PowerWalker VFI 3/3 Series VFI 30000TP/40000TP 3/3 BE/BI 380/400/415V 50/60Hz (3-phase input/output) User Guide
EN ©2013 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.
User Guide UPS 30/40kVA B, 380/400/415V, 50/60 Hz (3-phase input/3-phase output) 614-09946-01 Contents 1. Safety instructions….....……………………………………………………....……….. 01 1.1 Safety caution….....………………….....………………….....…………………..... 01 1.2 Audience caution….....………………….....………………….....……………… 01 1.3 CE marking….....………………….....………………….....………………….....… 02 1.4 User precaution….....………………….....………………….....………………02 1.5 Environment….....………………….....………………….....…………………..... 03 1.6 Inquiries….....………………….....………………….....
21 5. Electrical installation…………………………………..............……………………… 5.1 Electrical Preparations…………………………………………………………… 21 21 5.2 Installation and wire connection diagram……………………………………… 24 5.3 Suggested cable and protective devices……………………………………… 5.4 Internal Battery Installation……………………………………………………26 5.5 Connecting the external battery………………………………………………34 35 5.6 Connections between battery cabinet and UPS……………………………… 5.7 Handling the batteries…………………………………………………………… 36 6.
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 reference 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 enclosure is earthed and IP20 rated against electrical shock and foreign objects.
Caution! Read the manual before operating or working on the UPS. EN 1.3 CE marking The product has the CE marking in compliance with the following European directives: LVD Directive (Safety) 2006/95/EEC EMC Directive 2004/108/EEC Note! This product for commercial and industrial application in the second environment Installation restrictions or additional Measures may be needed to prevent disturbances. 1.
1.5 Environment The UPS must be installed according to the recommendations in this manual.Under no circumstances 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.
2 Introduction The product described in this manual is an Uninterruptible Power Supply (UPS). It is a true online, continuous duty, double conversion, solid state, three-phase system, providing conditioned 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.
2.2 Basic system configuration 2.
① 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; ③ Battery: This light will turn "yellow" when UPS is powered by batteries; ④ Bypass: This light will turn "green" when UPS load is powered by Bypass Input; ⑤ 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”
CHGR FAN Battery trays Front view(door open) 7
3 Technical data 3.1 Standards EN UPS VFI 30000TP 3/3 BE/BI VFI 40000TP 3/3 BE/BI Safety IEC62040-1:2008,EN62040-1:2003 and EN60950-1:2005 EMC IEC62040-2:2006 and EN62040-2:2005 Product IEC62040-3:1999 and EN62040-3:2001 3.
3.4 Characteristics VFI 30000TP 3/3 BE/BI Noise (ISO 7779) VFI 40000TP 3/3 BE/BI <57dB at 75% load Efficiency-nominal load Up to 92% 3.5 AC input VFI 30000TP 3/3 BE/BI VFI 40000TP 3/3 BE/BI Rectifier input 3 phases + N Bypass input 3 phases + N Voltage (L-N) 121V-274 Volts without using battery Frequency 40-70 Hz Power factor 0.99 Input distortion < 5% THD(I) Rated input voltage Rated input current 380V/400 V/415V 43A/41A/40A 57A/54A/52A 3.
3.7 AC output VFI 30000TP 3/3 BE/BI Active power VFI 40000TP 3/3 BE/BI 24KW 32KW Number of phases 3-phases + N Frequency 50/60HZ Voltage (L-N) Overload capability (Mains available) Overload capability (battery available) EN 220/230/240 VAC 110%150% 0.
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 & trays)(Only for model without batteries) 4.
EN 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.
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 required 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.
4.4 Cabinet installation Note! EN Please use stabilizing devices 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). 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.
The switching sequence for circuit breaker from normal position to maintenance position: The normal positions of the MBS switches.
The maintenance positions of the MBS switches EN Transfer UPS from normal mode to maintenance bypass mode: 1.The normal start position should be following: 2.
1)Switch-off picture 2)If it is in single machine mode, the following will appear 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. 5.Turn the Maintenance switch to “MAINTENANCE” side. 6.Turn OFF the Bypass Input switch and N switch.
7.UPS is now in the maintenance bypass mode, see below (Note: the Serv disconnect i.e. battery breaker must be turned off): EN Transfer UPS from maintenance bypass mode to normal mode: 1.The normal start position should be following: 2.Turn ON the Bypass Input switch and N switch When the LED of bypass turns green,the UPS enters into bypass mode. 3.Turn the Maintenance switch to “UPS” side.
Then the UPS turn to bypass mode. 4.Turn ON the Rectifier Input switch and battery breaker. 5.
6.UPS is now in the normal mode,see below: EN 7.Remount the locking plate of maintenance switch to the position to prevent the use of it.
5 Electrical installation 5.1 Electrical Preparations Note! It must be ensured that no line input source can accidentally be connected to the UPS during installation. Warning! Installation may only be carried out by qualified technicians and in conformity with the applicable safety standards. Warning! The UPS unit is not applicable to the IT power distribution system. 5.
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 approximate length of 770mm and 4 black wires (B8) with an approximate length of 65mm for BAT-; 4 black wires (B12, B13, and B17) for BAT- connection. EN 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.
2.If 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. Terminal block diagram Warning! High touch current earth connection essential 23 before connecting supply.
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. 5.
Routing of 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 30000TP 3/3 BE/BI VFI 40000TP 3/3 BE/BI Rectifier Input L1, L2, L3, N, Bypass Input L1, L2, L3, N, min. conductor cross section[mm ] max.
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). EN Warning! ENSURE THAT THE UNINTERRUPTIBLE POWER SYSTEM IS ISOLATED BEFORE WORKING ON THIS CIRCUIT. 5.
3. Assemble the battery packs.There are eight batteries in each battery pack, four packs in each shelf and total is four shelves. Step1: Put batteries into the trays (see Fig. 2). Fig. 2 Step2: connect the wires between the batteries (see Fig. 3). Front Back Fig.
Please refer to the following figure(Fig.4) for wire connections of the four battery packs. EN Fig. 4 Step3: Install the top tray downward, and fold both the top and bottom tray flanges (see Fig 5). Fig.
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 Fig. 6 Step5: Paste the labels to the battery packs (see Fig. 7). Fig.
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). EN Fig. 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). Fig.
5. Connect the cables to each shelf respectively (see Fig. 10). REMARK: MAKE SURE TO CONNECT WIRES WITH THE SAME COLOR. Fig.
6. Secure each fix-plate with four screws (see Fig. 11). EN Fig.11 7. Tie up the wires properly(see Fig. 12). Fig.
8. Reinstall the battery cover and secure it with the eighteen screws.
5.5 Connecting the external battery Before connecting the external battery, please read the notice and warning label on the UPS. EN Warning! In the event of malfunction, the battery cabinet chassis or battery cabinet frames may become live! Warning! Special care 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.
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 applicable EC directives are met and declare conformity. Connect the battery cabinet as follows: Turn off the UPS. Check the internal battery breaker is off and/or any external battery switchs open. Connect PE first.
5.7 Handling the batteries Warning! EN 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 Warning! When recharging, observe the indications on the packaging. Exchanging batteries Warning! Before replacing batteries, make sure that those to be installed are fully charged.
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 PARALLEL 4 PARALLEL AS400 5 EPO 7 RS485 Intelligent slot SERVICE RS232 Expanded slot 2 6 8 1. Intelligent slot: suitable for WebPower card of remote supervising management,enabling you to realize remote supervising management on UPS through Internet. 2.
RS232 port EN RS485 port 38
AS400 port Note! The UPS have to be manually reset if remote shutdown occurs.
7 User operations EN Warning! 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 the precaution, warnings and only perform the described operation.
Remark: the following drawing takes PowerWalker VFI 30000TP 3/3 BE/BI as an example and statistics are only for reference.
5)Press ▼ again to obtain the below 6)Press ▼ again to obtain the below information information EN 7)Press ▼ again to obtain the below 8)Press ▼ again to obtain the below information information VFI 30000TP 3/3 42
Note! If malfunction occurs, “x” will appear at the lower right corner of the display,while a warning occurs, “ ” will appear at the same position (as illustrated in the below picture with battery mode as an example). 4.
3)Select “Yes, Confirm” to switch on 4)Normal Switch-on the machine EN 5)Battery power supply (switch off line input switch) 44
5.
5)Select “Yes, Confirm” to switch off 6)Normal Switch-off the machine EN Note! If you intend to switch off only one set of UPS among the parallel machine system, select “single machine switch-off”; if switch-off is intended for the entire parallel machine system, select “parallel machine switch-off”. 6.
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 the following programs. 1)Action display (bypass power supply) 2) Press ▼ 3)Enter respective password 4)Select action item 8. The Series is capable of DC start-up without AC input, panel display being similar to switch-on picture with AC supply.
9. Procedures of DC switch-on: Activate DC switch-on function set under UPS bypass mode Make sure that “+”, “-” and “N” wires of batteries are properly connected to UPS Switch on batteries Lightly touch ENTER Manually conduct switch-on order within about 1min after LCD self-inspection EN Note! UPS will be switched off automatically if there is no operation within 1min after LCD self -inspection is completed! 7.
Parallel machine wire connection drawing(one battery supply) Parallel machine wire connection drawing(separate battery supply) 49
Single machine wire connection drawing EN 50
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.
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 metallic substances on the batteries. 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.
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 Batteries change Batteries test Cooling fan change Interval 3-5 years or according to battery suppliers recommendations 18 months 5 years 8.3 Cooling fan The cooling fan lifespan of the UPS unit is about 60 000 operating hours.
9 Parallel systems EN Note! 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.
Note! Parallel signal cable should be connected as a loop.
11 Display reference Table EN 56
Should any display or warning message excluded in the above table be found,please contact 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 2.Line loss 3.Neutral loss 4.Line phase error 5.Bypass loss 6.Bypass phase error 7.Battery open 8.Low battery voltage 9.Over charger 10.Battery reverse 57 11.Charger failure 12.Battery over restrict 13.Battery over temperature 14.Fan over restrict 15.
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