Kohler PW 6000 User Manual

User Manual

Pioneering solutions for
total power protection

Kohler PW 6000

UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

Document Control

ISSUE DATE REVISION SUMMARY

1.0 02-05-12 Initial issue of 60-500kVA Manual

1.1 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

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 i

Table of Contents

1 Safety

1.1 Description of symbols used in this manual 1-1

1.2 User precautions 1-1

2 Description

2.1 Introduction 2-1

2.1.1 Reliability and quality standards 2-1

2.1.2 Key features 2-1

2.2 Kohler PW 6000 Model range 2-2

2.2.1 Single/Parallel system configurations 2-2

2.3 Kohler PW 6000 functional description 2-2

2.3.1 Kohler PW 6000 block diagram 2-3

2.3.2 UPS internal operating modes 2-3

2.3.3 System operating modes 2-5

2.3.4 Multi-cabinet parallel system concept 2-5

2.4 Warranty 2-7

2.5 Extended warranty 2-8

2.6 Additional service/maintenance support 2-8

3 Installation

3.1 Introduction 3-1

3.2 Taking receipt of the UPS 3-1

3.2.1 Site transportation 3-1

3.3 Unpacking 3-2

3.4 Storage 3-2

3.5 Planning the installation (site considerations) 3-3

3.5.1 Clearances 3-3

3.6 Planning the installation (cabling considerations) 3-4

3.6.1 General requirements 3-4

3.6.2 Cable and fuse sizing 3-5

3.6.3 Power cable terminations 3-8

3.6.4 Power cabling in a parallel system 3-10

3.7 UPS Cabling procedure 3-11

3.7.1 Connecting the input cables 3-11

3.7.2 Connecting the UPS output cables 3-12

3.8 Battery connections 3-17

3.8.1 ‘Sidecar’ battery enclosure (60-100kVA) 3-17

3.8.2 Remote battery enclosure 3-18

3.8.3 Connecting the batteries 3-18

3.9 Multi-module control cabling and configuration 3-18

3.9.1 Connecting the parallel communication bus cables 3-18

3.9.2 Configuration DIP switch selection 3-19

3.9.3 Module communications interface facilities 3-20

ii UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

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

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 User responsibilities 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 & 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) 7-3

7.4.1 60-300kVA Model interface connections 7-3

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

7.5.1 SNMP monitoring software 7-7

7.5.2 WAVEMON UPS monitoring and control software 7-7

7.5.3 PowerREPORTER™ management software 7-8

8 Specifications

8.1 General specifications 8-1

8.2 60-300kVA Fuses & cables quick reference 8-6

8.3 400-500kVA Fuses & cables quick reference 8-7

UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012 1-1

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: 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 is a Class A UPS product (according to EN 62040-3). In a
domestic environment the UPS may cause radio interference. In such an environment the user
may be required to undertake additional measures.

1: Safety

1-2 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012 2-1

2

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 enviro nments. 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 con trol environments where ma nufacturing
continuity is essential.

2.1.1 Reliability and quality standards

The Kohler PW 6000 UPS is available over a model range of 60kVA to 500kVA and incorporates the latest
technological developments in power engineering. Representing a completely new generation of hig h power
three phase UPS systems, its advanced double conversion VFI (Voltage and Frequency Independent)
topology responds fully to both the highest availability and environmentally friendly requirements compliant
with IEC 62040-3 (VFI-SS-111) standards.

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

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 ac-ac 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)
Blade-server-friendly power; full power from

0.9 lead to 0.9 lag

No de-rating required with leading PF loads

Very low input current distortion THDi
THDi = < 3.5% @ 100% load

Gen-set power and installation cost saving

2: Description

2-2 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

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 100kVA 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 system 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 multi­module 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.

2.3 Kohler PW 6000 functional description

Figure 2.1 Kohler PW 6000 UPS block diagram

Key Point: All the UPS modules connected to a parallel system must be of the same power rating.

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

UPSMODULE

RECTIFIER INVERTER

STATIC

SWITCH

Charger

STATICBYPASSLINE

3

4

5

1

2

UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012 2-3

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; h owever in a standard UPS module
the bypass supply terminals (2) are usually linked to th e mains supply terminals (1 ) so the UPS effectively
requires only a single mains supply connection. (See paragraph 3.6.2 for de tails concerning ‘Sin gle Feed’ &
‘Dual Feed’ input supply configurations.) The byp ass supply is show n connected to the sta tic 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 p ower 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

This is the normal
operating mode and
the only one that
provides the load with
continuously
processed and
backed-up power.

In this mode, the
mains supply is
converted to DC by
the rectifier which then
charges the battery
and provides
operating power for
the inverter; which
converts the rectifier
output back to AC
suitable to provide the
load power.

If the mains supply
fails or strays outside
a preset voltage
range, the rectifier
shuts down and the
battery provides an
alternative DC power
source for the inverter;
which continues to
operate until the
battery is discharged.

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

UPSMODULE

Charger

INVERTER

STATIC

SWITCH

RECTIFIER

STATICBYPASSLINE

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

UPSMODULE

Charger

INVERTER

STATIC

SWITCH

RECTIFIER

STATICBYPASSLINE

Figure 2.2 Load on inverter

2: Description

2-4 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

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 various 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

In the ‘Load on
Bypass’ mode the load
supply is connected to
the unprocessed static
bypass line via the
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.

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

In this mode of
operation the manually
closed maintenance
bypass switch
connects the load
supply directly to the
unprocessed bypass
supply. This is used to
keep the load supplied
(albeit without any
power protection)
whilst allowing the
remainder of the UPS
to be shut down for
service repair.

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 an d maintenance bypass lines
are never connected in parallel. Therefore when transferring from the ‘load on inverte r’ 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.

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

UPSMODULE

Charger

INVERTERRECTIFIER

STATIC

SWITCH

STATICBYPASSLINE

Figure 2.3 Load on bypass

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA2

UPSMODULE

Charger

INVERTER

STATIC

SWITCH

RECTIFIER

IA1

STATICBYPASSLINE

Figure 2.4 Load on maintenance bypass

UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012 2-5

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 normally 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 o verload 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 chargi ng, and the inverter section i s
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 l oad is retransferred back to th e static 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.

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 wil l 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.

The parallel control bus performs many functions including:

• System-wide load transfer control

• Inter-module (and bypass) frequency synchronisation

• Load sharing

WARNING: The on-line mode must always be used for critical load protection.

2: Description

2-6 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

.

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. Conversel y, when operating on b ypass 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 sharing

Using sensing signals passed over the p arallel control b us, each UPS is ab le to compare its o wn 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 as 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).

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

Load
Supply

IA1

IA2

UPSMODULE1

INVERTER

STATIC

SWITCH

RECTIFIER

Charger

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

IA1

IA2

UPSMODULE2

INVERTER

STATIC

SWITCH

RECTIFIER

Charger

MAINTENANCEBYPASSLINE

BATTERY

Bypass
Supply

Mains
Supply

IA1

IA2

UPSMODULE3

INVERTER

STATIC

SWITCH

RECTIFIER

Charger

Load
Supply

LoadDist.Panel

Control

Logic

Control

Logic

Control

Logic

ParallelControlBus ParallelControlBus

STATICBYPASSLINE

STATICBYPASSLINE

STATICBYPASSLINE

UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012 2-7

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 on e module fails, or is ta ken off-line,
then the remaining two modules are capable of sustaining the full rated lo ad. The ability to lose one module
yet still 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 b attery ban k for each mo dule, as i llustrated in
figure 2.5, it again avoids a potential single point of failure and effectively e xtends the system redun dancy 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 bei ng 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.

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 materials and workmanship for a period of one year from th e date of origina l 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. All 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 customer assumes all such risks

• the liability of Kohler Uninterruptible Power is adequately protected under the circumstances

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.

CAUTION: The UPS may contain batteries that must be re-cha rged 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 th e wa rra n ty.

2: Description

2-8 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

2.5 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 [phone] for further details.

2.6 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 Pier Road
Singapore 619159

Tel: [phone]
Fax: [phone]
Email: [e-mail]

UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012 2-9

2: Description

Thank you for your enquiry, which will receive our prompt attention.

If you need to contact us immediately call free on [phone],

or E-mail us on [e-mail]

Regional Office (South East Asia)
Kohler Uninterruptible Power
7 Jurong Pier Road
Singapore 619159

Tel: [phone]

Name: ............................................................................................

Job Title: ................................. ... .................................... ....................

Company: ............................................................................................

Address: ............................................................................................

............................................................................................

............................................................................................

............................................................................................

Post Code ............................................................................................

Tel. ............................................................................................

Fax. ............................................................................................

E-mail ............................................................................................

Please contact me to discuss:

Extended Warranty options for my Kohler PW 6000 UPS

Extended warranty options for my UPS System as below:

Manufacturer:...................................................................

Model Nº:..........................................................................

Rating kVA:.......................................................................

Replacement Batteries......................................................................

Other .................................... ..............................(please specify)

Fax to: [phone]

www.kohlerups.sg

2: Description

2-10 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012 3-1

3

Installation

3.1 Introduction

This chapter contains essential information concerning the unpacking, positioning, installing and cabling of
the Kohler PW 6000 UPS.

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.

The packing container protects the UPS from mechanical and enviro nmental damage during transit. Thi s
protection is further increased by wrapping the Kohler PW 6000 UPS with a plastic sheet.

Upon receiving the UPS you should carefully examine the packing container for any sign of physical damage.
The external 'Tip&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&Tel'
indicator is suspect, inform both the carrier and Kohler Uninterruptible Power immediately.

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.

WARNING: All cabling operations must be supervised by an authorised electrician or other
suitably qualified person. All installation and operating procedures must be carrie d out in strict
accordance with the instructions contained in this manual. Kohler Uninterruptib le Power will
take no responsibility for any personal injury or material damage caused by the incorrect
installation, cabling or operation of this product.

WARNING: Once the UPS equipment is installed it must be commissioned by an engineer
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 th e
application of electrical power to this equipment before it has been fully commissioned.

CAUTION: Observe the following precautions when off-loading and moving the UPS:

• Always keep the packages in an upright position.

• Do not drop the equipment.

• Due to the high-energy batteries involved and heavy weight, do not stack the pallets.

CAUTION: Clai ms for visible shipping damage must be notified to the carrier immediately on
receipt. Other shipping damage claims must be filed immedi ately 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.

CAUTION: Transportation:

• When transporting the equipment, use the front and rear shipping brackets to secure
the cabinet to help prevent the UPS from toppli ng over.

• Do not at any time tilt the cabinet by more than 10° from vertical.

3: Installation

3-2 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

3.3 Unpacking

1. If the 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.

2. Cut the wrappers and remove the packing container by pulling it upwards.

3. Remove the plastic sheeting covering the UPS.

4. Remove any anchor bolts securing the cabinet to the pallet then remove the UPS from the pallet.

5. Retain the packaging materials for possible future shipment of the UPS.

6. Examine the UPS for signs of damage and notify your supplier immediately if any damage is found.

7. Check that the details on the UPS nameplate corresponds to the purch ased 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 plan to store the UPS cabinet prior to use it should be held it in a clean, dry environ ment with a
temperature between -5°C to +40°C and RH <90%. 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 dep ends 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°C.

CAUTION: Potential dangers:

• If the UPS/battery cabinet is tilted by more than 10° it could cause internal damage. If
tilting 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:

• – 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.

• The UPS system and the battery sets must be protected from humidity < 90% RH
(non-condensing).

CAUTION: Sealed batteries must never be stored in a fully or partially discharged state.
Extreme temperature, under-charge, overcharge or over-discharge will destroy batteries!

• Charge the battery both before and after storing.

• Always store the batteries in a dry, clean, cool environment in their original packaging.

• If the packaging is removed protect the batteries from dust and humidity.

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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 in to account when pla nning a suitable UPS location and op erating
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) The installation site humidity should be <90% 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.
c) 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) The location must be vibration free.
d) If the 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

Figure 3.1 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.

> 200mm

> 1000mm

> 900mm

400/500kVA UPS400/500kVA UPS

60-300kVA 60-300kVA60-300kVA

> 200mm

400/500kVA UPS400/500kVA UPS

60-300kVA 60-300kVA60-300kVA

> 900mm

> 1000mm

50-100mm

50-100mm

3: Installation

3-4 UPS413-01-00 Kohler PW 6000 (60-500kVA) User Manual 25 June 2012

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 90º. 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 cabin et and the partition to al low the do ors 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 cabin ets to allow adequate
exhaust air flow.

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 en able the rectifier to operate correctly an d allow the
UPS to function properly when operating on batter y. The input neutral must also be g rounded to permit
correct operation when the UPS is running on battery.

Figure 3.2 Input neutral grounding

60-100 kVA 120-200 kVA 250-300kVA 400-500kVA

Dimensions
(WxHxD)mm

550x1820x750

970x1820x750 (Batt cab A)

1180x1820x750 (Batt cab B)

850x1820x750 1100x1920x750 1650 x 1994 x 850

Accessibility Totally front accessibility for service and maintenance
Positioning (for ventilation) Min. 200 mm rear space Min. 400mm space

above cabinet

Input and Output
Power Cabling

From the bottom at the front

Key Point: As the input neutral must be unswitched and conne cted to the UPS at all time s, a 4­pole input switch or isolator must not be used at the LV Distribution board on a TN-S system.

0V

230V

UPS

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3: Installation

3.6.2 Cable and fuse sizing

Single feed / Dual feed inputs

The UPS can be wired for a ‘single feed’ input (stand ard), whereby the UPS inpu t supply terminals and
bypass supply terminals are internally linked; or it can be wired for a ‘dual feed’ input, whe re 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.

Key Point: This information in figures 3.3 and 3.4 is given for guidance only:

• Fuse and Cable recommendations are to IEC 60950-1:2001.

• All external fuses, isolators and power cables must be rated and installed in accordan ce
with the prescribed IEC standards or local regulation – e.g. BS7671:2008.

• External DC Cables and battery fuses are bespoke to the installation.