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Summary of Contents for Tecnoware EVO STAR
- Page 1 EVO STAR Uninterruptible Power Supply EVO STAR 60 – 800 KVA Installation and User Manual...
- Page 2 ________________________________________________________________________________ Copyright 2007 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. EVO STAR 60-800...
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Page 3: Table Of Contents
4.7.4 REMOVE ROOF............................. 23 4.7.1 REMOVE SIDE DOORS ........................23 5 STARTING-UP AND SHUTTING DOWN THE MACHINE........24 5.1 STARTING-UP THE MACHINE ........................24 5.1.1U.P.S with independent reserve line ......................... 24 5.1.2 First time starting-up............................24 5.2 SHUTTING DOWN.............................. 25 EVO STAR 60-800... - Page 4 INSTALLATION OF REMOTE PANEL WITHOUT E.P.O................. 43 INSTALLING THE REMOTE PANEL WITH E.P.O.................... 45 11 EMERGENCY POWER OFF ................46 11.1 EPO TYPE................................46 11.1.1 EPO ON CONTROL PANEL ........................46 11.1.2 EPO ON REMOTE PANEL.......................... 46 11.2 PROGRAM EPO ..............................46 EVO STAR 60-800...
- Page 5 DESCRIPTION OF THE MAX 32 BATTERIES CABINET UP TO 44Ah..........51 15.1.2 DESCRIPTION OF THE MAX 32 BATTERIES CABINET UP TO 120 Ah......... 52 TECHNICAL CHARTS ..................53 BREAKER BOX ....................56 INPUT TWELVE PULSES AND FILTERS..............57 INPUT TWELVE PULSES......................... 57 GREEN MODE .....................58 EVO STAR 60-800...
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Page 6: Introduction
This handbook is to be used only inside the works in order to find all necessary information to prevent injuries and to install and use the U.P.S. Not right use of this information is very danger for device an people EVO STAR 60-800... -
Page 7: Warning
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. EVO STAR 60-800... -
Page 8: Emergency Procedures
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 EVO STAR 60-800... -
Page 9: Identifying Packaged U.p.s
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. EVO STAR 60-800... -
Page 10: Handlind, Storing And Positioning
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. EVO STAR 60-800... -
Page 11: Positioning
• The rooms where the U.P.S. is installed must be equipped according to fire and safety Safety rules regulations. EVO STAR 60-800... -
Page 12: General Description
When the power supply is not in the set parameters, the equipment maintains output voltage by taking power from the batteries (9). The system is provided with a current control that keeps the current inside set parameters in the event of current overloaded. EVO STAR 60-800... -
Page 13: Rectifier
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 EVO STAR 60-800... -
Page 14: Manual By-Pass
U.P.S. and also to protect the user from accidental contacts with live parts. A = Display board B = Relay board C = Interface connector D = Terminal E = Breakers F = Fuse cards = Earthing U.P.S. from 60 to 100 KVA Picture 3.4 EVO STAR 60-800... - Page 15 ________________________________________________________________________________ U.P.S. from 120 to 150 KVA F F F F F F F F Picture 3.5 EVO STAR 60-800...
- Page 16 ________________________________________________________________________________ U.P.S from 200 to 800 Rectifier fuses Battery fuses Spare fuses Battery switch Mains switch Relay board Reserve switch Output switch By-pass switch Neutral bar Battery RS 232 connection Picture 3.6 Reserve Input Output EVO STAR 60-800...
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Page 17: Breakers
IMPORTANT spare fuses are supplied together with the U.P.S. If they have to be purchased please make sure that they are extra-fast fuses for the current same as on machine so as to guarantee total protection. EVO STAR 60-800... -
Page 18: Terminal Connectors
Therefore with the help of cable terminals, knurled screws and nuts a suitable connection for the current values in circulation. As for the connection references please refer to the alphanumeric specifications on the copper bars which respect the same specifications present on the terminal boards in equipment up to 200KVA. EVO STAR 60-800... -
Page 19: Connecting The U.p.s. To The Mains Supply
However, it is always a good rule to size the wires so as the voltage drop on each wire is below 3% of the applied voltage. Particularly important is the sizing of the neutral wire especially when the U.P.S. is used to power unbalanced EVO STAR 60-800... -
Page 20: Protection Of The U.p.s. Output Line
12. If you need to connect external battery compartments please proceed to the following paragraph. 13. Replace the second access panel and fasten its screws. 14. Lock the front door with its key Reassemble the side grids on the supporting base EVO STAR 60-800... -
Page 21: Connection Without Back-Up Line
________________________________________________________________________________ 4.5.1 CONNECTION WITHOUT BACK-UP LINE INPUT LINE U-V-W Mains switch Battery switch By-pass BATTERY switch Output switch U2-V2-W2-N2 USER Picture 4.3 EVO STAR 60-800... -
Page 22: Connection With Back-Up Line
________________________________________________________________________________ 4.5.2 CONNECTION WITH BACK-UP LINE MAINS LINE BACK-UP LINE L1 RESERVE L2 RESERVE L3 RESERVE LN RESERVE U-V-W U1-V1-W1 Mains Reserve switch switch Battery switch By-pass Battery switch Output switch U2-V2-W2-N2 Picture 4.4 USER EVO STAR 60-800... -
Page 23: Connecting The Batteries To The U.p.s
10. Make sure that the corresponding battery breaker placed on the U.P.S is off, then shut down the battery switch on the cabinet 11. Using a multimeter verify the correct polarity on the U.P.S. battery terminals 12. Close the second access of the U.P.S. by fastening its screws 13. Reassemble the side grids on the supporting base EVO STAR 60-800... -
Page 24: Mecanical Operations
Remove ground wire fix under roof (remember to connect it before closing roof) 4.7.1 REMOVE SIDE DOORS • Remove the four screws on side door • Lift door • Remove the four screws on roof • Remove ground wire fix on door (remember to connect it before closing door) EVO STAR 60-800... -
Page 25: Starting-Up And Shutting Down The Machine
4. Carry out a power shortage test by turning off the “Mains switch” and make sure that the U.P.S. goes into alarm mode and that led D starts flashing and led F stays green (picture 1and 7) then turn on the “Mains switch” and check that normal functioning has been restored. EVO STAR 60-800... -
Page 26: Shutting Down
Press the switch on button for about five RESTORING FROM TOTAL SHUTDOWN seconds and wait till the end of the shutdown procedure. EVO STAR 60-800... -
Page 27: Activating The Manual By-Pass
2. Press keys F6 and F2 at the same time, using the scroll keys select “On reserve” and confirm your choice by pressing F6; make sure that led “F” become yellow 3. Turn on the “Manual by-pass” breaker 4. Turn off the “Output switch” breaker EVO STAR 60-800... -
Page 28: Restoring Normal Functioning From The Previous Condition
1. Make sure the led “F” is yellow 2. Turn on the “Output switch” breaker 3. Turn off the “Manual by-pass” breaker 4. Press keys F6 and F2, at the same time and wait until led “F” turns green By-pass line Auxiliary Picture 6.1 EVO STAR 60-800... -
Page 29: Control Pannel
Includes devices for conversion from alternating to direct voltage BATTERY Includes the device for energy storage INVERTER Includes devices for conversion from alternating to direct voltage BACK-UP This is the emergency mains supply BREAKERS Includes all the breakers in the U.P.S. EVO STAR 60-800... -
Page 30: Monitoring
The diagnostic tools allow checking the U.P.S. functioning state, by checking for the presence of alarms in progress or already activated and Battery State. The available diagnostic tools are: 1. Event menu 2. History menu 3. Battery test EVO STAR 60-800... -
Page 31: Event And History Menus
Anomaly: If the alarm is caused by a temporary event User: If incorrect or intentional manoeuvring by the user causes the alarm Failure: If the alarm is caused by a system failure that can be restored only by the user EVO STAR 60-800... -
Page 32: Battery Test
F3 keys together then press F6 to confirm, as specified in diagram 1. The test lasts for a minute, during which the U.P.S. takes the necessary energy to maintain its load from the battery. At the end of the test the result will appear under the form of “Good Battery” or “Bad battery”. EVO STAR 60-800... -
Page 33: Functioning Mode Configuration
Internal buzzer is associated to summary alarm, you can turn on or turn off it press F2 key. If you turn off buzzer it will be off as long as all alarms off and other alarm start. EVO STAR 60-800... -
Page 34: Structure Menu
________________________________________________________________________________ 7.1.6 STRUCTURE MENU EVO STAR 60-800... - Page 35 ________________________________________________________________________________ EVO STAR 60-800...
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Page 36: Other Information
On inverter: total time in which load was supplied by UPS On reserve: total time in which load was supplied by back-up line On battery: total time in which load was supplied by UPS and UPS supply by batteries Summary time: UPS on time. EVO STAR 60-800... -
Page 37: Other Board
Colour SUPP Input voltage board OK green PHMKO Input order phases wrong BTEST Battery test in progress yellow RDON Rectifier on green BOOST Battery boost (not used) yellow HTEMP Temperature high VMKO Mains voltage out of range EVO STAR 60-800... -
Page 38: Power Supply
The fuses used are extra-fast fuses for the current specified in charts 9a and 9b. If you replace fuses with models different to the above described the guarantee will no longer be valid. 8.6 STATIC DRIVER Static switch is made by SCR, this board drives them. EVO STAR 60-800... -
Page 39: Transformer Board
The positioning of boards on device is as in picture 8.2, on CN1 enters AC voltage to measure, from CN2 comes out a signal proportional to this voltage, CN3 supplies voltage to A04, CN4 supplies AC voltage to fans (CN4 on A08 position 1 supplies A04). EVO STAR 60-800... -
Page 40: Rectifier Driver
Measure current on phase S generate to inverter FC14 Measure current on phase T generate to inverter FC17 Measure output system current on phase R FC17 Measure output system current on phase S FC17 Measure output system current on phase T EVO STAR 60-800... -
Page 41: Relay Board
Battery switch LOW BATTERY 19 N.C. DC Link fault By-pass switch VOLTAGE(OPTIONAL) 21 N.A. Pre Temp. Alarm Output switch 22 N.C. High Temp. Alarm Reserve switch OUTPUT CURRENT > 125%(OPTIONAL) 24 N.A. Voltage out KO Main switch EVO STAR 60-800... -
Page 42: Rectifier Filter
Picture 8.4 8.11 RECTIFIER FILTER This board is a RC filter on DC voltage generated from rectifier. 8.12 BATTERY FUSE It is on battery connection line. It is placed on A13 wire to protection against battery overcurrent. EVO STAR 60-800... -
Page 43: Back-Up Line
Please remember that the remote panel needs a 220-240V/50-60Hz power supply, which is to be taken only from the U.P.S. output. A specialized technician is recommended to install these devices. E.P.O. Switch (optional) Cable passage Picture 10.1 Please refer to picture 7.1 for the meaning of the state of the leds. EVO STAR 60-800... -
Page 44: Installation Of Remote Panel Without E.p.o
Fasten the board as specified in picture , to the supports you have just inserted Create a connection with the supplied flat-cable between connector A and connector CN3 on the relay board , respecting polarity, that is to say, the coloured wire level with the sign on the board EVO STAR 60-800... - Page 45 2. Supplies it (220-240V/50-60Hz) from socket M3 (picture 10.2), where pin1 is the phase, and pin 3 is a neutral, pin 2 must be void 3. A14 and A16, must be connected by 14 poles wire not supplied. Corrispondance between A14 and A16 connector is as follows: EVO STAR 60-800...
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Page 46: Installing The Remote Panel With E.p.o
17) chapter 6.1 must turn red and the message (Emergency EPO block) will appear Reset the switch Continue the starting procedure (chapter 4) (if already operative restore functioning from U.P.S by-pass following the instructions in paragraph 5) EVO STAR 60-800... -
Page 47: Emergency Power Off
Is possible to select between three modes: Not active Partial shutdown Total shutdown Esc to program menu and remove J1 to A11 11.3 RECOVERY FROM EPO Press epo button and then press start green button on control panel EVO STAR 60-800... -
Page 48: Rs232 Serial Connetcion
Wire for RS232 must be serial male DB9 socket on side U.P.S (connect to B24), and serial female DB9 socket on side PC. Max distance for connection is about 20 mt. Connection pin of connection wire Computer Female DB9 Male DB9 Pin 2 Pin 9 Pin 3 Pin 6 Pin 5 Pin 7 EVO STAR 60-800... -
Page 49: Snmp
It is possible to set input/output frequency to 50 Hz or 60 Hz. In order to change frequency ask a qualified technicians Don’t turn on the U.P.S. if input and output frequency are not equal Frequency conversion is an operation made to F2000 devices that are not the subject of this manual. EVO STAR 60-800... -
Page 50: Batteries
The buffer system used is composed of a string of 32 batteries connected in series. The capacity of each single string corresponds to the capacity of a battery, whereas for parallel series it results in the sum of all the strings. In this manner it is possible to increase system autonomy. EVO STAR 60-800... -
Page 51: External Battery Cabinets
3 (strings) X 7 (A/h) = 21 A/h total capacity. Sizes Cabinet model Width Depth Height Max 32 batteries Up to 44 Ah Max 32 batteries 1800 Up to 120 Ah Tabella 2 For more information about autonomy and batteries configuration contact Tecnoware. EVO STAR 60-800... -
Page 52: Description Of The Max 32 Batteries Cabinet Up To 44Ah
To connect to the U.P.S. we suggest using the specific cable passage. The use of both cable passages will occur when you are connecting battery cabinets in parallel. CABLE PASSAGE FUSE DISCONNECTING SWITCH TERMINAL BOARD BATTERY SHELF SEEN FROM ABOVE JUMPERS TO BE RE-CONNECTED Picture 28 EVO STAR 60-800... -
Page 53: Description Of The Max 32 Batteries Cabinet Up To 120 Ah
1 plane there are the short circuits for the intenal connections and the disposition for the ground connection. VERTICAL VIEW FOR BATTERY PLANE JUMPERS TO BE RE-CONNECTED Chart 29 EVO STAR 60-800... -
Page 54: Technical Charts
Front ELECTRIC DATA Nominal power Kva Active power Kw Efficiency Ac/Ac 100% 91.2 91.5 91.7 91.8 91.8 92.1 92.2 92.2 92.4 92.4 92.5 Load Noise @ 7 mt dB(A) Output current @ 400V e 1156 cosphi 0.8 EVO STAR 60-800... - Page 55 Output frequency From internal 50/60 Hz +/-0.01% quartz Frequency +/-5% windows Overloading 125% per 10 minute, 125%-150% per 60 second (on inverter) Short circuit (on 150% of nominal currentel for 60 sec with in limitation system inverter) EVO STAR 60-800...
- Page 56 +/-10% of nominal system voltage (adjustable) Overload (on 125% continuous, 200% for 5 minute, 1000% for ½ cycle bypass) Manual bypass Standard switch Serial RS232 / Option: SNMP adapter, RS485 (xor RS232) Contact relay Board with 8 programable relay EVO STAR 60-800...
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Page 57: A Breaker Box
For connection see terminal breakers on external box as follows: MAINS LINE : Connect to mains supply TO U.P.S. : Connect to input U.P.S. FROM U.PS. : Connet to output U.P.S. OUTPUT : Connect load U-V-W-N : Names of phases MAINS LINE SWITCH : Input breaker EVO STAR 60-800... -
Page 58: B Input Twelve Pulses And Filters
(is necessary plan a generator power three time or more than UPS power. In a UPS with input twelve THD is typical of 12% with input current wave as in picture B2. Picture B1 Picture B2 EVO STAR 60-800... -
Page 59: C Green Mode
This configuration is recommended only for not critical load, for example pc or server. Picture C2 Picture C1 Typical use of this configuration is in lights control, or for user that don’t require continuos supply. The system performance is more than traditional configuration (about 98%). EVO STAR 60-800... - Page 60 TECNOWARE S.r.l. www.service.tecnoware.com...
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