Ever UPS POWERLINE DARK 60-33/80-33/100-33/120-33/150-33/200-33 User manual

EVER POWERLINE DARK 33 60-200 kVA UPS Operating Manual 
Type 01          2023-11-29 15:12 
Technical Assistance, phone: +48 61 6500 400 
www.ever.eu 
2 
 
TABLE OF CONTENTS 
TABLE OF CONTENTS .................................................................................................................................................................... 2 
INTRODUCTION ............................................................................................................................................................................... 3 
GENERAL FEATURES OF THE UPS UNIT .................................................................................................................................. 4 
SAFETY INSTRUCTIONS AND RECOMMENDATIONS............................................................................................................ 6 
TECHNICAL DESCRIPTION......................................................................................................................................................... 12 
THE UPS UNIT DESIGN AND COMPONENTS ........................................................................................................................ 12 
USER INTERFACE....................................................................................................................................................................... 13 
USER INTERFACE MENU STRUCTURE .................................................................................................................................. 16 
Cabinet ..................................................................................................................................................................................... 16 
Module ...................................................................................................................................................................................... 18 
Setting ....................................................................................................................................................................................... 21 
Log ............................................................................................................................................................................................ 22 
Operate ..................................................................................................................................................................................... 25 
Scope ........................................................................................................................................................................................ 26 
UPS OPERATING MODE ............................................................................................................................................................ 27 
PROTECTIONS............................................................................................................................................................................. 29 
Overload protection .................................................................................................................................................................. 29 
Short-circuit protection ............................................................................................................................................................ 29 
Against overvoltage (Anti-surge) .............................................................................................................................................. 29 
Thermal protection ................................................................................................................................................................... 29 
EPO .......................................................................................................................................................................................... 30 
INSTALLING THE UPS .................................................................................................................................................................. 30 
ELECTRIC INSTALLATION IN THE BUILDING ..................................................................................................................... 30 
UNPACKING THE PRODUCT .................................................................................................................................................... 30 
INSTALLING THE UPS UNIT ..................................................................................................................................................... 31 
EXTERNAL BATTERIES ............................................................................................................................................................ 33 
Connecting an external battery pack ........................................................................................................................................ 33 
Disconnecting an external battery pack .................................................................................................................................... 34 
CONNECTING THE UPS ............................................................................................................................................................. 35 
Connecting elements – POWERLINE DARK 33 60 – 120 kVA................................................................................................. 35 
Connecting elements – POWERLINE DARK 33 150 – 200 kVA ............................................................................................... 36 
Starting the UPS (power supply from the main lines) ............................................................................................................... 38 
Start-up (no voltage on the main lines) – cold start .................................................................................................................. 40 
Switching from MAINS mode to BYPASS mode (service bypass) ............................................................................................. 40 
Switching from BYPASS (service) mode to MAINS (normal) mode .......................................................................................... 41 
SWITCHING THE UPS OFF ................................................................................................................................................... 42 
POWER MODULES ..................................................................................................................................................................... 43 
UPS UNIT’S ADDITIONAL FUNCTIONS .................................................................................................................................... 44 
DRY CONTACTS ......................................................................................................................................................................... 44 
Ambient and battery temperature detection .............................................................................................................................. 44 
EPO .......................................................................................................................................................................................... 44 
Powering from a Generator ...................................................................................................................................................... 45 
Battery switch ........................................................................................................................................................................... 45 
Battery low ............................................................................................................................................................................... 46 
Alarms ...................................................................................................................................................................................... 47 
No mains ................................................................................................................................................................................... 47 
COMMUNICATION WITH EXTERNAL ..................................................................................................................................... 48 
MANAGEMENT/CONTROL SYSTEMS ....................................................................................................................................... 48 
COMMUNICATION THROUGH RS232 OR USB ...................................................................................................................... 48 
SNMP/HTTP NETWORK MANAGEMENT CARD.................................................................................................................... 49 
Installation of the management card ........................................................................................................................................ 49 
OPERATING INSTRUCTIONS ...................................................................................................................................................... 51 
OPERATION OF THE UPS WITH POWER GENERATORS ..................................................................................................... 51 
STORAGE, MAINTENANCE AND TRANSPORT ..................................................................................................................... 52 
DISPOSAL .................................................................................................................................................................................... 53 
TECHNICAL PARAMETERS ........................................................................................................................................................ 54 
LEGAL REGULATIONS AND WARRANTY ............................................................................................................................... 57 
DECLARATION OF CONFORMITY .......................................................................................................................................... 57 
WARRANTY ................................................................................................................................................................................ 57 

EVER POWERLINE DARK 33 60-200 kVA UPS Operating Manual

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INTRODUCTION

Thank you for choosing the EVER POWERLINE DARK 33 UPS. The UPS was

designed to provide the best protection to the connected devices against power failures

and their consequences.

This manual contains information about operating the UPS and safety precautions. We

recommend carefully reading the manual before using the EVER POWERLINE DARK

33 UPS to better understand how to use it properly.

EVER POWERLINE DARK 33 UPS units are ONLINE (VFI) UPS units designed to

operate with devices powered from 3-phase mains.

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GENERAL FEATURES OF THE UPS UNIT

Alongside their excellent performance and reliability, POWERLINE DARK 33 UPS

units offer a number of other advantages:

• On-line operation with real double conversion, sine wave output voltage

(ensuring top quality VFI--SS-111 parameters).

• User-friendly interface – colour LCD touch screen with Polish menu.

• Dry Contacts as a standard feature.

• Increased reliability of the power supply system - a redundant, parallel system in

(N+x) configuration, with x ≤ 2. Up to 3 units can be connected in parallel.

• Power scaling thanks to optional parallel operation (with up to 3 units).

• Dynamic cooling control algorithm for adaptive scaling of performance of the

cooling system to match the device's current state (to minimize power losses and

costs resulting from cooling demand).

• The unit's battery charging system with thermal compensation protects the built-in

batteries, prolongs their life and consequently wires to reduced maintenance costs.

• Optional ECO mode – further improves the efficiency of the power supply system

(by differentiating between periods with varying degrees of safeguards).

• Scalability (extension) of autonomous operation time thanks to the possibility of

connecting more battery modules to the UPS.

• The Start-on-battery function enables the UPS to be started even if power from

the mains is not available ("Cold start").

• 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).

• Event log – for storing information about historical events (operating modes,

alarms and messages related to the operation of the UPS).

POWERLINE DARK 33 UPS units comprise the following functional blocks:

• a rectifier,

• an inverter,

• a battery charger,

• an automatic bypass circuit (static bypass),

• a manual bypass circuit (manual UPS / bypass switch).

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Rectifier

AC/DC

Main

Static Bypass

Manual Bypass

Inverter

DC/AC

Charge/

Discharge

Output

Battery

Bypass

Figure 1: Simplified block diagram of the UPS.

The rectifier converts the mains AC into DC. The direct current bus is the main source

of power for the inverter, which, in turn, generates sine alternating current that powers

the connected receivers.

The automatic bypass circuit enhances the entire system's safety. If the inverter's

permissible parameters are exceeded, the receivers are powered directly from the

mains. This way, the automatic bypass circuit acts as an additional, passive protection.

Activating the bypass manually allows to switch the load to the mains entirely. This

allows to supply power to the receivers from the mains bypassing the UPS unit's

internal functional blocks.

The back-up time depends on the power of the connected receivers and the type and

number of the used batteries. Please remember that batteries with the same rated

capacity, but made by different manufacturers, may provide different back-up times for

the same receiver.

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SAFETY INSTRUCTIONS AND RECOMMENDATIONS

A) General considerations

CAUTION! Before commencing the various procedures described in this

manual, make sure to read the general (and specified here) safety

instructions, OHS information, environmental precautions and legal

stipulations, and observe them.

CAUTION! The UPS may not be repaired by the user, because this poses

a risk of injury or death. Any repairs or battery replacement procedures

should be carried out only by suitably qualified service technicians holding

professional licenses required by law.

CAUTION! The UPS should be operated and stored in conditions

conforming to its specification (technical documentation).

CAUTION! To completely disconnect the UPS from the mains it is

necessary to disconnect the power cord.

CAUTION! The device operates with an external, continuous source of

power (battery modules). Its output may be live, even if it is not connected

to the mains.

CAUTION! The user should place warning labels on all mains isolating

disconnectors of the primary power supply installed far away from the UPS

to warn electric service personnel that the circuit is supplied with power

from a UPS. The following or equivalent text should be printed on the

warning label:

DISCONNECT THE UPS SYSTEM BEFORE STARTING WORK ON THIS

CIRCUIT.

CAUTION! Opening the housing poses a risk of electric shock.

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CAUTION! Before disconnecting the power, no electric connectors or

metal elements inside the UPS may be touched.

CAUTION! All openings and places allowing access to the UPS unit’s

electric connectors must be secured with their relevant covers. Failure to

do so may put at risk the health and life of individuals touching such

connectors or damage the device.

CAUTION! Severe burns may result from the high current occurring during

short circuits.

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

CAUTION! POWERLINE DARK 33 UPS units are not intended to operate

directly with medical equipment, life-supporting equipment or any other

equipment that may have effect on health.

B) Installation information and requirements

CAUTION! POWERLINE DARK 33 UPS units may only be installed and

maintained by suitably qualified service technicians.

CAUTION! Before installing the UPS, OHS regulations with regard to

electric devices operating with voltage up to 1 kV must be consulted.

CAUTION! Before connecting the wires or making connections inside the

UPS or in the electric installation, make sure the electric terminals and

wires are not live.

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

operating with specified rated voltage and with an earthing connector. The

mains to which the UPS is connected must be protected against overload

and short circuit.

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CAUTION! Only TN-S or TN-C-S mains configurations are allowed at the

UPS unit's input, and only a TN-S configuration is allowed at the UPS unit’s

output.

CAUTION! No extension cords may be used for connecting the UPS.

CAUTION! The UPS must not be installed near inflammable materials!

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

to health and/or life.

• Water vapour may begin condensing shortly after bringing the UPS from a cold

room to a warm room. The UPS must be completely dry before installation and

operation. The acclimatization should last 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 wires, cables,

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

• The device must be connected to a power supply circuit with a PE protection line.

Failure to do so puts the user at the risk of 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 reconnected after making all required

connections.

• The earthing wire in the electric installation carries the leakage current away from

the receivers. The leakage currents of the receivers connected to the unit’s output

are summed in the UPS unit’s power lead. The total leakage current may trip the

protections (residual current circuit breaker) and result in disconnecting the power

supply to the receivers.

• The UPS is connected in a permanent manner. Consequently, the fixed wiring

should feature a circuit breaker.

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• 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 wires should be placed so that people walking over them will not step

or trip on 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 minimize the fire hazard, the connections should only be made to a circuit

(electric installation) whose load capacity is adequate to the connected loads and

which features a properly selected overcurrent protection. The circuit breaker

should have at least 3 mm of air insulation clearance.

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.

• The instructions should be followed step by step. If any problems arise when

following the instructions presented in the document, contact the EVER service

department (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 the connection of external

batteries).

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

• WARNING: This is a C3 category UPS. Product for commercial and industrial

applications, in secondary environment. Additional precautions or limitations may

have to be applied to installations in order to prevent the emission of disturbances.

D) Maintenance, repair and breakdown information

• Dangerous voltage is present inside the UPS. Only qualified service technicians

may perform maintenance works.

• CAUTION - risk of electric shock. Even if the device is not connected to the mains

(its terminals), the elements inside the UPS are connected to the battery, which

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may pose a risk. All external battery packs must be disconnected before

commencing service or maintenance works. Make sure there is no dangerous

voltage on the unit’s internal DC elements.

• WARNING: Only properly authorized and qualified service technicians who have

legally required protection gear may replace batteries.

• CAUTION - risk of electric shock. Dangerous voltage may be present between the

battery circuit and the earthing point.

• Batteries have high short circuit current and pose an electric shock risk. The

following precautions must be observed when working with batteries:

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

－ only use tools with insulated grips.

• The same number and type of batteries should be used when replacing them. Using

batteries of wrong type may pose a risk of explosion.

• Always dispose of used batteries according to relevant instructions.

• WARNING: Disposing of batteries in a fire may result in explosion.

• WARNING: Opening or damaging 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.

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

aerosol 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.

• Due to its mass, the device uses wheels for convenience.

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• The UPS should be operated and stored in conditions conforming to its

specification. The UPS should be stored in dry, well ventilated rooms.

• If the UPS is to be stored for a longer time, the batteries should be recharged at

least every 6 months. The recharging procedure should be documented.

• Check the recharging date. If the batteries have not been recharged within the

specified deadline, the UPS must not be used. Contact the service representative

in such a situation.

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TECHNICAL DESCRIPTION

THE UPS UNIT DESIGN AND COMPONENTS

Depending on the UPS model, its elements are shown in Figures 2a - 2b, respectively.

a) Model 60 - 120 kVA

b) Model 150 - 200 kVA

1) information panels of power modules, 2) dry contacts, 3) USB communication interface,

4) RS232 communication interface, 5) RS485 communication interface, 6) power module,

7) cold start button, 8) management card slot (optional), 9) parallel operation card slot

(optional), 10) cover terminals connectors, 11) input and output line protections and bypass

switch 12) castors, 13) bypass line switch

Fig. 2: UPS STRUCTURE

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USER INTERFACE

An LCD touch screen serves as the user interface and features: an EPO button, a UPS

operation synoptic block diagram (with LED indicators) and three function keys. The

elements of the front panel of the POWERLINE DARK 33 60 - 200 kVA UPS are shown

in Fig. 3, along with their description. Table 1 shows the meaning of LED indicators

and the signalisation of each operating mode. Table 2 contains the description of the

UPS sound signalisation and Table 3 contains the description of individual control

keys.

The display shows the UPS unit's parameters and operating modes and allows to

modify some of these. The operation of the interface and the meaning of specific states

and parameters are described in other sections of the manual.

1. LCD touch screen

2. EPO button

3. UPS operation synoptic block

diagram

4. Function keys

Fig. 3: Control and display panel.

Table 1. Selected UPS status visual signals

Indicator

Status LED

UPS status

Rectifier LED

(REC)

Green LED on

Rectifier operation correct (all power

modules).

Green LED flashing

Rectifier is starting.

Red LED on

Rectifier fault

Red LED flashing

Power supply parameters of at least one

power module are incorrect

Light off

Rectifier is off.

Battery LED

(BAT)

Green LED on

Batteries are being charged (mains

operation).

Green LED flashing

Batteries are being discharged (battery

operation).

Red LED on

Batteries are defective, no batteries

connected to the UPS or reversed

polarisation. Charger is defective

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(damaged, overloaded or overheated),

EOD (battery cut-off voltage).

Red LED flashing

Low battery power

Light off

Batteries and charger in good operating

condition, batteries charged.

Bypass LED

(BYP)

Green LED on

The UPS is operating in the BYPASS

mode. Receivers powered from the

bypass line.

Red LED on

Bypass line power supply parameters

exceeded or static switch faulty.

Red LED flashing

Incorrect voltage value for bypass line.

Light off

Bypass OK

Inverter LED

(INV)

Green LED on

The UPS is operating in the mains

mode. Receivers powered from the

inverter.

Green LED flashing

Inverter is starting, synchronising or in

stand-by (ECO mode) for at least one

power module.

Red LED on

Inverter fault in at least one power

module. Receivers not powered from the

inverter.

Red LED flashing

Inverter fault in at least one power

module. Receivers powered from the

inverter.

Light off

Inverter off (all power modules)

Load LED

(OUTPUT)

Green LED on

The UPS is operating correctly (mains

mode). Receivers powered from the

inverter.

Red LED on

Prolonged UPS output overload, short

circuit in the output or no power in the

output.

Red LED flashing

UPS output overloaded

Light off

No power in the UPS output

STATUS LED

Green LED on

UPS operating normally

Red LED on

UPS defective

Red LED on

The UPS is operating in the bypass

mode

Table 2. UPS status sound signals

Sound signals

UPS status

Intermittent sound signal: two

short beeps, one long beep

Warning status, e.g. no input power.

Continuous sound signal

The UPS is operating in the bypass mode or is defective, e.g.

inverter block fault, burnt fuse.

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Table 3. Functions of the control panel keys

Key

Function

EPO

UPS emergency shut-down. Long press, cut off the load power (shut down the

rectifier, inverter, static bypass and battery)

BYP

UPS is switched to the bypass mode (make sure to switch the button in the back

of the door upwards).

INV

UPS is switched to the inverter mode (mains operation).

MUTE

Switching the UPS sound signal on / off.

The front panel of the UPS unit presents useful information on the current functional

state of the UPS unit: operating modes, the input and output parameters, the load level,

alarms and messages. A default screen is displayed on the LCD after the power is

switched on and the UPS has completed self-diagnostics. Table 4 presents the

description of individual LCD display windows.

Fig. 4: Default screen on the LCD display

Table 4. Description of individual windows on the display

Window no.

Function

1

Information about the UPS model, the number of installed power modules and the

current time.

2

Information about the supply voltage for the main line (MAIN) and the bypass. Output

voltage value (OUTPUT) and the voltage value of the connected batteries

(BATTERY). A bar diagram shows the current UPS load level (LOAD). The green

area shows load below 60%, the yellow area shows load from 60% to 100% and the

red area shows load over 100%.

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3

The window shows alarms and messages.

4

The UPS unit's main menu for operating and controlling it. Fig. 5 shows the UPS

main menu structure.

USER INTERFACE MENU STRUCTURE

Fig. 5 presents the main menu structure of the POWERLINE DARK 33 60 – 200 kVA

UPS. The main menu has six branches (menu options); Cabinet, Power unit - Module,

Setting, Log, Operate and Scope. To switch between menus and submenus, press the

corresponding menu or submenu icon. Press Home to return to the main menu. All

screens shown on the LCD display are described in the manual's further sections.

Home

Cabinet Power

unit Setting Log Operate Scope

Bypass

Main

Output

Load

Battery

Input

Output

Load

Info.

S-code

Date &Time

Language

Comm.

User

Battery

Service

Rate

Configure

Mute

Fault clear

Transfer to

Bypass

Transfer to

Inverter

Battery Test

Battery

Maintenanc

e

Battery

Boost

Battery

Float

Output Voltage

Output Current

Bypass Voltage

Fig. 5: Main menu structure

Cabinet

The Cabinet menu is divided into five submenus: Bypass, Main, Output, Load and

Battery. The individual screens show the current, voltage, frequency and PF for the

main power supply line, the bypass and the output line from the UPS. The Load screen

displays the per cent load of the unit’s individual phases and the value of the load

(active, reactive and apparent power). The Battery screen displays the key parameters

of the batteries, such as the charging level and voltage. To switch between the

individual items in the Cabinet menu, press the corresponding icon.

Fig. 6 - 10 show the individual screens of the Cabinet menu. Table 5 presents the

description of individual LCD windows for the Bypass submenu.

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Fig. 6: Bypass submenu screen

Table 5. Description of individual windows on the display

Window no.

Function

1

Name of the currently selected submenu in the Cabinet module.

2

Values of parameters for the currently selected submenu.

3

Submenu selection: Bypass, Main, Output, Load, Battery.

4

Graphical presentation of the current UPS operating mode and the status of

individual UPS blocks (green means a correctly operating block, white - a block that

is off, red - a block that is off or faulty).

5

Firmware information (LCD - display, MTR - system)

Fig. 7: Main submenu screen

Fig. 8: Output submenu screen

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Fig. 9: Load submenu screen

Fig. 10: Battery submenu screen

Module

The Module menu (power module) is divided into five submenus, similarly to the

Cabinet menu: Input, Output, Load, Info, S-Code. Individual screens show parameters

(values of current, voltage, power, temperature and error codes) for individual power

modules installed in the UPS.

To switch between the individual items in the Module menu, press the corresponding

icon. Fig. 11 - 15 show the individual screens of the Module menu. Table 6 presents

the description of individual LCD windows for the Input submenu and Table 7 presents

the description of individual parameters for each submenu in the Module menu.

Fig. 11: Input submenu screen in the Module menu

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Table 6. Description of individual windows on the display

Window no.

Function

1

Name of the currently selected submenu in the Module menu.

2

Values of parameters for the currently selected submenu.

3

Submenu selection: Input, Output, Load, Info, S-Code.

4

A list of the installed power modules with a visual representation of the operating

status of individual blocks (rectifier, inverter, batteries).

Green - a correctly operating block

Black - no power

Red - a deactivated or faulty block

For example, for power module no. 5 the symbol means: rectifier block and

inverter block are operating correctly, no batteries are connected.

5

Firmware version: REC – rectifier block, INV – inverter block for the selected power

module

Fig. 12: Output submenu screen

Fig. 13: Load submenu screen

Fig. 14: Information submenu screen

Fig. 15: S-Code submenu screen

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Table 7. Description of individual parameters of the Module menu

Submenu

Contents

Parameter

INPUT

V

Input voltage of individual phases of the selected power

module.

A

Input current of individual phases of the selected power

module.

Hz

Input voltage frequency of the selected power module.

PF

Power factor of the selected power module.

OUTPUT

V

Output voltage of individual phases of the selected power

module.

A

Output current of individual phases of the selected power

module.

Hz

Output voltage frequency of the selected power module.

PF

Power factor of the selected power module.

LOAD

V

Load voltage of the selected power module.

%

Per cent load of individual phases of the selected power

module.

kW

Real output power of the selected power module.

kVA

Apparent output power of the selected power module.

INFORMATION

BATT+(V)

Voltage and current of the positive battery section.

BATT-(V)

Voltage and current of the negative battery section.

BUS

Bus voltage (positive and negative).

Charger (V)

Charger voltage (positive and negative battery section).

Fan Time

The total time of operation of the selected power module's

fan.

Inlet Temperature

(°C)

Temperature at the inlet of the selected power module.

Outlet

Temperature (°C)

Temperature at the outlet of the selected power module.

S-CODE

Error code

For technicians.

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Ever UPS POWERLINE DARK 60-33/80-33/100-33/120-33/150-33/200-33 User manual

Ever UPS POWERLINE DARK 60-33/80-33/100-33/120-33/150-33/200-33 User manual

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