Kohler PowerWAVE 3000/P1 User manual

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Please comply with all warnings and operating
instructions in this manual. This equipment
should only be installed, serviced, and
maintained by qualified personnel. Do not
operate this unit before reading through all
safety information and operating instructions
carefully.
Disclaimer
We assume no responsibility or liability for loss or damages, whether direct, indirect,
consequential or incidental, which might arise out of the use of such information. The use of
any such information will be entirely at the user’s risk. Information in this manual is subject to
change without notice. We make no commitment to update or keep current the information in
this manual. If you find information in this manual that is incorrect, misleading, or incomplete,
we would appreciate your comments and suggestions.

Table of Contents
1. SAFETY AND EMC INSTRUCTIONS ................................................................................................ 1
1-1. TRANSPORTATION AND STORAGE ..............................................................................................................1
1-2. PREPARATION......................................................................................................................................1
1-3. INSTALLATION .....................................................................................................................................1
1-4. CONNECTION WARNINGS ..............................................................................................................2
1-5. OPERATION ........................................................................................................................................3
1-6. STANDARDS ........................................................................................................................................3
2. INSTALLATION AND OPERATION ................................................................................................. 4
2-1. UNPACKING AND INSPECTION ..................................................................................................................4
2-1-2 POSITIONING ....................................................................................................................................4
2-2. REAR SYSTEM VIEW..............................................................................................................................5
2-3. SINGLE UPS INSTALLATION ....................................................................................................................7
2-4. UPS INSTALLATION FOR PARALLEL SYSTEM .................................................................................................9
3. OPERATIONS ............................................................................................................................... 10
3-1. INITIAL OPERATION ............................................................................................................................10
3-2. SCREEN DESCRIPTION .........................................................................................................................10
3-3. AUDIBLE ALARM.................................................................................................................................26
3-4. SINGLE UPS OPERATION......................................................................................................................27
3-5. PARALLEL OPERATION .........................................................................................................................29
3-6. FAULT CODE .....................................................................................................................................30
3-7. WARNING CODE ................................................................................................................................31
4. TROUBLE SHOOTING................................................................................................................... 32
5. STORAGE AND MAINTENANCE.................................................................................................... 33
5-1. STORAGE .........................................................................................................................................33
5-2. MAINTENANCE...................................................................................................................................33
6. SPECIFICATIONS ........................................................................................................................ 34
7. OPTIONS ..................................................................................................................................... 35
7-1 SNMP CARD -OPTIONAL ......................................................................................................................35
7-2 NETFEELER ENVIRONMENT MONITORING CARD.......................................................................................36
7-3 DRY PORT RELAY CARD -OPTIONAL .......................................................................................................37

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1. Safety and EMC instructions
All safety instructions in this document must be read, understood and followed.
1-1. Transportation and Storage
Please transport the UPS system only in the original packaging to protect against shock and
damage.
The UPS must be stored in a room where the temperature is well regulated. Ambient
temperature should not exceed 40°C.
1-2. Preparation
Condensation may form if the UPS system is moved instantly from a cold to warm environment.
The UPS system must be dry before being installed. Please allow at least two hours for the UPS
system to acclimatise to the environment.
Do not install the UPS system near water or in humid environments.
Do not install the UPS system where it would be exposed to direct sunlight or nearby heat
source.
Do not block ventilation holes on the UPS housing.
1-3. Installation
Do not connect appliances or devices which would overload the UPS (e.g. big motor-type
equipment) to the UPS output terminal.
Place cables in such a way that no one can step on or trip over them.
Do not block air vents on the housing of the UPS. Ensure proper unit spacing of ventilation.
UPS chassis must both be connected to Site Potential Earth Terminals. Battery chassis must
have a Potential Earth connection directly to UPS, or the battery chassis must be connected to
site Potential Earth terminals directly.
The UPS must be installed only by a qualified engineer.
An appropriate disconnect device such as short-circuit backup protection should be incorporated
during installation.
An integral emergency shutoff switch which prevents additional load from the UPS in any mode
of operation should be implemented during the installation.
Secure the grounding/earthing wire to the terminal before connecting any live cable.
Installation and Wiring must be in accordance with the local electrical laws and regulations.

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1-4. Connection Warnings
•There is no standard backfeed protection inside of the UPS. However, there are relays on the Input to
cut off line voltage and while the neutral is still connected to UPS.
Main
Input
Input Rly
UPS
L1
L2
L3
N
Main
Input
Input Rly
UPS
L1
L2
L3
N
Bypass
Input
Input Rly
L1
L2
L3
N
Input relay diagram Input relay diagram for dual-input model
•This UPS should be connected with TN grounding/earthing system.
◼The power input for this unit must be three-phase rated in accordance with the equipment
nameplate. It also must be suitably grounded.
•Use of this equipment in medical instrument or any life-sustaining equipment where failure of this
equipment can reasonably be expected to cause the failure of the life-sustaining equipment or to
significantly affect its safety or effectiveness is not recommended. Do not use this equipment in the
presence of a flammable mixture with air, oxygen or nitrous oxide.
•Connect grounding terminal of UPS to a grounding electrode conductor.
•In accordance with safety standard EN-IEC 62040-1, installation has to be provided with a《Backfeed
Protection》system, as for example a contactor, which will prevent the appearance of voltage or
dangerous energy in the input mains during a mains fault. (Respect the wiring diagram of «Backfeed
Protection» depending if the equipment is with signal or three phase input).
There shouldn’t be a spur circuit from the «Backfeed Protection» to the UPS, as the standard
safety would be infringed.
•Warning labels should be placed on all primary power switches installed in places away from the unit to
alert the electrical maintenance personnel of the presence of a UPS in the circuit. The label will bear the
following or an equivalent text:
Before working on this circuit
-Isolate Uninterruptible Power Supply (UPS)
-Then check for Hazardous Voltage between all terminals including the protected earth
Risk of Voltage Backfeed
WARNING
HIGH LEAKAGE CURRENT
EARTH CONNECTION ESSENTIAL
BEFORE CONNECTING SUPPLY

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1-5. Operation
Do not disconnect the grounding/earthing conductor cable on the UPS or to the building wiring
terminals under any circumstance.
The UPS system features its own, internal current source (batteries). The UPS output sockets or
output terminal blocks may be electrically live even if the UPS system is not connected to the
building mains/live wires. (only for standard models)
In order to fully disconnect the UPS system, first press the “OFF” button and then disconnect
the mains/live cables.
Ensure that no liquid or other foreign objects can enter into the UPS system.
The UPS can be operated by any individuals with no previous experience.
1-6. Standards
* Safety
IEC/EN 62040-1
* EMI
Conducted Emission...............................:IEC/EN 62040-2
Category C3
Radiated Emission..................................:IEC/EN 62040-2
Category C3
*EMS
ESD........................................................:IEC/EN 61000-4-2
Level 4
RS..........................................................:IEC/EN 61000-4-3
Level 3
EFT.........................................................:IEC/EN 61000-4-4
Level 4
SURGE...................................................:IEC/EN 61000-4-5
Level 4
CS..........................................................:IEC/EN 61000-4-6
Level 3
Power-frequency Magnetic field................:IEC/EN 61000-4-8
Level 4
Low Frequency Signals............................:IEC/EN 61000-2-2
Warning: This is a product for commercial and industrial application in the
second environment-installation restrictions or additional measures may be
needed to prevent disturbances.

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2. Installation and Operation
2-1. Unpacking and Inspection
Unpack the package and check the package contents. The shipping package should contain:
● One UPS
●One user manual
● One monitoring software CD
●One RS-232 cable (option)
●One USB cable
●One parallel cable (only available for parallel model)
●One shared current cable (only available for parallel model)
●1 x 2Way / 1 x 3Way / 1 x 4Way DIN Terminal Jumper Bars
NOTE: Before the installation, please inspect the unit. Be sure that there is no physical damage to the unit.
Do not turn on the unit and notify the carrier and dealer immediately if there is any damage or missing parts
and accessories. Please keep the original packaging for future use. It is recommended to keep each
equipment and battery set in their original packaging because they have been designed to provide
maximum protection during transportation and storage.
2-1-2 Positioning
The UPS system is on wheels and can be maneuvered on solid floor.
The “Positioning Diagram”below details the recommended clearance space around the UPS for correct air
flow.
Terminals are located on rear of UPS and access should be provided during installation and maintenance.
NOTE: For Maintenance purposes 600mm side clearance is required to access batteries and components on
both sides. If 600mm side clearance is not available, extra cable should be fitted to allow the UPS to be
withdrawn from its position to allow access.
Positioning Diagram

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2-2. Rear System View
Diagram 1 Rear Panel Diagram 2: Input/Output terminals
1. RS-232 port
11. Line input terminals
2. USB communication port
12. Output terminal
3. Emergency power off connector (EPO
connector)
13. Input ground terminal
4. Parallel Share current port
14. Output ground terminal
5. Parallel port
15. Bypass input circuit breaker/switch
6. Intelligent slot –SNMP or DRY Port
16. Bypass input terminals
7. External battery connector/terminal
17. Output switch
8. Line input circuit breaker/switch
18. Service start
9. Maintenance bypass switch
19. External Maintenance Bypass Switch connector
(EMBS)
10. Input/Output terminals (Refer to diagram 2
for the details)

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1. RS232 Port –Port is used by Maintenance Service engineer to enable updates to internal firmware
of the UPS System. Not for Customer Use
2. USB Port –Communication port for Customer to connect monitoring Software directly to local PC,
provides Alarms and functional monitoring.
3. EPO –EPO port is NC in normal Operation. Breaking this NC loop forces the UPS Inverter to
disconnect the output to the load.
4. Parallel Share Current Port –Used when multiple UPS systems are connected in Parallel
5. Parallel Port –Used when multiple UPS systems are connected in Parallel
6. INTELLIGENT SLOT –One Slot provided can hold either an SNMP card or Dry port card.
a. SNMP CARD –OPTIONAL (Further details in Section 7.1)
b. DRY PORT RELAY CARD –OPTIONAL (Further details in Section 7.3)
18. SERVICE START –Allows UPS to be started directly from the battery with no incoming mains
supplied.
19. EMBS (External Maintenance Bypass Switch) –Port is NC in Normal Operation.
The EMBS port can be linked to an external Maintenance bypass switch to ensure an interlock is
connected to the UPS internal static switch. When installed and the EMBS is closed the Inverter is
shutdown and the static transfer switch connects the load directly to the incoming mains supply.

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2-3. Single UPS Installation
Installation and wiring must be carried out in accordance with the local installation regulations by trained
professionals.
1) Make sure that the mains cable and breakers of the building are rated for the capacity of the UPS to
prevent electric shock or risk of fire.
NOTE: Do not use a standard wall mains socket as the input power source for the UPS, as its rated current
is less than the UPS’s maximum input current. The socket may be damaged and destroyed.
2) Switch off the mains switch in the building before installation.
3) Turn off all the connected devices before connecting to the UPS.
4) Prepare cables based on the following table:
Model
Wiring spec (mm² & Max A Per Phase)
Bypass
Input
(if used)
Input
(1Ph)
Input
(3Ph)
SINGLE
Input
(3Ph)
DUAL
Output
(Ph)
Neutral
Battery
Ground
PW3000/P1 10K
10mm
(67A)
10mm
(67A)
10mm
(67A)
4mm
(23A)
10mm
(45A)
10mm
10mm
(60A)
10mm
PW3000/P1 20K
25mm
(132A)
25mm
(132A)
25mm
(132A)
10mm
(45A)
25mm
(86A)
25mm
25mm
(110A)
25mm
NOTE 1: The selection for cable sizing should be based on the cable specification used and the type
of cable installation. Local electrical laws and regulations should be followed.
NOTE 2: The selections for color of cables should be followed by the local electrical laws and
regulations.
NOTE 3: Maximum current is based on Input Voltage of 209V, 130% load with 12A Charger fully
operating.
5) Remove the terminal block cover at the rear panel of UPS. Then connect the wires according to the
following terminal block diagrams: (Connect the grounding/earthing wire first when making wire
connections. Disconnect the earth wire after you disconnect the power wire.)
Terminal block wiring diagram