Tecnoware EVO DSP TT User Manual
1
Uninterruptible Power Systems
EVO DSP TT
10-100kVA
User’s manual
2
Important Notice
Thank you for purchasing TECNOWARE UPS.
This document provides instructions about safety, installation and handling of the UPS. It is necessary to
read the manual completely before working on this equipment.
Read the manual completely before working on this equipment!
Keep this manual near UPS for easy consultation!
Symbols
This symbol points out the instructions which are especially important.
This symbol points out the risk of electric shock if the following instruction is not obeyed.
This symbol points out the instructions, which may result in injury to the operator or damage to
the equipment if not obeyed.
Copyright 2009 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.
Manual Version 1.0 – May 2009 – Initial Issue
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Index
1 Safety ...................................................................................................................................................... 5
2 Installation ............................................................................................................................................. 6
2nd1 Transportation ................................................................................................................................................................... 6
2nd2 Unpacking........................................................................................................................................................................... 6
2nd3 Storage ................................................................................................................................................................................. 6
2nd4 Location and Connection of the UPS ........................................................ Errore. Il segnalibro non è definito.
2nd4.1 Environmental Requisites ....................................................................................................................................... 6
2nd4.2 Electrical Requisites .................................................................................................................................................. 7
2nd5 Connections ....................................................................................................................................................................... 8
2nd5.1 Power Connections .................................................................................................................................................. 8
2nd5.1.1 Protective Earth (Ground) Connections ............................................................................................................... 10
2nd5.1.2 Input Connection ....................................................................................................................................................... 10
2nd5.1.3 Separated by-pass mains input connection (optional) ........................................................................................ 11
2nd5.1.4 External Battery Connection .................................................................................................................................... 11
2nd5.1.5 Output Connection .................................................................................................................................................... 11
2nd5.2 Communication Interface Connections.............................................................................................................. 11
3 Modes of Operation .............................................................................................................................. 12
3rd1 Bypass Mode .................................................................................................................................................................... 13
3rd2 Normal Mode .................................................................................................................................................................. 14
3rd3 Battery Mode .................................................................................................................................................................... 14
4 Control and Monitoring ........................................................................................................................ 15
4th1 Front Panel ....................................................................................................................................................................... 15
4th1.1 Keypad ...................................................................................................................................................................... 15
4th1.2 Mimic Panel ............................................................................................................................................................. 16
4th1.3 Liquid Crystal Display (LCD) and User Menu .................................................................................................. 17
4th1.4 Buzzer ....................................................................................................................................................................... 20
5 Operating Procedures ........................................................................................................................... 21
5th1 Commissioning ................................................................................................................................................................ 21
5th2 Decommissioning ........................................................................................................................................................... 21
5th3 Switching into manual by-pass during operation ...................................................................................................... 22
5th4 Returning from manual bypass to UPS ....................................................................................................................... 22
5th5 Connection to a generator ............................................................................................................................................. 22
6 Operating Procedures for Parallel Systems .......................................................................................... 23
6th1 Introduction ..................................................................................................................................................................... 23
6th2 Procedure for Commissioning and Start Up ( First Installation ) ........................................................................ 23
6th3 Procedure for Transferring to Static Bypass .............................................................................................................. 26
6th4 Procedure for Transferring to ( Maintenance ) Manual Bypass .............................................................................. 26
6th5 Procedure for Switching OFF ...................................................................................................................................... 26
7 Features and operating limits .............................................................................................................. 27
7th1 Mains limits for normal operation ............................................................................................................................... 27
7th2 By-pass mains limits for bypass operation.................................................................................................................. 27
7th3 Battery test ........................................................................................................................................................................ 27
7th4 Overload behavior .......................................................................................................................................................... 28
7th5 Electronic short circuit protection ............................................................................................................................... 28
8 Communication ................................................................................................................................... 29
8th1 RS232 Communication .................................................................................................................................................. 29
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8th2 RS422 Communication .................................................................................................................................................. 29
8th3 Digital Inputs (UPS OFF and GEN ON) .................................................................................................................. 30
8th4 Free Contact Communication ...................................................................................................................................... 30
9 Maintenance .......................................................................................................................................... 31
9th1 Battery fuses ..................................................................................................................................................................... 31
9th2 Batteries ............................................................................................................................................................................ 31
9th3 Fans ................................................................................................................................................................................... 31
9th4 Capacitors ......................................................................................................................................................................... 31
10 Troubleshooting ................................................................................................................................... 32
11 Technical Specifications ...................................................................................................................... 35
12 Internal Battery Location & Connection Instructions ......................................................................... 37
13 Internal Battery Location & Connection Diagram .............................................................................. 38
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1 Safety
Information related to the safety of the UPS, loads and the user is summarized below.
But the equipment should not be installed before reading this manual completely.
The equipment may only be installed and commissioned by authorized technical persons.
When the UPS is brought from a cold place to a warmer place, humidity in the air may cause
condensation in the UPS. In this case, allow UPS to stand for two hours in the warmer place
before beginning with the installation.
Even if no connection has been done, hazardous voltages may exist on connection terminals and
inside the UPS. Do not touch these parts.
Connect the PE (Earth) ground connector before connecting any other cable.
Do not put the battery fuses into the fuse holder before operating the equipment and seeing the
“NORMAL” message on the LCD.
The connections shall be made with cables of appropriate cross-section in order to prevent the
risk of fire. All cables shall be of insulated flexible type (tri-rated) and shall not be laid out on the
walk path of persons. Cables crossing a path must be protected in accordance with local
electrical and safety regulations.
Do not expose UPS to rain or liquids in general. Do not put any solid objects into any access
/vent hole or space .
The equipment shall be operated in an environment, which is specified in “Location and
Connection of the UPS” section of this manual.
Affix a label bearing the following expression, on the distribution panels feeding the UPS :
“Isolate the Uninterruptible Power Supply before working on this circuit”
Do not plug the communication cables in or out during lightening or electrical storms.
The equipment shall only be maintained and fixed by authorized technical persons.
In case of a fault situation (damaged cabinet or connections, penetration of foreign materials into
the cabinet etc.) de-energize the UPS immediately and consult with Tecnoware Technical Service.
Used/dead batteries must be disposed of at an authorized waste disposal centre – local
regulations may apply – batteries must not be put in a land fill .
Keep this manual nearby the UPS for easy consultation.
The equipment shall be packed properly during transportation.
The equipment is compliant with the European Community directives. Hence it is marked:
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2 Installation
2.1 Transportation
The UPS must remain in a vertical position throughout the transportation.
Make sure that the floor can support the weight of the system – check with building engineer if not sure.
2.1 Unpacking
Equipment and batteries whose packaging is damaged during transportation shall be inspected by
a qualified technical person before starting with the installation.
The procedure is as follows:
Remove the bands and the protective packaging from the UPS.
Use suitable equipment to remove the UPS from the pallet.
Mount the cabinet parts supplied with the UPS after positioning and connecting the UPS.
The equipment shall be packed properly during transportation. Therefore it is recommended to
keep the original package for future needs (eg. Further transportation or return to Service
Department).
Check if the following are provided with the equipment
Key of the cabinet door
Battery fuses (three pieces)
Test report
2.1 Storage
Recommended storage temperature, humidity and altitude values are listed in the “Technical
Specifications” section.
If the batteries will be stored for longer than 2 months, they must be charged periodically. Charge period
depends on the storage temperature. The relationship is as shown below:
Every 9 months if the temperature is below 20 °C,
Every 6 months if the temperature is between 20 °C and 30 °C,
Every 3 months if the temperature is between 30 °C and 40 °C,
Every 2 months if the temperature is over 40 °C
2.1 Location and Connection of the UPS
2.1.1 Environmental Requisites
This product meets the safety requirements for devices to be operated in restricted access locations
according to EN 60950-1 safety standard, which states that the owner should guarantee the following:
Access to the equipment can only be gained by service persons or by users who have been
instructed about the reasons for the restrictions applied to the location and about any precautions
that shall be taken and,
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Access is through the use of a tool or lock and key, or other means of security and is controlled
by the authorised person responsible for the location.
Recommended operating temperature, humidity and altitude values are listed on the “Technical
Specifications” section. Air conditioning may be required to provide these values.
Other requisites are:
The equipment and the batteries shall not be exposed to direct sunlight or placed near to a heat
source.
Do not expose UPS to rain or any liquids in general. Do not introduce any solid objects.
Avoid dusty environments or areas where dust of conductive or corrosive materials is present.
Air outlets of the UPS are on sides, front and back. Leave at least 75 cm at the front and both
sides and 50 cm at the back for maintenance and ventilation.
2.1.1 Electrical Requisites
The installation must comply with local national installation regulations.
The electrical distribution panels for the mains and separate by-pass mains inputs must have a protection
and disconnection system. Disconnection devices used in these panels shall disconnect all line conductors
and the neutral conductor simultaneously. The following table shows the recommended size of the mains
and separate by-pass mains input protection devices (thermal, magnetic and differential) and the cable
cross-sections for the linear loads.
UPS
Input
thermal
protection
Bypass
mains input
thermal
protection
Input cable
cross-
section
Bypass
mains input
cable
cross-
section
Battery
cable cross-
section
Neutral
Cable
Cross
section
Leakage
current
protection*
10 kVA
25 A 25 A 6 mm2
6 mm2
6 mm2
10 mm
2
30 mA
15 kVA
25 A 25 A 6 mm2
6 mm2
6 mm2
10 mm
2
30 mA
20 kVA
40 A 40 A 10 mm
2
10 mm
2
10 mm
2
16 mm
2
30 mA
30 kVA
63 A 63 A 16 mm
2
16 mm
2
16 mm
2
25 mm
2
30 mA
40 kVA
80 A 80 A 16 mm
2
16 mm
2
16 mm
2
25 mm
2
30 mA
60 kVA
100 A
100 A
25 mm
2
25 mm
2
25 mm
2
35 mm
2
30 mA
80 kVA
125 A
125 A
35 mm
2
35 mm
2
35 mm
2
50 mm
2
30 mA
100 kVA
160 A
160 A
35 mm
2
35 mm
2
35 mm
2
50 mm
2
30 mA
Input magnetic protection devices shall have D characteristic.
*Load leakage currents are added to those generated by the UPS. If loads with high leakage currents are
present, adjust this value accordingly. It is recommended to adjust the protective device after measuring
the total leakage current with the UPS installed and operational with the intended load.
During transitory phases (power failure, return and voltage fluctuations) short leakage current peaks may
occur. Make sure that the protection is not activated in such cases.
If the loads have a nonlinear characteristic, the current on the mains input, separate by-pass
mains input and output neutral conductors may have a value that is 1.5-2 times the phase value
during operation. In this case, size the neutral cables and the input/output protection accordingly.
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According to EN 62040-1-2, the user shall place a warning label on the input distribution panel
and the other primary power isolators, in order to prevent the risk of electric shock caused by a
fault voltage on the UPS. The label shall carry the following wording:
Isolate uninterruptible power supply (UPS) before working on this circuit
2.1 Connections
Connections shall be done by authorized technical staff only.
When the UPS is brought from a cold place to a warmer place, humidity of the air may
condensate in it. In this case, wait for two hours before beginning with the installation.
Layout of the connection terminals and boards are shown below:
A1: Communication interface board
A2: Parallel connection board (optional)
F1: Input circuit breaker
F2: Output circuit breaker
F3: Manual by-pass circuit breaker
F4: By-pass circuit breaker (optional)
F5: Battery circuit breaker
F6: Inrush fuse
X1: Battery terminals
X2: Input mains terminals
X3: Separate by-pass mains terminals (optional)
X4: Output terminals
2.1.1 Power Connections
Devices with internal batteries may have dangerous voltages on the battery terminals
The power screw terminals are located on the lower front side of the UPS. Refer to the names of each
terminal to identify it during connection
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10-15-20-30kVA UPS Terminal Connections
40-60kVA UPS Terminal Connections
* If Split/separated bypass is not used – link input to these terminals (connections are
then common). Ensure cables are same for each connection (L1 input & L1 bypass etc)
BATTERY (-)
BATTERY
NEUTRAL
BATTERY
(+)
PE
INPUT
L1
INPUT
L2
INPUT
L3
INPU
T
NEUTRAL
OUTPUT
L1
OUTPUT
L2
OUTPUT
L3
OUTPUT NEUTRAL
SPLIT
-
BYPASS NEUTRAL
SPLIT BYPASS L3
SPLIT BYPASS
L2
SPLIT BYPASS L1 (*)
PE
BATTERY (
-)
BATTERY
NEUTRAL
BATTERY
(+)
INPUT
L1
INPUT
L2
INPUT
L3
INPUT NEUTRAL
SPLIT BYPASS NEUTRAL
SPLIT BYPASS L3
SPLIT BYPASS L2
SPLIT BYPASS L1
OUTPUT NEUTRAL
OUTPUT L3
OUTPUT L2
OUTPUT
L1
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80-100kVA UPS Terminal Connections
Cables shall be passed through the hole under the connection terminals.
Make sure that all circuit breakers are “OFF”/”0” before starting with the installation.
Connections shall be done in the order below only.
2.1.1.1 Protective Earth (Ground) Connections
The device shall be earthed for a safe and reliable operation. Connect the PE ground connectors
before connecting any other cable
Input protective earth connection terminal (PE) of the UPS shall be connected to ground with a low
impedance connection.
PE terminals of the loads shall be connected to output protective earth terminal of the UPS.
If there is an external battery cabinet present, it shall be grounded via battery protective earth terminal of
the UPS. Battery case must be earthed only – do not connect any DC/ battery point to PE earth.
2.1.1.1 Input Connection
Bring the circuit breaker on the distribution panel to “OFF” or “0” position before making the
connections
Connect the phases to input (X2) L1, L2 and L3 terminals.
PE
BATTERY (
-)
BATTERY NEUTRAL
BATTERY
(+)
INPUT
L1
INPUT NEUTRAL
INPUT
L2
INPUT
L3
OUTPUT NEUTRAL
OUTPUT L3
SPLIT BYPASS NEUTRAL
SPLIT BYPASS L3
OUTPUT L2
OUTPUT
L1
SPLIT BYPASS L2
SPLIT BYPASS L1
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A definite phase sequence is needed for the UPS to operate. If you encounter “IN SEQ FLR” alarm at
start up, stop and switch off the UPS, ensure the protection devices (breakers/isolators) on the input
distribution panels are “0”/”OFF” and then interchange any two phases on the UPS input only.
Connect neutral to N terminal of X2.
2.1.1.1
Separated by-pass mains input connection (optional)
Bring the circuit breaker on the distribution panel to “OFF” or “0” position before making the
connections
Connect the phases to bypass (X3) L1, L2 and L3 terminals.
Make sure that the phases have the same sequence with the input supply.
Connect neutral to N terminal of X3.
2.1.1.1
External Battery Connection
Do not put the battery fuses into the fuse holder (F5) before operating the equipment and seeing
the “NORMAL” message on the LCD.
Devices with internal batteries may have dangerous voltages on the battery terminals
To connect external batteries, do the following:
Switch the circuit breaker of the external batteries to “OFF” or “0” position.
Connect the (-) pole of the external batteries to the battery (-) terminal,
Connect the (+) pole of the external batteries to the battery (+) terminal,
Connect the midpoint of the external batteries to the battery N terminal.
Danger of explosion and fire if batteries of the wrong type are used.
2.1.1.1
Output Connection
To enable the short circuit protection feature of the UPS, each load shall be fed over a separate
circuit breaker chosen according to the load current. This may provide quick disconnection of the
short circuited load and operation continuity of the other loads. To obtain maximum protection,
the rating of each individual load circuit breaker shall have the minimum value, which is enough
to carry the full load current continuously.
Rated apparent and active power of the loads shall be less than the UPS power ratings.
Connect the loads to output (X4) Line and N terminals.
2.1.1 Communication Interface Connections
Related information is given in “communication” section.
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3 Modes of Operation
There are three operation modes, which differ in the path of the energy flow.
UPS block diagrams and the energy flow path in each operation mode is shown below:
When UPS has no separate bypass mains input, bypass line is also fed from the mains input. Thus, if such
a device is in question, mains input shall be comprehended when the bypass mains input is referred in the
following sections of the manual.
UPS behavior at the start-up is different from the usual operation. The UPS can only operate in bypass
mode during start-up. So, in order for the UPS to start-up, frequency/waveform/rms value of the bypass
mains voltage shall be in acceptable limits and bypass shall be enabled.
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