Kohler PW1000 2 kVA, PW1000 3 kVA, PW1000 1 kVA User Manual

PowerWAVE 1000

(1–3 kVA)

User Manual

TS_600_00 PW1000 1-3kVA User Manual 6/4/17

TS_600_00 PW1000 1-3kVA User Manual 6/4/17

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PDF ISSUE DATE REVISION SUMMARY

TS_600_00 06/04/2017 First Issue

TS_600_00 PW1000 1-3kVA User Manual 6/4/17

Uninterruptible Power Supplies Ltd 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.

© 2017 Uninterruptible Power Supplies Ltd

This manual may not be copied or reproduced without written permission
of Uninterruptible Power Supplies Ltd.

USEFUL CONTACTS

www.upspower.co.uk UPS Limited web site

[e-mail] Service department – booking service, fault reporting etc.

[e-mail] Technical queries

[e-mail] Hardware sales

[e-mail] Extended warranty agreements etc

TS_600_00 PW1000 1-3kVA User Manual 6/4/17 I

Table of Contents

Safety 1

1.1 Description of symbols used in this manual 1

1.2 User precautions 1

1.3 Important safety notes 2

1.4 Storage instructions 2

General Description 3

2.1 Introduction 3

2.1.1 Advanced design features 3

2.1.2 PW1000 1-3kVA Model range 4

2.2 UPS Operating principles 4

2.2.1 Basic block diagram 4

2.2.2 System operating modes 5

2.3 Operator control panel 7

2.3.1 LED Indicators 7

2.3.2 Operator keypad 8

2.3.3 LCD Display 8

2.4 UPS Rear view 10

2.4.1 Communication Ports 10

2.5 External battery cabinet 12

2.6 Warranty 13

2.6.1 Extended warranty 13

2.6.2 Additional service/maintenance support 13

Installation 14

3.1 Unpacking the UPS equipment 14

3.2 Selecting a suitable installation location 14

3.2.1 Clearances 15

3.3 Assembling the UPS mounting hardware 17

3.3.1 Hardware accessories pack 17

3.3.2 Stand-alone Tower assembly 17

3.3.3 Rack installation 17

3.4 Assembling the external battery cabinet mounting hardware 20

3.4.1 Stand-alone tower installation 20

3.4.2 Combined tower installation 21

3.4.3 Rack installation 21

3.5 Electrical installation 22

3.6 Initial UPS power-up and commissioning 22

Operation 23

4.1 Introduction 23

4.2 UPS start-up procedures 24

4.2.1 How to start the UPS (from utility mains) 24

4.2.2 How to start the UPS (from battery) 25

:

II TS_600_00 PW1000 1-3kVA User Manual 6/4/17

4.2.3 How the monitor the UPS input/output operating conditions 26

4.3 UPS shut down procedures 27

4.3.1 How to turn off the UPS (from ON INVERTER or ECO Mode) 27

4.3.2 How to turn off the UPS (from ON BATTERY Mode) 27

4.4 Manual load transfer between inverter and bypass 27

4.5 Functions menu 28

4.5.1 How to disable the alarm buzzer operation 28

4.5.2 How to perform a battery test 28

4.5.3 Functions menu 29

4.5.4 Operating parameters setting menu 30

Maintenance 31

5.1 Introduction 31

5.2 Scheduled maintenance 31

5.2.1 Preventative maintenance inspection 31

5.2.2 Battery maintenance and testing 31

Troubleshooting 33

6.1 Introduction 33

6.2 Fault identification 33

6.2.1 Error codes 33

6.2.2 Audible warning alarm 33

6.2.3 Warning symbols 34

6.3 Troubleshooting a fault condition 34

6.4 Troubleshooting an operational problem 35

6.5 UPS Fault handling 35

6.5.1 Output load short circuit when the output supply is via inverter 36

6.5.2 Output short-circuit when the output supply via the bypass line 36

6.5.3 Inverter/internal over-temperature 36

6.5.4 Inverter over-current and output voltage out of tolerance 36

6.6 UPS System reset 36

Options 37

7.1 Communications options 37

7.2 RS-232 Computer serial interface 37

7.3 Emergency Power Off (EPO) / Remote ON/OFF (ROO) 38

7.4 CS141 /SMNP adapters 38

7.5 AS400 (dry contact) card 39

Specification 40

TS_600_00 PW1000 1-3kVA User Manual 6/4/17 1

1

Safety

1.1 Description of symbols used in this manual

1.2 User precautions

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.

WARNING: Do not attempt to install this UPS system until you are satisfied that you have read and understood
ALL the safety instructions and hazard warnings contained in this manual.

WARNING: Keep this manual with the UPS for future reference.

WARNING: DO NOT OPEN THE CASE. If you open the case of the UPS you will be exposed to dangerous

voltages. The UPS does not contain any user-serviceable parts, so do not attempt to repair this unit yourself as
doing so will void your warranty. If the UPS malfunctions it must be serviced or repaired by a trained engineer.
Always contact your local service agent if repair is necessary.

WARNING: Do not disconnect the power cord from the UPS AC Input socket while the UPS is turned on. The
UPS is equipped with an EMI filter, and to prevent a potential leakage current hazard the AC mains supply must
be securely grounded at all times. You should double check that the UPS supply earth connection is properly
grounded before you connect AC mains to the UPS.

WARNING: Uninterruptible Power Supplies Ltd will assume no responsibility or liability for accidents or injuries
due to incorrect operation or manipulation of the UPS or peripheral equipment.

CAUTION: The PW1000 1-3kVA is a Class A UPS product (according to EN 62040-3).
In a domestic environment the UPS may cause radio interference and the user may be required to undertake
additional measures.

1: Safety

2 TS_600_00 PW1000 1-3kVA User Manual 6/4/17

1.3 Important safety notes

1. The UPS warranty will become null and void if liquids are spilt on the UPS case, or foreign objects are dropped into
the unit. Such mishaps could severely damage the UPS and present a shock hazard to anyone who touches the unit.

2. The ventilation grills on the UPS front panel must be kept free of obstruction at all times.

3. The UPS is must be installed in a sheltered and controlled environment away from direct sunlight. The operating
temperature should be between 0~40°C (ideally 20°C) with relative humidity of 0~90%, non-condensing. Further
details concerning the installation environment are included in the installation chapter of this manual.

4. Before installing the equipment you must check to ensure that the input voltage stated on the UPS data-plate on the
back of the unit matches your local utility supply voltage.

5. The UPS warranty will be rendered void, and the manufacturer reserves the right to refuse replacement or
compensation, if the UPS malfunctions due to:

• Accidental damage to the UPS.

• Damage or malfunction due to installing the UPS in an environment that does not meet the conditions specified in

this manual.

• Damage or malfunction due to improper installation, configuration or maintenance carried out by an unauthorised

person.

1.4 Storage instructions

If you intend to store the UPS for an extended period, in a moderate climate, the batteries should be charged for 12 hours
every 3 months by connecting the UPS to the utility supply. If the ambient temperature at the storage location is above
25°C, this should be carried out every 2 months.

CAUTION: Please read the following notes carefully prior to installation and use.

CAUTION: Always switch off the UPS before moving it.

TS_600_00 PW1000 1-3kVA User Manual 6/4/17 3

2

General Description

2.1 Introduction

Congratulations on your purchase of the PW1000 1-3kVA UPS.

High reliability, low operating cost and excellent electrical performance are just some of the highlights of this innovative
UPS solution.

Uninterruptible Power Supplies Ltd. specialises in the installation and maintenance of Uninterruptible Power Systems; and
this 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.

2.1.1 Advanced design features

By using the latest technological developments in power engineering, the PW1000 1-3kVA represents a new generation of
transformerless UPS-System. Its advanced double conversion Voltage and Frequency Independent (VFI) topology
responds fully to both the highest availability and environmentally friendly requirements, compliant with IEC 62040-3 (VFI­SS-111) standards. A full UPS specification is provided in Chapter 8 of this manual.

Following, are some of this unit’s advanced design features:

• True online technology continuously supplies your critical applications with stable, regulated, transient-free pure

sine-wave AC power.

• High-Frequency Transformerless technology and tower-convertible enclosure enables the UPS to be integrated

into even the most difficult environments with space constraints.

• User-friendly design that permits simple and trouble-free installation. All units are supplied with input and output

power cables as standard.

• Smart battery management system which extends the battery life span.

• Highly efficient PWM sine-wave technology yields excellent UPS efficiency. The high crest factor of the inverter

handles peak inrush current loads and so avoids a need to upgrade to a UPS with a higher power rating.

• Compliant with various stringent international EMC standards for electromagnetic interference & protection.

• Selection of output voltages (200/208/220/230/240) available to match the UPS to local supply specifications or

specific load voltage requirements.

• A selectable bypass voltage tolerance (low/high sensitivity) restricts the range of voltages that can be applied to the

load when the UPS operates on bypass. The ranges are ±15% (low sensitivity) and ±10%V (high sensitivity). For
example, if the output voltage setting is 230V the bypass sensitivity Low range is 230V ±15%.

• Selectable 50Hz or 60 Hz operation.

• Fully digitized control logic for better functionality and enhanced power protection. Digital signal processing (DSP)

also provides efficient communication capabilities for enhanced remote control and monitoring flexibility.

• Active power factor correction (PFC) control function constantly maintains the UPS input power factor to >0.99 at

100% load, with resulting outstanding energy efficiency.

• Wide input voltage tolerance, from 110V~300V, allows the UPS to operate normally without draining the battery

unnecessarily during significant mains voltage dips, which helps extend the battery service life.

• DC-start function permits the UPS to be started during a utility power failure if required.

• Overload protection system automatically switches the UPS to bypass mode if an overload occurs and

automatically switch back to inverter mode once the overload condition ceases. Should the output become short­circuited, the UPS puts the system in stand-by mode, provides visible and audible alarms, and turns off the output
supply automatically until the short circuit situation is resolved manually.

2: General Description

4 TS_600_00 PW1000 1-3kVA User Manual 6/4/17

2.1.2 PW1000 1-3kVA Model range

The PW1000 1-3kVA UPS range comprises 1 kVA, 2 kVA and 3 kVA models, each of which is designed as a self­contained UPS comprising a rectifier, battery charger, inverter, static switch and battery pack. All the models in this range
are easy to install, and supplied with suitably terminated power cables.

The PW1000 1-3kVA operates as a stand-alone UPS module and can be mechanically configured as a floor-standing
tower unit or installed in a standard 19 inch rack. An accessory pack which contains all the parts necessary to configure
the unit for either type of installation is supplied with the UPS.

Optional external battery cabinets are available to increase the UPS autonomy time. The battery cabinet design
compliments the UPS cabinet and the two cabinets can be mechanically connected together to form a single unit when
installed as a tower system – see chapter 3 (Installation) for mechanical configuration details.

2.2 UPS Operating principles

2.2.1 Basic block diagram

Figure 2.1 UPS Functional block diagram

EMI Filters

The UPS has an input and output EMI filter to reduce the effects of electromagnetic noise generated by the UPS on other
adjacent equipment – e.g. reduces external radio interference.

Battery charger

A regulated battery charger, power from the AC Input supply, charges the battery whenever the input supply is available.

DC/DC Boost converter

In times of AC Input supply failure, the DC/DC Boost Converter turns on and boosts the battery voltage to a level suitable
for use by the inverter. It provides a regulated DC output for the inverter while the battery voltage decays during discharge
and includes voltage and current monitoring and overload protection.

1 kVA 2 kVA 3 kVA

Maximum output power (0.9 pf) kVA (kW) 1.0 (0.9) 2.0 (1.68) 3.0 (2.7)

Dimensions (WxHxD) mm 440 x 88 x 400 440 x 88 x 600 440 x 88 x 600

Weight (with internal batteries) kg 12 22 26.5

Sound level dBA <

50 <50 <50

EMI

FILTER

EMI

FILTER

AC/DC (PFC)
CONVER TER

DC/AC

INVERTER

STATIC

SWITCH

BATTERY

CHARGER

DC/DC BOOST

CONVER TER

BATTERY

AC

Input

AC
Output

Bypass Line

Safety

Relay

Input

CB

TS_600_00 PW1000 1-3kVA User Manual 6/4/17 5

2: General Description

AC/DC Converter

As its name suggests, the AC/DC Converter converts the AC Input supply into a controlled DC supply that is suitable for
use by the inverter. The converter uses a leading-edge switched-mode technique which produces an input power factor of
almost unity over its full operating range (0.99 at full rated linear load) and thereby maximises the UPS efficiency.

The converter can satisfy the inverter DC power demands over an AC Input voltage range of between 110V~300V which
means that the battery is not called upon during power dips (brownouts), thereby maximising battery life and availability.

DC/AC Inverter

The inverter converts the DC voltage connected to its input, from the AC Input supply via the AC/DC converter or from the
battery via the DC/DC converter, and produces a regulated AC Output voltage that is suitable to power the connected load
equipment. The control logic associated with the Inverter power block is substantial, and in addition to the controlling the
output sine wave voltage it also provides various levels of overload protection, frequency regulation and synchronisation,
and output voltage error detection.

Static switch

The static switch provides a means of connecting the UPS AC Output (load) to the inverter output or the bypass line,
which is connected directly to the UPS AC Input. The control logic within this power block will transfer the load to the
bypass supply in the event of overload or UPS (inverter) malfunction. The load can also be transferred between the
inverter and bypass line manually if required. Note that a controlled transfer can take place only if the inverter and bypass
line are synchronised in frequency and phase.

2.2.2 System operating modes

ON-INVERTER operation

Figure 2.2 ON-INVERTER operation

• The battery is being permanently charged by the battery charger.

• The AC/DC converter is processing the AC Input supply and turning it into controlled DC.

• The inverter is converting the AC/DC converter output back into AC suitable for the load.

• The static switch is connecting the inverter output to the UPS AC Output terminals.

EMI

FILTER

EMI

FILTER

AC/DC (PFC)

CONVER TER

DC/AC

INVERTER

STATIC

SWITCH

BATTERY

CHARGER

DC/DC BOOST

CONVER TER

BATTERY

AC

Input

AC
Output

Bypass Line

Safety

Relay

Input

CB

2: General Description

6 TS_600_00 PW1000 1-3kVA User Manual 6/4/17

ON BATTERY operation

Figure 2.3 ON-BATTERY operation

• The battery is discharging through the DC/DC boost converter which presents the inverter with a controlled input

voltage as the battery discharges.

• The Inverter is converting the DC/DC boost converter output back into AC suitable for the load.

• The static switch is connecting the inverter output to the UPS output terminals.

• The load will continue to receive its regulated power until the battery discharges to its low voltage cut-out level.

ON BYPASS operation

Figure 2.4 ON-BYPASS operation

• The battery is being permanently charged by the battery charger as long as the battery charger is still serviceable

and able to operate. If the load has transferred to bypass due to an internal malfunction the battery charger may
have shut down.

• The AC/DC converter, DC/DC boost converter and inverter are all inoperative.

• The static switch is connecting the bypass line to the UPS output terminals.

Note: When operating in this mode the load is unprotected from utility power disturbances.

EMI

FILTER

EMI

FILTER

AC/DC (PFC)

CONVER TER

DC/AC

INVERTER

STATIC

SWITCH

BATTERY

CHARGER

DC/DC BOOST

CONVER TER

BATTERY

AC

Input

AC
Output

Bypass Line

Safety

Relay

Input

CB

EMI

FILTER

EMI

FILTER

AC/DC (PFC)
CONVER TER

DC/AC

INVERTER

STATIC

SWITCH

BATTERY

CHARGER

DC/DC BOOST

CONVER TER

BATTERY

AC

Input

AC
Output

Bypass Line

Safety

Relay

Input

CB

TS_600_00 PW1000 1-3kVA User Manual 6/4/17 7

2: General Description

2.3 Operator control panel

The UPS is controlled from the operator control panel located on the front of the unit.

The user-friendly UPS control panel comprises three areas:

Figure 2.5 Operator control panel

2.3.1 LED Indicators

Input mains supply status

This led is permanently ON if the mains supply is within in the normal operating range of 160~300 VAC, and
flashes if the supply falls to 120~159 VAC. If the led is OFF it indicates a mains supply failure.

Programmable outlet status

The programmable outlets are normally connected to less critical loads which can be shed when the utility
power fails. This reduces the load on the battery as it discharges and thereby increases the back-up time for
the more critical loads which are connected to the unswitched UPS outlet(s). The indicators are permanently
ON when the outlets are live.

Bypass supply status

This led is permanently ON when the UPS is operating in the ECO mode and flashes when the load is
transferred to bypass – either manually or due to a detected fault.

UPS fault indication

This LED illuminates to indicate the presence of a fault condition within the UPS that needs attention. It is
usually accompanied by an audible alarm.

ON OFF Enter

Function

INPUT

UPS

LOAD

Service

Overload

Utility

?

Wiring Fault

Alarm

Bypass

Fault

Parallel IDMode

KVA
WHz
Mins
%

C

BypassStep

Utility Invert er

VoltageAdjust

Buzzer Code

BatteryAutonomy

FrequencyWindow

Low

Testi ng

1

2

Led indicators

A row of LEDs indicate the UPS input and
output power status, together with a
general fault warning.

LCD Display

Provides indication of the UPS operating
mode together with the input, output, and
battery supply parameters. It also displays
error messages and UPS set-up data via a
system of configuration menus.

Operator Keypad

The keypad contains 6 keys that are used
to navigate through the UPS control menu
system and turn the UPS OFF/ON.

1

2: General Description

8 TS_600_00 PW1000 1-3kVA User Manual 6/4/17

2.3.2 Operator keypad

2.3.3 LCD Display

The LCD display contains a row of warning symbols, a mimic diagram which indicates the power path through the UPS, a
battery status indicator and a multi-function 3-digit numerical display which can be selected to indicate a range of
operating parameters. Each of these areas are described below.

Figure 2.6 LCD Display

ON Button

This button is used to turn ON the UPS and activate certain functions when operated in combination
with other buttons (as described later in this chapter). The button must be pressed for approximately
one second to turn ON the UPS – accompanied by double ‘beep’.

This symbol shows that the ON button is also used to cancel the audible alarm. When the alarm is
cancelled, the audible warning will turn OFF but the alarm LED will remain ON if the fault is still present.

OFF Button

This button must be pressed for approximately one second to turn OFF the UPS – accompanied by
double ‘beep’.

ENTER Button

The ENTER button is used to select a parameter from the UPS monitoring and configuration menus.

UP (BACK) Button

This button is used to navigate UP through the UPS menus, or change a menu parameter. It is also
used with the ON button to manually transfer the load between the UPS and bypass supply.

DOWN (NEXT) Button

During normal operation, this button is used to scroll through the metered parameters shown on the
LCD display. It is also used in conjunction with the ON button to access the UPS configuration menus.

FUNCTION Button

This button is used to access the UPS configurations display menu.

ON

OFF

Enter

Function

INPUT

UPS

LOAD

Service

Overload

Utility

?

Wiring Fault

Alarm

Bypass

Fault

Parallel ID Mode

KVA
WHz
Mins
%

C

Bypass Step

Utility Inverter

VoltageAdjust

Buzzer Code

BatteryAutonomy

Frequency Window

Low

Testing

Warning symbols

Mimic diagram

Battery status

Metering parameters

3-Digit alpha-numeric display

TS_600_00 PW1000 1-3kVA User Manual 6/4/17 9

2: General Description

Warning symbols

Mimic diagram

The LCD Mimic diagram indicates the existing power flow through the UPS. The INPUT, UPS, LOAD and BATTERY
symbols are permanently shown on screen and their interconnecting lines appear, or disappear, depending on the UPS
mode of operation – see the table below.

Bypass input abnormal:

UPS fails to transfer to bypass, bypass abnormal in ECO mode

Utility input abnormal:

The utility mains supply is outside the UPS pre-set operating window

Wiring fault:

Site wiring problem such as reversed Line-Neutral connection

Alarm buzzer silent

The alarm buzzer has been silenced or disabled

Overload:

The UPS output is overloaded

Service:

The UPS is operating in its service mode

Alarm:

An alarm condition is present. This remains active after the audible alarm is reset if the alarm still exists.

UPS OFF

This mimic is displayed when the utility power is first applied to the UPS, or if the UPS is
turned OFF. It shows that the battery is being charged from the utility supply (INPUT) but
the LOAD is not connected to the UPS, and is therefore unpowered.

ON INVERTER

This mimic is displayed during normal UPS operation. It shows the battery being
charged from the utility supply (INPUT) and the LOAD connected to the UPS output
(Inverter), and is therefore being supplied with processed, backed-up power.

ON BATTERY

This mimic is displayed if the utility supply fails. It shows the battery now providing the
UPS (Inverter) and LOAD power. The battery will sustain the UPS output until it is fully
discharged, whereupon the UPS will shut down.

Bypass

Utility

?

Wiring Fault

Overload

Service

Alarm

INPUT

UPS

LOAD

INPUT

UPS

LOAD

INPUT

UPS

LOAD