Ever UPS POWERLINE GREEN 10-33/15-33/20-33 PRO User manual

EVER POWERLINE GREEN 33 PRO UPS Range Operating Manual

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TABLE OF CONTENTS

TABLE OF CONTENTS .................................................................................................................................................................... 2

INTRODUCTION ............................................................................................................................................................................... 3

GENERAL FEATURES OF THE UPS UNIT .................................................................................................................................. 4

SAFETY INSTRUCTIONS AND RECOMMENDATIONS............................................................................................................ 7

TECHNICAL DESCRIPTION......................................................................................................................................................... 13

THE UPS UNIT DESIGN AND COMPONENTS ........................................................................................................................ 13

THE USER INTERFACE .............................................................................................................................................................. 14

SCREENS ...................................................................................................................................................................................... 17

Main Menu ............................................................................................................................................................................... 18

MEASUREMENTS Sub-menu ................................................................................................................................................... 19

CONTROL Sub-menu ............................................................................................................................................................... 24

CONFIGURATION Sub-menu .................................................................................................................................................. 27

ALARMS Sub-menu .................................................................................................................................................................. 29

STATISTICS Sub-menu ............................................................................................................................................................. 31

PANEL SETTINGS Sub-menu .................................................................................................................................................. 32

IDENTIFICATION Sub-menu ................................................................................................................................................... 34

EVENTS Sub-menu ................................................................................................................................................................... 35

SERVICE Sub-menu ................................................................................................................................................................. 36

SCHEDULE PLANNER Sub-menu ........................................................................................................................................... 36

The RELAYS Sub-menu............................................................................................................................................................. 39

INPUT Sub-menu ...................................................................................................................................................................... 40

MODES OF UPS OPERATION .................................................................................................................................................... 41

PROTECTIONS AND SAFEGUARDS ........................................................................................................................................ 44

Overload protection .................................................................................................................................................................. 44

Short-circuit protection ............................................................................................................................................................ 44

Anti-surge protection ................................................................................................................................................................ 45

Battery protection ..................................................................................................................................................................... 45

Thermal protection ................................................................................................................................................................... 47

EPO .......................................................................................................................................................................................... 47

UPS UNIT INSTALLATION ........................................................................................................................................................... 48

ELECTRICAL SYSTEM ON THE PREMISES............................................................................................................................ 48

UNPACKING THE PRODUCT .................................................................................................................................................... 48

INSTALLING THE UPS UNIT ..................................................................................................................................................... 49

CONNECTING THE UPS TO THE MAINS ................................................................................................................................ 51

Connecting elements ................................................................................................................................................................. 51

Starting-up the UPS unit (power supply from the main line) .................................................................................................... 53

Start-up (no supply in the main lines) – “cold start” ................................................................................................................ 53

Switching off and disconnecting the UPS unit .......................................................................................................................... 54

BATTERY PACK (option) ............................................................................................................................................................ 55

Connecting the battery packs .................................................................................................................................................... 56

Disconnecting the packs ........................................................................................................................................................... 57

ADDITIONAL FUNCTIONALITIES OF THE UPS UNIT .......................................................................................................... 58

ADDITIONAL FUNCTIONAL ELEMENTS ............................................................................................................................... 58

Manual bypass function ............................................................................................................................................................ 58

Control input and DC power supply ports ................................................................................................................................ 58

Programmable outputs ............................................................................................................................................................. 59

REACTIVE POWER COMPENSATION ..................................................................................................................................... 60

HYBRID OPERATION ................................................................................................................................................................. 61

COMMUNICATION WITH EXTERNAL MANAGEMENT/CONTROL SYSTEMS .............................................................. 63

COMMUNICATION USING RS232 OR USB PORTS ................................................................................................................ 63

EVER SNMP/HTTP NETWORK MANAGEMENT CARD ........................................................................................................ 64

Installing the management card................................................................................................................................................ 65

COMMUNICATION USING THE MODBUS PROTPCOL ........................................................................................................ 66

OPERATING INSTRUCTIONS ...................................................................................................................................................... 67

UPS OPERATION WITH POWER GENERATORS .................................................................................................................... 68

STORAGE, MAINTENANCE AND TRANSPORT ..................................................................................................................... 68

DISPOSAL .................................................................................................................................................................................... 70

TECHNICAL PARAMETERS ........................................................................................................................................................ 71

LEGAL REGULATIONS AND WARRANTY ............................................................................................................................... 74

DECLARATION OF CONFORMITY .......................................................................................................................................... 74

WARRANTY ................................................................................................................................................................................ 74

APPENDICES.................................................................................................................................................................................... 75

DESCRIPTION OF MODBUS REGISTERS ................................................................................................................................ 75

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INTRODUCTION

Thank you for purchasing the EVER POWERLINE GREEN 33 PRO UPS system.

This UPS system has been designed and engineered to meet your expectations and

provide the highest standard of protection against power failure.

This manual contains all relevant information to ensure correct and safe operation of

the unit. Please read this manual carefully and thoroughly prior to using the EVER

POWERLINE GREEN 33 PRO unit. This will help to operate the unit and correctly

and safely. The UPS unit has been designed, engineered and manufactured

in Poland. Its design and construction are fully compliant with the CE marking

standards.

The POWERLINE GREEN 33 PRO units are ONLINE (VFI) class units designed to

work with equipment supplied from three-phase electric power mains. These units

are designed to work with particularly sensitive equipment. It is a range of advanced

power supply units designed mainly for computer servers, computer networks and

data processing systems.

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GENERAL FEATURES OF THE UPS UNIT

Alongside their excellent performance and reliability, the POWERLINE GREEN 33

PRO range of UPS units offers a number of other advantages which include:

 On-line operation using real double conversion, with sinusoidal output voltage

(with the highest quality VFI-SS-111 parameters).

 UPS input reactive power compensation – with tangible financial benefits

resulting from reduced bills for reactive power consumption.

 High short-circuit current which helps to achieve high selectivity of the

protection available for the power distribution lines.

 Hybrid operation mode – extending backup time (in BATTERY mode) by

ensuring power is supplied to the inverter concurrently from batteries and from the

power grid with poor/insufficient parameters - this is available for a specific range

of network voltage degradation (very wide input voltage window).

 Achieving high efficiency over a wide range of loads thanks to the use of high

quality components.

 Dynamic cooling management algorithm designed to allow adaptive

adjustment of the cooling system capacity to the current state of the UPS unit (to

minimize power losses and to reduce the costs associated with the demand for

cooling).

 The Intelligent Battery Management technology utilizes the advanced battery

management strategy in order to extend battery life and to optimize the charging

time and charging energy efficiency.

 Availability of the ECO mode – further improves the efficiency of the power supply

system (through the ability to differentiate between periods with varying degrees

of supply reliability).

 Scalability (extending) of the backup operation time thanks to the possibility of

connecting larger number of external battery packs to the UPS unit (optional).

 The scalability of the power supplied by the UPS.

 The Start-on-battery function enables the UPS unit to be started even if power

supply from the mains is not available (the so-called "Cold start” feature).

 Capable of operating in conjunction with external control panels (using the

Android system), and using a RS232, RS485 or USB communication interface,

SNMP/HTTP network management card, control inputs and programmable volt-

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free outputs. It uses an integrated LCD operator’s control panel (with adjustable

angle). All these are designed to allow a customised UPS remote control

strategy.

 Remote Emergency Power Off (Remote EPO) functionality which interrupts

power supply from the UPS output to loads in extreme situations or in emergency

(e.g. fire).

 Obtaining information about temperature and humidity on the basis of

measurements – making it possible to analyse the environmental parameters.

 Events Log – records and stores the data related to the events that have

occurred during the operation of the UPS unit (recording the modes of operation,

alerts and messages related to the device).

 “Soft start” – ensures correct start of the UPS system (provides protection

against formation of transitional states).

The POWERLINE GREEN 33 PRO UPS systems consists of the following functional

blocks:

 rectifier,

 inverter,

 battery set,

 microprocessor-based control system with measurement circuits,

 automated by-pass system (static BYPASS),

 manual (service) bypass system (UPS/BYPASS manual switch) – optional

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Figure 1: Simplified block diagram of the UPS unit

The rectifier transforms the alternating current voltage from the mains into direct

current voltage. It also doubles as a battery charger. The DC voltage bus is the basic

source of power for the inverter system which in turns generates sinusoidal AC

voltage to be used to power the loads. The microprocessor-based control systems

ensure precision and reliability of the entire power supply system.

The automated bypass system helps to increase the overall operating security of the

entire system. In cases where the permissible inverter parameters have been

exceeded, receivers will be supplied directly from the mains. In this way the

automated by-pass system works as an additional passive protection of the power

supply. The manual switching function for the bypass system allows switching over

completely to supplying power to the connected loads from the mains only. In this

way the connected loads are powered from the mains, thus bypassing the internal

UPS modules.

Duration of the power back-up operation depends on the number of loads as well as

the type and number of batteries used with the UPS. Please note that even in case

when batteries from different suppliers have the same rated capacity, the backup

time for the same load may vary.

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SAFETY INSTRUCTIONS AND RECOMMENDATIONS

A) General information

CAUTION! Before starting the procedures described in this manual,

please read the general safety instructions (including the instructions

found in this document), health & safety information, environmental

protection information and legal regulations that may apply. Always

observe the instructions and recommendations found in these

documents.

CAUTION! It is strictly forbidden for the user to perform any repairs, as

this would constitute a health hazard and may result in death. Any

repairs and replacement of batteries should be carried out only by

suitably qualified service technicians, with professional licences required

by law.

CAUTION! The unit should be operated and stored in conditions

complying with the requirements set in the specification (technical

documentation).

CAUTION! The UPS is disconnected from the mains only when the

power lead is disconnected removed from the mains socket.

CAUTION! The unit is equipped with an internal power source (batteries)

or it may operate in combination with a fixed, external source of power

(battery packs). Dangerous voltage may be present at the output

terminal(s), even if the unit has been disconnected from the mains.

CAUTION! The user should place warning labels on all remotely

installed primary isolation switches in order to warn electrical service

technicians that the circuit is powered by a UPS unit. The following (or

equivalent) text should be used on such warning labels:

DISCONNECT THE UPS SYSTEM BEFORE STARTING WORK ON THIS

CIRCUIT.

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CAUTION! Opening the unit’s casing may result in electric shock.

CAUTION! Do not touch any electrical connectors, terminals and internal

metal elements unless power supply has been properly disconnected.

CAUTION! All openings and spaces designed to provide access to the

unit's electrical connections must remain covered (with applicable

covers). Failure to observe this requirement may create hazard

potentially resulting in injury or death for persons who touch such

connectors. It may also cause damage to the unit.

CAUTION! In the event of a short circuit, the resulting high current may

cause serious burns or scalds.

CAUTION! There are no user-serviceable parts inside the UPS unit.

CAUTION! The POWERLINE GREEN 33 PRO range of UPS units is not

intended to work directly with medical equipment, life-supporting

equipment or any other equipment that may have effect on health.

B) Installation information and requirements

CAUTION! The POWERLINE GREEN 33 PRO range of UPS units may

only be installed and maintained by suitably qualified service technicians.

CAUTION! Before installation of the UPS unit, the staff and users must

become familiar with the Health and Safety regulations when working

and handling electrical equipment up to 1 kV voltage.

CAUTION! Before connecting any cables or making any connections

within the UPS unit or in the electrical system, make sure there is no

dangerous voltage on electrical terminals and cables in the system.

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CAUTION! The UPS may only be connected to a power system with

indicated rated voltage, with a suitable grounding connection installed.

The facility's electrical system to which the UPS unit is connected must

be fitted with overload and short-circuit protection.

CAUTION! Only TN-S or TN-C-S configuration is allowed on the UPS

unit's input side, and only TN-S configuration is allowed on the UPS

unit's output side.

CAUTION! No extension cords should be used for connecting the UPS

unit.

CAUTION! It is forbidden to install the UPS unit in the vicinity of

flammable materials or substances!

 Technicians must not work alone in hazardous conditions that may be dangerous

to health and/or life.

 Shortly after the UPS unit has been moved from a cold environment to a warm

environment, moisture condensation may appear. The UPS unit must be

completely dry before installation and operation. The acclimatisation time should

be at least 2 hours.

 UPS units and battery packs must not be installed in humid environment.

 UPS units and battery packs must not be installed in places where they would be

exposed to direct sunlight. They must not be installed near sources of heat.

 Ventilation openings in the UPS unit casing must not be blocked. Always observe

distances to ventilation openings specified in the manual.

 Before connecting the units, is necessary to check the condition of all leads,

cables, connectors, sockets and plugs, as well as that of the unit itself.

 The unit must be connected to a power circuit with a PE grounding conductor.

Failure to observe this requirement may result in electric shock.

 To reduce the risk of electric shock (in case the grounding cannot be checked),

the unit must be disconnected from the mains before installation or connecting to

other equipment. The power lead may only be connected again after making all

required connections.

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 The electric system's grounding conductor leads the leakage current away from

the receivers. The leakage currents of all loads connected to the UPS unit's

output are totalized in the UPS unit's power lead. The summary leakage current

may trigger protective devices (RCD) and result in disconnecting power to the

loads.

 A UPS unit is a fixed connection device; consequently, a breaker should be used

in the fixed cabling.

 When connecting and disconnecting signal cables, all actions should be

performed with one hand only (if feasible). This is to avoid electric shock when

touching two surfaces with different electrical potentials.

 Connecting leads should be routed in such a way to ensure they are

protected against treading on them or tripping over them.

 An emergency power-off button (EPO), dedicated to the UPS system, should be

installed in the building's electrical system. This is to allow disconnecting, in

emergency, the UPS unit from the connected loads regardless of the mode in

which the UPS is operating.

 To minimise the risk of fire, connections should only be made to circuits (electrical

systems) whose rating is adequate for the connected loads, with properly selected

overcurrent protection. Additionally, the breaker should feature at least a 3 mm

insulating air gap.

C) Operation of the UPS unit

 Health and Safety regulations and guidelines specified in the UPS unit operating

manual must be observed when handling and operating the UPS unit.

 All these instructions must be executed step by step. Should any problems

emerge when executing the instructions listed in this manual, please contact

EVER service support (www.ever.eu).

 Never disconnect the grounding at the UPS unit or at the terminals of the

building's electrical system, as this will disable the UPS unit's protective

grounding.

 There may be voltage on the UPS unit's output terminals, even if the UPS is

disconnected from the building's electrical system (due to presence of power in

the unit's internal batteries and/or battery packs).

 Liquids and foreign bodies must not be allowed to penetrate the UPS casing.

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 WARNING: The unit described here is a C3 category UPS. This is a product

designed for commercial and industrial applications, meeting the Second

Environment levels. Additional precautions or restrictions to be observed

during installation may be required to prevent the emission of interferences.

D) Maintenance, repair and breakdown information

 Dangerously high voltages are present in the UPS unit. Repairs and maintenance

may only be performed by suitably qualified service technicians.

 CAUTION - Risk of electric shock! Even if the unit has been disconnected from

the mains (from terminals of the electrical power supply), parts inside the UPS

unit remain connected to the batteries, which may create hazards. Disconnect the

battery and/or battery packs before carrying out any servicing and/or

maintenance. Make sure there is no dangerous voltage on the DC circuit internal

elements.

 WARNING: Batteries may only be replaced by suitably qualified service

technicians holding professional licences and wearing personal protection

equipment required by law.

 CAUTION - Risk of electric shock! Dangerous voltage may be present between

the battery circuit and the grounding point!

 Batteries have high short-circuit current and pose a risk of electric shock. The

following precautions should be taken when working with batteries:

－ remove jewellery, watches, rings and other metal items,

－ only use tools with insulated handles.

 When replacing batteries, always use the same type and the same number of

batteries. Using batteries of incorrect type may result in explosion.

 Always dispose of used batteries according to relevant instructions.

 WARNING: Disposing of batteries in fire is prohibited as this may result in

explosion.

 WARNING: Opening or damaging the batteries may cause electrolyte to leak;

electrolyte is harmful to skin and eyes, and may also be toxic.

 To avoid the danger of fire and damage to the mains or power supply system,

always replace broken or blown fuses with fuses of the same type and

parameters.

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 Disconnect the device from the mains before cleaning. Do not use liquid or

sprayed cleaning agents.

 UPS units may only be disassembled by suitably qualified service technicians.

E) Transport and packaging requirements

 Exercise particular care when transporting the equipment, due to its heavy weight.

 Heavy equipment must be moved by at least two or more persons.

 UPS units may be transported only in their original packaging boxes to ensure

adequate protection against shocks, vibrations and impact.

 The unit is very heavy and has been fitted with a wheel set to facilitate moving.

 The unit should be operated and stored in conditions meeting the requirements in

the product specification. UPS units must be stored in a dry room with suitable

ventilation.

 If a UPS is to be stored over a longer period of time, its batteries must be

recharged at least every 6 months. The recharging procedure must always be

recorded and documented.

 Always make sure to check the date when recharging is due. Do not use the UPS

unit if the deadline has passed and the batteries have not been recharged. In

such cases always contact service support.

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TECHNICAL DESCRIPTION

THE UPS UNIT DESIGN AND COMPONENTS

Figure 2: View of the rear panel.

1) EPO connector, 2) Communication bus connectors for parallel operation,

3) Programmable outputs (non-voltage contacts), 4) Control inputs, 5) USB communication

interface, 6) RS232 communication interface, 7) RS485 communication interface,

8) Adapter/expansion card slot plug, 9) Fans, 10) BYPASS (service) system switch

(optional), 11) Protection, internal batteries (F1, F2), 12) Protection, DC input lines (F5) –

optional, 13) Protection, basic input lines (F4) and optionally BYPASS input lines (F3),

14) Cover, terminal connectors, 15) Mounting brackets, 16) Caster wheels to move the UPS,

17) DC power connection (12 V DC / 1A non-stabilised)

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Figure 3: View of the connection terminals (on the rear panel, with the cover removed)

1) Protections and connections, main input lines (F4), 2) Connections, N neutral lines,

3) Connections, output lines, 4) PE protective cable connection point, 5) Tabs for connecting

cable rail, 6) Protections and connections, bypass input lines (F3) (optional), 7) Connections,

external battery pack (optional)

THE USER INTERFACE

The user interface consists of the following control panel (Fig. 4). features the LCD

display and the synoptic block diagram showing the UPS unit’s operation, and a 4-

button keypad.

These controls are used to monitor the UPS unit’s parameters and modes of

operation. They also allow modification of some of those parameters. Correct use of

the interface and the meaning of individual states and parameters are described

below.

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Figure 4: View of the user interface:

The UPS unit also uses sound chimes for individual device states (see Table 1).

Table 1. Acoustic signal

Action

Acoustic signal

NORMAL mode

None

HYBRID Mode

Intermittent signal; frequency increases proportionally to the level of discharging of the

batteries until it turns into a continuous sound.

BATTERY Mode

Enforced switching to the

STANDBY mode

Intermittent signal - two short signals followed by a pause

EMERGENCY Mode

Depending on the type of event

Overload

Continuous signal

Short circuit

Rapid intermittent 50% / 50% signal

Overheating

Slow intermittent 50% / 50% signal

EPO activation

Intermittent, with signal on/signal off frequency of 1s / 5s

All subsequent screens shown on the LCD display are organised into the tree

hierarchy shown on Fig. 5.

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Figure 5: Map of the LCD screens organised into the tree structure.

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SCREENS

SCREENSAVER

Description:

The information page/screen starts to be displayed as a

screensaver after 5 minutes of inaction since the last button was

pressed. It also turns off the LCD panel illumination.

Type:

Readout

Parameters:

Q

– battery charge level

U+

– voltage, hot battery section (+)

U-

– voltage, cold battery section (-)

Ld

– UPS load level

Tau

– expected duration of UPS backup operation

TrybPracy

– UPS mode of operation

i: …, A: …

– additional information as shown in Table 4

View of the

screen:

General messages (tab. 2) (i:) characterize all the UPS unit operation modes with the

exception of EMERGENCY operation which is signalled with a separate set of alarm

alerts (A:).

Table 2. List of general information messages and alarm alerts and their respective meanings.

General information messages

Alarm alerts

Abbreviation

Meaning

Message

Meaning

i:Charging

Charging

A:ShortCircuit

Short circuit F)

i:Overload

Overload

A:Overload

Overload F)

i:RecOverTemperature

Rectifier block overheated

A:RecOverTemperature

Rectifier block overheated

P)

i:InvOverTemperature

Inverter block overheated

A:InvOverTemperature

Inverter block overheated F)

i:MinChargeWaiting

Waiting to achieve minimum required

battery charge following STANDBY

A:EPO

Emergency EPO F)

i:LowBattery

90 sec of UPS backup operation

remaining

A:RecInternalError

Internal rectifier block

fault R)

i:Service

Periodic servicing recommended

A:InvInternalError

Internal inverter block fault

R)

i:Bypass

BYPASS active

i:RecCommFail

Lost communications with the rectifier

block

F) Message cancelled by

ClearIncFault (3/4 control)

P) Message cancelled by

ClearRecFault (3/4 control)

R) After an internal fault has

occurred it is mandatory to

switch off the unit (by

completely cutting off the power

supply) and to contact a service

agent.

⃰ Time duration depends on the

type and number of batteries

installed. See the note in the

description of the Menu

(Battery)

i:InvCommFail

Lost communications with the inverter

block

i:BypPhasesSeqFail

Incorrect phase sequence for the

BYPASS line

i:BypOutOfRange

BYPASS line supply parameters out of

range

i:MainsOutOfRange

Rectifier block supply parameters out of

range

i:MainsPhasesSeqFail

Incorrect phase sequence for the rectifier

supply system

i:SchedulerActive

Message indicating that the function is

active scheduler, which allows the user

to program a periodic controlling the

power supply

i:DRPC Active

Enabled dynamic reactive power

compensation

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When the date for the scheduled service approaches, the screensaver turns into a

warning message to remind the user about the need for servicing.To exit this state

keep the Esc key depressed for the duration of 5 sec.

Main Menu

To jump to the Main Menu press the Esc key. Similarly, it is possible to force the

return to the Screensaver by hitting the Esc key (as shown on Fig. 5, relating to the

screen hierarchy).

The Main Menu uses four screens. Individual Main Menu screens are shown below.

Switching between individual screens is done by using the ▼▲ keys. To confirm the

selection (at each point) press the key. Then, once the selected menu appears,

make the desired sub-menu selection also by using the ▼▲ keys. Pressing the ESC

key takes the user one level up (to the previous screen).

The arrow to the left of the sub-menu name shows the actual position of the selection

check mark. The arrow only appears once the screen has been confirmed by hitting

the key. To jump to the selected submenu or parameter, pressing the key.

Pressing the ESC key takes the user one level up (to the previous screen).

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MEASUREMENTS Sub-menu

The MEASUREMENTS Sub-menu uses two screens divided into six subject groups:

RECTIFIER, BYPASS, OUTPUT, BATTERY, TEMPERATURE, ENVIRONMENT.

Navigation within this menu is similar to the way shown earlier.

RECTIFIER 1/5

Description: The UPS unit’s input parameters

Type: Readout

Parameters:

ULn

– rectifier input voltage for the n line

ILn

– rectifier input current for the n line

View of the

screen:

RECTIFIER 2/5, 3/5, 4/5

Description: The UPS unit’s input parameters

Type: Readout

Parameters:

PLn

– rectifier, input active power for the n line

SLn

– rectifier, input apparent power for the n line

PFLn

– rectifier input power factor for the n line

View of the

screen:

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RECTIFIER 5/5

Description: The UPS unit’s input parameters

Type: Readout

Parameters:

P

– summary input active power for rectifier

S

– summary input apparent power for rectifier

f

– rectifier input frequency (measured for the L1 line)

View of the

screen:

BYPASS 1/5

Description: Input parameters for the BYPASS line

Type: Readout

Parameters:

ULn

– BYPASS line voltage (n line)

ILn

– BYPASS line current (n line)

View of the

screen:

BYPASS 2/5, 3/5, 4/5

Description: Input parameters for the BYPASS line

Type: Readout

Parameters:

PLn

– BYPASS line input active power (n line)

SLn

– BYPASS line input apparent power (n line)

PFLn

– BYPASS line input power factor (n line)

Percentage values - show the levels for a given n line

View of the

screen:

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Ever UPS POWERLINE GREEN 10-33/15-33/20-33 PRO User manual

Ever UPS POWERLINE GREEN 10-33/15-33/20-33 PRO User manual

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