 Installation 3 8 Battery connections 3 8 1 Sidecar
3. UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 2 1 KOHLERPOVVER 2 Description Buninterruptible 2 2 Kohler PW 6000 Model range The Kohler PW 6000 UPS range includes 60 80 100 120 160 200 250 300 400 and 500kVA models Models in the 60 100kVA range are available in three cabinet sizes two of which incorporate internal battery housings Modules greater than 100 require the UPS batteries to be mounted in a separate battery enclosure or mounted on a purpose designed battery rack A range of optional battery closures are available For a complete description of the various cabinets weight and dimensions see Chapter 8 Specifications 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 system s overall reliability by providing a degree of module redundancy Note In this manual the terms multi module system and parallel system are synonymous Parallel system operation When operating as part of a parallel UPS system it is critical that various control functions such as load sharing frequency synchronisation and load transfer are observed by all the connected UPS modules In the Kohler PW 6000 UPS s
4. LINE 1 INVERTER BY PASS Off BATTERY INVERTER Off BATTERY Green 5 The UPS module is now line and connected to the parallel system UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 4 9 KOHLERPOVVER 4 Operation Buninterruptible Module shut down Use this procedure to power down a single module in a redundant module system 1 Simultaneously press the two ON OFF buttons on the UPS control panel a The LED display will give the following indications By PASS LED Colour LOAD LINE 1 Green LINE 2 Off BY PASS Off BATTERY INVERTER Off Green Open the parallel isolator switch IA2 In the UPS cabinet open the input supply and bypass supply fused isolators F1 IA3 F2 IA4 Identify the battery cabinet rack associated with the UPS module and open the fused battery isolators Open the UPS input supply isolator and UPS output isolator on the LV distribution panels wD UPS module is now totally shut down and volt free WARNING Allow 10 minutes for the internal DC capacitors to discharge before touching the UPS internal components 4 4 3 Transfer to maintenance bypass mode If needed to perform service or maintenance it is possible to transfer the load to the maintenance bypass supply and power down the UPS module s whilst leaving the load connected to the raw bypass mains supply
5. the input and output power cables are routed through the bottom of the UPS cabinet below the power connectors busbars See the following assembly diagrams for details Figure 3 7 60kVA 100 kVA Module details Figure 3 8 120kVA 200 kVA Module details Figure 3 9 250kVA 300 kVA Module details Figure 3 10 400kVA 500kVA Module details 3 8 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Buninterruptible 3 Installation Battery connections O OF OF OF OF O 60kVA 100kVA Power connections O Off Of O OJO Of OJO O Single dual feed links 2N 21 22 23 3L1 33 Single dual feed links i Battery connections 120 200 2 Power connections 1 444114 1 101 112 113 3 3L2 _ 2N 21 2L2 2L3 3L1 3L3 N FE Single dual feed links Battery connections o 250kVA 300kVA Power connections PE PE 400kVA 500kVA Power connections P O O O m N O O O O O 11111111
6. Card Figure 7 5 SNMP Internal and external adapters 7 5 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 WAVEMON can be used for monitoring and controlled UPS shutdown PowerREPORTER can be used to automatically email Kohler Uninterruptible Power details of monitored parameters and alarm events for appropriate service support response 7 5 4 SNMP monitoring software The SNMP adapter described above requires a PC with terminal connections and for normal operation at least one Ethernet network connection It also requires that the network operating system in use is SNMP compatible 7 5 2 WAVEMON UPS monitoring and control software WAVEMON is designed to operate in conjunction with many of the systems supplied by Kohler Uninterruptible Power and features both UPS monitoring and automatic UPS server shutdown facilities The system comprises a bespoke software package which is installed on a local PC and communicates with the UPS over a standard RS232 cable of up to 15m in length Kohler Uninterruptible Power offer suitable monitoring software with SNMP functionality for NetWare OS 2 all Windows NT systems on INTEL and ALPHA network platforms The main features of WAVEMON are On screen autonomy time battery time countdown On screen server lo
7. 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 8 5 KOHLERPOVVER 8 Specifications Buninterruptible 82 60 300kVA Fuses amp cables quick reference Mains Supply 3x380 400 415 Mains 3x380 400 415 Bypass 3x380 400 415 Fuse A Cable Static Bypass Line Static Bypass Line Maint Bypass EXTERNAL BATTERY EXTERNAL BATTERY Single feed input Power kVA Fuse Agl CB Cable A Cable D 60 3x100 5x35 5x35 80 3x125 5x50 5x50 100 3x160 5x50 5x50 120 3x200 5x70 5x70 160 3x250 5x120 or 5x 2x50 5x120 or 5x 2x50 200 3x315 5x185 or 5x 2x70 5x185 or 5x 2x70 250 3x400 5x240 or 5x 2x95 5x240 or 5x 2x95 300 3x500 5x 2X120 5x 2X120 Dual feed input Power kVA Cable D 5x35 5x50 Cable C Cable 5x35 5x50 Fuse Agl CB Fuse B Agl CB 5x35 5x50 100 3x160 5x50 3x160 5x50 5x50 120 3x200 5x70 3x200 5x70 5x70 160 3x250 5x120 or 5x 2x50 3x250 5x120 or 5x 2x50 5 120 200 3 315 5 185 5 2 70 3 315 5 185 or 5x 2x70 5x185 250 3x400 5x240 or 5x 2x95 3x400 5x240 or 5x 2x95 5x240 or 5x 2x95 5x 2x120 5x 2x120 5x 2x120 Note Battery ca
8. TT 12 X2 Volt free switched alarm status outputs 11 13 1 Castell Interlock function 8 9 4 12 13 o e 3 Figure 3 43 UPS Communications interface board connectors 3 20 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 4 41 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 WARNING Power must not be applied to the Kohler PW 6000 UPS system before it has been commissioned by an Kohler Uninterruptible Power approved service engineer Kohler Uninterruptible Power will accept no responsibility for the UPS safe operation or the safety of any personnel if power is applied before commissioning Additionally the manufacturer s warranty is immediately invalidated if the UPS is put into use before it has been correctly commissioned 42 UPS Control panel The user friendly control panel is composed of three parts shown below Mimic LED Indicators Operating Keys Power Management Display PMD KOHLERPOVVER Muninterruptible W 6000 Figure 4 1 UPS C
9. IML Les du KOHLER POVVER Muninterruptible Document Control ISSUE DATE REVISION SUMMARY 1 0 02 05 12 Initial issue of 60 500kVA Manual 1 4 08 05 12 Minor typographic errors corrected 1 2 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 KOHLERPOVVER Buninterruptible Kohler Uninterruptible Power 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 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 Table of Contents 1 Safety 1 1 Description of symbols used in this manual 1 2 User precautions 2 Description 2 1 Introduction 2 1 1 Reliability and quality standards 2 1 2 Key features 2 2 Kohler PW 6000 Model range 2 2 1 Single Parallel system configurations 2 3 Kohler PW 6000 functional description 2 3 1 Kohler PW 6000 block diagram 2 3 2 UPS internal operating modes 2 3 3 System operating modes 2 3 4 Multi cabinet parallel system concept 2 4 Warranty 2 5
10. Model interface connections Terminal Contact Signal Display Function Gnd 12Vdc Power source max 200mA 12Vdc REMOTE SHUTDOWN 12Vde Do not remove the factory fitted bridge if this feature is not used Gnd Battery Temperature Sensing 13 3V If connected this input is battery temperature dependent Gnd Customer Specific Input 1 12Vde Function on request Gnd Customer Specific Input 2 12Vde Default NC Generator on line Alarm COMMON Common ALARM No Alarm Condition Common System Alarm active Status LOAD ON Common MAINS No Load On Bypass Load on Bypass Mains active Alarm BATT LOW Common Battery OK Battery Low active Status LOAD ON INV Common Load not On Inverter Load on Inverter active Alarm MAINS OK Common Mains Failure Mains Present UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 7 3 7 Options KOHLERPOVVER Buninterruptible 7 4 2 400 500kVA Customer interface connections Terminal NC NO NC NO NC NO NC NO NC NO 230Vac N Contact Signal Status Status Display GENERATOR OPER ON EXT MAN BYP REMOTE SHUTDOWN REMOTE SHUTDOWN COMMON ALARM LOAD ON MAINS BATT LOW LOAD ON INV MAINS OK EXT MAN BYP Function Battery Temperature Sensing If connected this input is battery temperature dependent Customer Specific Input 2 No defined default function Customer Specific Input 1 Default NC
11. The parallel control bus performs many functions including System wide load transfer control nter module and bypass frequency synchronisation Load sharing UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 2 5 2 Description KOHLERPOVVER Buninterruptible MAINTENANCE BYPASS LINE STATIC BYPASS LINE Parallel Control Bus UPS MODULE 1 MAINTENANCE BYPASS LINE STATIC BYPASS LINE v a re 25 2 Parallel Control Bus UPS MODULE 2 MAINTENANCE BYPASS LINE STATIC BYPASS LINE UPS MODULE 3 Figure 2 5 Kohler PW 6000 UPS Parallel system System wide load transfer operation All the modules that are connected to the load in a parallel system must be in the same internal mode of operation at all times i e it is not permissible for one module to be operating with Load on Inverter while the remaining modules are in the Load on Bypass mode such a situation would damage the UPS module s In a parallel system if you activate the LOAD TO BYPASS command on any one module then all the modules will simultaneously switch to the Load on Bypass mode Conversely when operating on bypass if you select the command LOAD TO INVERTER on any one module all the UPS modules will simultaneously transfer the load to their inverters provided a sufficient number of modules are operating to satisfy any system redundancy requirements Frequency synchronisation and load s
12. The UPS Parallel Isolator IA2 is open OFF 5 S gt 3 7 1 Connecting the input cables 1 Gain internal access to the UPS and remove the UPS terminal cover 2 Connect the earth cable from the mains distribution board to the protective earth PE busbar located just below the UPS input terminals as shown in Figures 3 7 to 3 10 Single Input Feed 3 Referto the schematic drawing and connection table in Figure 3 3 4 Connect the UPS input supply cables to terminals 1L1 112 113 and 1N on the UPS terminal block Ensure correct clockwise phase rotation A CAUTION The input Neutral cable must be unswitched and ALWAYS connected 5 Secure the cables to the fixing rail under the connection terminals UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 3 11 KOHLERPOVVER 3 Installation Buninterruptible Dual Input Feed 6 Referto the schematic drawing and connection table in Figure 3 4 7 The UPS is supplied for single feed input as standard For a dual feed configuration remove the links between 1L1 2L1 1L2 2L2 1L3 2L3 and 1N 2N on the UPS terminal block 8 Connect the UPS input supply cables to terminals 1L1 1L2 1L3 and 1N on the UPS terminal block Ensure correct clockwise phase rotation A CAUTION The input Neutral cable must ALWAYS be connected 9 Connect the earth cable from the bypass mains distribution board to the protective earth PE busbar located just below the UPS bypass
13. amp cables quick reference 8 7 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 Safety 1 1 Description of symbols used in this manual A 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 1 2 User precautions A A A A A A 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 This UPS must be serviced by qualified personnel 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 Kohler PW 6000 i
14. battery enclosure 60 100kVA Two sidecar battery enclosures are available for attaching to the left hand side of the UPS cabinet for modules rated up to and including 100kVA Where used these enclosures are permanently affixed to the UPS cabinet and form an integral part of the UPS The optional enclosures are nominated as Enclosure A and Enclosure B See Figure 3 11 Battery Enclosure A Battery Enclosure B Battery string lt mis P Fused isolators Figure 3 11 Sidecar battery enclosures 60kVA 100kVA UPS models only The sidecar enclosures are designed to be used with 24Ah or 38Ah battery blocks The type A enclosure can house up to 80 blocks on 16 shelves whereas the type B enclosure can accept 120 blocks on 24 shelves which equates to 5 blocks per shelf in each case Each column of shelves can be wired as an individual battery string with a fused isolator for each string fitted in front of the lower shelf As the battery enclosure is shipped already attached to the UPS the internal wiring between the battery isolators and the UPS battery connection terminals is already made The final assembly and connection of the battery blocks will be carried out by the commissioning enginee
15. 2012 KOHLERPOVVER Muninterruptible 4 Operation During normal operation pressing the two ON OFF buttons simultaneously will immediately shutdown the UPS In a single module installation this will disconnect the UPS from the load and transfer the load to the UPS internal static bypass n a parallel module system the UPS module will shutdown and will effectively be removed from the parallel load bus However the load may or may not transfer to bypass depending on whether or not the number of remaining live modules satisfies the system s redundancy i e if there are a sufficient number of modules remaining to support the system s 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 43 Description of the LCD display 4 3 1 Status screens DESCRIPTION LCD DISPLAY gt 1 Load is protected by UPS power supplied by inverter normal operation LOAD FROTECTED 2 Load is not protected by UPS power supplied by mains power load on LOAD bypass HOT PROTECTED 3 Load supply interrupted UPS has been switched off by ON OFF LOAD OFF Fed buttons SUPPLY FAILURE 4 The UPS module is not supplying load LOAD DISCOMMEC TED Fed The output switch is open PARALLEL OFEM On the right hand side of the LCD Display there is a 3 digit indicator which shows a module s position in a multi module system The maximum numbe
16. 4 3 4 Measurements menu screen 4 4 4 3 5 Commands menu screen 4 5 4 3 6 UPS Data menu screen 4 5 4 3 7 Set up user menu screen 4 6 4 3 8 Set up service menu screen 4 6 4 4 Operating instructions 4 7 4 4 1 Starting the UPS system from the maintenance bypass 4 7 4 4 2 Individual module start stop procedure 4 9 4 4 3 Transfer to maintenance bypass mode 4 10 4 4 4 Complete system shutdown 4 12 5 Maintenance 5 1 Introduction 5 1 5 2 Userresponsibilities 5 1 5 3 Routine maintenance 5 1 5 4 Battery testing 5 2 6 Troubleshooting 6 1 Alarms 6 1 6 2 Menu Commands Event Log Measurements 6 1 6 2 1 Event log screen 6 1 6 2 2 Fault identification and rectification messages and alarms 6 2 6 3 Contacting service 6 3 7 Options 7 1 Introduction 7 1 7 2 Serial RS232 Computer interface USB amp JD1 Smart Port 7 2 7 3 RS485 Interface for multidrop JR1 JR2 for 400 500kVA 7 2 7 4 Dry ports customer interface X1 X1 X3 7 8 7 4 1 60 300 Model interface connections 7 8 7 4 2 400 500kVA Customer interface connections 7 4 7 4 3 Remote emergency stop option 7 5 7 4 4 Generator ON facilities 7 6 7 4 5 SNMP Card slots 7 6 7 5 UPS Monitoring and automated control software 7 7 7 5 4 SNMP monitoring software 7 7 7 5 2 WAVEMON UPS monitoring and control software 7 7 7 5 3 PowerREPORTERTM management software 7 8 8 Specifications 8 1 General specifications 8 1 8 2 60 300kVA Fuses amp cables quick reference 8 6 8 3 400 500 Fuses
17. 410 Colour Graphite Grey RAL 7024 Batteries Fitted in external enclosure Input and output power cable entry Bottom Exhaust cooling air Rear MECHANICAL CHARACTERISTICS 400 500kVA Rating kVA Dimensions WxHxD 1650 x 1994 x 850 Dimensions with elevation kit WxHxD mm 1650 x 2094 x 850 Weight kg 950 1000 Colour Graphite Grey RAL 7024 Batteries Fitted in external enclosure Input and output power cable entry Bottom Exhaust cooling air Top SYSTEM CHARACTERISTICS Topology On line double conversion Voltage and Frequency Independent VFI Technology Second generation transformerless design Parallel configuration expansion 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 25 50 75 100 fully charged battery and linear load PF 1 96 eff 95 5 96 0 95 5 95 0 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 8 Specifications INPUT CHARACTERISTICS Nominal input voltage V 3x 380 220V N 3x 400 230V N 3x 415 240V N Input voltage tolerance ref to 3x400 V 23 to 15 3x308 177 V to 3x460 264 V for lt 100 load 230V 30 to 15 3x280 161 V to 3x460 264 V for lt 80 load for Loads in 40 to 15 3x240 138 V to 3x460 264 V for lt 60 load Input frequency Hz 35 70 Inr
18. Active Output Power all three phases ACTIVE POHER BELGE 12 Reactive Output Power all three phases REACTIVE POHER 2 13 Apparent Output Power all three phases AFFAREHT POHER 14 Output Power all three phases OUTPUT POHER 52 AE 15 Battery capacity BATT CAPACITY Ae aa 4 3 5 Commands menu screen 1 Transfer Load to inverter gt LOAD TO INVERTER LOAD TO BYPASS 2 Transfer Load to bypass gt LOAD BYPASS FERFORM BATT TEST 3 Battery Test PERFORM BATT TEST 4 3 6 UPS Data menu screen 1 These general UPS Data are installed at the manufacturing plant UFS SERIAL NUMBER TiTi TiTiTITITI 2 Manufacturing date DATE OF MANUFACTURE 15 03 09 3 EPROM Version EPROM VERS 3 0 4 Actual Date and Time DATE TIME rns ss UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 4 5 KOHLERPOVVER 4 Operation Muninterruptible 4 3 7 Set up user menu screen DESCRIPTION LCD DISPLAY 1 Set up language gt SET LANGUAGE SET DATE AND TIME EMGL ISH FRANCAIS DEUTCH DUTCH SPAM ISH FOL ISH FOR TOGUESE 2 Setup Date and Time gt SET UP DATETIME SET UF BATT TEST DO Me Ss 55 3 Set up battery test gt SET UP BATT TEST SET UP GEH SET OFER DAY OF 1 319 OF D
19. Event log menu screen DESCRIPTION Logging Control a log of the last 64 events is stored in the Power Management Display Every stored event is identified with a sequential number and time stamp By pressing ENTER the code of the event will be displayed 4 3 4 Measurements menu screen DESCRIPTION Battery Runtime UPS Output Frequency Bypass Frequency Battery Voltage Battery Charger Current Battery Discharge Current Rectifier Input Voltage all three phases Bypass Input Voltage all three phases LCD DISPLAY gt EVENT LOG MEASUREMENTS gt MERSUREMEHTS gt COMMANDS SET UP DATA gt SET UP DATA SET UP USER gt SET LIF USER SET UP SERVICE gt SET UP SERVICE LCD DISPLAY 81 83 15 65 14 38 36 LOAD TO IHM 05 10 85 14 35 25 1 LOAD TO EYF mna 0605 18 85 14 39 14 LOAD OFF LCD DISPLAY BATT RUM TIME 91042 Beh Benn OUTPUT FREQUENCY i2 FREQUENCY CHE 3 BATTERY VOLTAGE v 65 6 6 8 BATT CHARGE CUR C 60 6 6 DISCHARGE CURRENT f RECTIFIER VOLTAGE 02 BRE BEE BRE BYPASS VOLTAGE v BEE eaa UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLER POVVER Muninterruptible 4 Operation 9 Output Voltage all three phases OUTPUT VOLTAGE cV o6 BRE BEE 10 Output Current all three phases OUTPUT CURREMT BEE BE 11
20. Generator on line External Manual Bypass Default NC External bypass closed 12Vdc Power source max 200mA RSD Remote Shut Down Leave jumper JP5 in place if no Remote Shut Down input is connected RSD Remote Shut Down For external switch Max 250Vac 8A 30Vdc 8A 110Vdc 0 3A 220Vdc 0 12A Common Auxiliary NO Auxiliary NC Common No Alarm Condition Common System Alarm active Common No Load On Bypass Load on Bypass Mains active Common Battery OK Battery Low active Common Load not On Inverter Load on Inverter active Common Mains Failure Mains Present Castell Interlock Function External Manual Bypass closed 230Vac 2AT UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 7 Options 7 4 3 Remote emergency stop option UPS Remote Shutdown Port eL k X1 7 X1 8 UPS Remote Shutdown Port X3 3 X3 4 Terminal block Remote shutdown Remote shutdown Figure 7 3 Remote emergency stop cabling On a standard UPS the remote emergency stop function is disabled and if this option is required it must be activated by a hardware code on the SETUP SERVICE menu Please contact your distributor to enable this operation The remote stop facility compri
21. WARNING Before you close the maintenance bypass isolator the UPS must be operating in its internal static bypass mode This procedure describes the sequence of operations necessary to transfer the load from the UPS inverter s to the maintenance bypass supply and then shut down and isolate the UPS module s Prior to commencing this procedure check and confirm the UPS system status on all cabinets in a multi module system Normally the load should initially be powered from the UPS inverter and the mimic panel LED indications should be as shown below on all UPS modules in a multi module system ree LED Colour LINE 1 Green LINE 1 INVERTER LINE 2 Green BY PASS OFF BATTERY INVERTER Green L BATTERY Green 4 10 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 4 Operation The LCD panel should display LOAD PROTECTED If anything other than LOAD PROTECTED is displayed then press the RESET button and if LOAD PROTECTED is still not displayed there is a problem with the UPS seek assistance Transferring the UPS to bypass mode 1 Onthe UPS module s mimic panel on any module in multi module system press the ENTER key once to access the menu system 2 Using the UP DOWN keys move the cursor so that it is adjacent to COMMANDS and then press the ENTER key 3 Using the UP DOWN keys move the cur
22. begin the UPS electrical installation 1 Do not commence this procedure until the UPS mechanical installation is completed 2 All the cable installation procedures detailed below must be supervised by a qualified electrician 3 Do not connect or operate the UPS if there is water or moisture present 4 When carrying out any work on the UPS power cables or terminals you must ensure that the UPS input and load supplies are isolated and locked out at their respective distribution boards Warning notices should be posted to prevent any inadvertent operation of the UPS mains supply isolators 5 Before you start connecting the UPS input cables ensure that the customer provided fuses and cables are suitably rated in accordance with the prescribed IEC standards or local regulations for example BS7671 2008 also see figures 3 3 and 3 4 6 Once the electrical installation is completed the UPS must be commissioned by an engineer authorised by the manufacturer before it is brought into use WARNING Do not apply electrical power to the UPS before it has been commissioned 7 When installing the UPS cables ensure that the connection procedures are performed under the following conditions No mains voltage is present at the UPS mains bypass distribution board terminals All loads are shut down and disconnected at the load distribution board The UPS is fully shut down and voltage free The UPS Maintenance Bypass Isolator IA1 is open OFF
23. bypass and the inverter returns to its standby function This mode of operation is slightly more energy efficient than the on line mode due to the reduced rectifier inverter losses during normal operation and it is sometimes referred to as the ECO mode However this mode is recommended only if the connected load equipment can tolerate power interruptions of 3 to 5 ms during the transfer period A WARNING The on line mode must always be used for critical load protection 2 3 4 Multi cabinet parallel system concept Up to ten Kohler PW 6000 UPS cabinets can be connected in parallel for increased power capacity or redundancy operation 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 A Kohler PW 6000 UPS parallel system has a decentralised bypass architecture in that each UPS module contains its own static bypass static switch This eliminates the need for a separate bypass cabinet as required by some manufacturers systems and avoids a potential single point of failure In a multi module parallel system the topology and internal operation of the UPS is identical to that described previously for a stand alone unit except that the UPS control logic is subject to additional system level control functions which are applied via a parallel control bus connected between each UPS
24. to provide an intelligent RS 232 serial port which allows the UPS to be connected to a computer When used in conjunction with the optional WAVEMON software this port allows the connected computer to continuously monitor the input mains voltage and UPS status and display a message in the event of any UPS system changes Figure 7 2 shows the cable wiring suitable for PC s with a 9 pin or 25 pin serial port respectively Note that the maximum length for the interconnecting RS232 cable is 15m 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 7 2 Connector Cable PC Serial Port 7 3 RS485 Interface for multidrop JR1 JR2 for 400 500kVA Using the Multidrop connection kit the computer interface JR1 JR2 for 400 500kVA is an intelligent 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 7 2 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 7 Options 7 4 Dry ports customer interface X1 X1 Customer I O interface facilities are made to Phoenix spring terminal blocks cable 0 2mm to 1 5mm annotated X1 X2 and All voltage free contacts are rated at 250Vac 8A 30Vdc 8A 110Vdc 0 3A 220Vdc 0 12A 7 4 1 60 300
25. 11 1 1 112 113 2N 211 212 213 3N 3L1 312 313 1 Battery connections PE Figure 3 5 Input output and battery power terminals UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 3 9 KOHLERPOVVER 3 Installation Buninterruptible 3 6 4 Power cabling in a parallel system In order to achieve equal load sharing between the various UPS cabinets in a multi cabinet installation the input cables from the mains distribution board to each UPS cabinet should be of equal length Similarly the UPS output cables to the load distribution board should be of equal length See Figure 3 6 Recommended cable configurations Rectifier Feed Bypass Feed UPS 1 UPS2 UPS 3 UPS 4 To Load Not recommended cable configurations Bypass Feed Rectifier Feed UPS 1 UPS2 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 KOHLERPOVVER Muninterru ptible 3 Installation 3 7 UPS Cabling procedure WARNING Opening or removing the UPS covers will create a risk of exposure to dangerous voltages if power is connected to the UPS Safety notes Please ensure you read and understand the following safety notes before you
26. 1650 x 1994 x 850 WxHxD mm 970x1820x750 Batt cab A 1180x1820x750 Batt cab B Accessibility Totally front accessibility for service and maintenance Positioning for ventilation Min 200 mm rear space Min 400mm space above cabinet Input and Output From the bottom at the front Power Cabling 3 6 Planning the installation cabling considerations 3 6 1 General requirements The information in this section should help with the preparation and planning of the UPS power cabling It is the customer s responsibility to provide all external fuses isolators and cables that are used to connect the UPS input and output power supplies The UPS input and bypass terminals should be connected to the utility mains supply through a suitable LV Distribution board containing a circuit breaker or fused isolator to provide both overload protection and a means of isolating the UPS from the mains supply when required Similarly the UPS output supply terminals should be connected to the load equipment via a suitably fused load distribution board Input neutral grounding A permanently connected input neutral is required to enable the rectifier to operate correctly and allow the UPS to function properly when operating on battery The input neutral must also be grounded to permit correct operation when the UPS is running on battery Key Point As the input neutral must be unswitched and connected to the UPS at all times a 4 pole input switch or i
27. 2 with linear load load UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 8 3 KOHLERPOVVER 8 Specifications Buninterruptible OUTPUT CHARACTERISTICS Continued 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 A 2 7 2 0 2 3x 1 8x 1 9x 2 1x 1 8x 2 0x 2 0x 2 0x x rated output for 40ms 60 80 100 120 160 200 250 300 400 500 Output voltage distortion with non 96 4 EN 62040 3 2001 linear load Output frequency Hz 50 or 60 Output frequency tolerance 96 0 1 free running quartz oscillator 2 or 4 with mains synchronised selectable Frequency slew rate Hz s 1 0 Output waveform Sinewave with 0deg phase imbalance 100 unbalanced load Permissible unbalanced load 100 all 3 phases independently regulated Overload capability on inverter At PF 1 0 110 load for 10 minutes Bypass short circuit capability 10x rated In for 10ms Crest factor 3 1 Bypass operation At 15 0 of nominal input voltage With 50 battery blocks only OUTPUT POWER VERSUS COS 0 Inductive lagging COS g Unity Capacitive leading COS Module 0 6 0 65 0 7 0 75 0 8 0 85 0 9 0 95 1 0 0 95 0 9 0 85 0 8 60 kVA 60 60 60 60 60 60 60 60 60 60 60 59 58 KW 36 39 42 45 48 51 54 57 60 57 54 50 46 80 kVA 80 80 80 80 80 80 80 80 80 80 80 78 77 KW 48 52 56 60 64 68 72 76 80 76 72 66
28. 413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 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 A separate mains supply 2 is shown connected to the static bypass in Figure 2 1 however in a standard UPS module the bypass supply terminals 2 are usually linked to the mains supply terminals 1 so the UPS effectively requires only a single mains supply connection See paragraph 3 6 2 for details concerning Single Feed amp Dual Feed input supply configurations The bypass supply is shown connected to the static switch 4 and the maintenance bypass line 5 UPS Output load supply Figure 2 1 shows that the UPS output Load supply can be provided through one of three power paths from within the UPS depending on the UPS operating mode From the inverter 3 via the static switch and isolator IA2 From the static bypass line 4 via the static switch and isolator IA2 From the maintenance bypass line 5 via the maintenance bypass isolator IA1 The criteria for operating under each of these UPS modes is described below 2 3 2 UPS internal operating modes Load on Inverter T
29. 5 port Interface for Multidrop connection between several UPS cabinets Multi Cabinet Configuration Switch Parallel BUS connector ONLY For paralleling cabinets Slot for optional SNMP card ONLY Input output power connections See Figure 3 5 Earth busbar Parallel Isolator Rect Fuse Byp Fuse 1 1 Isolator Figure 3 8 120kVA 200 kVA Module details 3 14 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLER POVVER Muninterruptible 00000000000000000000090000000000000000000 00000000 USB PC Interface cp anal Interface UPS systern to computer 11 ID DOO Customer Inputs 2 Customer interface on Phoenix Terminals X2 Potential free contacts JR2 RS485 on 45 port Remote panel connection JR1 RS485 on RJ 45 por
30. 500 5x 2x120 3x500 5x 2x120 5x 2x120 400 3x630 5 3 95 or 5x 2x185 3x630 5 3x95 or 5x 2x185 5x 3x95 or 5x 2x185 500 3x800 5x 3x150 3x800 5x50 5 3 150 Note Cable E and 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 3 7 KOHLERPOVVER 3 Installation Buninterruptible 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 Battery Maxadmissible Tightening 3 N PE 3 N 3 N PE N PE cable section Torque mm Nm 4x35 mm 8 4 35 mm 4 35 mm 8 4 35 3 5 80kVA 4x50 mm 8 4x50mm 4x50 mm M8 4xM8 50 5 100kVA 4 70 2 8 4x70mm 4 70 2 8 4xM8 95 8 120kVA 5xM10 4 10 5 x M10 4 M10 185 50 160kVA 5 x M10 4x M10 5 x M10 4x M10 185 Max 50 200kVA 5 x M10 4x M10 5 x M10 4 M10 240 50 250kVA 5 x M10 4x M10 5 x M10 4 M10 240 50 300kVA 5xM10 4 10 5 x M10 4 M10 240 50 400kVA 3x 5 x M12 3x 4 x M12 3x 5x M12 3x 4 x M12 240 Max 84 500kVA 8x 5 x M12 3x 4 x M12 8x 5 M12 3x 4x M12 240 Max 84
31. 61 100 kVA 100 100 100 100 100 100 100 100 100 100 100 98 97 KW 60 65 70 75 80 85 90 95 100 95 90 83 77 120 kVA 120 120 120 120 120 120 120 120 120 120 120 117 116 KW 72 78 84 90 96 102 108 114 120 114 108 100 92 160 KW 96 104 112 120 128 136 144 152 160 152 144 132 122 200 200 200 200 200 200 200 200 200 200 200 200 195 194 KW 120 130 140 150 160 170 180 190 200 190 180 166 154 250 kVA 250 250 250 250 250 250 250 250 250 250 250 245 241 KW 150 163 175 188 200 213 225 238 250 238 225 208 192 300 kVA 300 300 300 300 300 300 300 300 300 300 300 294 291 KW 180 195 210 225 240 255 270 285 300 385 270 249 231 400 kVA 400 400 400 400 400 400 400 400 400 400 400 392 388 KW 240 260 280 300 320 340 360 380 400 380 360 333 310 500 kVA 500 500 500 500 500 500 500 500 500 500 500 490 485 KW 300 325 350 375 400 425 450 475 500 475 450 417 338 kVA 160 160 160 160 160 160 160 160 160 160 160 156 154 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 8 Specifications ENVIRONMENTAL CHARACTERISTICS 60 Audible noise 100 50 load dBA lt 65 lt 69 lt 71 Ambient temperature for UPS 0 40 Ambient temperature for batteries C 20 recommended Battery storage time at ambient Maximum 6 months temperature Fan assisted cooling air flow Front entry rear exit Front entry top exit Airflow 25 30 C with m h 1300 1500 1
32. 700 2500 3350 6550 10096 non linear load Heat dissipation with w 3830 5106 6368 7660 10213 12766 15957 19149 24000 30000 10096 non linear load Heat dissipation with BTU h 13071 17428 21785 26142 34856 43570 54462 65355 81913 102389 10096 non linear load Heat dissipation without load w 850 1500 2300 4000 Relative air humidity Maximum 95 non condensing Max altitude above sea level without derating 1000m 3300ft without derating De rating factor for use at altitudes above 1000m sea Height above sea level m ft Derating factor for power level according IEC 62040 3 1500 4850 0 95 2000 6600 0 91 2500 8250 0 86 3000 9900 0 82 Safety EN62040 1 1 2003 EN60950 1 2001 A11 2004 Electromagnetic compatibility IEC EN 62040 2 2005 IEC EN61000 3 2 2000 IEC EN61000 6 2 2001 Performance EN 62040 3 2001 Product certification CE Degree of protections IP20 COMMUNICATION OPTIONS Power Management Display PMD LCD display and mimic diagram showing UPS operational status Customer Interfaces Dry Ports Volt free output interface provide status and alarm outputs for remote indication and interfacing with BMS systems Together with customer inputs interface for connecting an Emergency Stop On Generator status etc RS232 on Sub D9 port For monitoring and integration in network management RS232 on USB port RS485 on RJ45 port Remote monitoring system with graphical display option
33. AY B 23 3 REPETITIVE gua 4 Set up operation with Gen Set gt 5ET UF GEH SET LOCK 42 BYPASS LOCK 4 3 8 Set up service menu Screen DESCRIPTION LCD DISPLAY 1 This Menu is reserved for authorized service engineers It is not to be gt SET UP SERVICE used by End Users FASSHORD 2 in password gt Key Point It is essential to enter the password 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 PO1 PO2 Single standard or Dual input feed Frequency converter 50 60Hz and 60 50Hz Synchronisation window 2 496 4 6 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 4 Operation 4 4 Operating instructions A WARNING The procedures given below must be performed only by a trained operator Under normal operating conditions all the UPS modules in a multi module system are running and operating in the On Line On Inverter mode The following procedures are provided in this section 1 How to start up the UPS system and transfer the load from the Maintenance Bypass to the inverters On Line mode See paragraph 4 4 1 How to stop start one module in a redundant multi module system See paragraph 4 4 2 How to t
34. Connect a bus cable between PORT JD6 of UPS cabinet 2 parallel adaptor and PORT JD5 of UPS cabinet 3 parallel adaptor 6 Continue with the above steps until a Bus cable is connected to all modules as shown below UPS Cabinet 1 UPS Cabinet 2 UPS Cabinet 3 Parallel Adaptor Parallel Adaptor Parallel Adaptor eene er Swz2 meum swa Parallel adapter board fitted to JD8 on UPS Parallel Adaptor communications interface board Master Slave Master Slave Output Input SW2 2 SW2 2 Configuration Switch JD6 JD5 Single Cabinet First Cabinet Middle Cabinet Last Cabinet SW2 1 ON OFF OFF ON SW 2 2 ON ON OFF OFF Figure 3 12 Bus lines connections 3 Modules shown 3 9 2 Configuration DIP switch selection DIP Switch SW1 9 DIP Switch SW1 9 on the UPS communications interface board See Figure 3 13 must be set to indicate the position of the cabinet in the parallel chain The three options are First cabinet Middle cabinet there may be several middle cabinets Last cabinet In each cabinet set Switch SW1 9 according to the table below Single Cabinet First Cabinet Middle Cabinet Last Cabinet 1 ON ON OFF ON 2 ON ON OFF ON 3 ON ON OFF ON 4 ON ON OFF ON 5 ON ON OFF ON 6 ON ON OFF ON 7 ON
35. Extended warranty 2 6 Additional service maintenance support 3 Installation 3 1 Introduction 3 2 Taking receipt of the UPS 3 2 1 Site transportation 3 3 Unpacking 3 4 Storage 3 5 Planning the installation site considerations 3 5 1 Clearances 3 6 Planning the installation cabling considerations 3 6 1 General requirements 3 6 2 Cable and fuse sizing 3 6 8 Power cable terminations 3 6 4 Power cabling in a parallel system 3 7 UPS Cabling procedure 3 7 1 Connecting the input cables 3 7 2 Connecting the UPS output cables 3 8 Battery connections 3 8 1 Sidecar battery enclosure 60 100 3 8 2 Remote battery enclosure 3 8 8 Connecting the batteries 3 9 Multi module control cabling and configuration 3 9 1 Connecting the parallel communication bus cables 3 9 2 Configuration DIP switch selection 3 9 3 Module communications interface facilities 1 1 1 1 2 1 2 1 2 1 2 2 2 2 2 2 2 3 2 3 2 5 2 5 2 7 2 8 2 8 3 1 3 1 3 1 3 2 3 2 3 3 3 3 3 4 3 4 3 5 3 8 3 10 3 11 3 11 3 12 3 17 3 17 3 18 3 18 3 18 3 18 3 19 3 20 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Buninterruptible 4 Operation 4 1 Commissioning 4 1 4 2 UPS Control panel 4 1 4 2 1 Power Management Display PMD 4 1 4 2 2 Mimic LED indicators 4 2 4 2 3 Operator keys 4 2 4 3 Description of the LCD display 4 3 4 3 1 Status screens 4 3 4 3 2 Main menu screen 4 4 4 3 3 Event log menu screen 4 4
36. M DISCHARGE MANUAL IS CLOSED There is a fault in the UPS and therefore normal operation cannot be guaranteed Mains power supply is outside prescribed tolerance There is a short circuit at the output of UPS on load side Load exceeds the UPS rated power UPS temperature has exceeded the allowed value The attached battery and the battery charger set up do not correspond or battery charger fault Inverter is faulty The inverter and mains are not synchronised Battery is near end of autonomy Maintenance bypass closed Load supplied by mains Call the authorised service centre for assistance The input power to UPS is too low or missing If site power appears to be OK check the input circuit breakers etc supplying the UPS Check all output connections and repair as required Identify which piece of equipment is causing the overload and remove it from the UPS Do not connect laser printers photocopiers electric heaters kettles etc to the UPS Check the ambient temperature of the UPS is less than 30 C If the ambient temperature is normal call the authorised service centre for assistance Call the authorised service centre for assistance Call the authorised service centre for assistance The frequency of the input voltage to the UPS is outside operational limits and the UPS static bypass has been temporarily disabled Shutdown load connected to UPS before the UPS switches it
37. ON OFF OFF 8 ON OFF OFF ON ON ON OFF ON UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 3 19 KOHLERPOVVER 3 Installation Buninterruptible 3 9 3 Module communications interface facilities Each UPS is fitted with a communications interface board which enables various external monitoring and control applications to be connected to the system to satisfy particular site requirements Details of the interface facilities and available options are provided in Chapter 7 Note All used options should be installed and connected prior to commissioning the UPS so that they be functionally checked as part of the commissioning procedure KEY IDENT FUNCTION 1 USB RS232 PC Interface on standard USB 2 401 RS232 PC Interface on Sub 09 Female 3 1 Customer Inputs 4 X2 Volt free switched alarm status outputs 9 5 JR2 RS485 on RJ45 port Remote panel interface B mm2 6 JR1 5485 on RJ45 port Multidrop interface di 1 7 SW1 9 Multi cabinet configuration DIP switch es 8 JD8 For parallel bus adapter JD5 JD6 FT 9 SNMP Siotfor optional SNMP card 17 E wam 10 Modem Slot for optional modem ethernet card only 11
38. OO OO fol Battery power connections Fuse A B See Figure 3 5 Protective 9 Earth busbar o o Battery connections See Figure 3 5 USB PC Interface JD1 RS232 Sub D9 female Interface UPS system to computer X1 Customer Inputs X2 Customer interface on Phoenix Terminals X2 Potential free contacts JR2 RS485 on RJ 45 port Remote panel connection see Section 3 JR1 RS485 on RJ 45 port Interface for Multidrop connection between several UPS cabinets SW1 9 Multi Cabinet Configuration Switch see section 4 JD8 Parallel BUS connector ONLY For paralleling cabinets use optional adapter JD5 Parallel BUS Input Connector JD6 Parallel BUS Output Connector SNMP Slot for optional SNMP card ONLY IA1 Maintenance Bypass IA2 Parallel Isolator F2 Bypass Line Fuse F1 Rectifier Fuse Figure 3 7 60kVA 100 kVA Module details UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 3 13 3 Installation KOHLERPOVVER Buninterruptible SSeS eo USB JD1 x1 2 JR2 JR1 SW1 9 JD8 SNMP PC Interface RS232 Sub D9 female Interface UPS system to computer Customer Inputs Customer interface on Phoenix Terminals X2 Potential free contacts RS485 on RJ 45 port Remote panel connection RS485 on RJ 4
39. RTER LINE 2 Green PASS Green BEE BATTERY INVERTER Off 9 Press the RESET button to cancel the audible alarm on all modules a The LCD display s will now indicate LOAD NOT PROTECTED 10 At this stage the load is being powered only through the UPS static bypass circuit Transferring the load to the inverter 11 On the control panel of any one module in a multi module system a Press the UP key once to access the menu system b 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 4 8 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 4 Operation 12 The UPS system will transfer the load to inverter on all modules in a multi module system a TheLCD display s will now indicate LOAD PROTECTED b Check and confirm that the LED display s are as shown below BY PASS Colour Green LINE 2 Green LINE 1 INVERTER BY PASS Off BATTERY INVERTER Green Green 13 The UPS is now operating in On Line mode and the load is being supplied by protected inverter power 4 4 2 Individual module start stop procedure If a multi module system is designed with built in redundancy it is possible to stop and star
40. Static Switch Static Bypass Line Cable A 5x35 Cable D 5x35 80 3x125 5x50 5x50 100 120 3 160 3x200 5x50 5x70 160 3x250 5x120 or 5x 2x50 200 3x315 250 300 8x400 3x500 5x185 or 5 2 70 T 5 240 or 5 2 95 5x 2X120 400 3x630 5x 3x95 or 5x 2x185 5x50 5x70 5x1200r5x 2x50 5x185 5 2 70 5 240 or 5x 2x95 5 2 120 2 185 500 _ 8x800 5 3x150 5x 3x150 Note Cable and Fuse are bespoke to the installation Figure 3 3 Single feed input fuse and cable ratings 3 6 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterru ptible 3 Installation Mains Supply 3x380 400 415 Mains Supply 3x380 400 415 UPS MAINS SUPPLY UPS BYPASS SUPPLY Static Bypass Line Cable C 5x35 5x50 Cable D 5x35 5x50 Power kVA Fuse Agl CB 60 3x100 80 3 125 Cable 5x35 5x50 Fuse C Agl CB 100 3 160 5 50 3 160 5 50 5 50 120 3x200 5x70 3x200 5x70 5x70 160 3 250 5x120 5 2 50 3 250 5 120 or 5 2 50 5x120 200 3 315 5x185 5x 2x70 3 315 5 185 5 2 70 5 185 250 3 400 5 240 5 2 95 3 400 5 240 or 5x 2x95 5 240 or 5x 2x95 300 3x
41. 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 3 3 3 Installation KOHLERPOVVER Buninterruptible A minimum of 900 1000mm clearance is required at the front of the cabinets for service access and where possible this should be increased to allow safe passage in front of the UPS with the doors open In order to gain full access to some internal components it is necessary to open the doors by slightly more than 90 If the cabinet is located adjacent to a partition or wall that extends beyond the front of the cabinet a clearance of 50 100mm should be provided between the cabinet and the partition to allow the doors to open adequately as illustrated in the lower diagram above Note that there is no space required between cabinets The 60 300 kVA cabinets are force cooled by rear mounted extraction fans which require a minimum of 200mm space at the rear of the cabinet to allow adequate exhaust air flow The 400 500 kVA cabinets are force cooled by roof mounted extraction fans and do not require any space at the rear of the cabinet but a minimum free space of 400mm is required above the cabinets to allow adequate exhaust air flow 60 100 kVA 120 200 kVA 250 300kVA 400 500kVA Dimensions 550x1820x750 850x1820x750 1100x1920x750
42. UPS you should carefully examine the packing container for any sign of physical damage The external Tip amp Tel FRAGILE and ARROW indicator should be intact if the equipment has been correctly transported in an upright position If the packaging has been ruptured in transit or if the Tip amp Tel indicator is suspect inform both the carrier and Kohler Uninterruptible Power immediately receipt Other shipping damage claims must be filed immediately when found and the carrier must be informed within a maximum of 7 days following receipt of the equipment If shipping damage is discovered store all packing materials for further investigation N CAUTION Claims for visible shipping damage must be notified to the carrier immediately on Ensure that the received UPS equipment corresponds to the description indicated in the delivery note 3 2 1 Site transportation Please observe the following precautions when you transport the UPS equipment from the off loading site and its intended installation or storage location CAUTION Transportation A When transporting the equipment use the front and rear shipping brackets to secure the cabinet to help prevent the UPS from toppling over Do notat any time tilt the cabinet by more than 10 from vertical UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 3 1 KOHLERPOVVER 3 Installation Muninterruptible CAUTION Potential dangers A If the UPS batter
43. ad distribution panel WARNING Perform the following steps only after the load has been fully isolated Verify that the loads are powered down Then carry out the following actions on every module in turn in a multi module system On the UPS control panel simultaneously press both ON OFF buttons a 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 KOHLERPOVVER Muninterruptible 4 Operation 5 Open the module s parallel isolator switch 2 BY PASS LED Colour LOAD LINE 4 Green LINE 2 Off BY PASS Off BATTERY INVERTER Off BATTERY Green Flashing Open the bypass line fuse holder F2 IA4 and the rectifier line fuse holder F1 IA3 Open the UPS input and bypass supply isolators or circuit breakers on the UPS input supply distribution panel 8 The UPS is now voltage free WARNING Allow 10 minutes for the internal DC capacitors to discharge before touching the UPS internal components UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 4 1 3 KOHLERPOVVER 4 Operation Buninterruptible 4 14 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 5 Maintenance 5 1 Introduction WARNING The procedures
44. alling and cabling of the Kohler PW 6000 UPS WARNING All cabling operations must be supervised by an authorised electrician or other suitably qualified person All installation and operating procedures must be carried out in strict accordance with the instructions contained in this manual Kohler Uninterruptible Power will take no responsibility for any personal injury or material damage caused by the incorrect installation cabling or operation of this product approved by Kohler Uninterruptible Power before it is powered up Kohler Uninterruptible Power will take no responsibility for any personal injury or material damage caused by the application of electrical power to this equipment before it has been fully commissioned i WARNING Once the UPS equipment is installed it must be commissioned by an engineer 3 2 Taking receipt of the UPS The UPS cabinet and accessories are delivered on purpose designed pallets that are easy to off load and move using a forklift or suitable pallet jack CAUTION Observe the following precautions when off loading and moving the UPS e Always keep the packages an upright position Do not drop the equipment Due to the high energy batteries involved and heavy weight do not stack the pallets 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
45. ally operate in the Load on Inverter mode In the unlikely event of an inverter fault or overload condition the UPS will transfer the load to the static bypass automatically and without interruption transfer time 0 If the transfer is due to a UPS overload the system will transfer back to the Load on Inverter mode if the overload clears and the inverter returns to normal operation This mode provides the highest degree of load protection especially in the event of a mains disturbance or failure and is always recommended if the critical load e g computer system will not tolerate even very brief supply interruption Off line line interactive operation When the Kohler PW 6000 is used in an off line or line interactive configuration the UPS is normally operated in its Load on Bypass mode with the load being supplied from the static bypass supply However the rectifier and battery charger are still powered up to maintain battery charging and the inverter section is turned on and operating on standby In the event of a bypass supply error or total failure the load is automatically transferred to the inverter Load on Inverter mode by the static switch within 3 to 5 milliseconds and if the rectifier mains supply is missing when the transfer takes place the UPS inverter will support the load operating from its battery power as described above If the bypass supply returns to normal the load is retransferred back to the static
46. bling Cable E and battery fuses Fuse E are bespoke to the installation 8 6 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 8 Specifications 8 3 400 500kVA Fuses amp cables quick reference SINGLE FEED INPUT standard x DUAL FEED INPUT option Mains Supply 3x380 400 415 Mains 3x380 400 415 Bypass 3x380 400 415 Fuse A Cable Rectifier IA Rectifier 3 Static Bypass Line Static Bypass Line EXTERNAL BATTERY EXTERNAL BATTERY Cable D Load Single feed input Power kVA Fuse A Agl CB Cable A Cable D 400 3x630 5 3x95 or 5x 2x185 5x 3x95 or 5x 2x185 500 3x800 5x 3x150 5x 3x150 Dual feed input Power Fuse B Agl CB Cable B Fuse C Agl CB Cable C Cable D 400 3x630 5x 3x95 or 5x 2x185 3x630 5x 3x95 or 5x 2x185 5 3 95 5 2 185 500 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 8 7 KOHLERPOVVER 8 Specifications Buninterruptible 8 8 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012
47. customer assumes all such risks the liability of Kohler Uninterruptible Power is adequately protected under the circumstances CAUTION The UPS may contain batteries that must be re charged for a minimum of 24 hours every six months to prevent deep discharging Batteries that have been deep discharged for whatever reason are not covered by the warranty UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 2 7 2 Description KOHLERPOVVER Buninterruptible Extended warranty The Standard Warranty may be enhanced by protecting the UPS with an Extended Warranty Agreement maintenance contract An Extended Warranty Agreement enhances the standard warranty by providing the following regular preventative maintenance inspections guaranteed speed of response to operational problems 24 hour telephone support fully comprehensive cover excluding batteries and capacitors Contact the Service Support Hotline on 65 6302 0708 for further details Additional service maintenance support In addition to providing support for the Kohler PW 6000 UPS Kohler Uninterruptible Power are able to provide maintenance and support on a wide range of different 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 Regional Office South East Asia Kohler Uninterruptible Power 7 Jurong Pie
48. described in this chapter must be performed by an authorised A electrician who has received the appropriate level of training on this UPS system As there are no user serviceable parts contained within the UPS the maintenance requirements are minimal However to maximise the useful working life and reliability of the UPS and its batteries we recommend that the UPS system and batteries are routinely inspected and checked for calibration on a 6 monthly basis as part of a preventative maintenance schedule 5 2 User responsibilities In order to obtain the best performance and reliability from the UPS system the operator must ensure on a daily basis that the environment in which the UPS operates should be kept cool and dust free at all times Any active alarm or status indication that indicates that the UPS is not functioning correctly should be dealt with immediately when found by referring to the troubleshooting chapter of this manual or contacting the manufacture s service desk 5 3 Routine maintenance When the UPS is commissioned the commissioning field service engineer will attach a service record book to the front of the UPS which will be used to log the full service history of the UPS To ensure optimum UPS operation and continuous efficient protection of the connected load we recommend that the system s operating parameters are checked every six months and recalibrated where necessary WARNING When working inside the UPS cabinet there
49. een commissioned 3 8 3 Connecting the batteries WARNING This procedure must be carried out or under the supervision of the approved UPS commissioning engineer To protect personnel during the battery installation ensure that the connections are performed under the following conditions o o See S Q gt No mains voltage is present the UPS mains bypass distribution board terminals All loads are shut down and disconnected at the load distribution board The UPS is fully shut down and voltage free The UPS and battery connection terminals are voltage free The UPS Maintenance Bypass Isolator IA1 is open OFF The UPS Parallel Isolator IA2 is open OFF Check that the battery fuses and cables are suitably rated Note that Battery fuse and cable ratings are bespoke to the installation 2 Ensure that the fused isolators and or circuit breakers in the external battery cabinet or racks are open Connect the protective earth cable PE between the UPS and external battery cabinet 4 Connect the battery power cables between the module battery terminals N and the corresponding terminals on the external battery cabinet 3 9 M Multi module control cabling and configuration In order to facilitate various control functions such as load sharing frequency synchronisation and load transfer the UPS modules connected to a parallel system communicate with each other continuousl
50. ency Independent topology responds fully to both the highest availability and environmentally friendly requirements compliant with IEC 62040 3 VFI SS 111 standards High reliability upgrade ability low operating costs and excellent electrical performance are only some of the highlights of this innovative UPS solution Kohler Uninterruptible Power specialises in the installation and maintenance of Uninterruptible Power Systems and this powerful UPS is just one example of our wide range of state of the art power protection devices that will provide your critical equipment with a steady and reliable power supply for many years 2 1 2 Key features The highlights of this innovative UPS solution include its high reliability upgrade ability low operating costs and excellent electrical performance KEY FEATURES Blade server friendly power full power from No de rating required with leading PF loads 0 9 lead to 0 9 lag Very low input current distortion THDi Gen set power and installation cost saving THDi lt 3 5 100 load Compact size small foot print Space saving on expensive floor space Flexible battery management Advanced management of battery charging and preventive failure diagnostics avoids premature deterioration of battery life Best in class efficiency up to 96 Energy Operational cost savings TCO Low input power factor near unity Cost savings during installation and the entire life cycle TCO
51. environment 1 The route to the installation location must allow the equipment to be transported in an upright position 2 The floor at the proposed installation site and en route from the off loading point must be able to safely take the weight of the UPS and battery equipment plus fork lift during transit 3 Locations with high ambient temperature moisture or humidity must be avoided a Theinstallation site humidity should be 9096 non condensing b The prescribed ambient temperature is 15 C to 25 C An ambient temperature of 20 C is recommended to achieve a long battery life Any requested cooling air flow must be available The air entering the UPS must not exceed 40 C d The air conditioning system must be able to provide a sufficient amount of cooling air to keep the room within the prescribed temperature range 4 The following environmental conditions should also be considered a Fire protection standards must be respected b The location must be free of dust and corrosive explosive gases c location must be vibration free d Ifthe UPS is located in bayed enclosures partition walls must be installed e The available space must permit the minimum cabinet clearances shown below 3 5 1 Clearances 400 500kVA UPS 400 500kVA UPS 60 300kVA 60 300kVA 60 300kVA 200mm 60 300kVA 60 300kVA 60 300kVA 400 500kVA UPS 400 500kVA UPS 1000m 900mm Figure 3 1
52. follows 1 Silence the audible alarm by pressing the RESET button 2 Identify the cause of the alarm condition by means of the events register in the main menu See paragraph 4 3 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 6 2 Menu Commands Event Log Measurements Chapter 4 contains a detailed description of the Menu Commands Event Log and Measurements that available on the operator control panel LCD 6 2 1 Event log screen DESCRIPTION LCD DISPLAY 1 Logging Control 82 16 68 14 28 LOAD TO IMM 2 A log of the last 64 events is stored in the Power Management Display 5 18 88 14 38 LOAD TO EYF 3 All events and alarms are indicated with their date and time of occurrence B As you step through the event memory make a separate note of each alarm condition as this will assist in the identification of any problems UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 6 1 6 Troubleshooting KOHLERPOVVER Buninterruptible 6 2 2 Fault identification and rectification messages and alarms The major alarm conditions that will be encountered are ALARM CONDITION MEANING SUGGESTED SOLUTION UPS FAULT BYP RECT FAULT OUTPUT SHORT OVERLOAD OVER TEMPERA TURE BATTER CHARGER OFF INVERTER FAULT FAULT BATTERY I
53. g 3 Close the parallel isolator switch IA2 and check that the PARALLEL SW CLOSED message is shown the LCD display UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 4 7 KOHLERPOVVER 4 Operation Buninterruptible 4 Onthe UPS mimic panel press and release both ON OFF buttons simultaneously and wait approximately 60 seconds a The UPS module will begin to power up b Initially LINE 2 LED will be red then change to green C At this stage the LCD display will indicate LOAD NOT PROTECTED and the module mimic LED indications should be as shown below LINE 2 BY PASS E LED Colour LOAD LINE 1 Green LINE 1 INVERTER LINE 2 Green BY PASS Green BATTERY INVERTER RED BATTERY Green 5 When powering up multi module system ensure that ALL the modules are in the state shown above before continuing with this procedure 6 Atthis stage the load is being powered through both the maintenance bypass switch and the UPS static bypass circuit which are effectively connected in parallel Transferring the load away from the maintenance bypass 7 Ensure that the BYPASS LED is green on all modules 8 Open the maintenance bypass switch IA1 on all modules a The LCD panels will display MANUAL BYPASS OPEN b The INVERTER LED will extinguish c An audible alarm will sound LINE 2 BY PASS RED LED Colour LOAD LINE 1 Green LINE 1 INVE
54. g off and shutdown procedure Time and date stamp event log Extensive logging of all UPS activity and power quality data Permits alarm warnings to be monitored remotely via email Scheduled UPS service mode and other systems status Graphical user interface for Windows compatible platforms Automatic unattended local shutdown Special modules for MS Office software to close and save open documents Compatible with all optional modules like UPSDIALER SNMP adaptors temperature sensors etc UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 7 7 KOHLERPOVVER 7 Options Buninterruptible 7 5 8 PowerREPORTER management software PowerREPORTER is a remote monitoring and management service which is a part of the premium power protection concept ThePowerREPORTER application Provides affordable continuous monitoring over mission critical facilities and offers peace of mind by detecting and warning of any potential system problems before they become a crisis Acquires key performance parameters and productivity information in real time to enable you to better understand machine performance and faster troubleshoot downtime events Gives total transparent information concerning all actions performed on the system such as all critical status changes coordination of equipment service reporting of all alarms with priorities Key features Redundant and secure communication Alarm ackno
55. haring Using sensing signals passed over the parallel control bus each UPS is able to compare its own frequency and output current with that of its neighbouring module This allows the UPS control logic to carry out fine adjustments to each module to achieve balanced conditions The control logic always observes one of the modules being the master and the others as slaves However if the master module goes faulty at any time the next module in the chain a former slave will immediately take over the role of master and the former master module will turn off Master slave configuration is achieved through selector switches located in each cabinet and is set up during commissioning See paragraph 3 9 2 2 6 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 2 Description Module redundancy If a system is designed with module redundancy then it contains at least one UPS module more than the number required to provide the specified system full load power For example if the system shown in figure 2 5 comprises 3x100kVA modules it could be employed as a redundant module system for a load of 200kVA This means that under normal circumstances each module shares the load equally and supplies up to 66 6kVA at full load but if one module fails or is taken off line then the remaining two modules are capable of sustaining the full rated load The ability to lose one module yet s
56. his is the normal operating mode and MAINTENANCE BYPASS LINE the only one that provides the load with STATIC BYPASS LINE continuously processed and STATIC backed up power SWITCH In this mode the Supply f mains supply is RECTIFIER INVERTER converted to DC by lt the rectifier which then Charger charges the battery and provides BATTERY operating power for md UPS MODULE the inverter which converts the rectifier output back to AC MAINTENANCE BYPASS LINE suitable to provide the supply load power gt If the mains supply 4 fails strays outside a a preset voltage Mains range the rectifier Supply shuts down and the battery provides an alternative DC power source for the inverter which continues to operate until the battery is discharged INVERTER RECTIFIER Charger BATTERY UPS MODULE Figure 2 2 Load on inverter UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 2 3 2 Description KOHLERPOVVER Buninterruptible When operating in the Load on Inverter mode the inverter output frequency is synchronised to the bypass supply provided the bypass supply frequency remains within preset limits If these limits are exceeded or if the bypass supply fails altogether the inverter frequency control reverts to a free running oscillator that will maintain the output frequency at a constant 50 60Hz When operating from battery power vari
57. ins not available LINE 2 GREEN Mains bypass OK RED Mains bypass not OK or not present ALARM OFF No alarm condition Flashing RED buzzer Alarm condition RED Alarm condition has been reset INVERTER GREEN Load on inverter RED Inverter fault OFF Inverter not operating BY PASS GREEN Load on bypass OFF Bypass not operating BATTERY GREEN Battery OK RED Battery fault or discharged Flashing RED Battery fuses blown Flashing GREEN On Battery 4 2 3 Operator keys The operator keys allow the user to Make settings and adjustments via the menu driven LCD display Start up and shut down the UPS and transfer the load between inverter and bypass Monitor and display the UPS operating voltages currents frequencies and other values on the LCD display Key function summary KEYS FUNCTION ON OFF Used to switch on or switch off the UPS ON OFF Scroll upwards through a displayed menu DOWN W Scroll downwards through a displayed menu RESET Cancels the audible alarm If the alarm condition was transient the ALARM LED will also extinguish otherwise it will remain red ENTER Confirms selects a chosen menu item ON OFF Start up and shutdown buttons 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 4 2 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June
58. is a risk of exposure to potentially lethal AC and DC voltages During a preventative maintenance inspection the field service engineer will check the following Site environment conditions Integrity of electrical installation Cooling airflow Rectifier operation and calibration nverter operation and calibration Static switch operation Battery status Load characteristics Integrity of alarm and monitoring systems 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 KOHLERPOVVER 5 Maintenance Buninterruptible 5 4 Battery testing The battery test is performed from the UPS control panel and takes approximately 3 minutes to complete 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 5 2 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 Troubleshooting 6 1 Alarms In the event of an alarm condition the red ALARM LED indicator will illuminate on the operator control panel and the audible alarm will sound In this case proceed as
59. ontrol panel 4 2 1 Power Management Display PMD The 2 20 character LCD Power management display simplifies communication with the UPS and also provides UPS monitoring information See paragraph 4 3 The menu driven LCD enables access to The event register Monitoring the input and output voltage current frequency amp power Monitoring battery run time UPS control commands such as UPS start up and shut down load transfer from INVERTER to BYPASS and vice versa Diagnostics service mode Adjustments and testing service mode UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER 4 Operation Buninterruptible 4 2 2 Mimic LED indicators The mimic diagram leds indicate the status of the general UPS power flow and change colour between Green and Red and OFF to indicate the current UPS operating conditions LINE 1 rectifier and LINE 2 bypass indicate the availability status of the mains power supply INVERTER and BYPASS if green indicate which of the two sources is supplying the critical load power The BATTERY LED indicator flashes when the battery is supplying the load e g following a mains failure The ALARM LED is a visual indication of any internal or external alarm condition that requires attention When activated it is accompanied by an audible alarm LED Indication summary Indicator Indicator Status Interpretation LINE 1 GREEN Mains available RED Ma
60. ous alarms are generated at preset voltages as the battery discharges This enables the operator to shut down the load in an orderly manner e g save data before the battery reaches its end of discharge voltage Various options are available to automate the load shut down process as described in Chapter 7 of this manual Options Load on Bypass d Load MAINTENANCE BYPASS LINE Bypass modetheload Bypass supply is connected to Supply STATIC BYPASS LINE the unprocessed static bypass line via the static switch STATIC SWITCH When operating in this mode the rectifier charger and inverter sections can be turned off entirely or remain running and continue to provide battery charging UPS MODULE Figure 2 3 Load on bypass Inverter Bypass load transfer As illustrated in the above diagrams the load is connected to the inverter or static bypass power circuits by means of the static switch This is a solid state switch which is operated by the UPS microprocessor control system and allows the inverter bypass operating mode to be selected manually via the UPS operator control panel or automatically depending on various UPS operating conditions see paragraph 2 3 3 Load on Maintenance Bypass MAINTENANCE BYPASS LINE Bypass Supply In this mode of operation tne manually closed maintenance bypass switch connects the load STATIC BYPASS LINE STATIC Mains SWITCH supply directly to the unprocessed b
61. plan to store the UPS cabinet prior to use it should be held it in a clean dry environment with a temperature between 5 C to 40 C and RH 9096 The UPS should be stored in the original packing and shipping carton If the packing container is removed you must take measures to protect the UPS from dust Battery The UPS uses sealed maintenance free batteries whose storage capacity depends on the ambient temperature It is important not to store the batteries for longer than 6 months at 20 C 3 months at 30 C or 2 months at 35 C storage temperature without recharging them For longer term storage the batteries should be fully recharged every 6 months 20 Extreme temperature under charge overcharge or over discharge will destroy batteries e Charge the battery both before and after storing Always store the batteries in a dry clean cool environment in their original packaging Ifthe packaging is removed protect the batteries from dust and humidity i CAUTION Sealed batteries must never be stored in a fully or partially discharged state 3 2 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLER POVVER Muninterruptible 3 Installation 3 5 Planning the installation site considerations A certain amount of pre planning will help ensure a smooth and trouble free installation of the UPS system The following guidelines should be taken into account when planning a suitable UPS location and operating
62. r WARNING Do not attempt to complete the battery wiring or close the battery isolators before the UPS system has been commissioned Number of battery strings 1 2 1 3 Terminal size 3x 8 3x M8 Fuse type very fast acting 2x3x100A 3x3x 100A Combined dimensions of UPS and battery sidecar WxHxD mm 970x1820x750 1180x1820x750 Weight w o trays and w o batteries kg 20 30 Battery configuration with BAT ENC amp B Bespoke to installation Note Only an even number of 12V battery blocks can be used UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 3 17 3 Installation KOHLERPOVVER Buninterruptible 3 8 2 Remote battery enclosure In a redundant system it is recommended to provide each UPS module with a dedicated battery so that the system redundancy is expanded to also include the batteries A range of bespoke battery enclosures can be supplied for the 60 500 modules which are designed specifically to suit individual site requirements In all cases the battery enclosure will be fitted with suitably rated fused isolators which are connected on site to the battery connection terminals inside the UPS module N WARNING The final assembly and connection of the battery installation must be carried out by the commissioning engineer Do not attempt to fit the batteries complete the battery wiring or close the battery isolators before the system has b
63. r section of wires 0 6 mm and maximum length of 100 m 2 Connectthe cable as shown in Figure 7 4 7 4 5 SNMP Card slots Simple Network Management Protocol SNMP is a world wide standardised communication protocol that can be used to monitor any network connected device via a simple control language and display the results in an application running within a standard web browser 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 An SNMP Ethernet adapter contains an RJ 45 connector which allows it to be connected to the network using a standard network cable Once connected the UPS Management software agent which is already installed in the SNMP adapter then monitors the UPS operating parameters and outputs its data in SNMP format to the connected network In a multi module UPS system the SNMP interface can communicate system wide data or data for an individual UPS module 7 6 UPS413 01 00 Kohler PW 6000 60 500 User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 7 Options The SNMP adaptor requires a PC with terminal connections and for normal operation at least one network connection Ethernet is also required External SNMP Adapter s Internal 5
64. r Inputs 13 x3 4 X2 Volt free switched alarm status outputs 1 2 14 7 1 5 JR2 RS485 on RJ45 port Remote panel interface 15 JR3 NR Li 15 6 JR1 RS485 on RJ45 port Multidrop interface 17 i 16 16 JR2 7 SW1 9 Multi cabinet configuration DIP switch TT 8 408 For parallel bus adapter JD5 JD6 13 9 SNMP Slot for optional SNMP card 8 10 Modem Slot for optional modem ethernet card only d d 17 xi Castell Interlock function 9 14 I 1 17 o o Figure 7 1 UPS interfacing connectors 7 1 Introduction Each UPS is fitted with a communication interface board as shown in Figure 7 1 which enables various external monitoring and control applications to be connected to the UPS system to satisfy particular site requirements These interfaces are described below RS232 Computer serial interface USB amp JD1 see paragraph 7 2 RS485 Interface for multidrop JR1 JR2 for 400 500 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 7 1 KOHLERPOVVER 7 Options Buninterruptible 7 2 Serial RS232 Computer interface USB amp JD1 Smart Port A serial RS 232 interface is available through a standard 9 pin D Type female socket JD1 or USB port
65. r Road Singapore 619159 Tel 65 6302 0708 Fax 65 6302 0717 Email serviceUPS sg kohler com 2 8 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Buninterruptible 2 Description Fax to 465 6302 0717 Name Regional Office South East Asia Kohler Uninterruptible Power 7 Jurong Pier Road Singapore 619159 Tel 65 6302 0708 JOD Tie ec Company LLL SL ees Address 5 6 Tel Fax E mail Please contact me to discuss L Extended Warranty options for my Kohler PW 6000 UPS Extended warranty options for my UPS System as below Manutfactlturer uu u REA Rating ae Replacement Other 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 www kohlerups sg UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 2 9 KOHLERPOVVER 2 Description Buninterruptible 2 1 0 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 Installation 3 4 Introduction This chapter contains essential information concerning the unpacking positioning inst
66. r of modules that can be used in a parallel system is 10 Stands for Single module The system consists only of one UPS cabinet 1 Stands for Parallel system and 01 identifies the cabinet as the 1st module MASTER in the system FE Stands for Parallel system and 02 identifies the cabinet as the 2nd module SLAVE in the system This number can range from 02 to 10 depending on the cabinet s position in the parallel system Setting the module position in a single multi module chain 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 4 3 4 Operation KOHLERPOVVER Buninterruptible 4 3 2 Main menu screen 1 DESCRIPTION A log of the last 64 events is stored in the Power Management Display See paragraph 4 3 3 Allows monitoring of voltages power frequencies currents etc See paragraph 4 3 4 Enables the commands Load to inverter Load to bypass and battery test to be executed See paragraph 4 3 5 Allows the UPS personalized information such as serial number to be entered See paragraph 4 3 6 Allows user to set up Date Time automatic battery test etc See paragraph 4 3 7 Password protected area for service engineer use only See paragraph 4 3 8 4 3 3
67. ransfer the load to the Maintenance Bypass and shut down the UPS system for maintenance purposes See paragraph 4 4 3 4 How to shut down the entire UPS system See paragraph 4 4 4 Key Point The location of the UPS fused isolators and circuit breakers are shown for each UPS model in Figures 3 7 to 3 10 4 4 1 Starting the UPS system from the maintenance bypass With the load initially powered from the maintenance bypass this procedure describes the sequence of operations necessary to power up the UPS module s and then transfer the load to the UPS Inverter s Prior to powering up the system check and confirm the UPS system status The load is supplied the maintenance bypass switch IA1 which is closed in all modules in a multi module system All UPS modules in multi module system are powered down Powering up the UPS s In a multi module system perform each of the following steps in turn on every module 1 the UPS module close the bypass line fuse holder F2 and the rectifier line fuse holder F1 IA4 if they are open 2 Close the battery fuses or circuit breaker on the associated battery cabinet rack a The UPS mimic panel LINE 1 LED will be permanent green b The BATTERY LED will be flashing green The LCD display will indicate LOAD OFF SUPPLY FAILURE BY PASS LED Colour LOAD LINE 1 Green LINE 2 Off BY PASS off BATTERY INVERTER Off BATTERY Green Flashin
68. rials and workmanship for a period of one year from the date of original commissioning or fifteen months from the date of original delivery whichever is the sooner This warranty is the only warranty given and no other warranty express or implied is provided This warranty is invalidated if the UPS is put into use without having been commissioned by a fully trained and authorised engineer This warranty does not apply to any losses or damages caused by misuse abuse negligence neglect unauthorised repair or modification incorrect installation inappropriate environment accident act of God or inappropriate application 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 repaired or replaced parts will remain the property of Kohler Uninterruptible Power As a general policy Kohler Uninterruptible Power does not recommend the use of its products in life support applications where failure or malfunction of the product can be reasonably expected to cause failure of the life support device or to significantly affect it s safety or effectiveness applications concerned with direct patient care Kohler Uninterruptible Power will not knowingly sell its products for use in such applications unless it receives in writing assurances satisfactory to Kohler Uninterruptible Power that the risks of injury or damage have been minimized the
69. s 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 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 1 1 KOHLERPOVVER 1 Safety Buninterruptible 1 2 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 Description 2 1 Introduction Congratulations on your purchase of the Kohler PW 6000 UPS Continuous power availability is essential in today s dynamic IT and process related work environments It is equally important that any installed power protection system is sufficiently resilient and adaptable to handle any changes brought about by the introduction of new server technologies migration and centralization Such demands are well met by the Kohler PW 6000 UPS system which provides the foundation for continuous power availability of network critical infrastructures both in enterprise data centres where business continuity has paramount importance and in process control environments where manufacturing continuity is essential 2 1 1 Reliability and quality standards The Kohler PW 6000 UPS is available over a model range of 60 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 Frequ
70. self off to protect its batteries This alarm is only displayed if the UPS is on maintenance bypass UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 6 Troubleshooting 6 3 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 7 Jurong Pier Road Singapore 619159 Tel 65 6302 0708 Fax 65 6302 0717 Email service UPS sg kohler com We recommend that your UPS is protected by an Extended Warranty Agreement see Section 2 for details These agreements assist us in caring for your UPS correctly ensuring that it is well maintained and attended to promptly should any problems occur UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 6 3 KOHLERPOVVER 6 Troubleshooting Buninterruptible 6 4 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 IDENT FUNCTION 1 USB RS232 PC Interface on standard USB 2 JD1 RS232 PC Interface on Sub D9 Female 3 x1 Custome
71. ses 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 1 Usea screened cable with 1 pair section of wires 0 6 mm 2 Connect the cable as shown in Figure 7 3 and maximum length of 100 m UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 7 5 KOHLERPOVVER 7 Options Buninterruptible 7 4 4 Generator ON facilities Generator Alarm Panel UPS Generator Port B xn 1 2 E xi E o I 5 Port Generator Alarm Panel x39 x3 10 x3 Figure 7 4 Generator ON Connection The generator ON facility must use a normally open contact which closes when a standby generator is running and supplying the UPS input power When used this facility enables the option to inhibit the operation of the battery charger and or static bypass See Set up user menu screen in section 4 3 7 1 Use a screened cable with 1 pai
72. sions with elevation kit WxHxD mm 970 x 1975 x 750 Weight without batteries fitted kg 250 260 285 Weight with 80 x 28Ah batteries fitted kg 1140 1150 1175 Colour Graphite Grey RAL 7024 Batteries Max configuration 80 x 28Ah Battery blocks Exhaust cooling air Rear MECHANICAL CHARACTERISTICS 60 100kVA Battery Enc B Rating kVA 60 Dimensions WxHxD 1180 x 1820 x 750 Dimensions with elevation kit WxHxD 1180 1975 750 Weight without batteries fitted kg 260 270 295 Weight with 120 x 28Ah batteries fitted kg 1590 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 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER 8 Specifications Buninterruptible MECHANICAL CHARACTERISTICS 120 200kVA Rating kVA Dimensions WxHxD 850 x 1820 x 750 Dimensions with elevation kit WxHxD mm 850 x 1975 x 750 Weight kg 280 290 310 Colour Graphite Grey RAL 7024 Batteries Fitted in external enclosure Input and output power cable entry Bottom Exhaust cooling air Rear MECHANICAL CHARACTERISTICS 250 300kVA Rating kVA 250 Dimensions WxHxD 1100 x 1920 x 750 Dimensions with elevation kit WxHxD mm 1100 x 1975 x 750 Weight kg 390
73. solator must not be used at the LV Distribution board on a TN S system Figure 3 2 Input neutral grounding 3 4 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterru ptible 3 Installation 3 6 2 Cable and fuse sizing Single feed Dual feed inputs The UPS can be wired for a single feed input standard whereby the UPS input supply terminals and bypass supply terminals are internally linked or it can be wired for a dual feed input where the bypass links are removed and the UPS bypass terminals are connected to a dedicated bypass supply Both configurations are shown in Figure 3 3 single feed and Figure 3 4 dual feed together with details of the recommended fuse and cable ratings Fuse and Cable recommendations are to IEC 60950 1 2001 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 P Key Point This information in figures 3 3 and 3 4 is given for guidance only UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 3 5 3 Installation KOHLERPOVVER Buninterruptible Power kVA 60 Fuse A Agl CB 3x100 Mains Supply 3x380 400 415 UPS MAINS SUPPLY Rectifier Inverter
74. sor so that it is adjacent to LOAD TO BYPASS and then press the ENTER key a The UPS system will transfer the load to static bypass on all UPS modules in a multi module system 4 modules check and confirm that a The INVERTER LED has extinguished b The BYPASS LED is green c TheLCD displays LOAD NOT PROTECTED LINE 2 BY PASS Green LINE 1 INVERTER LINE 2 Green BY PASS Green BATTERY INVERTER Off Green Closing the maintenance bypass switch 5 Close the maintenance bypass switch IA1 in all modules in a multi module system 6 modules check and confirm that a The INVERTER LED has turned to red b The 55 LED is green c TheLCD displays MANUAL BYP IS CLOSED LINE 2 BY PASS men LED Colour LOAD LINE 1 Green LINE 1 INVERTER LINE 2 Green p BY PASS Green EHE BATTERY INVERTER RED BATTERY Green UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 4 11 4 Operation KOHLERPOVVER Buninterruptible Powering down a UPS module When the load is connected to the maintenance bypass supply as described above the UPS module s can be powered down for example if required for maintenance testing using the following procedure Note Carry out the following procedure on each module in a parallel system 7 the UPS control panel simultaneously press both ON OFF but
75. t Interface for Multidrop connection between several UPS cabinets SW1 9 Multi Cabinet Configuration Switch JD8 Parallel BUS connector ONLY For paralleling cabinets SNMP Slot for optional SNMP card ONLY RS 3 Rect Fuse Byp Fuse 1 2 IA1 JD8 Parallel Isolator Byp Isolator Earth Input output power connections Battery connections Earth See Figure 3 5 See Figure 3 5 Figure 3 9 250kVA 300 kVA Module details UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 3 1 5 3 Installation KOHLERPOVVER Buninterruptible
76. t one module without affecting the operational status of the overall system e g one module can be taken off line for servicing whilst the remaining modules maintain the protected load supply Module start up Use this procedure to start a module and connect it to a working multi module system This procedure assumes the following initial conditions The UPS input supply isolator is open on the building s LV distribution panel The fused battery isolators are open in the battery cabinet n the UPS cabinet the fused isolators F1 IA3 F2 IA4 and the parallel isolator IA2 are open 1 In the UPS cabinet close the input supply and bypass supply fused isolators F1 IA3 F2 IA4 and the Parallel Isolator IA2 2 Close the UPS input supply isolator at the LV distribution panel a TheLINE 1 indicator will illuminate green b TheLCD display will indicate LOAD OFF SUPPLY FAILURE If necessary press the RESET button to obtain this display Identify the battery cabinet rack associated with the UPS module and close the fused battery isolators Simultaneously press the two ON OFF push buttons on the UPS control panel a The UPS will run through an automated start up sequence accompanied by the following indications LINE 2 LED lights red then changes to green INVERTER LED lights green BATTERY LED lights green constant b LCD displays the LOAD PROTECTED message BY PASS LED Colour LOAD LINE 1 Green LINE 2 Green
77. terminals as shown in Figures 3 7 to 3 10 10 Connect the UPS bypass mains supply cables to terminals 2L1 2L2 2L3 and 2N on the UPS main terminal block Ensure correct clockwise phase rotation Note For 120 200kVA modules connect the bypass neutral to the same neutral terminal N as that used for the input supply A CAUTION The bypass Neutral cable must ALWAYS be connected 11 Secure the cables to the fixing rail under the connection terminals Note The UPS commissioning engineer will re configure the UPS electronics to operated with a dual feed input at the time of commissioning 3 7 2 Connecting the UPS output cables It is recommended that a separate load distribution board is provided for the load Before you begin connecting the UPS output cables to the load distribution board Check that the potential full load does not exceed the UPS output power rating OUTPUT POWER on the nameplate ensure the load circuit breakers on the load distribution board are correctly sized with respect to the load rating and associated cabling Ensure that the maximum total load rating and maximum load rating of each individual load socket is indicated on the load distribution board The circuit breakers must comply with the prescribed IEC Standards e g BS7671 2008 1 Gain internal access to the UPS and remove the UPS terminal cover if fitted 2 Connectthe protective earth cable from the load distribution board to the protecti
78. till provided the full load with processed backed up power significantly increases the overall system reliability 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 include the batteries which is highly recommended Isolating a module from the system As explained immediately above if a parallel system incorporates module redundancy it is possible to isolate a module from the system for service repair purposes without affecting the remaining modules or load Every UPS module is provided with an output parallel isolator IA2 which can isolate the module from the parallel load bus Once IA2 is open there is no load power being drawn from the inverter and the module can be shut down in the normal way using the ON OFF buttons on the UPS control panel Using these buttons will shut down the associated module only and will not cause the remaining modules to shutdown or transfer the load to bypass WARNING When the UPS module is shut down its output terminals will be live even if the module s input mains and bypass supplies are isolated 2 4 Warranty The Kohler PW 6000 UPS is supplied with a limited warranty that the UPS and its component parts are free from defects in mate
79. tons a 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 On the UPS module open the module s parallel isolator 2 BY PASS LED Colour LOAD LINE 1 Green LINE 2 Off BY Pass Off BATTERY INVERTER BATTERY Green Flashing 10 Open the bypass line fuse holder F2 IA4 and the Rectifier Line fuse holder F1 1 P P CAUTION The load is now powered directly from the bypass mains supply and is not protected against power failure WARNING The UPS module is still live at its input and output power terminals due to the activation of Maintenance Bypass circuit Allow 10 minutes for the internal DC capacitors to discharge before touching any UPS internal components 4 4 4 Complete system shutdown The UPS system may be shutdown completely if the load does not require power for an extended period of time Use this procedure to totally turn of the load power and shutdown the entire UPS system P 1 gt m gt CAUTION This procedure will totally disconnect load power Ensure that it is safe to lose power to all the loads connected to the UPS system before you begin this procedure Isolate all load equipment connected to the output of the UPS system by opening the fused isolators or circuit breakers in the UPS output lo
80. ush current A Limited by soft start Max Input Power with rated output kW 64 85 107 128 170 213 266 319 426 532 power and charged battery pf 1 0 Max Input Current with rated output A 93 123 154 185 247 308 386 463 617 771 power and charged battery pf 1 0 Max Input Power with rated output kW 70 94 117 141 187 234 293 351 468 585 power and discharged battery pf 1 0 power and discharged battery pf 1 0 Load 25 50 75 100 Input power factor leading 0 96 0 985 0 99 0 99 Input current distortion THDi 9 0 6 0 4 5 3 5 Max Input Current with rated output A 102 136 170 204 271 339 424 509 679 848 BATTERY CHARACTERISTICS Variable number of 12V battery No 44 50 50 44 50 blocks only even numbers allowed battery charger current A 25 50 60 100 Battery type Maintenance free VRLA or NiCd Temperature controlled charger Yes temperature sensor optional Battery charging curve Ripple free IU DIN 41773 Battery test Automatic and periodic adjustable OUTPUT CHARACTERISTICS Output rated power kW 60 80 100 120 160 200 250 300 400 500 min 44 battery blocks Output current In PF 1 0 A 87 116 145 174 232 290 361 433 577 722 min 44 battery blocks Output rated voltage V 3x 380 220 or 3x 400 230 or 3x 415 250 Output voltage stability Static 96 lt 1 0 Output voltage stability Dynamic 96 lt 4 with load step 0 100956 100 095 Output voltage distortion with linear lt
81. ve earth PE busbar in the UPS 3 Connect the UPS output supply cables to terminals 3L1 3L2 3L3 and 3N on the UPS main terminal block Ensure correct clockwise phase rotation A CAUTION The output Neutral cable must ALWAYS be connected 4 Secure the cables to the fixing rail located under the UPS connection terminals 5 Ensure the output cables are connected to the correct power terminals on the load distribution board 3 1 2 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 3 Installation e do pus eee 99 IL Il 100000000000000000 crx racn oj 0010 0 oo 9 5 Input output HS O
82. wledgment 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 User administration with passwords and permission level Administration of Log file Data logging with statistical analysis and diagnostics report Visualization of the UPS data Current status Measured values for single or three phase Recording function including graphs with zooming capabilities for selected measured values Display of event log file Display of UPS parameters Web server functionality for data access from any web browser 7 8 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 Specifications 8 1 General specifications MECHANICAL CHARACTERISTICS 60 100kVA No Battery Enc Rating kVA 60 Dimensions WxHxD 550 x 1820 x 750 Dimensions with elevation kit WxHxD mm 550 x 1975 x 750 Weight kg 205 225 230 Colour Graphite Grey RAL 7024 Batteries Fitted in external enclosure Input and output power cable entry Bottom Exhaust cooling air Rear MECHANICAL CHARACTERISTICS 60 100kVA Battery Enc A Rating kVA Dimensions WxHxD 970 x 1820 x 750 mounted on 16 shelves Input and output power cable entry Bottom Dimen
83. y by means of communication bus cables that are daisy chained between each module as shown below in figure 3 12 Once the cables are fitted each module must be configured by means of a DIP switch according to its position in the parallel system 3 9 4 Connecting the parallel communication bus cables 1 To protect personnel during the UPS installation ensure that the connections are performed under the following conditions V2 fk No mains voltage is present the UPS mains bypass distribution board terminals All loads are shut down and disconnected at the load distribution board The UPS is fully shut down and voltage free The UPS and battery connection terminals are voltage free The UPS Maintenance Bypass Isolator IA1 is open OFF The UPS Parallel Isolator IA2 is open OFF 2 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 amp JD6 3 18 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterru ptible 3 Installation 3 Set DIP switch SW2 2 on each parallel adaptor board according to the position of the UPS cabinet in the parallel configuration See Figure 3 12 4 Connect a bus cable between PORT JD6 of UPS cabinet 1 parallel adaptor and PORT JD5 of UPS cabinet 2 parallel adaptor 5
84. y cabinet is tilted by more than 10 it could cause internal damage If tilling occurs do not connect the UPS to the mains electrical supply The weight of the UPS battery equipment can cause serious personal injury and or structural damage to the surrounding area if dropped in transit Always take extreme care when moving the equipment CAUTION Storage A The UPS should be stored in the original packing and shipping carton The recommended storing temperature for the UPS system and batteries is between 5 C and 40 C UPS system and the battery sets must be protected from humidity lt 90 non condensing 3 3 Unpacking 1 Ifthe cabinet is shipped inside a wooden case remove the screws at the base and sides of the case then carefully remove the case from the equipment pallet Cut the wrappers and remove the packing container by pulling it upwards Remove the plastic sheeting covering the UPS Remove any anchor bolts securing the cabinet to the pallet then remove the UPS from the pallet Retain the packaging materials for possible future shipment of the UPS Examine the UPS for signs of damage and notify your supplier immediately if any damage is found Check that the details on the UPS nameplate corresponds to the purchased material mentioned in the delivery note The rating specifications can be found on a nameplate located inside the UPS door 3 4 Storage UPS Cabinet If you
85. ypass an En supply This is used to keep the load supplied albeit without any power protection whilst allowing the 4120 BATTERY remainder of the UPS to be shut down for Figure 2 4 Load on maintenance bypass service repair UPS MODULE Note Live voltages are still present on the UPS input and output power terminals when in this mode To prevent possible inverter damage it is important that the inverter output and maintenance bypass lines are never connected in parallel Therefore when transferring from the load on inverter mode to the load on maintenance bypass mode it is important that the load is first transferred to the static bypass 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 2 4 UPS413 01 00 Kohler PW 6000 60 500kVA User Manual 25 June 2012 KOHLERPOVVER Muninterruptible 2 Description 2 3 3 System operating modes The previous section described the various UPS internal operating modes but UPS systems are also categorised according to the way in which they operate at a system level and are typically described as being an on line off line or line interactive UPS system The Kohler PW 6000 can be operated in all three of the above categories On line operation When used as an on line UPS the Kohler PW 6000 is configured to norm
86. ystem this is achieved by a parallel control bus which allows all the connected modules to communicate with each other and carry out the necessary synchronous control operations Due to its Decentralised Parallel Architecture DPA design each Kohler PW 6000 UPS can take the leadership role when operating in a multi module system This avoids single points of failure in the parallel chain once again ensure the highest level of power availability Parallel system expansion Most data centres present a low initial power demand which increases as the data centre grows to its full capacity and it is essential that the installed power protection system can be expanded to meet the growing demand without compromising the existing load This situation is easily managed in a Kohler PW 6000 multi module installation which allows an additional module to be connected to an existing parallel system without having to temporarily transfer the load to the raw mains by pass supply Thus the load still receives UPS protected power at all times during the upgrade process without interruption Key Point All the UPS modules connected to a parallel system must be of the same power rating 2 3 Kohler PW 6000 functional description MAINTENANCE BYPASS LINE Bypass Supply STATIC BYPASS LINE Mains SWITCH Supply RECTIFIER INVERTER UPS MODULE Figure 2 1 Kohler PW 6000 UPS block diagram 2 2 UPS

413-01-00 PW6000 60-500kVA User Manaual (UK).book

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