PowerWalker VFI 10000 TP 3-1 BI Service Manual

Online UPS

owerWalker VFI 10000TCP 3/1

PowerWalker VFI 10000TP 3/1 PowerWalker VFI 20000TP 3/1

Manual

EN/DE

Uninterruptible Power Supply System

CONTENT:

1. Safety ........................................................................................................... 1

1.1 Installation............................................................................................... 1

1.2 Operation ................................................................................................ 2

1.3 Maintenance, Servicing and Faults ........................................................ 3

1.4 Transport ................................................................................................ 4

1.5 Storage ................................................................................................... 4

1.6 Standards ............................................................................................... 5

2. Description of Commonly Used Symbols ................................................ 6

3. Introduction ................................................................................................. 7

3.1 System and Model Description ............................................................... 7

3.2 Product Specification and Performance ............................................... 10

4. Installation ................................................................................................. 13

4.1 Unpacking and Inspection .................................................................... 13

4.2 Input and Output Power Cords and Protective Earth Ground

Installation ................................................................................................... 16

4.3 Operating Procedure for Connecting with The External Battery .......... 21

5. Operation ................................................................................................... 23

5.1 Display Panel ........................................................................................ 23

5.2 Operating Mode .................................................................................... 27

5.3 Turning On and Turning Off UPS ......................................................... 29

5.4 LCD Operation ...................................................................................... 31

6. Special function ........................................................................................ 40

6.1 HE Function .......................................................................................... 40

6.2 Converter Function ............................................................................... 40

6.3 Parallel Function ................................................................................... 41

6.4 PowerWalker VFI 10000TCP 3/1 Optional Design of Charger Current 47

6.5 Backfeed Protection ............................................................................. 48

7. Trouble Shooting ...................................................................................... 51

7.1 Trouble Shooting According To Warning Indication .............................. 51

7.2 Trouble Shooting According To Fault Indication ................................... 53

7.3 Trouble Shooting In Else Cases ........................................................... 54

8. Battery Maintenance, Replacement and Disposal ................................. 56

8.1 Maintenance ......................................................................................... 56

8.2 Replacement and Disposal of Batteries ............................................... 57

9. Communication Port................................................................................. 60

9.1 RS232&USB Interface .......................................................................... 60

9.2 Intelligent Slot ....................................................................................... 60

9.3 AS400 Interface (Option) ...................................................................... 60

10. Software Installation ..................................... Error! Bookmark not defined.

1. Safety

Please read carefully the following user manual and the safety instructions before installing the unit or using the unit!

1.1 Installation

★ Condensation may occur if the UPS is moved directly from a

cold to a warm environment. The UPS must be absolutely dry before being installed. Please allow an acclimatization time of at least two hours.

★ Do not install the UPS near water or in damp environment. ★ Do not install the UPS where it would be exposed to direct

sunlight or near heat.

★ Do not block ventilation openings in the UPS’s housing. ★ Do not connect appliances or items of e quipment w hi ch would

overload the UPS (e.g. laser printers, etc) to the UPS output.

★ Place cables in such a way that no one can step on or trip over

them.

★ UPS has provided earthed terminal, in the final installed

system configuration, equipotential earth bonding to the external UPS battery cabinets.

★ An integral single emergency switching device which prevents

further supply to the load by the UPS in any mode of operation should be provided in the building wiring installation.

★ An appropriate disconnect device as short-circuit backup

protection should be provided in the building wiring installation.

★ For thre e-phase equipmen t connection to an IT power syste m,

a four-pole device which disconnect all phase conductors and the neutral conductor should be provided in the buil ding wiring installation.

★ This is permanently connected equipment, it must be installed

by qualified maintenance personnel.

★ Earth connection essential before connecting to the building

wiring terminal.

1.2 Operation

★ Do not disconnect the ea rth con ductor ca ble on the UPS or the

building wiring terminals in any time since this would cancel the protective earthing of the UPS system and of all connected loads.

★ The UPS output terminal block ma y be electrically liv ed eve n if

the UPS system is not connected to the building wiring terminal.

★ In order to fully disconnect the UPS, turn the M1/M2/N input

breaker in the “OFF” position (for PowerWalker VFI 10000-20000 TP 3/1), turn the R/S/T/N input switch in the “OFF” position (for PowerWalker VFI 10000TCP 3/1), then disconnect the mains lead.

★ Ensure that no liquid or other foreign objects can enter the

UPS.

1.3 Maintenance, servicing and faults

★ The UPS operates with hazardous voltages. Repairs should be

carried out only by qualified maintenance personnel.

★ Caution - risk of electric shock. Even after the unit is

disconnected from the mains power supply (building wiring terminal), components inside the UPS are still c onnected to the battery which are potentially dangerous.

★ Before carrying out any kind of service and/or maintenance,

please disconnect the batteries. Verify that no current is present and no hazardous voltage exists in the capacitor or BUS capacitor terminals.

★ Batteries must be replaced only by qualified personnel. ★ Caution - risk of electric shock. The battery circuit is not

isolated from the in put v oltage. Hazardous v oltages may occu r between the battery terminals and the ground. Verify that no voltage is present before servicing!

★ Batteri es have a high shor t-circuit current and pose a risk of

shock. Take all precautionary measures specified below and any other measures necessary when working with batteries:

－ remove all jewellery, wristwatches, rings and other metal

objects

－ use only tools with insulated grips and handles.

★ When changing batteries, replace with the same quantity and

the same type of batteries.

★ Do not attempt to dispose of batteries by burning them. It

could cause explosion.

★ Do not open or destroy batteries. Effluent electrolyte can cause

injury to the skin and eyes. It may be toxic.

★ Please replace the fuse only by a fuse of the same type and of

the same amperage in order to avoid fire hazards.

★ Do not dismantle the UPS, except the qualified maintenance

personnel.

1.4 Transport

★ Please transport the UPS only in the original packaging (to

protect against shock and impact).

1.5 Storage

★ The UPS m ust be stockpiled in the room w here it is ventilated

and dry.

* Safety

IEC/EN 62040-1

*EMS

ESD........................................:IEC/EN 61000-4-2

Level 3

RS..........................................:IEC/EN 61000-4-3

Level 3

EFT.........................................:IEC/EN 61000-4-4

Level 4

SURGE....................................:IEC/EN 61000-4-5

Level 4

Low Frequency Signals .............:IEC/EN 61000-2-2

1.6 Standards

* EMI

Conducted Em i ss i on .. ...............:IEC/EN 62040-2 Category C3

Radiated Emission...................:IEC/EN 62040-2 Category C3

Warning: This is a product for c om mer cial and industrial application in the second environment-installation restrictions or additional measures may be needed to prevent disturbances.

2. Description of Commonly Used Symbols

Some or all of the following symbols may be used in this manual. It is advisable to familiarize yourself with them and understand their meaning:

3. Introduction

3.1 System and model description

This Online Series is an uninterruptible power supply incorporating double-conversion technology. It provides perfect protection specifically for computer equipment, communication systems to computerized instruments.

Its true online double-conversion design eliminates all mains power disturbances. A rectifier converts the alternating current from the utility power to direct current. This direct current powers the inverte r. On the basis of this DC voltage, the inverter generates a pure sinusoidal AC voltage, which is constantly powering the loads.

Computers and Peripherals are thus powered entirely by the UPS. In the event of power failure, the maintenance-free batteries power the inverter.

This manual is applicable to the PowerWalker VFI 10000-20000 TP 3/1 models and PowerWalker VFI 10000T CP 3/1 model.

The tower 3-phase series UPS providing outstanding performance and reliability, the UPS’s unique benefits include:

 Online UPS design with pure sine wave output.  True online d ouble-conv ersion te chnolog y with hi gh power densit y,

utility frequency independence, and generator compatibility.

 Overall high efficiency > 93%, saving the operating cost.  True three-phase power factor correction and high input power

factor (PF>0.99). Save the installation cost and reduce the pollution back feed into upstream power system.

 High output power factor (0.9), to adapt more type load.  Intelligent Battery Management technology that uses advanced

battery management to increase battery service life, optimize recharge time.

 Selectable High Efficiency mode (ECO mode) or CVCF mode

operation.

 Combo input (single phase or three phase) auto detection  Back-feed protection  Start-on-battery capability for powering up the UPS even if utility

power is not available.

 Standard communication options: one RS-232 communication port,

one USB communi cation port.

 Optional connectivity cards with enhanced communication

capabilities.

 Remote shutdown control through the Remote Power-off (RPO)

port.

 For tower PowerWalker VF I 10000-20000 TP 3/1, Maintenances are

simplified by allowing the safe replacement of batteries without powering down the UPS. But PowerWalker VFI 10000TCP 3/1 model have no this function.

 N+X parallel redundancy to increase the reliability and flexibility.

The max p ar a llel numb er is 4.

 User-friendly LCD display and LED indicators.  For tower PowerWalker VFI 10000-20000 TP 3/1, easily battery

exchange or extension and ava ilable to exten d the ba ckup time. But PowerWalker VFI 10000TCP 3/1 model have no this function.

The appearance of tower 3-phase series Refers to Fig. 3-1

PowerW a lk er VFI 10000 TP 3/1 REAR VIEW

PowerWalker VFI 20000 TP 3/1 REAR VIEW

10000TP 3/1

20000TP 3/1

10000TCP 3/1

Power Rating

10KVA/9KW

20KVA/18KW

10KVA/9KW

Frequency (Hz)

50/60

Current

L1/L2/L3：23A MAX

L1/L2/L3：46A MAX

L1/L2/L3：23A MAX

Battery

Voltage

288VDC

240VDC

Parallel Port (Optional)

Intelligent Slot

EPO、、RS232 USB

Fan

AS400

Input Breaker

Terminal Blocks Cover

External Battery

IEC Connector

Maintenance and Output Switch Cover

PowerWalker VFI 10000TCP 3/1 REAR VIEW

3.2 Product Specification an d Performance

1) General Sp e c i f ic ation

Input

Fig. 3-1 the rear view of the tower 3-phase series UPS

Model

Voltage (110-276)VAC (Depends on Load Level)

PowerWalker VFI

Current

43A MAX

86A MAX

51.8A MAX

Voltage

200VAC/208VAC/220VAC/230VAC/ 240VAC*

3.5A/41.7A

7.0A/83.3A

3.5A/41.7A

(WxDxH) mm

Net Weight (kg)

127

188

Model

Voltage

Frequency

Power Factor

PowerWalker VFI PowerWalker VFI PowerWalker VFI

10000TCP 3/1

Output

Dimension

Current

45A/48.1A/45.5A/4

350x650x890 260*550*708

90A/96.2A/90.9A/8

45A/48.1A/45.5A/4

2) Electrical Performan c e

Input

10000TP 3/1 20000TP 3/1

Three-phase 50/60 Hz±10% >0.99(@Full load)

*：If output voltage be set 200V, output power will derating to 90% of power

rating

Power

Output

Voltage

Regulation

±1% 0.9 lag

Power Factor

Frequency

tolerance.

Synchronized 50/60Hz±10% in Line mode (AC mode)

±0.1% of normal frequency in Battery mode

Distortion Overload capacity

100%-110% load transfers to Bypass mode after 5 minutes

THD<2%

Full load

(Linear

Load)/

<5% for

reference

non-linear

load

110%-130% load transfers to Bypass mode after 1 minutes

130%-150% load transfers to Bypass mode after 10 second

>150% load transfers to Bypass mode after 2 second

Current

crest ratio

3) Operating Environment

Temperature Humidity Altitude Storage temperature

0°C-45°C

<95% <1000m

-15°C-50°C

3:1

Note: if the UPS is installed or used in a place where the altitude is above than 1000m, the output power must be derated in use, please refer to the following:

Altitude (M) 1000 1500 2000 2500 3000 3500 4000 4500 5000

Maximum

100% 95% 91% 86% 82% 78% 74% 70% 67%

4. Installation

The system may be installed and wired only by qualified electricians in accordance wit h applicable safety regulations!

4.1 Unpacking and Inspection

1. Moving to th e in stallation site

The tower 3-phase series UPS has wheels making it easy to move the UPS to the installation site after it has been unpacked. However, if the receiving area is far from the installation site, we recommend you to move the UPS by using a pallet jack or a lifter before you start to unpack the UPS.

2. Unpacking and inspection

1) At the installation site, the utmost care shall be taken when removing t he pac kaging i n o rder to a voi d damagi ng t he equi pment. Check all packaging materials to ensure that no items are missing. The shipping package contains:

● A UPS

● A user manual

● A communication cable

● Parallel port cover plate

Tools kit

Remove the packa ging foll owing t he seque nce illustrated in Fig. 4-1 to Fig. 4-4. （only for PowerWalker VFI 10000-20000 TP 3/1）

Lifter

Scissors

Phillips screwdriver

Wrench

Fig. 4-1 Unpacking-step1 Fig. 4-2 Unpacking-step2

Fig. 4-3 Unpacking-step3 Fig. 4-4 Unpacking-step4

The shipping materials are recyclable. After unpacking, save them for later use or dispose of them appropriately.

2) Inspect the appearance of the UPS to see if there is any damage

during transportation. Do not turn on the unit and notify the carrier and dealer immediately if there is any damage or lacking of some parts.

4.2 Input and Output Power Cords and Protective Earth Ground Installation

1. Notes for installation

1) The UPS must be installed in a location with good ventilation, far away from water, inflammable gas and corrosive agents.

2) Ensure the air vents on the front and rear of the UPS are not blocked. Allow at least 0.5m of space on each side.

3) Condensation to water drops may occur if the UPS is unpa cked in a very low temperature environment. In this case it is necessary to wait until the UPS is fully dried inside out before proceeding installation and use. Other wi se t here are hazards of electric sh oc k .

4) Once the installation is completed, the side mounting brackets （used in shipping）shall be fixed back to ensure the sta bility of the

UPS enclosure. If impossible, additional stability can be added by anchoring the mounting br ackets to the floor with M8 bolts. See Fig. 4-5. （only for PowerWalker VFI 10000-20000 TP 3/1）

Fig. 4-5 Additional stability

2. Installa t ion

Installation and wiring must be performed in accordance with the

local electric code and the following instructions by professional personnel.

For safety, please cut off the mains power switch before installation.

1) Op en the terminal block cover located on the rear panel of the UPS, please refer to the appearance diagram.

2) For tower PowerWalker VFI 10000TCP 3/1 UPS, it is recommended to select the UL1015 8AWG(10mm

) wire or other insulated wire which complies with AWG Standard for the UPS input and output wirings.

3) For PowerWalker VFI 20000TP 3/ 1 U PS, it is recommended to select the UL1015 6AWG(25mm

) wire or other insulated wire which complies with AW G Standa rd f or the UPS in put and out put wirings.

Note: Do not use the wall receptacle as the input power source

for the UPS, as its rated current is less than the UPS’s maximum input current. O therwise t he receptacle m ay be burned and destroyed.

4) C onnect the input and output wires to the corresponding input and output terminals according to the following diagram.

Note: you must make sure that the input and output wir es and

the input and output terminals are connected tightly.

5) The protective earth ground wire refers to the wire connection between the equipment which consumes electri c eq uipment an d the ground wire. The wire diameter of protective earth ground wire should be at least as above mentioned for each model and green wire or green wire with yellow ribbon wire is used.

6) A fter having completed the installation, make sure the wiring is correct.

7) P lease install the output breaker between the output terminal and the load, and the breaker should with leakage current protective function if necessary.

8) To connect the load with the UPS, please turn off all the loads first, then perform the connection and finally turn on the loads one by one.

9) No matter the UPS is connected to the utility power or not, the output of the UPS may have electricity. The parts inside the unit may still have hazardous voltage after turning off the UPS. To make the UPS have no output, power off the UPS, and then disconnect the utility power supply.

10) Suggest charging the batteries for 8 hours before use. After connection, turn the M1/M2/N input breaker (for PowerWalker VFI 10000-20000TP 3/1), turn the input switch (for PowerWalker VFI 10000TCP 3/1 ) in the "ON" position, the UPS wil l cha r ge the batteries automatically. You can also use the UPS immediately without charging the batt eries first, but the backup time may be less than the standard value.

11) If it is necessary to connect the inductance load such as a monitor or a laser printer to the UPS, the start-up power should be used for calculating the capacity of the UPS, as its start-up power consumption is too big when it is started.

PowerW a lk er VFI 10000-20000TP 3/1

10000TP 3/1

20000TP 3/1

Max.conducto r cross se ct io n[ mm2]

Input L1,L2,L3 breaker (A)

40A,250VAC

60A,250VAC

Max.conducto r cross se ct io n[ mm2]

Input M2 breaker (A)

63A,250VAC

100A,250VAC

Input fuse (A)

30A,250VAC

50A,690AC

Max.conducto r cross se ct io n[ mm2]

PowerWalker VFI 10000TCP 3/1 model

Fig. 4-6 Input and output Terminal Block wiring diagram

Important notes: If the UPS is used in single mode, JP1 and JP2 must be connected. If the UPS is used in parallel mode, the J umper between JP1 and JP2 must be removed.

Use cable cross section and protective device specification

Model PowerWalker VFI

Input L1,L2,L3 Min.conductor cross section[mm

Input N, M2 Min.conductor cross section[mm

Output L,N, Min.conductor cross section[mm

]

2.5

PowerWalker VFI

Max.conducto r cross se ct io n[ mm2]

protection in line input.

Protective Earthing conductor[mm2]

Max.13

Max.25

Torque for fixing above terminals

(10 1b in)

(18 1b in)

External Battery Cabinet Positive Pole(+),Neutral pole,Negative pole(-), Min.conductor cross section[mm

]

Line input Backfeed protection device

M2 input Backfeed protect io n dev ice A 2-pole disconnection device with

A 4-pole disconnection device with 100A/250VAC, less than 15s break time and min. 1.4mm clearance will be used in final installation for backfeed

100A/250VAC, less than 15s break time and min. 1.4mm clearance will be used in final installation for backfeed

Sheet.1 PowerWalker VFI 10000-20000TP 3/1 models

Model PowerWa lk er VFI 10000TCP 3/1

Input L2,L3 Min.conductor cross section[mm2] Max.conducto r cross se ct io n[ mm2] Input L1,L2,L3,N switch (A) 63A,250VAC

2.5 4

Output switch(A)/maintain switch(A) 63A,250VAC Input L1,N Min.conductor cross section[mm2] Max.conducto r cross se ct io n[ mm2] Input fuse (A) 30A,250VAC Output L,N,

Min.conductor cross section[mm2]

Max.conducto r cross se ct io n[ mm2] External Battery Cabinet Positive Pole(+),Neutral pole,Negative pole(-), Min.conductor cross section[mm2] Max.conducto r cross se ct io n[ mm2] Protective Earthing conductor[mm2] MAX 13 Torque for fixing above terminals (10 1b in)

10 13

Sheet.2 PowerWalker VFI 10000TC P 3/1 model

4.3 Operating Procedure for Connecting with The External Battery

1. For P owerWalk er VFI 10000-20000TP 3/1, The nominal DC voltage of external battery pack is 288VDC. Each battery pack consists of 24 pieces of 12V maintenance free batteries in series. For PowerWalker VFI 10000TC P 3/1 model, the nominal DC voltage of external batter y pack is 240VDC. Each battery pack consists of 20 pieces of 12V maintenance free batterie s in series ,To achieve longer backup time, it is possible to connect multi-battery packs, but the principle of “same voltage, same type” should be strictly followed.

2. For PowerWalker VFI 10000-20000TP 3/1, select the UL1015 8AWG (10mm

)/6AWG ( 25mm2) wire respectively or other insulated wire which complies with AWG Standard for the UPS battery wirings. The procedure of installing bat tery bank should be c omplie d with strictly. Otherwise you may encounter the hazardous of electric shock.

1) For tower 3/1 series if the UPS has internal bat tery pack, first of

all, disconnect the internal battery pack DC connectors.

PowerWalker VFI 20000TP 3/1 PowerWalker VFI 10000TP 3/1

Fig. 4-7 Disconnect the internal battery pack DC connectors

2) A D C breaker mus t be connected between the external battery

pack and the UPS. The capacity of break er must be n ot less than the data specified in the general specification.

3) Set the external battery pack breaker in “OFF” position and

connect the batteries (24 pieces for PowerWalker VFI 10000-20000TP 3/1, 20 pieces for PowerWalker VFI 10000TCP 3/1) in series.

4) For PowerW alke r VFI 10000-20000TP 3/1, Connect the external

battery pack to the battery terminals. For PowerWalker VFI 10000TCP 3/1 model, Connect the external battery pack to the battery anderson connect or.

5) Reconnect the internal battery pack DC connectors, if you had

did step one.

3. Do not attempt to connect any loads to the UPS now. You should connect the input power wire to t he right position first. And then set the breaker of the battery pack in the “ON” position. After that set the input breaker in the “ON” position. The UPS begins to charge the battery packs at the time.

5. Operation

5.1 Display Panel

The UPS has a four-button graphical LCD with dual color backlight. Standard back-li ght is used to light u p the display with w hite text and a blue background. When the UPS has a critical alarm, the backlight changes the text to dark amber and the backgrou nd to red. Besides the graphical LCD, the UPS has four colorized LEDs to provide you more convenient info.

See Figure Below

Fig. 5-1 PowerW a lk e r VFI 10000-20000TP 3/1/ PowerWalker VFI

10000TCP 3/1 UPS Control Panel

Table 5-1 Co n tr ol Button Functions

The Button Function Illustration

Power on

When the unit is no power and has connected with battery, press this button for >100ms&<1s to power on

Turn on

Turn off

Enter main menu

Exit main menu

Scroll up

Scroll down

Enter next menu tree

When the unit is powered on and in Bypass mode, press this button for >1s to turn on

When the unit has been turned on, press this button for >3s to turn off

When displaying default UPS status summary screen, press this button for >1s to enter the main menu tree

Press this button for >1s to exit the present menu to default system status display menu without executing a command or changing a setting

Press this button for >100ms&<1s to scroll up the menu option

Press this button for >100ms&<1s to scroll down the menu option

Press this button for >100ms&<1s to select the present menu option, or enter next menu, but do not change any settin g

Press this button for >100ms&<1s to select the present menu option, or enter next menu, but do not change any setting

Press this button for >1s to confirm the edited options and change the setting

Select one menu option

Confirm the present setting

(Green)

(Yellow)

(Red)

with no output

with output

Table 5-2 LED definition

UPS state

Bypass mode

Turning on Line mode Battery mode HE mode Battery test mode Fault mode Warning

Normal LED

△ △

●

△ △

↑ ↑

↑

Battery LED

△ △

Bypass LED

★

●

↑

Note：

●: Lightened constantly

△: #1-#4 Lightened circularly ★: Flashing

↑: Depended on the fault/warning status or other status

Fault LED

↑

↑ ↑ ↑

●

★

Table 5-3 Buzzer definition

UPS condition Buzzer status

Fault active Continuous Warning active Beep every second Battery output Bypass output Beep every 2 minutes

Beep every 4 seconds, if battery low, buzzer Beep every second

The UPS provides useful information about UPS itself, load status, events, measurements, identification, and settings through the front panel display.

After powering on, the LCD will display the “WELCOME” logo for several seconds and then enter to the default page which shows the UPS status summary. The display automatically returns to the default UPS status summary screen when no button has been pressed within 15 minutes.

On the UPS status summary screen it provides the following information:

 Status summary, including mode and load  Alarm status, if any are present

Notes: alarm including fault and warning information

 Battery and charger status, including battery voltage, charger

level and charger status

 Running information including parallel UPS and running time

Fig. 5-2 The default LCD display

The more detailed operation of LCD is illustrated in the chapter of 5.4.

5.2 Operating Mode

The different graphic symbol could be displayed corres ponding to current operating mode or status.

Table 5-4 St atu s Summary Screens

Status Summary Screen

Fig 5-3

Fig 5-4

Fig 5-5

Description Normal mode:

The UPS is operating in Normal mode from utility power.

Battery mode:

When the UPS is running in battery mode, the buzzer beeps once every 4 seconds.

Bypass with output:

The UPS does not have the backup function when it is in bypass mode. The power used by the load is supplied from the utility power via internal filter. The UPS will beep once every 2 minutes in bypass mode.

Fig 5-6

Bypass without output:

The UPS in bypass mode without output

+ 105 hidden pages

PowerWalker VFI 10000 TP 3-1 BI Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual