BlueWalker 10120175 uninterruptible power supply (UPS)
Contents
1. Ll Forklift g Uu from here Check the information on the type designation label of the equipment to verify that the unit is of the correct type The type designation label includes ratings a CE marking a type code a part number and a serial number The serial number is important when making inquiries It allows individual recognition of the equipment 12 PowerWalker 4 3 Planning before installation The equipment must be installed in upright position The equipment requires space to front and back to enable cooling airflow Service and maintenance require more than 500mm clearance on right hand side All cooling air enters at front and exits at unit rear The re quired minimum clearance from unit rear to an obstruction is 400mm Because the service and user access is in the front there should be reserved enough space min 800mm Preparation for installation 1 Avoid extremes of ambient temperature excessive dust moisture or vibration flammable gases and corrosive or explosive atmospheres 2 Altitude for normal UPS function should not exceed 1000m 3 The battery cabinet should work within a temperature range from15 C to 25 4 The maximum ambient temperature for normal UPS performance should not exceed 40 13 4 4 Cabinet installation AN Note Please use stabilizing device2. 380 400 415VAC 50 60Hz L1 L1 Rectifier 12 L2 Bypass 13 gt LBs input N N input PE PE Customer Customer Breaker1 Breaker2 2 Mains E Breaker Internal Battery Backfeed RY NC Sem Bypass disconnect _ Braker 59 5 2 Rectifier d RY NC p Inverter DC DC Booster Electronic 1 Output switch External RY Battery MBS IL L1 L2 L3 N b L1 12 13 N PE 380 400 415VAC 50 60Hz 22 PowerWalker 211 UPS rectifier input and bypass input are supplied from one mains only Connect the mains supply cables to the UPS rectifier input terminals L1 L2 L3 N and PE The following three jumpers must be fixed between the rectifier and bypass input terminals L1 L1 L2 L 2 L3 L3 Rectifier t2 3 380 400 415VAC 50 60Hz input N PE e Customer Breaker1 1 LLNS Mains 11 Breaker x Internal sx Switch Battery u Bypass Ser Jisconnali 5 1 S Rectifier 16 gt Backfead t T RY NC fee SE Inverter
3. Shelf 3 B10 B16 I Shelf 2 B9 15 I 1 Fig 10 31 PO PowerWalker 6 Secure each fix plate with four screws see Fig 11 8 7 up the wires properly see Fig 12 Fig 12 32 O PowerWalker 8 Reinstall the battery cover and secure it with the eighteen screws Table1 Battery cable list Lable 1 B2 83 4 B5 B6 B7 B8 B9 10 11 12 13 14 15 16 817 B18 Colour Red Brn Blu Blu Red Red Red Blk Blk Blu Blu Blu Blk Blu Quantity 56 56 8 4 4 4 4 8 1 2 1 1 2 4 1 2 1 1 Length mm 70 70 770 65 65 770 770 65 662 490 152 490 152 262 90 152 90 770 70 4621 290 152 290 152 152 33 5 5 Connecting the external battery Before connecting the external battery please read the notice and warning label on the UPS Warning the event of malfunction the battery cabinet chassis battery cabinet frames may become live Warning Special car
4. di di Output distribution pane u Load Load S 2 a 54 LtL2L3NPE P DR EIS wh N nt i Output st Load am 400011 O S0He UPS1 je 1 NES ana N LTS TI L E PARALLEL Q MOL I 2 UPS2 12 TET E PE N N tw ea igi B VES Ee 49 PARALLEL 1 N DA uj A u UPS8 12 1 ju E x 1 7 t 2 919 zu 1 3 y e PARALLEL Mains 400 230V 50Hz Note Parallel signal cable should be connected as a loop 55 FowerWalker 11 Display reference Table Indicator Senet working condition Bypass Line Inverter Battery BUZZER light light light light 1 Standby Mode Normal one flashing every 8 sec
5. Battery charging current A Q PowerWalke 3 7 AC output VFI 30000 3 3 BE BI VFI 40000TP 3 3 BE BI Active power 24KW 32KW Number of phases 3 phases N 50 60HZ Voltage L N 220 230 240 VAC 10 minutes minimum Overload 110 lt Load lt 125 then transfer to bypass and alarm capability 1 minutes minimum Mains 125 lt Load lt 150 then transfer to bypass and alarm available 0 5 seconds minimum 0 Load gt 150 then transfer to bypass and alarm 1950 10 minutes minimum Overload 110 lt Load lt 125 then transfer to bypass and alarm capability 1 minutes minimum battery then transfer to bypass and alarm available 0 5 seconds minimum Load gt 150 then transfer to bypass and alarm 3 8 Battery and Charger VFI 30000 3 3 VFI 40000 3 3 Internal battery package Panasonic LC RW 1245W CSB HR 1234WF2 Dimensions 94 151 64 5 pc Panasonic 94 151 65 pc CSB Strings 2x16 Stored energy time up to 8605 At Rated liner Load 25 C up to 540s At Rated liner Load 25 C Restored energy time 8Hours Up to 9096 charge Charger Input Protection 8Afuse Rated Charge Voltage 216V Default for Integrated bettery Initial Charging Current 4 5A Battery Leakage lt 3 5mA Ba ery protection 30A Fuse 3 For PCBA level Fuse 2 3 For PCBA level 125A Breaker Max
6. Em 08 3 2 u 08 3 3 Dimensional 8 2 08 3 4 Characteristi6S 09 ESSI m HP 09 EI IPIS e MEER 09 2 25 2 dvo Eod Te Pv tea 10 3 8 Battery and See OE ae 10 4 Mechanical 11 4 1 Delivery mene eren seen 11 4 2 Unpacking and visual 11 4 3 Planning before 13 4 4 Cabinet installation err rp re t adh E ER Le 14 4 5 Maintenance Bypass Switch MBS 14 27757722 21 5 1 Electrical 222222 21 5 2 Installation and wire connection 21 5 3 Suggested cable and protective 24 5 4 Internal Battery Installation sss 26 EN 5 5 Connecting the external 34 5 6 Connections between battery cabinet and UPS 35 5 7 Handling the batteri
7. 11 12 L3 PE ERES BIST E2 INE 50 PowerWalker 8 Maintenance Warning The Maintenance must be performed by a service engineer form the manufacturer or form an agent authorised by the manufacturer PowerWalker VFI 30000TP 40000TP 3 3 BE BI requires minimum maintenance 1 If battery is switched off loaded equipments will not be covered for power off protection 2 Make sure UPS vent are properly ventilated and clean side frames and fan vents from dusts every half a year switch off AC battery cabinet and internal battery fuse prior to cleaning 8 1 Battery Maintenance The battery is key component of the UPS The battery life depends on the ambient tem perature charge and discharge times High ambient temperature and deep discharge will shorten the battery life 1 Sealed maintenance free lead acid battery be used in the standard When being con nected to the utility power and if the UPS has been turned on the UPS keeps charging the battery and also offers the protective function of charging and discharging 2 Keep the ambient temperature between 15 C 25 C 3 If the UPS has not been used for a long period charging is recommended at the interval of 3 months 4 Normally the battery should be charged and discharged every 4 to 6 months Charging should be started after the UPS shut down automatically in the course of discharging In the regions of hot c
8. 29 P PowerWalker PowerWalker VFI 3 3 Series VFI 30000TP 40000TP 3 3 BE BI 380 400 415 50 60 2 3 phase input output User Guide N 2757722 92013 BlueWalker GmbH All Rights Reserved The contents of this manual are the copyright of the publisher and may not be reproduced even extracts unless permission granted Every care has been taken to ensure the accuracy of the information contained in this manual but no liability can be accepted for any errors or omission The right to make design modifications is reserved Contents 1 Safety jio Rm 01 1 1 Safety 01 1 2 Audience 01 13 IMAMKING 02 1 4 User precaution 02 125 lt 5 ER 03 1 6 03 2 4 OF 2 1 System description 04 2 2 Basic system 05 2 9 Panel e 05 2 4 Exterior e Poeno due 06 3 uu y 08
9. one beep every 8 sec Warning one flashing every 4 sec one beep every 4 sec Overload one flashing every 1 sec one beep every 1 sec 2 Bypass Mode Normal e one flashing every 2 beep every 2 min Warning e one flashing every 4 sec one beep every 4 sec Bypass phase error or bypass loss e one flashing every 2 sec beep every 2 sec Overload e one flashing every 1 sec beep every 1 sec 3 Line Mode Normal e e None Warning e e one flashing every 4sec one beep every 4 sec Overload e e one flashing every 1 sec one beep every 1 sec 4 Battery Mode Normal e e one flashing every 4 one beep every 4 sec Warning e e one flashing every 4 sec beep every 4 sec Low battery voltage e one flashing every 1 sec one beep every 1 sec Overload e e one flashing every 1 sec one beep every 1 sec 5 Battery Self Diagnosis Mode Normal None None Warning one flashing every 4 sec one beep every 4 sec Low battery voltage e one flashing every 1 sec one beep every 1 sec Overload e one flashing every 1 sec one beep every 1 sec 6 Fault Mode Normal Long light Long beep 7 Converter Mode Normal Warning e one flashing every 4 sec beep every 4 sec 8 ECO Mode Normal e fag every None one beep every 1 min Warning e one flashing every 4 sec beep every 4 sec 56 Poner Wer A Should any display or warning message excluded in the above table
10. see Fig 1 breaker Fig 1 26 PowerWalker A 3 Assemble the battery packs There eight batteries in each battery pack four packs each shelf and total is four shelves Step1 Put batteries into the trays see Fig 2 Step2 connect the wires between the batteries see Fig 3 Fig 3 27 9 G PowerWalker Please refer to the following figure Fig 4 for wire connections of the four battery packs 4PCS 4PCS Battery Pack 3 Battery Pack 4 4PCS 4PCS Fig 4 Step3 Install the top tray downward and fold both the top and bottom tray flanges see Fig 5 28 Ct Step4 Tape two sides see Fig 6 Make sure the cable is placed between the tray edges during tape mounting Front Back Battery Pack Assembly Step5 Paste the labels to the battery packs see Fig 7 Battery Pack 1 Please place the battery pack in correct direction 29 PowerWalker Make sure to paste the correct label to each battery pack and the battery packs are placed conformably with the labels i e the battery terminals are located on the bottom right corner see Fig 8 Battery Pack 1 Battery Pack 2 Battery Pack 3 Battery Pack 4 A Please place the battery N Please place the battery N Please place the batte
11. DC DC t3 22 Booster Electronic Output switch External RY Battery veal ll NTS L1 L2 L3 N PE 380 400 415VAC 50 60Hz Terminal block diagram Warning High touch current earth connection essential before connecting supply 23 LLL In order to gain access to the external electrical connections it is necessary to remove the front terminal protective panel of the UPS Before the cables are connected they shall be passed through the cable glands to hold them in position and tightened Connect the Protective Earthing PE cable first Connect other cables as shown in the connection terminal representations on the preceding and following pages Ensure that the UPS is isolated before removing front terminal protective panel RECTIFIER INPUT BYPASS INPUT BATTERY OUTPUT 11 12 13 11 12 13 PE PE 11 12 13 N PE A 5 3 Suggested cable protective devices N Caution cables should always use copper cable type The conductor cross sections apply for maximum currents 1 For
12. I P VOLT 230 230 231 O P VOLT 230 230 230 PLEASE WAIT 50 0Hz STATUS NORMAL BATTERY PARAMETER Pos BAT VOLT 216V Neg BAT VOLT 216V CAPACITY 93 BACKUP TIME 44 5 Switch off action press ESC to exit above picture 1 Switch off picture 2 If it is in single machine mode the following will appear CONFIRM LOAD OFF INVERTER map COMMAND HELP NO CANCEL up YES CONFIRM ESC A lt 3 If it is in parallel machine mode the 4 Press ENTER following will appear LOAD OFF LOAD OFF INVERTER LOAD OFF SINGLE gt LOAD OFF PARALLEL NO CANCEL gt YES CONFIRM 45 LL 7 PA 4 5 Select Yes Confirm to switch off 6 Normal Switch off the machine UPS IS OFF UPS IS LOADING OFF PLEASE WAIT PRESS ANY KEY Note System select parallel machine switch off If you intend to switch off only one set of UPS among the parallel machine system se lect single machine switch off if switch off is intended for the entire parallel machine 6 Help 1 Help picture 2 Press ENTER on help picture COMMAND HELP MAINTAIN PROCEDURE CONFIGURATION ALARM CONTROL ONLY FOR SERVICE 46 7 Configuration press ESC to exit the above picture You are able to access Setting picture by using user combination default 1234 subject to personal modification so as to set
13. INPUT MAINS INPUT 111213 BREAKER O 111213 MAINTENANCE BYPASS SWITCH INTERNAL BATTERIE FOR EXT BATTERIES 15 maintenance positions of the MBS switches BYPASS INPU ELECTRONIC 111213 BYPASS BREAKER o RECTIFIER INPUT MAINS INPUT oureur L1L2L3 BREAKER zzz 111213 Q rn o n o_ N NEUTRALSWITCH SERV DISCONNECT MAINTENANCE BYPASS SWITCH INTERNAL BATTERIE FOREXT N BATTERIES Transfer UPS from normal mode to maintenance bypass mode 1 The normal start position should be following Maintenance Rectifier Bypass switch Input Input Battery N breaker OFF ON ON ON 2 Use LCD to turn the UPS from normal mode to bypass mode Switch off action press ESC to exit above picture 16 PowerWalker 1 Switch off picture 2 If it is in single machine mode the following will appear CONFIRM map COMMAND LOAD OFF INVERTER HELP NO CANCEL gt YES CONFIRM Remember to verify the transfer before proceeding the next step 3 Remove the locking plate of maintenance switch 4 Turn OFF the Rectifier Input switch and battery breaker Maintenance Rectifier Bypass N Battery switch Input Input breaker OFF OFF ON OFF 5 Turn the Maintenance switch to MAINTENANCE side Maintena
14. PVC insulated copper cables at 70 C 2 When routed in conduits for electrical installations 3 When air temperature surrounding the conduits does not exceed 30 C 4 For cable lengths up to 30 m N Notice Should there be any variation in the conditions it will be necessary to verify whether the cable dimensions satisfy the requirements of 287 and DIN VDE 0298 In cases where the cables are so long that they cause a drop in voltage of 2390 a larger dimen sion shall be selected 24 PowerWalker A Routing communication cables or data lines should be kept separate from the UPS input output and external battery cables Use cable cross section and protective device specification Model VFI 30000 3 3 BE BI VFI 40000 3 3 Rectifier Input L1 L2 L3 N Bypass Input L1 L2 L3 N pole Negative pole min conductor cross section mm 10 16 max possible cross section mmz 35 35 Rectifier Input L1 L2 L3 N breaker A 80A 230VAC 100A 230VAC Bypass Input L1 L2 L3 breaker A 80A 230VAC 100A 230VAC Rectifier Input fuse A 80A 250VAC 100A 250VAC Bypass Input fuse 80A 250VAC 100A 250VAC Internal battery switch 125A 690VAC Output L1 L2 L3 N min conductor cross section mm 10 16 max possible cross section mm 35 35 External Battery Cabinet Positive pole Neutral pole Negative pole min conductor cross section mm 1
15. be found please con tact distributor or call PowerWalker Hot line for advice Indicator light is on Indicator light flashes Warning include one or more than one of these 1 EPO active 11 Charger failure 2 Line loss 12 Battery over restrict 3 Neutral loss 13 Battery over temperature 4 Line phase error 14 Fan over restrict 5 Bypass loss 15 BUS capacitor over restrict 6 Bypass phase error 16 Fan failure 7 Battery open 17 Fan disconnected 8 Low battery voltage 18 Low temperature Battery 9 Over charger 19 communication disconnected 10 Battery reverse 20 Auxiliary charger failure 57 T 2 2224 EV 614 01719 00
16. discharging current 87A Ubat 308VDC Full RCD load 116 Ubat 308VDC Full RCD load 10 PowerWalker 4 Mechanical installation The UPS and accessories are delivered on a specifically designed pallet that is easy to move with a forklift or a pallet jack Keep the UPS always in upright position and do not drop the equipment Do not stack the pallets 4 1 Delivery check The UPS is delivered with the following items 1 Winpower disc 2 RS 232 serial cable 3 User Guide 4 Key 5 Battery kit wires amp trays Only for model without batteries 4 2 Unpacking and visual inspection Check that there are no signs of shipping damages The equipment should be transported in the upright position N Note A claim for shipping damage must be filed immediately and the carrier must be in formed within 7 days of receipt of the equipment The packing materials should be stored for further investigation Unpack the equipment by removing the packing and shipping materials Make a visual inspection Remove the equipment from the pallet and make sure that the floor surface is solid and suitable for the wheeling and heavy weight Remove cover plate Remove side plate Remove stuffing and fix 11
17. the following programs 1 Action display bypass power supply 2 Press V gt COMMAND COMMAND CONFIGURATION gt CONFIGURATION 3 Enter respective password 4 Select action item SET UP gt USER KEY gt SELFTEST LANGUAGE RE START OTHER SERVICE KEY PASSWORD TIME 8 The Series is capable of DC start up without AC input panel display being similar to switch on picture with AC supply DC switch on and off are available by following instruc tions appearing in the pictures 47 9 Procedures of DC switch on e Activate DC switch on function set under UPS bypass mode e Make sure that and wires of batteries are properly connected to UPS e Switch on batteries e Lightly touch ENTER e Manually conduct switch on order within about 1min after LCD self inspection EN N Note UPS will be switched off automatically if there is no operation within 1min after LCD self inspection is completed 7 2 Parallel machine operation Redundancy introduction is currently the most reliable power supply structure in which indicates the minimum UPS number required for the total load and X is the redundant UPS number namely the malfunctioning UPS number that the system can simultaneously bear The larger X is the higher reliability of system will be For instance if the total load of a customer registers 55 we can use 20KVA for desi
18. the precaution warnings and only perform the described opera tion Any deviations from the user manual could be dangerous to the user or cause ac cidental load loss Should the UPS be intended for application above 1000m progressive decrease of rated output should be applied as listed in the following chart Altitude M 1000 1500 2000 2500 3000 3500 4000 4500 5000 100 95 91 86 82 78 74 70 67 7 1 Single machine operation 1 Make sure L1 L2 and L3 phase sequences are correctly connected and then supply power to UPS 2 Close internal battery breaker 3 Turn on the switch on battery box if the UPS equipped with External battery make sure that the N and of terminal are in accordance with those on the battery box 4 Switch on Input Switch Rectifier Input Switch Bypass Input Switch on UPS and fans start to rotate for UPS self inspection Main menu can be accessed within about 4sec and then operations should be carried 40 Remark the following drawing takes PowerWalker VFI 30000TP 3 3 BE BI as example and statistics are only for reference 1 Power on 2 Automatic access within about 4s POWERWALKER VFI 30000TP 3 3 gt COMMAND CONFIGURATION UPS SELF TESTING PLEASE WAIT AMOMENT HELP 3 Press ESC to access or automatically 4 Press to obtain the below informa within 1min with
19. 6 25 max possible cross section mmm 35 35 External Battery Cabinet Fuse A in Positive pole Neutral pole 120A 250VAC 150A 250VAC Negative pole External Battery Cabinet breaker in Positive pole Neutral 120A 250VAC 150A 250VAC Backfeed protection device 60A 250V AC Clearance distances gt 1 4mm Break time lt 15s Protective Earthing conductor mn Max 35 Torque for fixing above terminals 2 8 3 Nm 25 Notice The following label must be displayed on all switching devices installed in the same electrical system as the UPS even when these are located at a distance from the area in which it is located according to European standard EN 62040 1 Warning ENSURE THAT THE UNINTERRUPTIBLE POWER SYSTEM IS ISOLATED BE FORE WORKING ON THIS CIRCUIT 5 4 Internal Battery Installation REMARK THE FOLLOWING WARNINGS SHOULD BE OBSERVED DURING THE OPERATION The batteries may contain potential electric shock danger because of high voltage Wear safety goggles Make sure to verify battery polarity before connecting Make sure to keep wires away from the adjacent legs and sharp edges of shelves handles Please complete the procedure below to install batteries 1 Make sure that the breaker is in off position Located in front of the unit 2 Remove the eighteen screws on the battery cover and take off the battery cover
20. RECTIF IER 5 m m ES ti 12 13 pe 12 u 12 12 t3 UPSI UPS Parallel machine wire connection drawing separate battery supply VP RECTIF TER V P BYPASS PE N 12 1 PE 12 13 NEB BAT NFB BAT re 21 oid al so NFB ag 12 1 N Pe un pe t2 UPSI UPS NFB NFB 12 13 ee or 49 Fonertaer Single machine wire connection drawing V P RECTIFIER VP BYPASS BAT 2 IN C1 RE NIL 12 13
21. arings The fan replacement is recommended once this symptom starts appearing Do not use other than manufacturer s specified spare parts 53 9 Parallel systems N Note ES Parallel is only connected to identical ports for the UPS of same models and kVA rating 1 Follow installation instructions for general installation requirements 2 Ventilation spacing between machines should allow for service access 3 Input wiring for each set of UPS should follow the requirements for that of single unit Each UPS input should be connected to the same input patch board 4 Each UPS output wire should be connected to the output patch board from which wires are distributed for load as illustrated in following figure Remark 1 common battery pack is applicable in parallel machine mode Remark 2 each battery pack should be of the same model from the same manufacturer Remark 3 requirement of output wiring length When the lead from the output terminal of each set of UPS to the output patch board is less than 20m wire difference should be less than 20 When the lead from the output terminal of each set of UPS to the output patch board is lon ger than 20m wire difference should be less than 10 Input distribution panel UPS1 UPS UPS3 UPS7 UPS8 E E
22. ctifier and bypass inputs Three phase L1 L2 L3 Neutral N and Protective Earth PE connection for the load output Positive pole Negative pole Common midpoint Neutral pole and Protective Earthing PE connection for the external batteries 56 red wires B2 with an approximate length of 70mm 4 red wires B3 with an approximate length of 770mm and 8 red wires B4 with an approximate length of 65mm for BAT 4 red wires B9 B10 and B11 for BAT connection 4 blue wires B5 with an approximate length of 65 mm 4 blue wires with an approximate length of 770mm B6 for BATN 21 Q Power Walke 8 blue wires B14 B15 B16 and B18 for BATN connection 56 black wires B1 with an approximate length of 70mm 8 black wires B7 with an approxi mate length of 770mm and 4 black wires B8 with an approximate length of 65mm for 4 black wires B12 B13 and B17 for BAT connection 1 If UPS rectifier input and bypass input are supplied from two mains Connect the mains 1 supply cables to the UPS rectifier input terminals L1 L2 L3 N and PE Connect the mains 2 supply cables to the UPS bypass input terminals L1 L2 L3 N and PE
23. e should be taken when working with the battery cabinet associated with the PowerWalker VFI 3 3 Series 30 40 kVA When the battery cabinet is connected the overall voltage exceeds 400V It is very important to ensure that the batteries are installed separately in a dedicated battery cabinet N Notice The most common battery type used in UPS installations is the valve regulated bat tery Valve regulated cells are not sealed The amount of gas given off is less than for flooded cells but when planning the battery installation allowance must be made for adequate ventilation and heat dissipation Valve regulated cells are not completely maintenace free They must be kept clean and their connections checked periodically to ensure they are tight and that there is no evidence of corrosion It is inevitable that the batteries will lose charge during transportation and storage before attempting to carry out an autonomy test ensure that the batteries are fully charged as this may take several hours Cell performance typically improves after a few discharge recharge cycles 34 PowerWalker N Notice The requirements of the EC directives are satisfied when battery cabinet are used with original accessories If alternative batteries are used you must ensure that the appli cable EC directives are met and declare conformity Connect the battery cabinet as follows Turn off the UPS Check the inter
24. eaker OFF ON ON ON ON 5 Use LCD to turn the UPS from bypass mode to normal mode Switch off action press ESC to exit above picture 1 Switch on picture 2 Press ENTER COMMAND CONFIRM LOAD ON INVERTER CONFIGURATION NO CANCEL gt YES CONFIRM 19 Fonertaer 6 UPS is now in the normal mode see below BYPASS INPU ELECTRONIC L1L2L3 BYPASS BREAKER RECTIFIER INPUT MAINS INPUT OUTPUT 11213 BREAKER SERV MAINTENANCE BYPASS SWITCH DISCONNECT INTERNAL BATTERIE FOR EXT BATTERIES 7 Remount the locking plate of maintenance switch to the position to prevent the use of it 20 PowerWalker 5 Electrical installation 5 1 Electrical Preparations N Note It must be ensured that no line input source can accidentally be connected to the UPS during installation AN Warning Installation may only be carried out by qualified technicians and in conformity with the applicable safety standards AN Warning The UPS unit is not applicable to the IT power distribution system 5 2 Installation and wire connection diagram The UPS unit has the following power connections Three phase L1 L2 L3 Neutral N and Protective Earth PE connection for the rectifier input Three phase L1 L2 L3 Neutral N and Protective Earth PE connection for the bypass input N is INTERNALLY common for re
25. ed and is to be reconnected the battery isola tor may only be reconnected after you have made certain that voltage with the correct polarity is present on both sides of isolating device 36 PowerWalker EV 6 Software and connectivity The Series provide Intelligent Slot Expanded Slot PARALLEL AS400 EPO RS485 and RS232 as well as SERVICE Supervising Communication Interface exclusively available to PowerWalker technical personnel 1 3 4 5 7 PARALLEL PARALLEL EPO RS485 SERVICE Intelligent slot mno Sot 1 Intelligent slot suitable for WebPower card of remote supervising management enabling you to realize remote supervising management on UPS through Internet 2 Expanded slot Reserved for special applications 3 PARALLEL communication interface for parallel machine mode 4 Standard AS400 interface provides AS400 and users can directly use UPS supervising function offered by AS400 system to realize power source management See Appendix for AS400 port Pin 5 EPO Emergency Power Off providing the possibility of emergency shut down Normally closed 6 Standard RS485 Interface It can be used to monitor parallel units for completely control of UPS See Appendix for RS485 port Pin 7 SERVICE Interface available only to PowerWalker technicians 8 Standard RS232 Interface applicable to WinPower supervising software of graphic man agement See Fi
26. es 36 6 Software and 2 2 7 37 Ee acia i 40 7 1 Single machine eene 40 7 2 Parallel machine 48 8 2 4 HEC 51 8 1 Battery Maintenance o e EE Rte Eo bebe t EPA 51 8 2 Regular eee 53 98 3 COOMNG 53 9 Parallel systems 54 10 Recycling the used UPS or 56 11 Display reference 57 PowerWalker 1 Safety instructions This user manual contains important safety instructions and operating instructions Please read the user manual carefully before operating or working on the UPS and save it for refer ence in the future 1 1 Safety caution The UPS operates with external AC mains battery cabinet s or bypass power It contains components that carry hazardous voltages and high currents The properly installed enclo sure is earthed and 20 rated against electrical shock and foreign objects The user 15 not permitted to open it Failure to observe this could result in electric shock risk Only qual
27. fied range Please refer to Light Reference Table of this User Manual first and then conduct proper treatment If problems still exist please record UPS model serial number as well as pur chase date symptom on fault light condition LCD malfunction or warning information Table of Malfunctions LCD DISPLAY OR POSSIBLE SYMPTOM CAUSE SOLUTION Overloaded in bypass or Unloaded to the required inverter operation mode value Check that the input wiring The Fault LED is lit Mains out of tolerance and input voltage are periodic beeps normal Check the battery switch Battery disconnected and the battery wiring Switch off and make sure Socket is properly connected Power up again LCD panel has no display 52 PowerWalker 8 2 Regular service intervals The UPS requires very little maintenance if installed in an appropriate environment In order to ensure maximum availability of the UPS manufacturer recommends signing a proactive service agreement with a local authorised service provider Maintenance Interval Batteries change 3 5 years or according to battery suppliers recommendations Batteries test 18 months Cooling fan change 5 years 8 3 Cooling fan The cooling fan lifespan of the UPS unit is about 60 000 operating hours The actual lifespan depends on the environment and ambient temperature Fan failure can be predicted by increasing noise from the fan be
28. fter conversion through inverter As the energy conversion efficiency reaches as high as 98 and transfer time less than 10ms under ECO mode when there is normal AC supply the energy saving effect of UPS is remarkable Remark ECO mode is applicable only to single unit A 2 2 Basic system configuration BYPASS INPU ELECTRONIC 111213 55 RECTIFIER INPUT MAINS INPUT m OUTPUT 111213 EAKER 1 1213 i oss Lo MAINTENANCE BYPASS SWITCH INTERNAL BATTERIE FOREXT BATTERIES 2 3 Panel figure 99 9 9 O PowerWalker D AC This light and inverter light will turn green when UPS is powered by Rectifier Input 2 Inverter This light will turn green when UPS load is through the inverter Battery This light will turn yellow when UPS is powered by batteries 9 Bypass This light will turn green when UPS load is powered by Bypass Input Fault If the UPS worked under fault condition this light would turn on and stay red with continuous warning tone being given off in case of UPS abnormal function or flash red with EN intermittent warning tone being given off 6 LCD Display UPS commands M Confirm Enter press this button to select a menu or confirm an operation w PageDown press this button to switch to next screen display under the same menu 9 A ageUp press th
29. gn With N taking up 3 X can be selected in ac cordance with reliability degree or cost requirement Supposing customer selects 2 and equalized UPS power supply is 11kVA for each unit when one set of UPS breaks down with malfunction the remaining four sets will provide power with almost 14kVA equalized current if two sets of UPS fail the remaining three sets of UPS are supposed to provide power supply with almost 18kVA equalized current The maximum allowance of this sys tem is for two sets of UPS going down at the same time the chances of which are much smaller than those of one UPS malfunction Therefore the reliability degree can be largely enhanced making it an optimal mode for application in locations where high degree of reli ability is always a focus PowerWalker VFI 30000TP 40000 3 3 BE BI is capable of direct parallel connection which only requires the parallel connection wires optional for 2 to 8 sets of UPS in parallel connection in order to realize power redundancy N X 48 Parallel machine wire connection drawing one battery supply VP
30. gure for RS232 port Pin 37 Oo B LA RS232 port Pin Description Vo 2 TXD Output 3 RXD Input 5 GND common TXD 31 RXD 59 GND 4 V RS485 port Pin Description 3 RXDA Input 4 RXDB Input 5 TXDB Output 6 TXDA Output I N U R T S P R gt T 5 T R I S Fo R 92 38 ot AS400 port Pin Description 1 UPS Fail Output 2 Alarm Output 3 GND Common 4 Remote Shutdown Input 5 Common Common 6 Bypass Output 7 Battery Low Output 8 UPS ON Output 9 Line Loss Output UPS FAIL for so BYPASS LU ALARM 92 BATTERY LOW 71 GND S REMOTE SHUTDOWN 5 t go LINE LOSS LU COMMON N Note The UPS have to be manually reset if remote shutdown occurs 39 7 User operations Warning 25 High touch current earth connection essential before connecting supply The only user operations permitted are Start up and shut down the UPS excluding the commissioning start up Use of the LCD control panel and Emergency Power Off EPO switch Use of optional connectivity modules and their software Warning The user must follow
31. ified personnel is allowed to install and service the UPS Warning Operations inside the UPS must be performed by a service engineer from the manufac turer or from an agent authorised by the manufacturer Use the optional Maintenance Bypass Switch MBS for service inside the UPS when stalled to the system Remember to open battery cabinet s breaker Always ensure by mea suring with a multimeter that no dangerous voltages are present For detailed MBS opera tion instructions please see 4 5 1 2 Audience caution The intended audiences of this manual are people who plan the installation install com mission and use or service the UPS The manual provides guidelines to check delivery installing and commissioning of the UPS The reader is expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols This manual is written for a global reader N Caution Read the manual before operating or working on the UPS 1 3 CE marking ES The product has the CE marking in compliance with the following European directives LVD Directive Safety 2006 95 EEC EMC Directive 2004 108 EEC AN Note This product for commercial and industrial application in the second environment Instal lation restrictions or additional Measures may be needed to prevent disturbances 1 4 User precaution The only user operations permitted are S
32. is button to return to next screen display under the same menu Esc Escape press this button to return to previous menu or cancel a certain operation Remark Refer to Chapter 12 for detailed information of LED in accordance with UPS condition 2 4 Exterior view Exterior figure of PowerWalker VFI 30000TP 3 3 40000 3 3 BE BI UPS PARALLEL Intelligent slot _ Service Extended slot T AS400 5485 5232 LCD panel Button LED indicator light 3 F ae Front view Rear view Ct A 2 i ____ Battery trays b 3 1 1 Front view door open 9 O PowerWalker 3 Technical data 3 1 Standards UPS VFI 30000 3 3 BE BI VFI 40000TP 3 3 BE BI Safety 62040 1 2008 62040 1 2003 and 60950 1 2005 62040 2 2006 62040 2 2005 62040 3 1999 62040 3 2001 3 2 UPS VFI 30000 3 3 VFI 40000TP 3 3 Working Temperature 40 C 30 C 65 C without batteries Storage Temperature 0 40 C with batteries Relative Humidity 5 90 no c
33. limates the battery should be charged and discharged every 2 months Moreover the standard charging time should be no less than 10 hours 5 It s not recommended to replace batteries individually Complete replacement should fol low instructions given by battery suppliers 6 Under normal conditions the battery life lasts 3 to 5 years Should batteries be found in poor performance replacement should be done as soon as possible only by qualified per sonnel with proper training Users are not allowed to replace without authorization 51 Q PowerWalke Remark A Prior to battery replacement switch off UPS and remove it from AC and battery take off internal battery breaker B Take off metallic articles such as rings and watches C Use screw drivers equipped with insulated handles and do not place tools or other metal lic substances on the batteries EN D Short circuit or reverse connection is forbidden for battery polarity connection The troubleshooting procedure gives simple remedial if a malfunction occurs in the UPS The operator should start the trouble shooting if there is an active alarm indicated on the LCD screen Service should be contacted if the active alarm is abnormal and displayed as a service code Should maintenance prove necessary the following steps should be followed 1 Check if UPS input wiring is done properly 2 Check if all air switches are tripped out 3 Check if voltage input is within speci
34. nal battery breaker is off and or any external battery switchs open Connect PE first Connect the battery cabinet s with cables sized according to cable cross setion and protec tive device specification to terminals positive pole negative pole and Neutral pole Refer to instruction provided with the battery cabinet or by vendor Warning ENSURE CORRECT POLARITY 5 6 Connections between battery cabinet and UPS Make sure the Protective Earthing PE connected first EXTERNAL BATTERY CABINET UPS N 9 External Battery Cabinet Connections 35 5 7 Handling the batteries Warning Batteries are a potential source of danger due to their electrical charge and chemical composition Therefore observe the battery handling instructions of the manufacturer These usually can be found in the material which accompanies the shipment Recharging batteries N Warning When recharging observe the indications on the packaging Exchanging batteries AN Warning Before replacing batteries make sure that those to be installed are fully charged Connecting external battery cabinet AN Warning If a battery cabinet has been disconnect
35. nce Rectifier Bypass N Battery switch Input Input breaker ON OFF ON OFF 6 Turn OFF the Bypass Input switch and N switch Maintenance Rectifier Bypass N Battery switch Input Input breaker ON OFF OFF OFF OFF 17 Power Walke 7 UPS is now in the maintenance bypass mode see below Note the Serv disconnect i e battery breaker must be turned off BYPASS INPU L1L2L3 ELECTRONIC BYPASS BREAKER RECTIFIER INPUT MAINS INPUT L1L2L3 BREAKER L1L2L3 HH NEUTRAL SWITCH SERV DISCONNECT MAINTENANCE BYPASS SWITCH INTERNAL BATTERIES FOR EXT BATTERIES Transfer UPS from maintenance bypass mode to normal mode 1 The normal start position should be following Maintenance Rectifier Bypass N Battery switch Input Input breaker ON OFF OFF OFF OFF 2 Turn ON the Bypass Input switch and N switch Maintenance Rectifier Bypass N Battery switch Input Input breaker ON OFF ON ON OFF When the LED of bypass turns green the UPS enters into bypass mode 3 Turn the Maintenance switch to UPS side Maintenance Rectifier Bypass N Battery switch Input Input breaker OFF OFF ON OFF 18 PowerWalker E Then the UPS turn to bypass mode 4 Turn ON the Rectifier Input switch and battery breaker Maintenance Rectifier Bypass switch Input Input Battery N pr
36. no button being pressed tion OUTPUT PARAMETER RN SN TN 2800 2310293 Tout 0 0 0 FRQ 50 LOAD 0 216V I P VOLT 230230231 O P VOLT 230230230 O P FREQ 50 0Hz STATUS BYPASS MODE 41 5 Press again to obtain the below 6 Press again to obtain the below information information INPUT PARAMETER POWER PARAMETER RN SN TN RN SN TN Wine 251 KW 0 0 0 0 0 0 50 KVA 0 0 0 0 0 0 7 Press again to obtain the below 8 Press again to obtain the below information information BATTERY PARAMETER OTHER PARAMETER Pos BAT VOLT 216V MODEL VFI 30000TP 3 3 Neg BAT VOLT 216V UPS CAPACITY 93 VER UPSX X XLCDX X X BACKUPTIME CHGR X X X X X 42 72222272 If malfunction occurs x will appear at the lower right corner of the display while a warning occurs N will appear at the same position as illustrated in the below pic ture with battery mode as an example BYS aaa orig iia REC INV REC INV L T L L1 L3 BAT CHGR BAT CHGR 4 Start up action press ESC to exit the above picture 1 Switch on picture 2 Press ENTER gt COMMAND CONFIRM LOAD ON INVERTER CONFIGURATION NO CANCEL gt YES CONFIRM 43 Power Walker 3 Select Yes Confirm to switch on 4 Normal Switch on the machine LOAD 0 NBAT 216V PSISLOADI
37. ondensation allowed Altitude derating coefficient See user operations section for more detail information Vibration IEC68 2 6 max 0 3mm 2 to 9Hz max 1m s2 9 to 200 2 sinusoidal 3 3 Dimensional drawings UPS VFI 3 3 BE BI VFI 40000TP 3 3 BE BI 470 700 1752 5 Without package 470 700 1752 5 Without package WXDXH mm 974 743 2008 With package 974 743 2008 With package 195 Without batteries 195 Without batteries Net Weight Kg 515 With batteries 515 With batteries 255 Without batteries 255 Without batteries Gross Weight Kg 575 With batteries 575 With batteries A 3 4 Characteristics VFI 30000 3 3 BE BI VFI 40000 3 3 Noise ISO 7779 lt 57dB at 75 load Efficiency nominal load Up to 92 3 5 AC input VFI 30000 3 3 BE BI VFI 40000 3 3 Rectifier input 3 phases Bypass input 3 phases N Voltage L N 121V 274 Volts without using battery Frequency 40 70 Hz Power factor 0 99 Input distortion lt 5 THD I Rated input voltage 380V 400 V 415V Rated input current 43A 41A 40A 57 54 52 3 6 DC circuit Battery number 2X16 Battery nominal volt Positive battery 192V DC age Negative battery 192V DC 154 2 DC when load gt 2kw Cut off voltage 176 2V DC when load lt 2kw 4 5A
38. r Supply UPS It is a true online continuous duty double conversion solid state three phase system providing con ditioned and uninterruptible AC power to protect the end user s load 2 1 System description PowerWalker VFI 3 3 Series products are high efficiency and high performance double conversion pure online and three phase input and three phase output UPS with unit capacity ranging between 20KVA 40KVA Categorized by capacity the products can be further divided into 20 30KVA 40KVA This series not only provides perfect solu tion for power source protection and successfully solves problems such as blackout boost brownouts sags decaying oscillation high voltage impulse voltage fluctuations surges harmonic distortion disturbances frequency fluctuation etc but also enhances adaptability to complicated working environments so that the application fields is well extended to com puter equipments communication equipments and other controlling equipments with good adaptability to complicated industrial environments as well Therefore this series products can be applied in a diversified multi industries field such as telecommunications financing transportation government manufacturing and energy sectors PowerWalker VFI 3 3 Series products are also capable of ECO mode ECO mode means UPS load is powered by bypass AC supply while in case of abnormal AC supply the load will be supplied by accumulator battery a
39. ry AN Please place the battery ZN pack in correct direction ZY pack in correct direction 1 pack in correct direction Z pack in correct direction B3 5 B8 J 8 4 Put the battery packs into the enclosure from left to right and bottom to top and cover each shelf with a fix plate see Fig 9 please refer to Fig 4 for correspending battery packs mE E nn fix plate Shelf 4 Shelf 3 Shelf 2 Shelf 1 3 L mj Cw Battery pack 1 Battery pack 2 Battery pack 4 Battery pack 3 Fig 9 30 PowerWalker D 5 Connect the cables to each shelf respectively see Fig 10 REMARK MAKE SURE TO CONNECT WIRES WITH THE SAME COLOR Breaker 1 2 3 Brown Line auc nactus RedLine B18 Blue Line H Shelf 4 Black Line B10 816 m Small connector
40. s to fix the UPS prior to the installation The required distance for UPS units should allow for service access The same applies to the battery cabinet s that should be installed next to the UPS cabinet s AN Caution UPS cabinet s can fall over if the installation brake pads are not used Both rear and front pads must be used to secure the UPS cabinet to the floor Use a 19mm wrench in clockwise direction to screw the brake pad down to the ground keeping the machine from moving 4 5 Maintenance Bypass Switch MBS AN Warning All operations inside the unit must be performed only by a service engineer from the manufacturer or from an agent authorised by the manufacturer The operation of the MBS is allowed for a service engineer from the manufacturer or from an agent authorised by the manufacturer The full UPS wiring diagram with a MBS switch is presented in the installation part of the manual 14 O PowerWalker The switching sequence for circuit breaker from normal position to maintenance position Maintenance Rectifier Bypass N Battery m switch Input Input breaker gt ON ON ON c gt Step1 OFF OFF ON Step2 ON ON ON Maintenance The normal positions of the MBS switches BYPASS INPUT ELECTRONIC 2 BYPASS BREAKER o RECTIFIER
41. tart up and shut down the UPS excluding the commissioning start up Use of the LCD con trol panel and Emergency Power Off EPO switch Use of optional connectivity modules and their software The user must follow the precautions and only perform the described opera tions Any deviations from the instructions could be dangerous to the user or cause acciden tal load loss Warning The user is not permitted to open any screws excluding connectivity plates and the Emergency Power Off EPO switch Failure to recognise the electrical hazards could prove fatal PowerWalker 1 5 The UPS must be installed according to the recommendations this manual Under cumstances the UPS should be installed in an airtight room in the presence of flammable gases or in an environment exceeding the specification Excessive amount of dust in the operating environment of UPS may cause damage or lead to malfunction The UPS should be always protected from the outside weather and sunshine The recommended operating temperature is from 15 to 20 Celsius degrees The recommended operating humidity 20 to 90 1 6 Inquiries Address any inquiries about the UPS and battery cabinet s to the local office or agent authorized by the manufacturer Please quote the type code and the serial number of the equipment 2 Introduction The product described in this manual is an Uninterruptible Powe
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