PowerWalker VFI 10-200K CPT 3/3, Manual

Page 1: ...PowerWalker VFI 10 200K CPT 3 3 Manual Uninterruptible Power Supply System ...

Page 2: ...on of separate static bypass line terminals X14 a X17 UPS B version only 5 2 3 Connection to the output terminals X6 to X9 5 2 4 Connection to the battery terminals of the equipment X11 X12 and X23 with the battery modules X47 X48 and X49 5 2 5 Connection to the input main protecting earth terminal X5 and the earth bonding terminal X10 5 2 6 Relay COM port Connector X32 5 2 7 RS 232 and RS 485 COM...

Page 3: ...8 2 WARRANTY CONDITIONS 8 2 1 Warranty terms 8 2 2 Out of the scope of supply 9 ANNEXES 9 1 PARTICULAR SPECIFICATIONS EQUIPMENTS LV 9 2 TECHNICAL SPECIFICATIONS EQUIPMENTS HV 9 2 GLOSSARY ...

Page 4: ...ment for future consults and keep it on hand during the installation and commissioning procedures In the next pages the equipment or unit and S T S terms are referred to the Uninterruptible Power Supply UPS and Service and Technical Support respectively 2 1 1 Conventions and used symbols Some of the symbols can be used and shown in the equipment batteries and or in the description of this document...

Page 5: ...s installed Alternating current a c Direct current d c 2 1 2 For more information and or help For more information and or help of your specific unit request it to our Service and Technical Support S T S 2 2 SAFETY INSTRUCTIONS Check the data ofthe nameplate are the required bythe installation Never forget that the UPS is an electrical energy generator so the end user must take all the needed cauti...

Page 6: ...completely dry before starting any installation task Do not store install or expose the equipment in corrosive wets warms dusty or with conductive parts environments and never outdoors Installation location will be cooled dry and far from heat sources and with easy access If possible in an environment with temperature control Avoid to locate install or store the equipment in places with direct sun...

Page 7: ...he equipment as it was with the protection cover put back and front door closed To shutdown the equipment completely follow the instructions in the start up and shutdown chapter Consult the documentation before doing any action A wrong manipulation over the switches can cause important production losses and or failures in the equipments Protection Earth cable of the UPS drives the leakage current ...

Page 8: ...ery circuit is not isolated from input voltage it is dangerous to touch any part of the batteries Dangerous voltages can be found between the terminals of the battery set and the earth Check that there is not any voltage at the input before taking any action over them Before doing any action inside the UPS disconnect the batteries Check that no voltage is present and there is not potential danger ...

Page 9: ...it do it by another one of the same type format and size After prolonged periods of time of disconnection it is needed to recharge the batteries for 12 hours as minimum every 6 months in order to avoid the irreversible degradation of them Never short the battery terminals due to the high risk that involves It involves thedetrimentof the equipmentand batteries Avoid mechanical efforts and impacts D...

Page 10: ... by end users EN IEC 60950 1 IT equipments Safety Part 1 General requirements EN IEC 62040 2 Uninterruptible power supply UPS Part 2 EMC requirements The manufacturer responsibility is excluded in the event of any modification or intervention in the product done by the end user This is a product for its use in commercial and industrial applications so restrictions and additional measures can be ne...

Page 11: ...ents of the same family because the needed electronic kit is already included Parallel connection can be done at any time when the upgrading requirements are needed to increase the supplied power of the equipment or in order to have redundant operating systems for installations with higher safety Do not connect UPS equipments of different features versions settings back up times or duplicated addr...

Page 12: ...F PB RD Fig 1 UPS front view from 7 5 to 30 kVA LV 10to 60 kVA HV with or without separate static bypass line B Fig 2 UPSfrontview from 40 to60kVA LV 80 to120kVA HV without separate static bypass and 40 kVA LV 80 kVA HV with separate static bypass B ...

Page 13: ... Front view with static bypass equipment Front view without static bypass equipment Attention Static bypass equipment needs to adjust the cabinet Fig 4 UPS front view of 80 and 100 kVA LV 160 and 200 kVA HV with front door closed ...

Page 14: ...11 1 Equipments with extended back up time only Fig 6 UPS Front view with door opened 7 5KVA to 20KVA LV 10KVA to 40KVA HV models Fig 7 UPS Front view with door opened 30KVA LV 60KVA HV models ...

Page 15: ...view with door opened 7 5KVA to 10KVA LV 10KVA to 20KVA HV models with separate static bypass line UPS B models Fig 9 UPS Front view with door opened 15KVA LV 30KVA HV models with separate static bypass line UPS B models ...

Page 16: ...13 Fig 10 UPS Front view with door opened models 20KVA LV 40KVA HV with separate static bypass line UPS B models Fig 11 UPS front view with door opened models 40kVA LV 80KVA HV ...

Page 17: ...14 Fig 12 UPS front view with door opened models 50 and 60 kVA LV 100 and 120 kVA HV without separatestatic bypass line ...

Page 18: ...15 Fig 13 UPS front view with door opened models 80 and 100 kVA LV 160 and 200 kVA HV without separatestatic bypass line ...

Page 19: ...16 Q8 X47 X49 X48 BF X5 PR X10 Fig 15 Battery cabinet front view No 1 with door closed Fig 16 Battery cabinet front view No 1 with door opened ...

Page 20: ...17 Q8 X47 X49 X48 X5 PR X10 Fig 17 Battery cabinet front view No 2 with door closed Fig 18 Battery cabinet front view No 2 with door opened ...

Page 21: ...18 Fig 19 Battery cabinet front view No 3 with door closed ...

Page 22: ...19 Batteries group No 2 Batteries group No 1 F8 F8 N F8 Q8 X48 X49 X47 X10 PR X5 Fig 20 Battery cabinet front view No 3 with door opened ...

Page 23: ...der switch with 3 fuses in models up to 20 kVA LV 40 kVA HV or switch for B1 versions and higher power rates models Q4a Static bypass switch two or three poles depending on the mains typology B version only Q5 Manual bypass switch Protection and manoeuvring parts Q in the battery cabinet Q8 Battery fuse holder switch of 3 fuses for models up to 60 kVA LV 120 kVA HV Battery switch in models higher ...

Page 24: ...xiliary contact of output switch To be connected to its external homologous X47 Battery positive terminal of the battery cabinet X48 Battery negative terminal of the battery cabinet X49 Battery neutral terminal N of the battery cabinet central tap X50 External EPO terminals X51 Terminalstripof twoterminals auxiliary contact of manual bypass switch To be connected to its external homologous Control...

Page 25: ...us it is used to filter the DC needed for the correct operation of PFC converter and inverter 4 3 3 Batteries This UPS series has a battery set that stores energy during the normal operating mode present mains and they are discharged during the emergency operation mains fault keeping the critical loads running during the required time Batteries are sized to supply full power to the assigned critic...

Page 26: ...he bypass stage is based on six double thyristors in semipack format working as AC switches three of them are for shifting the input over the output and the other three are for shifting the inverter over the output The managing system of the SCR switches is based on drivers designed with a shifting system that responds to the following requirements Full static shifting system Shifting with no high...

Page 27: ...ion This allows consigning a battery discharging current even with mains present This quality performance will make possible to do a battery test both in full load and no load conditions Output three phase rectifier controller independent per phase it is easy adapted to different settings either single phase or three phase It is highlighted the use of the AFC control technique that allows getting ...

Page 28: ...is the UPS goes back to operate as it is described in the previous section 4 4 1 Normal operating 4 4 3 Operating with non active inverter The inverter is non active due to alarm conditions like overloads over temperatures etc In this case the rectifier is still charging the batteries in order to keep their optimal charge status The inverter is also non active if the start up has not been done thr...

Page 29: ...W N Inp Out COM connec tions Inp Out Fig 27 Single line diagram connection of parallel system up to 4 units of UPS models COM connec tions Inp Out R S T N R S T N COM connec tions U V W N Inp Out COM connec tions Inp Out Fig 28 Single line diagram connection of parallel system up to 4 units of UPS B models ...

Page 30: ...nd assures an AC power supply of quality for the most critical loads The quantity of redundant equipments to be connected has to be studied according to the requirements of the application Parallel connection redundant or not adds several advantages a part from the connection itself Higher punctual power and back up time in a parallel system of N M equipments it is considered the nominal maximum l...

Page 31: ... attached to the impact indicator located to the packaging Unpacking To check the contents the packaging must be removed Complete the unpacking according to the Unpacking procedure of the supplied document together with this manual and or attached to the CD Contents Standard equipment up to 20 kVA LV 40 kVA HV CD manual and battery fuses Standard equipment 20 kVA LV 40 kVA HV CD and manual Battery...

Page 32: ...he location type of floor resistance of the floor kg m2 5 1 4 Location immobilised and considerations 5 1 4 1 Location for single equipments As i e Fig 29 shows two typical cases depending on the model The one that is based on a single cabinet UPS with batteries fitted in and the one of the UPS with batteries in a separate cabinet or extended back up time For extended back up times with more than ...

Page 33: ... the instructions described in this section referred to the installation of a single equipment or parallel system Switchgear or external manual bypass panel boards It is advisable to have an external manual bypass panel board equipped with input output static bypass UPS B version only and manual bypass protections in single installations For parallel systems up to two units it is very advisable ha...

Page 34: ...gher power rate are supplied in a separate cabinet Therefore battery protection is arranged as follows In the UPS stated in this document as Q3 Battery fuse holder switch with 3 fuses in models up to 20 kVA LV 40 kVA HV or switch for B1 versions and higher power rates In the battery cabinet and standard back up time Battery fuse holder switch with 3 fuses in models up to 60 kVA LV 120 kVA HV State...

Page 35: ... from panel board to each equipment Connection to three phase mains Connect the power supply cables R S T N to the input terminals X1 X2 X3 and X4 respecting the phase rotation and neutral indicated on the label of the equipment and in this manual If the phase rotation is not respected the equipment will not operate In case of discrepancies between the label and the instructions of this manual the...

Page 36: ... loads to U V W N output terminals X6 X7 X8 and X9 respecting the phase rotation and neutral indicated on the label of the equipment and in this manual If the phase rotation is not respected the equipment will not operate In case of discrepancies between the label and the instructions of this manual the label will always prevail Connection to single phase output Connect the loads to U N output ter...

Page 37: ...ing one side to terminals X11 X23 and X12 of UPS and the other one to terminals X47 X49 and X48 of battery module always respecting the stated polarity on the labelling of each element and this manual as well as the colour of the cables red for positive black for negative blue for middle tap N and green yellow for earth bonding see Fig 34 Repeat the same procedure with the other UPS This set can b...

Page 38: ...h a communication cable of just 3 wires Physical structure of the RS 232 Pin 2 RXD Serial data reception Pin 3 TXD Serial data transmission Pin 5 GND Ground signal Physical structure of the RS 485 Unlike other serial communication links this uses only 2 wires pins 4 and 9 of the female DB9 connector to make the dialogue among the systems connected to the network The communication will be establish...

Page 39: ...be that allows compensating the floating voltage according to the ambient temperature Any wire connected to the terminals X34 X45 and X51 will be entered into the equipment through the cable bushing PR 5 2 9 1 Terminal strip auxiliary contact of manual bypass switch X51 Terminal strip X51 of two pins of the UPS is connected in parallel with the normally opened auxiliary contact of the switch or ma...

Page 40: ...cation BUS To do it connect them in a sequential way two lines of the communication BUS between a unit and its adjacent Together with each UPS of a parallel system it is supplied a 15 wires bundle with HDB15 connectors at both ends one male and the other one female with a length of 5 m Therefore there will be as many communication BUS bundles BC as quantity of equipments to parallel have the syste...

Page 41: ...cts to be a guide to clarify the possible doubts on how the communication loop has to be connected To see the physical layout of the COM connectors for each power rate refer to the illustrations of figures 6 to 14 The base of front door PF has a slot to facilitate the entering and way out of the communication cables inside the UPS Watch to not trap them between the door and cabinet when closing it...

Page 42: ... the loads directly from mains on the bypass mode operating mean while the input voltage is available In those installations without the external manual bypass panel board omit the actions and steps that involve the manoeuvring of their switches Fig 38 Procedure start up shutdown 6 1 PRELIMINARY CONSIDERATIONS It is very important to always operate in the established order in the described instruc...

Page 43: ...t turned on yet The first UPS to start up the inverter will be set as Paral Mst Byp initially the one with the highest address as Paral Slv By Rsv and the rest if there are any as Paral Slv By Obviously in those systems with two equipments the Paral Slv By will not exist The UPS heriarchy relating to the rest of equipments of the system is a dynamic depending on the status of the rest of the equip...

Page 44: ...tch and the inverter voltage as well as the one of the Slave equipments Equipments are sharing the load on inverter Therefore Output switches Q2 are turned On Inverters are running and static switches are on inverter 6 3 SHUTDOWN OF ONE EQUIPMENT OF THE SYSTEM Turn the output switch Q2 of the UPS to shutdown Off In the screen 0 0 from LCD panel will display 6 4 START UP THE PREVIOUS UPS AGAIN Star...

Page 45: ...use Holder Q8 of each pack to Off In standard units set the input switch Q1a to Off position In UPS B units set the input switch Q1a and static bypass switch Q4 to Off position The UPS is supplying output voltage directly from the mains through the manual bypass in units or from the mains of the static line bypass in the version UPS B units through the manual bypass The UPS is completely shutdown ...

Page 46: ...eys the value is selected To confirm press ENT Next field will blink to continue doing settings proceed in the same way or press ESC to return to no setting situation Validation of orders or commands When pressing key ESC from any screen of any submenu it is gone back to previous screen unless we are in any screen of Parameters menu and setting any of them If so the first pulsation of key ESC will...

Page 47: ...n on UPS Screen 1 3 to order a battery test On the second row information about the battery test is given Possible messages NOT AVAILABLE The battery test is not available PRESS ENTER Press ENTER to run the battery test EXECUTING The battery test is running SUCCESSFUL The battery test has been successful NOT SUCCESSFUL The battery test has not been successful Fig 43 Screen 1 0 Control Screen Confi...

Page 48: ...er output phase to neutral units 0 1V Inverter output current per each phase for three phase equipments or per phase for single phase equipment units 0 1A Three phase bypass voltages phases to neutral or for single phase bypass phase to neutral units 0 1V Bypass current per each phase for three phase equipments or per phase for single phase equipment units 0 1A Charge battery currents positive and...

Page 49: ...nits 0 1 Estimated backup time units 1minute 7 3 4 Settings level screen menu 3 0 See Fig 45 Fig 45 Screen 3 0 Settings and its submenus Screen 3 1 You can select the Theme of Main screen choosing one of your favourite Theme You can program the time hh mm ss hours minutes seconds and the date dd mm yy day month year You can select the display language between the following options English_UK 简体中文 ...

Page 50: ... the battery test is friday SAT the selected day to run weekly the battery test is saturday SUN the selected day to run weekly the battery test is sunday The line Hour Minute only have sense to be programmed if the automatic battery test is enabled you can program the time hh mm hours minutes in 24h format The Line Month Day only have sense to be programmed if the automatic battery test runs month...

Page 51: ...el connection Unit is on master state Parallel Slave Parallel connection Unit is on slave state Internal firmware versions of both Digital Signal Processor DSP Ver and microcontroller uC Ver In the sample screen ver 3 2 a and ver 2 4 b respectively UPS Serial Number expressed with 10 characters Possible characters ranges are 0 9 A Z and also blank space See sample screen And the Service Informatio...

Page 52: ...t voltage or the bypass input frequency are out of margins These margins are programmable but by default the bypass voltage range is 12 17 and the bypass frequency range is 0 5Hz Alarm 11 The UPS is on bypass for any reason It must be restarted by display keypad Alarm 12 This is an alarm for parallel systems It appears when some UPS of the parallel system block because the maintenance bypass switc...

Page 53: ...nverter Failure Inverter Block 66 UPS Blocked BLK Rectifier BLK UPS UPS BLOCKS 54 Internal Initialisation Error UPS Block DSP 55 Internal Execution Error UPS Block DSP 56 UPS Blocked BLK Inverter BLK UPS 57 Internal Communication UPS Block DSP 58 Parallel System Discharging UPS Block 59 UPS Over temperature UPS Block 60 Rectifier Overload UPS Block 61 Inverter Desaturations UPS Block 62 DSP Intern...

Page 54: ...urrent by default The short circuit is detected when the output voltage phase to neutral is lower than 8 of nominal voltage The system will retry twice to restart Alarm 35 With the inverter is running if there s a bypass phase rotation error the inverter will shut down Alarm 36 This alarm appears when there is a DSP Internal Error in the UPS module shutting down the UPS immediately There will be 2...

Page 55: ...th high inrush current or also if it is detected a wrong transient voltage in the inverter i e if there is a fault in an inverter transistor In such case the inverter will be shutdown for while and load will be transferred to bypass immediately The equipment will retry to start up the inverter several times see description of the Alarm 66 too Alarm 66 After several attemps detecting Inverter Fault...

Page 56: ...r or break in the communications has been detected by the Slaves equipments which will be blocked permanently Rectifier and Inverter are shutdown output voltage is not supplied to the output of the system by displaying this alarm Alarm 77 Error in configuration memory DSP Internal Error can happen for the following reasons Watch Dog failure Wrong ADC mesures Communication errors between DSP and up...

Page 57: ...tween 3 and 7 years if the ambient temperature is between 10 and 20ºC To have more information of its status activate the battery test Risk of fire and or explosion exists if a wrong quantity or type of batteries is used Do not dispose the batteries to the fire they can explode Do not open and mutilate the batteries the dumped electrolyte is dangerous for the skin and eyes It can be toxic 8 1 3 Fa...

Page 58: ...rest factor 3 4 to 1 3 2 to 1 2 8 to 1 3 2 to 1 3 to 1 Permissible power factor 0 7 leading to 0 7 lagging Unbalancedoutputvoltage 100 unbalancedload 1 Current limit High overload short circuit RMS voltage limit High current crest factor Peak voltage limit Efficiency on battery mode 100 linear load 94 6 94 8 95 3 95 6 95 9 96 4 96 1 95 9 96 4 STATIC BYPASS Type Solid state SCR Bypass line Common S...

Page 59: ...ad THD i 5 0 100 load THD i 1 5 50 load THD i 2 0 10 load THD i 6 0 Current limit High overload PFC limit discharging batteries Power factor 0 99 from 10 load INVERTER Output nominal voltage Single phase 220V 230V or 240V Three phase 3x380V 3x400V or 3x415V 4 wires 3 phases N Output power factor 0 9 for three phase three phase setting 0 8 for L M and N settings 0 8 Accuracy Static 1 Dynamic 2 step...

Page 60: ... UPS CONFIGURATIONS WITH STANDARD BACK UP TIME Quantity of cabinets 1 UPS batteries 1 UPS 1 batteries Maximum dimensions mm Depth x Width x Height UPS UPS B1 770x450x110 875x590x1320 850x900x1900 UPS B UPS B B1 875x590x1320 875x870x1320 850x1225x1900 Batteries 770x450x1100 1050x650x1320 850x1300x1900 Casters without brake Equipment batteries YES YES YES YES NO NO NO Cabinet weight kg UPS B1 100 10...

Page 61: ...cuit through which are sent or received signals from a system or subsystems toward others kVA The voltampere is the unit of the apparent power in electrical current In direct current is almost equal to the real power but in alternating current can defer depending on the power factor LCD LCD acronym of Liquid Crystal Display device invented by Jack Janning who was employee of NCR It is an electric ...