PowerWalker VFI 6-10kVA AT Uninterruptible Power Supply User Manual

PowerWalker VFI 6-10kVA AT Uninterruptible Power Supply

Specifications

• Model: VFI 6-10kVA AT(L)
• Interfaces: USB, RS232, Intelligent slot
• Software Installation: Available

Safety
Please read the user manual and safety instructions before installing or using the unit.

Installation

• This equipment must be installed by qualified maintenance personnel.
• Avoid condensation by allowing acclimatization time if moved between temperature extremes.
• Avoid installation near water, direct sunlight, or heat sources.
• Do not overload the UPS with high-power appliances or equipment.
• Ensure proper ventilation by keeping at least 0.5m space around the UPS.
• Connect the UPS with TN earthing system and ensure suitable grounding of power supply.
• Avoid cable tripping hazards and ensure proper earthing of UPS and external battery source.

Operation

• Avoid disconnecting main cables during operation to maintain protective earth connection.
• The UPS output terminal block may remain live; disconnect mains lead after turning input breaker OFF.
• Follow instructions to prevent output loss or equipment damage when operating switches.

FAQ :
Q: Can I connect high-power devices like laser printers to the  UPS?
A: It is recommended not to connect appliances that would overload the UPS, such as laser printers. Ensure the connected load does not exceed 5% of the rated value of input current.

Safety

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

Installation

• This is permanently connected equipment, and it must be installed by qualified maintenance personnel.
• 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 connect appliances or items of equipment which would overload the UPS (e.g. laser printers, etc.) to the UPS output.
• Do not block ventilation openings in the UPS’s housing. Ensure allow at least 0.5m of space on front and rear of the UPS.
• This UPS should be connected with TN earthing system.
• The power supply for this unit must be single-phase rated in according with the equipment nameplate. It also must be suitably grounded.
• Place cables in such a way that no one can step on or trip over them.
• Connect UPS with the earth reliably before connecting to the building wiring terminal, and external battery source must also be earthed.
• 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.
• The equipment is powered by two sources: the mains source, the internal battery or the external battery source.
• With the installation of the equipment, the sum of the leakage current of the UPS and the connected load does not exceed 5% of rated value of input current.

Operation

• Do not disconnect the main cable on the UPS or the building wiring terminals during operation since this would remove the protective earth from the UPS and all connected loads.
• The UPS output terminal block may still be electrically lived even if the UPS is not connected to the building wiring terminal, for there is internal current source (batteries).
• In order to fully disconnect the UPS, first turn the input breaker in the “OFF” position, then disconnect the mains lead.
• Indiscriminate operation of switches may cause output loss or damage to equipment. Refer to instruction before conducting any control.
• While the UPS work as a parallel system, the external parallel cable should be reinforced insulation.
• Ensure that no liquid or other foreign objects can enter the UPS.

Maintenance, Servicing and Faults

• Do not remove the enclosure since the UPS operates with hazardous voltages. It is to be serviced 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 connected to the battery which are potentially dangerous.
• Before carrying out any kind of service or maintenance, isolate UPS and disconnect the batteries. Verify that no current is present and no hazardous voltage exists in the capacitor or BUS capacitor.
• Batteries must be replaced only by qualified personnel.
• Batteries have a high short-circuit current and pose a risk of shock. Take all precautionary measures specified below and any other necessary measures 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.
• The UPS may be connected to external battery package. Proper disposal of batteries is required. Refer to your local codes for disposal requirements.
• Do not open or destroy batteries. Effluent electrolyte can cause injury to the skin and eyes. It may be toxic.
• Replace the fuse only by a fuse of the same type and of the same spec in order to avoid fire hazards.

Transport
Please transport the UPS only in the original packaging to protect against shock and impact.

Storage
The UPS must be stockpiled in the room where is ventilated and dry.

Standards

• Safety

  IEC/EN 62040-1

• EMI
  Conducted Emission……………………………. :IEC/EN 62040-2| Category C3
  Radiated Emission………………………………. :IEC/EN 62040-2| Category C3
• 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
  Warning : This is a product for commercial and industrial application in the second environment-installation restrictions or add it ional measures may be needed to prevent disturbances.

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 :

Introduction

This On-Line series is an uninterruptible power supply incorporating double- converter technology. It provides perfect protection specifically for computer equipments, communication servers, and data centers.
The double-converter principle eliminates all mains power disturbances. A rectifier converts the alternating current from the mains power to direct current. On the basis of this DC voltage, the inverter generates an AC sinusoidal voltage, which constantly supplies the loads. In the event of power failure, the maintenance-free batteries power the inverter.
This manual covers the UPS listed as follows. Please confirm whether it is the model you intend to purchase by performing a visual inspection of the Model No. on the rear panel of the UPS.

Standard

| VFI 6000 AT(L)| ****

Extended backup time

VFI 10000 AT| VFI 10000 AT(L)

” L” Model: Extended backup time.

* EPO Port can be set to a ROO port in setting configuration
EPO: Enable Power-Off in emergency from a remote location.
ROO: Power ON/OFF from a remote location.

Feature
This series UPS is a new generation of UPS, which provides the outstanding reliability, and most cost-performance ratio in the industrial. Following benefit the product has:

• True online double-conversion technology with high power density, frequency independence and generator compatibility.
• High input power factor ≥0.99,overall high efficiency ≥92%,save power and wiring expense. Low input current distortion, avoid power pollution.
• Output power factor is 0.9, perfect output sine waveform, suitable almost all critical equipment.
• Outstanding adaptability to the worst mains input condition. Extra wide input voltage, frequency range and waveform, avoid excessive dissipating limited battery energy.
• ECO mode with high efficiency ≥96%, save power expense for user.
• Start-able without battery.

Electrical Specifications

Input

Model NO.

| VFI 6000 AT (16)

VFI 6000 AT (20)

| VFI 10000 AT (16)

VFI 10000 AT (20)

192Vdc| 240Vdc| 192Vdc| 240Vdc
Phase| Single
Voltage Range| 110~300VAC (Depends on load level)
Frequency Range| (45~55)/(54~66)Hz
Rated Current| 31(38)A| 25(30)A| 50(57)A| 42(50)A
Power Factor| ≥0.99@full load
Battery
Rated Voltage| 192Vdc| 240Vdc| 192Vdc| 240Vdc
Rated Current| 31A| 25A| 50A| 42A
---|---|---|---|---
Output
Power Rating| 6kVA/5.4kW| 10kVA/9kW
Voltage*| 208/220/230/240Vac

Frequency

| Synchronized50/60×(1±10%)Hz @Line mode

50/60×(1±0.1%)Hz @Battery mode

Wave Form| sine
Load Type| PF 0.5~1, lagging
THDV| ≤ 4% @ full linear load

≤ 5% @ full nonlinear load

Overload**

| In Line mode:

10 min 105%~110%

5 min 110%~130%

10s> 130%

In Battery mode:

3min 105%~110%

30s 110%~130%

10s> 130%

*The load capacity would be derated to 90% automatically when the output voltage is adjusted to 208Vac.
**The overload capacity would be derated automatically in Line mode while the circumstance temperature is larger than 35 degree.

Operating Environment

Note: The load capacity should be derated 1% every 100m heightened on the basis of 1000m.

Dimensions and Weights

Installation

system must be installed and wired only by qualified electricians in accordance with applicable safety regulations! For safety, please cut off the mains power switch before installation! When installing the electrical wiring, please note the nominal amperage of your incoming feeder.

Unpacking

• A UPS
• A user’s manual

CAUTION! 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.

Power Wires Installation
Notes for installation:

1. UPS must be installed in a location with good ventilation, faraway 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 unpacked in a very low temperature environment. In this case it is necessary to wait until the UPS is fully dried inside out before proceed installation and use. Otherwise there are hazards of electric shock.

Installation
Use cable cross section and protective device specification

mm² (UL1015 8AWG)
Input L, N

Min conductor cross section

| 6mm² (UL1015 10AWG)| 10 mm² (UL1015 8AWG)
Input breaker| 40A/250Vac| 63A/250Vac
External Battery Cabinet

Positive Pole(+), Negative pole(-), Min conductor cross section

| ****

6mm² (UL1015 10AWG)

| ****

10 mm² (UL1015 8AWG)

External Battery Cabinet Fuse

in Positive Pole(+), Negative pole(-)

| ****

40A

| ****

60A

External Battery Cabinet Breaker in

Positive Pole(+), Negative pole(-)

| ****

40A

| ****

60A

Torque for fixing above terminals| 3.95~4.97Nm (35~44 1b in)

1. It is suggested to install an external isolating device against current back feed between mains input and UPS. After the device is installed, it must add a warning label with the following wording or the equivalent on the external AC contactor: RISK OF VOLTAGE BACKFEED. Isolate the UPS before operating on this circuit, then check for hazardous voltage between all terminals.
   

2. No matter the UPS is connected to the mains power or not, the output of the UPS may be electrically live. The parts inside the unit may still have hazardous voltage after turning off the UPS. To make the UPS have no output, turn off the= UPS, and cut off the mains power supply, wait the UPS shut down completely, finally cut off the battery connection.

3. Open the terminal block cover located on the rear panel of UPS, please refer to the appearance diagram.

4. For 6K(L), it is recommended to select the UL1015 10AWG (6mm²) or other insulated wire which complies with AWG Standard for the UPS input and output wirings.

5. For 10K(L), it is recommended to select the UL1015 8AWG (10 mm²) or other insulated wire which complies with AWG Standard for the UPS input and output wirings.

6. Ensure the capacity of mains power supply. 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. Otherwise the receptacle may be burned and
   destroyed.

7. The protective earth ground wire should be installed first according to th following diagram. It is better to use green wire or green wire with yellow ribbon wire.

8. Connect other input and output wires to the corresponding input and output terminals according to the following diagram.
   

9. It is requested to use the accessorial terminal splices which can be compacted on the wires tightly, to ensure the connection between the wires and the terminal block is reliable.

10. Install an output breaker between the output terminal of UPS and the load, and the breaker should be with leakage current protective function if necessary.

11. Turn off all the loads first before connecting the load with the UPS, then perform the connection and finally turn on the loads one by one.

12. After completing the installation, please check the wires to make sure all were connected correctly and tightly.

13. Suggest charging the batteries for 8 hours before use. After Installation, turn on the mains power switch and turn the input breaker in the “ON” position, the UPS will charge the batteries automatically. It can also use the UPS immediately without charging the batteries, but the backup time may be less than the standard value.

14. 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 to make the UPS which capacity is small fail easily.

External Battery Pack Connecting Procedure

1. The nominal DC voltage of external battery pack is 192Vdc. 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 6KL, select the UL1015 10AWG (6mm²)respectively or other insulated wire which complies with AWG Standard for the UPS battery wirings.
3. For 10KL, select the UL1015 8AWG (10mm²)respectively or other insulated wire which complies with AWG Standard for the UPS battery wirings.
4. The external battery pack must be independent for each UPS. It is forbidden that two UPS use one external battery pack.
5. The procedure of installing battery pack should be complied with strictly. Otherwise it may encounter the hazardous of electric shock.
6. Ensure the UPS is not powered on and the mains input breaker is set in the OFF” position.
7. A DC breaker must be installed between the external battery pack and the UPS. The capacity of breaker must be not less than the data specified in the general specification.
8. Set the external battery pack breaker in “OFF” position and connect the 16 pieces of batteries in series.
9.  Connect the external battery pack to the battery terminals. Check the polarity of connection is correct.
10. Set breaker of the battery pack in the “ON” position.
11. Set the mains input breaker in the “ON” position, the UPS would power on and start to charge the battery pack.

EPO Connection
EPO(Emergency power off):when the emergency occurs, such as the failure of load, the UPS can cut off the output at once by operating the EPO port manually.

The connection：
Normally the EPO connector is closed with a wire on the rear panel (Fig.4-4),which is supplied in the accessory. Once the connector is open, the UPS would stop the output and enter EPO status (Fig.4-3).

To recover to normal status, first EPO connector should be closed (Fig.4-4),and press button OFF more than 1 second to clear EPO status, then UPS would stop alarm and recover to Bypass model. And UPS needs be turned on by manual operation.

Maintenance bypass switch operation
When UPS need to be executed maintenance:

1. Remove the protection cover of MBS, then the Micro-Switch is activated.
   UPS will transfer to bypass mode immediately.

2. Switch the MBS to “BYPASS”position, then utility power will be sent to output terminal through the MBS.
   

3. Turn off the input breaker of the UPS, the load will be supported by utility power from MBS, you can do maintenance now without power failure.

4. After UPS maintenance is finished, turn on the input breaker, switch the MBS to “UPS” position and install the protection cover of MBS. At last, turn on the UPS to normal mode.

Operation

Display Panel

Button functions

In line mode, ECO mode, or converter mode, press the “ON” button for 5 seconds to activate the battery test.

OFF| Press this button to turn off UPS.
ENTER| Press this button for 5 seconds to get into setting mode while in bypass mode, or standby mode.

In setting mode, press this button to confirm selection, or press this button for long time to exit setting mode and saving changes.

Press this button to scroll up in the LCD menu.

ESC| In setting mode, press this button to display next selection, or press this button for long time to exit setting mode without saving changes.

Press the “ESC” button for 5 seconds to disable and enable buzzer alarm.

Press this button to scroll down in the LCD menu.

ENTER + ESC| Switch to bypass mode: When the main power is normal, press these two buttons simultaneously for 5 seconds, then UPS will enter to bypass mode.

LCD Operation

LCD displays 6 pages in total

LCD SETTING CONFIGURATION
There are 5 UPS settings that can be configured by the user.

1. Press and hold the “ENTER” button for 5 seconds to activate the setting mode.
   The first configuration parameter will be displayed on the LCD screen.
   Note: The manual settings programming mode can ONLY be invoked while UPS is in Bypass mode or Standby mode. To make UPS on Standby mode or Bypass mode, connect utility power to UPS and do not turn on UPS.

2. Press the “ENTER” button to select the setting you want to configure.

3. Press the “ESC” buttons to scroll through the different parameters and select the parameter you want.

4. Press the “ESC” button for 5 seconds to cancel and exit setting mode. Press the “ENTER” button for 5 seconds to save all the settings you just do and exit setting mode.

• When operating in ECO Mode, the efficiency of UPS is higher than that in online mode, but transfer time should not be 0ms
• When operating in Converter Mode, the frequency of output should be always 50Hz or 60Hz, but load capacity will be derated by 40%.
• This function would be set as 0% when Converter Mode is enabled.
•  UPS has no bypass when Converter Mode is enabled.
•  ROO (Remote On/Off): If ROO is enabled, UPS can be turn on/off by the ROO port. If ROO port is disconnected, UPS will be turned off. If ROO port is connected,
  UPS will be turned on when the utility is normal.

1. UPS cannot detect the numbers of external battery automatically, so manual input from user is necessary.
2. For standard models, this setting is disabled.
3. For long run models, the default number is 1.

Special Function
The series UPS has some special functions, which could satisfy some special application of user. And the functions have own features, please contact your local distributor for further information before using the function.

ECO Function

Brief introduction of ECO function：
If ECO function is set to enable, after the UPS is turned on, the power used by the load is directly supplied from the mains power via internal filter while the utility power is in normal range, so the economy mode could be gained in ECO mode. Once the mains power is loss or abnormal, the UPS would transfer to Line mode or Battery mode and the load is supplied continuously.
The great virtue is overall high efficiency≥96% of UPS, to save power for user.

But the disadvantage is:

1. The load can’t be protected as well as in Line mode, for the load is directly supplied from the mains;
2.  The transfer time of UPS output from ECO mode to Battery mode is about 10ms. So the function is not suitable to some sensitive loads, and the region where the mains power is unstable.

Set the function：
The function could be enabled through the LCD setting.

Converter Function
Brief introduction of Converter function：
In converter mode, the UPS would free run with fixed output frequency (50Hz or 60Hz). Once the mains power is loss or abnormal, the UPS would transfer to
Battery mode and the load is supplied continuously.
The great virtue is the output frequency is fixed, which is required by some very sensitive loads. But the disadvantage is the load capacity of UPS should be derated to 60% in converter mode.

Set the function：
The function could be enabled through the LCD setting.

Trouble Shooting

If the UPS system does not operate correctly, first check the operating information on the LCD display. Please attempt to solve the problem using the table below. If the problem still persists, consult your dealer.

Trouble Shooting According to Warning Indication

status.

59| Battery open| ****

Battery is disconnect

| Do the battery test to confirm;

Check the battery bank is connected to the UPS; Check the battery breaker is

turn on

69| Fan warning| Fan blocked or

disconnected

| Check the fan status

51

| Site fail| The ground wire is disconnected, or phase and neutral conductor at input of UPS system arereversed| Check the Ground wire status; Reverse mains power wiring
56| **** Battery low| Battery Volt/Cap/Remain Time is low| When audible alarm sounding every second,

battery is almost empty

60|

Over Charge

| **** Battery is over charged| The UPS will turn off the

charger until the battery voltage is normal

**** 64

| ****

**** Over Load

| ****

**** Over Load

| Check the loads and remove some non-critical loads; Check if some loads are

failed.

environment ventilation
68| Over

Temperature

| Inside temperature of UPS

is too high

| Check the ventilation of UPS

and the ambient temperature

53| Fuse open| Input fuse break| Check the input fuse status

Trouble Shooting According to Fault Indication

Warning

code

| Problem

Displayed

| Possible cause| Remedy
---|---|---|---

09

| ****

Output Short

| ****

Output short circuit

| Remove all the loads. Turn off the UPS. Check if UPS output and loads is short circuit .Ensure short circuit is removed before turning on

again.

14

| ****

Over Load

| ****

Over Load

| Check the loads and remove some non-critical loads; Check if some loads are

failed.

16

| ****

Neg power fail

| ****

The load is pure inductive and capacitive

| Remove some non-critical loads;

Bypass supplies the load

first, ensure there is no overload, then turn on UPS

19

| Over Temperature| Inside temperature of UPS is too high| Check the ventilation of UPS and the ambient temperature.
18| Fan fail| Fan blocked or disconnected over time| Check the fan status.
17| Back feed| Output voltage is returned to input| Consult dealer
05| DC short| Bus short| Consult dealer
02| DC Over| Bus Over Voltage| Consult dealer
03| DC Under| Bus Under Voltage| Consult dealer
04| DC

Unbalance

| Bus Unbalance| Consult dealer
---|---|---|---
01| DC soft fail| Bus Soft start fail| Consult dealer
06| Output soft

fail

| Output Soft start fail| Consult dealer
08| Output Volt low| Output Volt low| Consult dealer
07| Output volt high| Output volt high| Consult dealer

Trouble Shooting in Else Cases

Please have the following information at hand before calling the After-Sales

Service Department :

1. Model number, serial number.
2. Date on which the problem occurred.
3. LCD display information, Buzzer alarm status.
4.  Mains power condition, load type and capacity, environment temperature,ventilation condition.
5. Other information for complete description of the problem.

Battery Maintenance

Battery replacement should be performed by qualified personnel

This series UPS only requires minimal maintenance. The battery used for standard models are value regulated sealed lead-acid maintenance free battery. These models require minimal repairs. The only requirement is to charge the UPS regularly in order to maximize the expected life of the battery. When being connected to the utility power, whether the UPS is turned on or not, the UPS keeps charging the batteries and also offers the protective function of overcharging and over-discharging.

• The UPS should be charged once every 4 to 6 months if it has not been used for a long time.
• In the regions of hot climates, the battery should be charged and discharged every 2 months. The standard charging time should be at least 12 hours.
• Under normal conditions, the battery life lasts 3 to 5 years. Incase if the battery is found not in good condition, earlier replacement should be made. Battery replacement should be performed by qualified personnel.
• Replace batteries with the same number and same type of batteries.
• Do not replace the battery individually. All the batteries should be replaced at the same time following the instructions of the battery supplier.
• If the battery service life (3~5 years at 25°C ambient temperature) has been exceeded, the batteries must be replaced.

Communication Port

USB Interface
The USB port is compliance with USB 1.1 protocol for its communication software.

RS232 Interface
The RS232 port is available for UPS monitoring, control, and firmware updates.

Intelligent slot
This series is equipped with an intelligent slot for other optional card to achieve remote management of the UPS through internet / intranet. Please contact your local distributor for further information.

Software Installation

Power Master+ management software provides a user-friendly interface for your power systems. The graphic user-interface is intuitive and displays essential power information at a glance. Please follow procedure below to install the software.

Installation procedure

1. Download Power Master+ from the website: https://powerwalker.com/software/#powermaster
2. Double-click the file and follow the installation steps. When your computer restarts, the Power Master+ software will appear as a blue icon located in the system tray.

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