Technoware EVO STAR 10 Installation And User Manual
EVO STAR
Uninterruptible Power Supply
EVO STAR 10 – 50KVA
Installation and user manual
Tecnoware Power Systems
EVO STAR 10-50
2
INTRODUCTION
The Uninterruptible Power Supply EVO STAR provides critical loads with continuous
computer grade power. Reliability and performance are the key design considerations. The UPS
design also maximizes isolation of the load from disturbances and interruptions, minimizes
maintenance and repair time with its slide out modular system, and provides monitoring of
significant system operating characteristics.
Proper installation and operation of the UPS are equally important factors in system
reliability. This manual provides complete information on installation, operating and
preventative maintenance of the UPS and Battery Cabinet. Illustrations showing the function of
all operator controls, instruments, alarms and indicating lights are also given.
This manual is for EVO STAR from 10 to 50 Kva.
Tecnoware Power Systems
EVO STAR 10-50
3
GENERAL INDEX
INTRODUCTION...........................................................................................2
EMERGENCY PROCEDURES...................................................................6
1
IDENTIFYING PACKAGED U.P.S................................................8
1.1 VERIFYING THE GOODS............................................................................... 8
2
HANDLING, STORING AND POSITIONING ............................9
2.1 HANDLING ........................................................................................................ 9
2.2 U.P.S. STORAGE .............................................................................................. 9
2.2.1 U.P.S. .......................................................................................9
2.2.2 BATTERY CABINETS....................................................................9
2.3 POSITIONING................................................................................................ 10
CHOOSING THE ROOM..............................................................10
2.3.1 10
3
GENERAL DESCRIPTION ............................................................11
3.1 OPERATING PRINCIPAL............................................................................. 11
3.1 DESCRIPTION AND PARTS .................................................................................. 11
3.1.1 RECTIFIER................................................................................12
3.1.2 INVERTER ................................................................................12
3.1.3 STATIC COMMUTATOR ...............................................................13
3.2 DESCRIPTION AND PARTS........................................................................ 13
3.3 PART LAYOUT ................................................................................................ 14
3.3.1 BREAKERS...............................................................................16
3.3.2 FUSES ....................................................................................16
3.3.3 TERMINAL CONNECTORS ..........................................................17
3.3.3.1 POWER UP TO 50 KVA.............................................................. 17
3.4 CONNECTING THE U.P.S. TO THE MAINS SUPPLY............................ 18
3.4.1 COMPATIBILITY WITH THE POWER SUPPLY .................................18
3.4.1.1 INDIRECT POWER SUPPLY ........................................................ 19
3.4.1.2 INPUT WIRE SIZING ................................................................ 19
3.4.1.3 PROTECTION OF THE U.P.S. OUTPUT LINE.................................. 19
3.4.2 CONNECTING THE SYSTEM........................................................20
3.5 CONNECTING THE BATTERIES TO THE U.P.S............................................... 21
3.5.1 CONNECTION TO A 120cm HEIGHT BATTERY CABINET ..................21
CONNECTING WITHOUT THE RISERVE LINE ( standard) .........................22
CONNECTING WITH RESERVE LINE ( optional) ......................................22
CONNECTING WITH RESERVE LINE ( optional) ......................................23
Tecnoware Power Systems
EVO STAR 10-50
4
3.5.2 CONNECTION TO A 180cm HEIGHT BATTERY CABINET...................24
4
STARTING-UP AND SHUTTING DOWN THE MACHINE .... 25
4.1 STARTING-UP THE MACHINE ...................................................................25
4.2 SHUTTING DOWN .........................................................................................26
4.2.1 EMERGENCY POWER OFF SWITCH (optional)................................26
5
ACTIVATING THE MANUAL BY-PASS .................................... 27
5.1 ACTIVATING THE BY-PASS KEEPING THE U.P.S SWITCHED ON.28
5.2 ACTIVATING THE BY-PASS SHUTTING DOWN THE U.P.S..............28
6
CHECK TOOLS................................................................................ 29
6.1 THE CONTROL PANEL AND ITS FUNCTIONS .......................................29
6.1.1 MONITORING ...........................................................................31
6.1.2 DIAGNOSTIC TOOLS .................................................................32
6.1.2.1 EVENT AND HISTORY MENUS ....................................................32
6.1.2.2 BATTERY TEST.........................................................................34
6.1.3 FUNCTIONING MODE CONFIGURATION .......................................34
6.1.3.1 BATTERY CHARGE MODE...........................................................34
6.1.3.2 FORCING ON INVERTER MODE ..................................................34
6.1.4 STRUCTURE MENU....................................................................35
6.2 P.C. INTERFACE .............................................................................................39
6.3 REMOTE PANEL (OPTIONAL)....................................................................39
6.3.1 INSTALLATION OF REMOTE PANEL WITHOUT E.P.O. .....................40
6.3.2 INSTALLING THE REMOTE PANEL WITH E.P.O. .............................42
7
BATTERIES ..................................................................................... 43
7.1 EXTERNAL BATTERY CABINETS...............................................................44
7.1.1 DESCRIPTION OF THE B2 BATTERY CABINET WITH BATTERIES FROM
40A/H 45
7.1.2 DESCRIPTION OF THE B4 MODEL BATTERY CABINET FROM 65 UP TO
130 A/H............................................................................................46
8
TECHNICAL CHARTS ................................................................... 47
Copyright 2006 TECNOWARE s.r.l. All rights reserved.
All trademark are property of their respective owners.
TECNOWARE s.r.l.
www.service.tecnoware.com
This manual has been printed and edited by TECNOWARE s.r.l.
Tecnoware Power Systems
EVO STAR 10-50
5
WARNING
PLEASE READ THIS TECHNICAL HANDBOOK VERY CAREFULLY
BEFORE CARRYING OUT INSTALLATION PROCEDURES
PLEASE KEEP THIS HANDBOOK IN A WELL-KNOWN PLACE
WITHIN REACH OF ALL UPS USER
In this handbook you will find explanations on how to install, set-up, and use the uninterrupted
static power supply.
All technicians and users who are about to use these UPS must have previously read this
handbook.
Only technicians trained by Tecnoware only must carry out the installation and maintenance.
Inside this machine there are continuously working fans, therefore do not insert
any type of object in the ventilation grids.
Please use protective rubber gloves when working on damaged batteries.
Never remove the doors and protection covers while the equipment is operative.
When working on the UPS you must remove any metallic objects you may be
wearing, such as rings, watches, pens and any other type of object which could
provoke a short circuit when operating inside the machine.
There are dangerous voltages in the uninterruptible static power supply even
when it’s turned off with all the switches switched off and with the access covers
removed!
There is a dangerous voltage at the ends of the batteries even when the switches
are disconnected.
Please operate very carefully on the batteries; a short circuit can cause great
damage to people or objects.
Do not smoke and do not use a naked flame when working on the equipment.
If the uninterruptible power supply system or the room where this is installed
should catch fire never use water to put out the flames.
Tecnoware Power Systems
EVO STAR 10-50
6
CAUTION!
EMERGENCY PROCEDURES
If there is an emergency it is possible to disconnect the power supply charge by switching
off all the switches on the control panel. On the machines that are equipped you may press the
E.P.O. button.
PEOPLE HIT BY ELECTRICAL DISCHARGE
Ask immediately for the help of a qualified and trained person.
When a rather high voltage and high intensity electric hit a body current this can provoke
burns. The burns appear in and around the areas where the current enters and exits the body.
Even if only small burns are visible on the skin, the tissues beneath could be seriously
damaged. In any case, and however serious the burn may be, NEVER TOUCH the injured
person with bare hands until you are sure that the electricity has been cut off.
SYMPTOMS AND SIGNS
Redness, edema, skin burns or skins carbonisation in the areas where the electricity
entered and exited the body.
The person may loose consciousness.
The person may stop breathing or his/her heart may stop beating.
Shock symptoms.
FIRST AID
Cut off the power supply and move the injured person away from the source of contact. Call
immediately for an ambulance and, if necessary, for the help of a technician specialised in
electrical equipment.
Tecnoware Power Systems
EVO STAR 10-50
7
PEOPLE WHO HAVE COME INTO CONTACT WITH CORROSIVE LIQUIDS
Ask immediately for qualified expert help.
All batteries installed in this system are completely dry and no corrosive liquids leak out of
their cases if the batteries are in perfect condition. If the storage batteries get damaged in any
way, this could provoke the leakage of the electrolyte or a short circuit of the internal cells; the
electrolyte is corrosive and causes burns.
SYMPTOMS AND SIGNS
A piercing sensation on the skin.
The skin will appear reddened sometimes with small blisters and exfoliation.
FIRST AID
Place the injured area under a strong jet of cold running water for at least 10 minutes so as
to avoid further damage to the tissues.
N.B. Make sure that the water can flow away freely as the substance that caused the burn
contaminates it. While swilling the injured area be careful not to splash yourself with
contaminated water. Call for an ambulance immediately.
.
If the electrolyte comes into contact with eyes you must intervene immediately by washing
them with running water until expert medical help arrives.
If the battery electrolyte is swallowed it is advisable to make the injured person drink plenty of
milk or water.
IN ALL CASES ASK FOR EXPERT MEDICAL HELP
Tecnoware Power Systems
EVO STAR 10-50
8
1 IDENTIFYING PACKAGED U.P.S.
On receiving the goods you should verify the contents. On the front of the package you will
find the sticker which will allow you to identify the contents.
In the picture you can see the identity sticker which is placed on the packaging of the
equipment:
Picture 1
In the picture you can see the identity sticker placed on the packaging of the battery:
Picture 2
1.1 VERIFYING THE GOODS
After making sure that the goods are those required, please check that the equipment has
not been damaged. In order to do this you must verify the integrity of the packaging. After
having removed the packaging check that the metal panels have not been damaged during
transport. If the goods are not compliant in any way please put them back in their original
packaging and send them back to the manufacturer.
1. Specifies voltage and frequency input
admittance
2.
Specifies voltage and frequency
output admittance
3.
Specifies the number of batteries
which may be
3. inside the machine
4. Specifies internal battery capacity
5.
Specifies the serial number of the
product
6. Specifies weight
1. Specifies the battery cabinet model
2.
Specifies the number of batteries
contained
3. Specifies battery capacity
4.
Specifies the serial number of the
product
5. Specifies weight
3
5
7
2
4
6
1
2
3
4
5
Tecnoware Power Systems
EVO STAR 10-50
9
2 HANDLING, STORING AND POSITIONING
2.1 HANDLING
1. Remove the screws which fasten the machine to the pallet (Picture 3).
2. Remove the wooden pallet by using a lift truck and carefully place it on the floor (Picture 4).
3. For floor handling you will only need a transpallet with a suitable loading capacity.
Picture 3
2.2 U.P.S. STORAGE
2.2.1 U.P.S.
If you need to store the UPS this must be protected from dust and dirt (even if it is well
packaged). It must not be exposed to the inclemency of the weather and the room shouldn’t
be too humid (humidity below 90% non-condensing), nor should the UPS be exposed to
sources of heat; room temperature should be between +1 e +40°C.
2.2.2 BATTERY CABINETS
If you need to store a complete battery cabinet, you should respect all the conditions
mentioned in the previous paragraph. You should also remember that battery discharge over
time, even when not in use, therefore it is necessary to recharge them every 4 months.
In any case, you must follow the manufacturers’ indications to store the batteries.
Non-compliance with these indications can cause an efficiency decrease and a
shorter life of the storage batteries.
Tecnoware Power Systems
EVO STAR 10-50
10
2.3 POSITIONING
Installation space varies according to the size of the U.P.S (see charts 8) and to the battery
cabinet. A distance margin from the walls of the room where the U.P.S. is positioned is also
necessary for air circulation and ordinary/extraordinary maintenance. Please refer to picture 5
for minimum margin distances. All models need a distance margin of at least 40cm either side
or at least a metre from the ceiling.
Picture 4
2.3.1
CHOOSING THE ROOM
Element Requirements
Room access
•
All the doors which the equipment has to go through in order to reach the
chosen room have to be large enough to allow the passage of the U.P.S
(charts 8) and its handling equipment
. We advise you to forbid access to
the place where the U.P.S. and its battery cabinets are placed to all non
authorized users.
Room size
•
Room space must be suitable to allow installation of the equipment and
periodical and extraordinary maintenance.
• Wh
en choosing the rooms please remember that the equipment must not
be exposed to the inclemency of the weather, to corrosive substances, to
excessive humidity (humidity below 90% non-
condensing) or to very high
sources of heat.
• The environment should not be
very dusty. Please be very careful if you
decide to carry out any building work after setting up the machine.
Floor load • According to the data in charts 8 you must check that the floors of the
chosen rooms can support the equipment’s weight.
Ventilation
• Room temperature should be preferably between 15° and 25°C
•
Ventilators expel the heat dissipated by the U.P.S. into the air, therefore the
room structure must be suitable to guarantee sufficient aeration to
eliminate the heat produced by the U.P.S.
• If room temperature does not comply with the recommended parameters or
if air circulation in the room is not adequate, you must supply the room with
a ventilation system or, if this should not be sufficient, install an air
conditioning system.
Safety rules
•
The rooms where the U.P.S. is installed must be equipped according to fire
and safety regulations.
40
40
40
U.P.S. from 10 to 50 KVA
Tecnoware Power Systems
EVO STAR 10-50
11
3 GENERAL DESCRIPTION
3.1 OPERATING PRINCIPAL
The U.P.S. is a continuous double conversion system with an output transformer. It works
by carrying out a continuous double conversion of the main supply, guaranteeing a constant
stablized supply of both voltage and frequency, maintaining charge and control of the batteries
(On-line functioning). In order to guarantee continuous supply when the voltage of the electric
system are no longer correct, power is drawn from the batteries. The system is supplied
complete with an automatic static commutator that connects the output to the back-up power
supply, or if there are special alarms such as the E.P.O. (Emergency Power Off) it shuts down
completely output voltage.
3.1 DESCRIPTION AND PARTS
During normal functioning (picture 5) the system takes power from the mains by means of the input terminal (1).
The voltage goes through the disconnecting switch (point 4) and the fuse board (point 6/a) in order to reach the rectifier
module (point 7), exiting which is a continuous controlled voltage available to charge or maintain battery efficiency
through the fuse (6/b) and the “battery disconnecting switch” (point 8) and to the inverter input (11). This step is to
generate a three-phase voltage, stabilized and synchronized with the back-up voltage. The static commutator (11) selects
the power source to power the load, usually on inverter (10). If there is an increase of output current or with specific
alarms, the device (12) will commutate to the emergency supply (7) maintaining output continuity. If transferring takes
place, output continuity is allowed by the synchronism of the voltages generated with the emergency voltage. If
asynchronous commutation should take place there will be a power “dip” for maximum 20 ms.
When the power supply is not in the set parameters, the equipment maintains output voltage by taking power from the
batteries (picture 9). The system is provided with a current control that keeps the current inside set parameters in the
event of current overloaded.
4
3
2
5
6/a
7
6/b
1
10
8
9
11
12
13
Emergency network
(optional)
Linea di by-pass
1. Main voltage
2. Manual By-pass
3. Disconnecting
switch back-up line
4. Disconnecting
switch main
5. Back-up network
fuse board
6. Fuse board
a) Main input
b) Battery
7. Rectifier
8. Battery switch
9. Battery
10. Inverter
11. Static
commutator
12. System output
disconnector
13. Exit
Picture 5
1/A
RECT. INV.
B.M.
B.S.
BATT.
Tecnoware Power Systems
EVO STAR 10-50
12
3.1.1 RECTIFIER
The rectifier, indicated in picture 5 with the abbreviation RECT. transforms alternating current voltage of the main
line to direct current voltage. Its engineering allows, through a six pulse absorption, to feed the inverter in its status of
maximum voltage output at the same time as the battery charge.
Normally, direct current voltage is constantly set at 436Vdc (sustaining voltage), but when recharging the batteries,
this voltage will be automatically limited by a current limiter.
3.1.2 INVERTER
The inverter, indicated in picture 5 with the abbreviation INV., has the role of transforming direct current voltage,
taken from the rectifier output, into sinusoidal voltage, which may be used by the user. This process is carried out by
using power semiconductors, piloted by a PWM signal, which through a transformer and a capacitance filter give us a
very stable three-phase voltage with a harmonic distortion lower than one unit.
The controlling logic of the inverter also controls output current intensity limiting it to a value which
corresponds to 150% nominal current voltage
Input voltage
TO BATTERIES
TO INVERTER
U
V
W
Output voltage
L1 L2
L3
LN
Tecnoware Power Systems
EVO STAR 10-50
13
3.1.3 STATIC COMMUTATOR
The static commutator indicated in picture 5 as B.S., is a commutator made with semiconductors which can select
which power source to connect appliances to. During normal functioning the U.P.S. output is taken at the inverter output
(U.P.S. on-line), but if there is an internal or external event it will commute to the reserve system.
Commutating from one source to another occurs without creating voltage “dips” only with
conditions of synchronism between inverter output and the reserve system. If there is forced
commuting, without synchronism, decided by the user, this will occur with a voltage dip of max.
20 Sm.
Commuting Conditions on inverter:
1. Inverter switched on and working and synchronized with the
reserve system
2. Loss of system
3. Voluntary forcing through control panel
Commuting Conditions on reserve:
1. Malfunctioning of the inverter
2. Current overcharge
3. U.P.S. switched off
4. Voluntary forcing through control panel
5. By-manual closing of the breaker
3.2 DESCRIPTION AND PARTS
During normal functioning (picture 6) the system takes power from the mains by means of
the input terminal (B). The voltage goes through the disconnecting switch and the fuse board
in order to reach the rectifier module (C), exiting which is a continuous controlled voltage
available to charge or maintain battery efficiency and to the inverter input (E). This step is to
generate a three-phase voltage, stabilized and synchronized with the back-up voltage. The
static commutator (F) selects the power source to power the load, usually on inverter (E). If
there is an increase of output current or with specific alarms, the device (F) will commutate to
the emergency supply (A) maintaining output continuity. If transferring takes place, output
continuity is allowed by the synchronism of the voltages generated with the emergency
voltage. If asynchronous commutation should take place there will be a power “dip” for
maximum 20 ms.
Picture 6
Tecnoware Power Systems
EVO STAR 10-50
14
When the power supply is not in the set parameters, the equipment maintains output
voltage by taking power from the batteries (Picture 7). The system is provided with a current
control that keeps the current inside set parameters in the event of current overloaded.
Picture 7
3.3 PART LAYOUT
It is important to be familiar with the parts that are necessary during the
connection procedures before connecting the equipment. In order to access the
parts which will be described you must remove the “second access”, which is
the metal panel used to protect the inside parts of the U.P.S. and also to
protect the user from accidental contacts with live parts.
Picture 8
KEY
A = Display board
B = Relay board
C = Interface connector
D = Terminal
E = Breakers
F = Fuse cards
= Earthing
Tecnoware Power Systems
EVO STAR 10-50
15
Main switch
Terminal board
Main input and battery
fuses
Back-up input fuses
(optional)
Battery switch
System output switch
Manual by-pass switch
Reserve switch
(optional)
User interface board
Battery cabinet
Loading...