Kohler PW 6000 User manual

User Manual
KOHLER PW 6000
Medium to high power three-phase uninterruptible power supply
(400-500 kVA)

© 2023 Kohler Uninterruptible Power 12/9/23
Document Control
Useful Contacts
All product, product specifications and data are subject to change without notice to improve reliability, function, design or otherwise.
Kohler Uninterruptible Power has taken every precaution to produce an accurate, complete and easy to understand specification
document and will assume no responsibility nor liability for direct, indirect or accidental personal or material damage due to any
misinterpretation of, or accidental errors, in this manual.
© 2023 Kohler Uninterruptible Power
This manual may not be copied or reproduced without written permission of Kohler Uninterruptible Power
ISSUE DATE REVISION SUMMARY
TS_830_01 21/08/2023 Rebranding to KUP International Version
UK
www.kohler-ups.co.uk Kohler Uninterruptible Power 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
IRELAND
www.kohler-ups.ie Kohler Uninterruptible Power web site
[e-mail] Service department, technical queries, hardware sales and extended
warranty agreements
SINGAPORE
www.kohler-ups.sg Kohler Uninterruptible Power web site
[e-mail] Hardware sales
[e-mail] Contract customer support, maintenance contracts renewals

© 2023 Kohler Uninterruptible Power 12/9/23
Document Control 1
Useful Contacts 1
1: Safety 1
1.1 Description of symbols used in this manual 1
1.2 User precautions 1
2: General Description 2
2.1 Introduction 2
2.1.1 Reliability and quality standards 2
2.1.2 Key features 2
2.2 KOHLER PW 6000 (400-500kVA) model range 3
2.3 UPS module functional description 4
2.3.1 UPS module block diagram 4
2.3.2 UPS internal operating modes 5
2.3.3 System operating modes 7
2.4 Multi-module parallel system 8
2.4.1 Parallel system concept 8
2.4.2 Parallel control functions 8
2.4.3 Common battery 10
2.5 Module Control Panel (standard LCD) 11
2.5.1 Module mimic LED indicators 11
2.5.2 Operator buttons 12
2.5.3 Power Management Display (PMD) 13
2.6 TFT Module control panel 15
2.6.1 Display header bar 15
2.6.2 Mimic diagram screen 16
2.6.3 Home screen 17
2.7 Warranty 19
2.8 Extended Warranty 19
2.9 Contacting service 19
3: Installation 20
3.1 Introduction 20
3.2 Taking receipt of the UPS 20
3.2.1 Reporting transportation damage 20
3.2.2 Local transportation 21
3.2.3 Storage 21
3.3 Unpacking 21
3.4 Planning the installation (environmental and mechanical) 21
3.4.1 Environmental considerations 21
3.4.2 UPS Cabinet installation 22
3.4.3 Top Cable Entry (TCE) extension cabinet installation 22
3.4.4 Battery installation 24
3.5 Planning the installation (cabling considerations) 24
3.5.1 General requirements 24
3.5.2 Parallel cabinet cabling recommendations 25
3.5.3 External maintenance bypass switch 26
3.5.4 Cable sizing 27
3.6 Electrical installation (cabling procedures) 28
3.6.1 Bottom entry cabling procedure 29
3.6.2 Top entry cabling procedure 32
3.6.3 Connecting the battery 35
3.7 Single/Dual feed conversion 36
3.8 Installation of remote monitoring and control facilities 37
3.8.1 Module communications interface facilities 37
4: Operating Instructions (LCD) 38

© 2023 Kohler Uninterruptible Power 12/9/23
4.1 Introduction 38
4.1.1 Commissioning 38
4.1.2 Operating procedure summary 38
4.1.3 General warnings and precautions 39
4.2 How to start the UPS system from a fully powered-down condition 39
4.3 How to start the UPS system from the maintenance bypass 41
4.4 How to transfer the load to maintenance bypass 41
4.5 How to shut down the complete UPS system 42
4.6 Operating in bypass (ECO) mode 43
4.6.1 How to Turn ON the UPS system and operate in ‘on bypass’ (ECO) mode 43
4.6.2 How to Turn OFF the UPS system when operating in ‘on bypass’ (ECO) mode 43
4.6.3 How to transfer between ‘on bypass’ (ECO) and ‘on inverter’ mode 43
5: Operating Instructions (TFT) 44
5.1 Introduction 44
5.1.1 Commissioning 44
5.1.2 Operating procedure summary 44
5.1.3 General warnings and precautions 45
5.2 How to turn on the UPS system from a fully powered-down condition 46
5.2.1 Power-up the load on the maintenance bypass: 46
5.2.2 Transfer the load to the static bypass line: 47
5.2.3 Transfer the load to inverter: 48
5.3 How to start the UPS system from the maintenance bypass 49
5.3.1 Power up the UPS system: 49
5.3.2 Transfer the load to the static bypass line: 50
5.3.3 Transfer the load to inverter: 50
5.4 How to transfer the load to the maintenance bypass and turn OFF the UPS 50
5.4.1 Transfer the load to the static bypass: 51
5.4.2 Transfer the load to the maintenance bypass: 52
5.4.3 Turn OFF the UPS 52
5.5 How to shut down the complete UPS system 52
5.6 Operating in bypass (ECO) mode 53
5.6.1 How to Turn ON the UPS system and operate in (ECO) mode 53
5.6.2 How to transfer the load to the maintenance bypass and Turn OFF the UPS system 53
5.6.3 How to transfer between ‘on bypass’ (ECO) and ‘on inverter’ mode 53
6: Maintenance 54
6.1 Introduction 54
6.2 User responsibilities 54
6.3 Battery testing 54
7: Troubleshooting 55
7.1 Alarms 55
7.2 LCD Control panel 55
7.3 TFT Control panel 55
7.4 Troubleshooting table 56
7.5 Contacting service 56
8: Options 57
8.1 Introduction 57
8.2 Serial RS232 Computer interface – USB & JD1 (Smart Port) 58
8.3 RS485 Interface for multidrop – JR2 58
8.4 Dry ports customer interface (X1, X2, X3) 59
8.4.1 Dry port connections 59
8.4.2 Remote Emergency Power Off (EPO) option 60
8.4.3 Generator ON facilities 60
8.5 SNMP Card slots 61

© 2023 Kohler Uninterruptible Power 12/9/23
9: Specification 62

© 2023 Kohler Uninterruptible Power 12/9/23 1
1Safety
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! Kohler Uninterruptible
Powerwill assume no responsibility nor liability due to incorrect operation or manipulation of the UPS.
WARNING: The Kohler PW 6000 (400-500kVA) 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.

2© 2023 Kohler Uninterruptible Power 12/9/23
2General Description
2.1 Introduction
Congratulations on your purchase of the KOHLER PW 6000 (400-500kVA) 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 requirement
changes brought about by the introduction of new server technologies, migration and centralization.
Such demands are well met by the KOHLER PW 6000 (400-500kVA) 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 (400-500kVA) UPS is available over a model range of 400kVA 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 Frequency Independent) topology responds fully
to both the highest availability and environmentally friendly requirements compliant with IEC 62040-3 (VFI-SS-111)
standards.
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
High reliability, upgrade-ability, low operating costs and excellent electrical performance are just some of the highlights
afforded by this innovative UPS solution. Other key features include:
•Compact size, small foot print – 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% – Saving on energy and operational cost (TCO)
•Low input power factor (near unity) – Saving cabling and supply distribution costs during installation and the over
the entire life cycle (TCO)
•Blade-server-friendly power – Full power available from 0.9 lead to 0.9 lag means that no de-rating is required with
leading power factor loads and therefore no need to ‘over-size’ the UPS system to cater for the load.
•Very low input current distortion THDi – The THDi is <3.5% @ 100% load, reducing the capital and installation
costs of an optional standby generator if used.
•Ease of expansion – Additional UPS cabinets (up to a maximum of 10) can be connected to an existing parallel
system without needing to disturb the load supply

© 2023 Kohler Uninterruptible Power 12/9/23 3
2: General Description
2.2 KOHLER PW 6000 (400-500kVA) model range
The KOHLER PW 6000 (400-500kVA) UPS line-up includes models ranging from 160 kVA up to 500 kW. This manual is
specific to the 400 kW and 500 kW models. A detailed specification can be found in Chapter 8.
Figure 2.1 KOHLER PW 6000 (400-500kVA) Model range
A key-lockable door is fitted to the front of the cabinet to provide controlled access; and within the cabinet all the major
power components are housed behind secured safety panels to further reduce the risk of accidental electrical shock.
The KOHLER PW 6000 (400-500kVA) UPS can be used as a single, stand-alone UPS module or up to ten modules can
be configured to operate as a parallel UPS system. A multi-module system is designed to increase the UPS system’s
output capacity and enhance the system’s reliability by providing module redundancy.
Note: In this manual the terms ‘multi-module system’ and ‘parallel system’ are synonymous.
MECHANICAL DETAILS STANDARD + TOP CABLE ENTRY (TCE)
CABINET
400 kW 500 kW 400 kW 500 kW
Rated output power kVA/kW 400/400 500/500 400/400 500/500
Cabinet dimensions (w x h x d)
(With elevation kit)
mm 1650 x 1994 x 850
(1650 x 2094 x 850)
2150 x 1994 x 850
(2150 x 2094 x 850)
Weight kg 950 1000 950+115 1000+115
Weight (TCE + single feed cables) kg 950+245 1000+24
Weight (TCE + dual feed cables) kg 950+285 1000+285
WARNING: If you remove a safety panel you will be exposed to a sever shock hazard.
The safety panel panels should be removed only by an Kohler Uninterruptible Powertrained engineer.
Key Point: ALL the UPS modules connected as a parallel system must have the same output rating, For
example, it is not permissible to connect 400 kW and 500 kW UPS module together in a parallel system.

4© 2023 Kohler Uninterruptible Power 12/9/23
2: General Description
2.3 UPS module functional description
Figure 2.2 KOHLER PW 6000 (400-500kVA) UPS module block diagram
2.3.1 UPS module block diagram
Figure 2.2 shows the major power blocks contained within the UPS system.
UPS Input supplies (1), (2)
The UPS is connected to two, 3-phase supplies, the ‘input mains supply’ and ‘bypass mains supply’. The input supply
cables must be protected by an external isolation device (fuse/circuit breaker) to provide a means of disconnecting the
mains supplies to the UPS. In practise, the bypass mains supply terminals are often linked to the input mains supply
terminals within the UPS cabinet so the UPS cabinet only requires one mains supply connection – see paragraph 3.5.1 for
details concerning ‘single feed’ & ‘dual feed’ input configurations.
Within the UPS cabinet the mains supplies are switched by isolators IA3 and IA4.
Maintenance bypass switch (3)
A maintenance bypass switch (IA1) provides a means of entirely bypassing the UPS power blocks and can be used to
temporarily connect the load to the bypass mains supply if it is necessary to fully power down the UPS module for test/
repair purposes. Note that the maintenance bypass switch is only rated for the individual cabinet’s load, so where two or
more cabinets are connected together to form a parallel system the internal maintenance bypass switch (IA1) should not
be used. In a parallel system an external maintenance bypass facility must be incorporated into the system design which
includes a system-rated maintenance bypass switch – a typical installation is shown on page 26.
Rectifier (4)
The rectifier converts the input mains supply to a DC power source that can satisfy the full inverter DC power demand over
an input mains voltage range of -23% to +15%. This wide input voltage range means that the battery is not called upon
during substantial power dips (brown outs), which helps maximise the battery life and availability. The rectifier control
system uses leading-edge switched-mode techniques which achieves a UPS input power factor of almost unity over its
operating range (0.99 at full rated linear load).
Battery booster/charger (5)
This block has bi-directional functions. When the UPS mains input supply is available, and the rectifier is turned on, the
booster/charger acts as a multi-stage battery charger which uses an intelligent charging profile to optimise the battery life
and ensure the battery recharges quickly following a deep discharge cycle.
When the UPS is operating from battery power the booster/charger boosts the battery voltage to provide a regulated DC
input to the inverter to allow the inverter to operate correctly from battery power as the battery discharges.
3
4
5
1
26 7 8
9

© 2023 Kohler Uninterruptible Power 12/9/23 5
2: General Description
Inverter (6)
The inverter converts the DC voltage produced by the rectifier (or the battery via the booster/charger) into a sinusoidal AC
output voltage suitable to connect to the load. In addition to providing output voltage regulation, the inverter control logic
also provides various levels of overload protection, frequency regulation and synchronisation, and output voltage error
detection.
Static switch (7)
The static switch provides a means of connecting the UPS output to the inverter or static bypass line. The static switch
control logic transfers the UPS output from the inverter to the static bypass line without a load-break in the event of an
output overload or UPS (inverter) malfunction.
Parallel isolator, IA2 (8)
IA2 is a manually-operated switch that is connected between the static switch and the UPS output supply terminals. In a
single-module installation IA2 can be used to isolate the UPS power electronics to enable repair/replacement procedures
to be carried out while the load is connected to the maintenance bypass line, via IA1. In a ‘redundant’ parallel system IA2
can be similarly used to isolate a UPS module from the parallel system while the remaining modules continue normal
operation.
Battery (9)
The UPS batteries are either installed in a dedicated battery cabinet or on a purpose-designed battery rack. The battery
installation is bespoke but it must include a fuse located near the battery source to enable the batteries to be disconnected
from the UPS. A range of external battery cabinets is available from Kohler Uninterruptible Power on request.
2.3.2 UPS internal operating modes
The following simplified block diagrams illustrate various UPS operating modes.
Load on Inverter
ON INVERTER is the normal UPS
operating mode and is the only one
that provides the load with
continuously processed and
backed-up power.
In this mode, the power rectifier
converts the AC input mains supply
to DC which provides the operating
power for the inverter and charges
the battery via the charger/booster.
The inverter then converts its DC
input to a controlled AC output that
is suitable to supply the load.
The ‘inverter side’ of the static
switch is closed and connects the
inverter AC output to the output
supply terminals via the closed parallel isolator switch (IA2).
When operating in the ON INVERTER mode, the inverter output frequency is synchronised to the bypass supply provided
the bypass supply frequency remains within preset limits (normally ±1 Hz). If the bypass supply fails altogether, the
inverter frequency is controlled by a free-running oscillator that will maintain the output frequency at a constant 50/60Hz.
Figure 2.3 Load on inverter