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MAKELSAN AG-SD-36 User Manual

Challenger series
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USER MANUAL
CHALLENGER SERIES
80 ‐ 120 KVA

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  • Page 1 USER MANUAL CHALLENGER SERIES 80 ‐ 120 KVA...
  • Page 3 USER MANUAL CHALLENGER SERIES 80‐120 KVA AG‐SD‐36 Document Y.No:1 Rev:0 AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 4 About The Manual This manual is prepared for the users of Challenger 80‐120 kVA. Companion Manuals For more info about this device and its options, please visit www.makelsan.com.tr . Updates Please, visit www.makelsan.com.tr for updates. Always use the latest manuals. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 5: Table Of Contents

    CHALLENGER SERIES 80‐120 KVA CONTENTS Contents 1.  SAFETY AND WARNINGS ........................ 6   1.1.  Warnings ..........................6  1.2.  Clearance and Access ......................7  1.3.  Storage ........................... 7  1.4.  Shipment ..........................7  2.  Product Description .......................... 8   2.1.  General Information ......................14  2.1.1.  Static Transfer Switch ....................14  2.1.2.  Battery Temperature Regulation ................15  2.2.  UPS’s Operation Modes .....................
  • Page 6 CHALLENGER SERIES 80‐120 KVA CONTENTS 3.1.3.  Positioning ........................30  3.1.3.1.  Positioning of UPS ....................30  3.1.3.2.  External Battery Configration ................. 30  3.1.4 Transportation Type of Cabinets .................. 32  3.1.5 Main, Load and Battery Connections ................32  3.1.5.1 External Protection ....................33  3.1.5.2 Cable and Fuse Selection ..................33  3.1.5.3 Connecting the Cables ....................33  3.1.5.4  Battery Connections ..................36  3.1.5.4.1  External Battery Installation Procedure and Connection ...... 37  3.1.5.5  Control and Communication Cable Connections ......... 39  3.2 ...

  • Page 7: Warnings

    CHALLE ENGER SERI ES 80‐120 K KVA SAFE ETY AND WA ARNINGS 1. SAFE ETY AN ND WA ARNING . Warning This man ual must be read before e installing t the UPS. The e device can n be installed d and starte d only by Makels san staff. Installatio on or start‐u up by unauth horized per sonal may c cause damag ge to the dev vice and ser ious injury or death. The UPS i is designed t to be used in n continuou us vertical fix xed position n application...

  • Page 8: Safety And Warnings

    CHALLENGER SERIES 80‐120 KVA SAFETY AND WARNINGS Fire extinguishing equipment must be kept nearby the UPS. 1.2. Clearance and Access Clearance There is no any air inlet or outlet grill on the left or right sides of our 80‐120 kVA UPS. All air goes in to UPS from the front and is evacuated from the rear through fans. There must be spaces at least 1 meter at the front side of UPS. Should not be permanent or temporary use within the limits specified. Otherwise, the UPS performance will decrease. Access Operator reaches UPS via front panel on 80‐120 kVA UPS. Therefore, enough area must be left for operator.. There is no limit to the sides of the device. 1.3. Storage UPS should be kept in a room or area where is protected from excessive moisture and heat before commissioning. WARNING: Unused batteries must be charged at regular intervals. This time interval is determined by the battery supplier. Charging can be performed periodically by connecting to a proper mains for a while. 1.4. Shipment Carrying vehicles must have enough features and characteristics to carry UPS. Be more careful of sudden movements, especially when batteries are inside of cabinet. Move the UPS as rarely as possible. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 9: Product Description

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION 2. Product Description General View CH80120EN02R0 AG‐SD‐36 Rev. No:0 Rev. Date:1511.2012 Publish No:1...
  • Page 10 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Front View CH80120EN03R0 320x240 6” Grafik LCD Ventilation Inlets Mimic Diagram Menu Keys EPO (Emergency Power Off) Button AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 11 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Front Cover View CH80120EN04R0 RS232 Serial Interface for Inverter RS232 Serial Interface for Rectifier Input Circuit Breaker External Bypass Circuit Breaker Output Circuitr Breaker Optional Card Slots AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 12 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Front Inside View CH80120EN05R0 Maintenance Circuit Breaker External Bypass Circuit Breaker Input Connectiion Terminals Output Connection Terminals Earth Ground Connection Battery Rapid Fuses and Battery Connection Terminals Output Circuit Breaker AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 13 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Top View CH80120EN06R0 Ventilation Outlets for inductors Ventilation Outlets for pfc, charger and inverter Parallel Interface AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 14 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Electrical Connection AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 15: General Information

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION 2.1. General Information General operation topology of Challenger Series UPS can be recognized as follows. The UPS is connected to the mains voltage through the CB1 breaker. As DC bus is ramped up, the rectifier starts to operate and converts the AC mains to DC Voltage. When the mains voltage is not available, the DC/DC booster pumps the battery voltage to the necessary level. DC DC bus voltage is then converted to mains synchronized AC voltage by the inverter. This is a high quality voltage. Generated AC power is applied the loads after passed from static semi‐conductor switches and output (load) breakers. 2.1.1. Static Transfer Switch Some blocks are named as “static switches” as can be seen above. These blocks consist of inverse parallel connected thyristors. These switches, which are under the control of the mainboard control unit (DSP), provides controlling of supplying the loads through either mains or inverters. The loads are supplied through inverter during the normal operating mode. Therefore, Inverter static switches are active if there is no problem with the system. User can switch the UPS between mains and inverter by using front panel. While the loads are fed directly by mains with the order of user, in case of either power off or mains values out of tolerances, the UPS will start to supply the loads through battery mode. If the user wants, can provide mains to feed load continuously by switching on the maintenance bypass without making adjustment on the front panel. Later on, the user can make the input and output switch fuses short circuit. If user wants, can provide mains to feed load continuously by switching on the maintenance bypass without making adjustment on the front panel. Later on, the user can make the input and output switch fuses short circuit. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 16: Battery Temperature Regulation

    ON. After that, input and output of UPS are switched OFF respectively. NOT: In the meantime, the loads are unprotected against the power‐off, damage, twist etc. problems. 2.1.2. Battery Temperature Regulation Optional temperature sensor is given with external battery cabinet. Battery temperature are perceived by mentioned temperature sensor. UPS adjusts battery charge parameters according to the information of the perceived temperature. These parameters can easily be adjusted via LCD or TELNET interface by authorized staff of MAKELSAN. In this case, We recommend you to order "External Battery Temperature Measurement Kit" to detect the temperature. 2.2. UPS’s Operation Modes Challanger series UPS's on‐line and has a double loop structure. Our products operate in the following modes:  Online Mode ...

  • Page 17: Battery(Stored) Mode

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION 2.2.2. Battery(stored) Mode UPS runs on battery mode when the mains voltage is bad.Battery Voltage is boosted for the sufficient Dc bus voltage. 2.2.3. Bypass Mode In an overload condition, or if there is a problem with the double conversion, the loads are fed by the bypass line. UPS switches to AC supply from inverter for that by static switches. Inverter must be synchronized with the mains supply for these transitions to be seamless.This transitions might take 15 ms depending on the type of load if inverter output is not synchronized with the mains.

  • Page 18: Maintenance Mode

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION 2.2.5. Maintenance Mode In maintenance mode, UPS equipped with a switch capable for not to be interrupted of the loads. This switch was choosen to meet the full load. 2.3. Battery Management Lead – Acid Batteries are used with UPSs as internal. 2.3.1. Normal Operation Mode Constant Charge Current Current is limited to 0.1C untill the float reaches to charge voltage. (adjustable between 0.05C ‐ 0.25C.) The applied current can not exceed maximum charge power. Float Charge Depending on the battery discharge current the third percent energy of the battery is charged at this level. Thanks to this level, batteries are kept ready for use at the highest capacity. For lead‐ acid batteries, this voltage varies between values 2.2‐2.35 V/cell This voltage may differ slightly with temperature adaptation. Option of setting this coefficient is provided with our UPS. If the temperature sensor is used, it is recommended to use. Deep Discharge Protection While the system operates on battery mode, if battery voltage has dropped below the discharge level UPS shuts down and stops absorbing energy from the batteries. This value varies between 1.6‐1.75 V/cell for Lead‐Acid batteries, and for Ni‐Cd batteries between 0.9‐1.1 V / cell. Low Battery Warning While the system operates in battery (stored) mode, according to actual loads if the battery capacity drops below its 40% value, it will give audible and visible alarms. This percentage value is adjustable for user between 20%‐70%.

  • Page 19: Advanced Level Functions (Automatic Battery Test)

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION 2.3.2. Advanced Level Functions (Automatic Battery Test) The auto battery test discharges 30% of the battery energy in a user defined period (default is 90 days). This period can be adjusted between 30‐360 days. Test reports the battery condition as “good or replace”. Results of the latest test can be seen on the battery screen from the status menu. WARNING: If the test result is “replace”, then the batteries are completely drained during the test. This situation may cause the load remained unpowered in case of mains voltage is out of the limits or mains power off. This test can be started by command from front panel monitor, via TELNET interface, via RS232 smart communication or via MAKNET (SNMP, see the options). It is checked that if the batteries can supply the minimum back‐up time needed in case of the first power‐off by using the results of all these tests. Checking the test results with a regular period is recommended. 2.4. User Panel User panel consists of mimic diagram, LCD screen, EPO button and menu keys. The UPS can be controlled via this panel. CH80120EN07R0 AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 20 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Rectifier indicator LED Flashes while the DC bus is ramping up. Illuminates when Rectifier works. AC/DC module (Rectifier) Boost mode indicator LED Illuminates in battery mode. Flashes when UPS is started up through batteries. Battery charge indicator LED Illuminates while the batteries are charging. Battery module DC/AC module (Inverter) Mains bypass indicator LED Illuminates while the loads are fed through bypass line. Inverter static switch indicator LED Illuminates when the load is fed by the inverter Alarm/Warning indicator LED 10‐ Menu keys 14 EPO (Emergency Power Off ) Button AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 21 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Main Screen Menu Flow Chart Manufacturer – Device Name Control Menu Date ‐ Time Status Menu Setup Menu Load Status as Percent Logging Menu Battery Charge Status as Percent Service Menu Remaining Back up (Autonomy) Time UPS Mode – Actual Alarms Main Menu Titles SERVICE* STATUS LOGGING SETUP CONTROL *Detailed Mains Log Code Date & Time Start service Output Date Battery Install Date Stop menu can be Bypass Time Auto Restart Output Bypass observed by Battery Log Records Auto Battery Test Output UPS only...

  • Page 22: Openning Screen

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION 2.4.1. Openning Screen When the front panel monitor is turned on, firstly opening screen is observed. Manufacturer – Device Name, Date – Time, Load Status as Percent, Battery Charge Status as Percent, Remaining Back up (Autonomy) Time, UPS Mode – Actual Alarms, Main Menu Titles can be observed here.Last event (log) is shown at the bottom left and active alarms list that appears 2,5 second intervals are shown at the bottom right. If no button is pressed for 5 minutes, system returns to the opening screen. 2.4.2. Main Menu Press ENT button to switch to the main menu. 2.4.3. Navigating Through the Menus Use UP and DOWN keys to move the cursor arrow. Press enter to open a sub‐ menu. Press ESC to go back to the previous menu. Control sub‐menu is shown on left. Hold the UP or DOWN key to navigate between the sub‐ menus. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 23: Password Protected Menus

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Some menus have changeable options like ON/OFF, durations or quantities. To change some setups in such a menu, press ENTER to choose the variable, use up and down keys. To change the value, press ENTER to set the new value, press ESC to cancel. 2.4.4. Password Protected Menus Some menus such as the control menu are password protected.Press UP and DOWN to set each digit and press ENTER to confirm. User level password is: 0000 (zero‐zero‐ zero‐zero) 2.4.5. Control Menu In the control menu, you can do one of the following:  Start Start the UPS  Stop Stop the UPS  Switch to BYPASS Switch to static BYPASS mode  Switch to UPS Switch to online mode  Bat. Quick Test Start the quick battery test  Bat. Capacity Test Start the deep battery test  Stop Battery Test Stop the battery test AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 24: Status Menu

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Battery status test, drains the 30% of battery energy and reports batteries which has more capacity than 15‐30% as “Good”, less capacity than 15% as “Replace” according to the test results. After UPS is started and every 24 hours, it makes a quick battery test ,if test counter value is zero (0). Note: Batteries must have been fully charged and kept in floating situation for at least one hour before performing the quick battery test. Status on the System > Battery > Remaining Time can be seen. If “Stop Battery Test” is chosen from the menu, the UPS cancels the battery test and goes back to the previous operating state. 2.4.6. Status Menu Mains Output, Bypass, Battery, Temperatures, inverter, Alarms and UPS information can be seen on this menu. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 25 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Mains UP, I, Hz Voltage (phase‐neutral), current and frequency of each phase. UL, S, P Voltage(phase phase), reactive and active power of each phase. PF, U, D Power factor, positive DC bus and negative DC Bus of each phase. Output UP, I, Hz Voltage(phase‐neutral), current and frequency of each phase. UL, S, P Voltage(phase phase), reactive and active power of each phase. PF, L, CF Load percentage for each phase and crest factor. Bypass UP, I, Hz Voltage(phase‐neutral), current and frequency of each phase. Voltage of each phase (phase to phase). Battery Mode Battery Mode. U, I, T Battery Voltage, Charge Current and Temperature. Charge % Charge Percentage. Battery Time The estimated battery run time with current load. Last Test Result Test type, test number, test date and time. Battery capacity and condition. Next Test Time Next test date Time Timer countdown for the next test availability. Temperature °C,°C,°C,°C,°C,°C,°C Rectifier, inverter, charger, ambient, battery and thyristor temperatures. Inverter U, I, P Voltage, current and frequency of each phase.

  • Page 26: Setup Menu

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION 2.4.7. Setup Menu The following adjustments can made on setup menu: Date & Time To set date and time, use up and down keys to choose the variable you want to set. Then use up and down keys to set the value, and press ENTER. Battery Replacement Date Set the date of battery installation through this menu. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 27 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Auto Restart On the battery mode, UPS operates until charging process completed. the device turns off at the end of battery discharge process. Auto‐ restart can be used to restart the UPS automatically when the mains comes back to limits. Turn on auto‐restart and set the time to define when the device will be started after the mains is normal. Auto Battery Test This function can be turned on to start the user independent battery tests. Time interval sets when the test will be repeated. Note: Auto Battery test is the equivalent of battery quick test. Screen Change the screen contrast to make it more visible on different environmental conditions. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 28 CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Beep Turn the beeper sound on/off. Language Set the menu language. Communication Set the protocol for the RS232 connection. The options are SEC, Megatech and TELNET. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 29: Logging Menu

    CHALLENGER SERIES 80‐120 KVA PRODUCT DESCRIPTION Economy Mode Economy mode (ECO) and UPS switch to static bypass mode at the specified days and hours. Use this menu to setup the days and hours. Service Menu Service menu is password secured, and cannot be accessed with the user password. 2.4.8 Logging Menu Last 500 events of the device can be seen in this menu. When viewing an event, press enter to see detailed info about the UPS. Use up and down keys to see older/newer event logs. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 30: Installation

    CHALLE ENGER SERI ES 80‐120 K KVA INSTAL LLATION 3. Inst tallati ion . Single M Mode Instal llation In this se ection, the w warnings wh hich must b e obeyed an nd the chec king which must be pe erformed before sta arting‐up th e UPS are st tated. Additi ionally, you can find inf formations a about the po oints you must pay attention d uring carryi ing the cabin nets, positio oning and co onnections.

  • Page 31: Positioning

    CHALLENGER SERIES 80‐120 KVA INSTALLATION 3.1.3. Positioning UPS and batteries are designed for indoor use; UPS must be placed in a places where has clean and easy air flow. 3.1.3.1. Positioning of UPS In Challenger 80‐120 kVA series, air enters the device from the front side ventilation holes, goes out from the rear side of UPS through fans. Air inlet and outlet ports should never be covered. It should be positioned in a place where is far from the risk of liquid contact. If the area is dusty, Optional filters must be used on dusty environments. The using of these filters will be made according to the instructions on. UPS is an energy‐loss system due to its nature. Energy losses emerges as heat. You can see what kind of a forced air‐cooling is needed in the following table. This table can be used to calculate the capacity of air conditioning which must be used in UPS ambiance. Bridge Load 100% (Non‐lineer) estimated Amount of BTU /h for BTU / h value for load UPS cooling working 80 KVA 17500 21000 100 KVA...
  • Page 32 CHALLENGER SERIES 80‐120 KVA INSTALLATION  Shelves will be accessible in touch if batteries are in battery room. Therefore please keep restricted accessing to battery room. Use necessary safety writings and strips Espacially, for the external cabinet batteries system of UPS, fuses must definitely be used. These fuses must be mounted as close as possible to the batteries. This closeness will increase the electrical operation safety. THE TABLE OF CHALLENGER EXTERNAL BATTERY USAGE Device Power (KVA) 100 120 Total number of Batt. @ V (A) 18,6 23,2 27,8 bat.max bat.max @ V (A) 136 170 204 bat.max cutoff Recommended internal fuse (A) 160...

  • Page 33: Transportation Type Of Cabinets

    CHALLENGER SERIES 80‐120 KVA INSTALLATION CH80120EN09R0 External Battery Cabinet Application 3.1.4 Transportation Type of Cabinets Carrying vehicles or handling accessories must have enough features and characteristics to carry UPS’s weight. Cabinet is equipped with four‐wheel. Thanks to this feature, it can be moved easily. These wheels must be used only on smooth surfaces. The front side wheels of UPS must be locked after positioning properly. The back side wheels are fixed. Be more careful of sudden movements, especially when batteries are inside of cabinet. Move the UPS as rarely as possible. Main, Load and Battery Connections 3.1.5 Makelsan strictly recommends a distribution board for the UPS outputs. Proper fuses and breakers must be used in such distribution board. A‐B type fuses or magnetic breakers are recommended if the load is suitable. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 34: External Protection

    35% higher rated than t the ones giv ven in the tab ble below. F Fuses must b be C‐type. Ground le eakages flow w to the grou und through h the EMI filt ters on the i input and th he output of the UPS. Makelsan n recommen ds the use o of 700mA ra ted relays fo or handling leakage cur rrents. Leakage c current relay ys that set a at the input o of UPS are s hown below  Resistant t to both pos sitive and ne egative DC p pulses, ...
  • Page 35 CHALLENGER SERIES 80‐120 KVA INSTALLATION CH80120EN10R0 Input Terminals Output Terminals Follow the steps below to electrical connections: 1. Make sure that the network and loads are isolated through cables by turning off the all breakers on the distrubution board. CH80120EN11R0 AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 36 CHALLENGER SERIES 80‐120 KVA INSTALLATION 2. Connect the ground cable. CH80120EN12R0 Make sure that the circuit breakers are off. The use of these circuit breakers are explained on the next sections. CH80120EN13R0 AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 37: Battery Connections

    CHALLE ENGER SERI ES 80‐120 K KVA INSTAL LLATION Connect t the input cab bles.; R to INPU UT L1,  S to INPU UT L2,  T to INPU UT L3,  N(Neutra al) to INPUT  CH80120E EN14R0 Check the e phase sequ uence. Repeat st teps 4‐5 for o output cable es. Use the ca able clips to stabilize th he cables wh hen the conn nections are done. WARNING G: Make sur re that the l oads are iso olated from the UPS ou...

  • Page 38: 4.1  External Battery Installation Procedure And Connection

    CHALLE ENGER SERI ES 80‐120 K KVA INSTAL LLATION  Preserve your eyes a nd skin agai inst possible e arcs.  Check for r leaks befor re connectin ng the batter ries.  Batteries have harmf ful content. I In case of co ontact wash with plenty y of water If irritation pe ersists, consult a doctor. Remove t the metal ac cessories su uch as ring ,w watch befor re working w with batterie 1.5.4.1 Ex xternal Ba attery Insta allation Pr rocedure a...
  • Page 39 CHALLENGER SERIES 80‐120 KVA INSTALLATION 11. Please check that whether there is appropriate battery voltage on the input terminals of the battery of UPS by measurement tool. The external battery cable selection is determined by the application. Recommended fuses are given for UPS and battery cabinet. The lowest diameter cable that can be connected to those fuses is recommended to be used. Please, refer to standard called EN 50525‐2‐31(VDE 0100‐430) in this subject. Bu konuda EN 50525‐2‐31(VDE 0100‐430) adlı standardı referans alınız. selection should be such that the cable will allow at most 0.5 Vdc decreasing.

  • Page 40: Control And Communication Cable Connections

    Parallel app plication sh hould be ma ade by auth horized per rsonal of M Makelsan ! In case of f need for re dundancy o or more pow wer, Challeng ger series U PS can be op perated in p parallel up to qua antity 8 (eigh ht). A schem matic diagram m which sho ows two UPS S connected d in parallel can be seen belo w.
  • Page 41 CHALLENGER SERIES 80‐120 KVA INSTALLATION Inputs and outputs of more than one UPS are connected to each other; but definitely each battery group is different from another, batteries can not be used in common. The following points should be considered while placement of UPS in parallel system and their electrical connections are made: UPSs connected in parallel must have the same power rating and must be the same series.  Devices must be running on the same firmware, if not, old firmwares must be updated.  Devices must be located as close as possible to each other (max. 6 x 110 cm paralleling cables.)  Each device must have its own neutral cable .  Each device must have its own ground connection.  UPS must be connected in paralel on the distribution panel and phases must be connected  correctly. (U ‐U ‐…‐U ), (V ‐V ‐…‐V ), (W ‐W ‐…‐W Each UPS must have their own battery set, batteries cannot be used for more than one device at ...
  • Page 42 CHALLENGER SERIES 80‐120 KVA INSTALLATION Parallel Settings Connect the parallel cable as shown in figure below. Only use the cables provided by Makelsan. CH80120EN18R0 CH80120EN19R0  Software settings on the user panel should be made by authorized personel. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 43: Operation

    CHALLENGER SERIES 80‐120 KVA OPERATION 4 OPERATION 4.1 Operation Procedure You can find informations about circuit breaker, first start‐up, types of UPS operation tests, turning UPS off, EPO and RS232 serial communication system in this section. 4.1.1 Circuit Breakers UPS has three circuit breakers that can be reached from the front panel, these are used for AC input, maintenance bypass and output connections respectively. Three‐phase AC voltage is applied through CB1 to input of UPS. AC input voltage is applied directly to loads through CB2. In this way, maintenance purposed switching is done properly. If UPS is actived while it is operating thanks to auxilary short circuit info located in CB3, mains makes the bypass static switches actived. The system will be switched to maintenance mode smoothly. CB3 is used to connect or seperate AC voltage that comes from static switches to the loads on UPS. Active Brakers Operation Mode Explanation CB1, CB3 Normal Mode UPS operates in normal mode.. UPS is overloaded, loads will be transferred to CB1, CB3 Static Bypass Mode static bypass line temporarily. UPS is ON, but loads will be fed through CB2 Test Mode mechanical bypass line.

  • Page 44: First Start-Up

    CHALLENGER SERIES 80‐120 KVA OPERATION 4.1.2 First Start‐Up WARNING: Wait for at least 5 seconds between each step. Turn the Maintenance (CB2) bypass breaker “ON” CH80120EN20R0 Turn the input (CB1) breaker “ON” CH80120EN21R0 AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 45 CHALLENGER SERIES 80‐120 KVA OPERATION Start the UPS using the front panel. Main menu> Control > Password > Start Wait for the operation of the rectifier. Rectifier LED on the mimic diagram will flash for a while, and then remain lit. CH80120EN22R0 Wait for the operation of the battery charge. Battery charge LED on the mimic diagram will be lit continuously.
  • Page 46 CHALLENGER SERIES 80‐120 KVA OPERATION Turn output circuit braker (CB3) ON. CH80120EN26R0 Turn the maintenance bypass braker (CB3) OFF. CH80120EN27R0 AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 47: Testing Of Types Of Ups Operation

    CHALLENGER SERIES 80‐120 KVA OPERATION 11. The loads which are connected to UPS can be turned on. After all these steps, check that load is fed through inverter static switches via mimic diagram. In a contrary situation, check UPS total and phase loads. The UPS gives audio alerts in an overload condition, without feeding critical AC loads. 4.1.3 Testing of Types of UPS Operation After first start‐up check device operation by switching between the following modes manually. 4.1.3.1 Switching from Online Mode to Battery Mode Turn CB1 OFF. This action cuts off the mains voltage and the UPS starts operating on battery mode. Turn CB1 back ON again if everything is ok. CH80120EN28R0 AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 48: Switching From Online Mode To Static Bypass Mode

    CHALLENGER SERIES 80‐120 KVA OPERATION 4.1.3.2 Switching from Online Mode to Static Bypass Mode Use the front panel to switch the device to static bypass mode. Check the mimic panel to make sure that the device has switched to bypass mode. Main menu> Control > Switch to Bypass CH80120EN24R0 NOTE: UPS will not switch to bypass mode if the inverter voltage is out of limits or there is and overload or overtemperature situation. 4.1.3.3 Switching from Static Bypass Mode to Online Use the front panel to switch the device to online mode. Check the mimic panel to make sure that the device has switched to online mode. Main menu > Control > Switch to UPS CH80120EN25R0 NOTE: The UPS will not switch to normal mode if the inverter voltage is out of limits, or there is and over load or over temperature situation. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 49: Switching From Online Mode To Maintenance Bypass Mode

    CHALLENGER SERIES 80‐120 KVA OPERATION 4.1.3.4 Switching from Online Mode to Maintenance Bypass Mode WARNING: Make sure that the inverter output is synchronous with the maintenance bypass line before switching to maintenance bypass mode. Otherwise there is a possibility of cutting off the load power for a short while. Use the front panel to switch the device to static bypass mode. Check the mimic panel to make sure that the device has switched to bypass mode. Main Menu > Control > Output BYPASS CH80120EN24R0 AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...
  • Page 50 CHALLENGER SERIES 80‐120 KVA OPERATION 1. Turn CB2 ON. CH80120EN20R0 Stop the UPS by using front panel. Main menu > Control > Stop AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 51: Performing A Complete Shutdown

    CHALL LENGER SER RIES 80‐120 KVA O OPERATION . Turn CB1 1, CB3 and C CB4 OFF. H80120EN29 9R0 WARNIN NG: Wait at least 5 min nutes before e opening u up the devic c e after it is s complete ly turned off, for s safety 4.1.4 Perf forming a Complete Shutdown Turn off t the loads co nnected to t the device. Use the fr ront panel to o turn the d evice OFF Main Me enu> Contr rol> Passw word> Stop AG‐SD‐3...

  • Page 52: Epo (Emergency Power Off)

    CHALL LENGER SER RIES 80‐120 KVA O OPERATION WARNIN NG: Make su ure that the ere are no c critical load ds on the UP PS output b before perfo orming a comp plete shutd down. 4.1.5 EP O (Emerge ency Powe er Off) UPS turn ns off rectifie er, amplifie r and inver rter respecti ively when the EPO bu utton is pres ssed. UPS is complete...

  • Page 53: Explanations Of Logging

    CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING 5 Explanations of Logging UPS will beep when any problem is detected. You can see the first information about the situation on the front monitor panel. This may not be enough most of the time. In this case, you can see the following warnings by using log screen. Warning Warning Description RS232 Start UPS was started by RS232 communication software. Command RS232 Stop Command UPS was stopped by RS232 communication software. After the batteries discharge totally, UPS restarted itself automatically Auto Restart after the mean time which adjusted that follows the mains getting back UPS Startup The main board of the UPS is energized. Soft Start Fail UPS could not ramp the DC bus up. Quick Battery Test Quick battery test has began. Deep Battery Test Battery capacity test has began. Battery Self Test Periodical battery test has began. Batteries’ voltage has gone below cut off voltage value while UPS was End Of Discharge operating on the battery mode. UPS has operated at overload more than time limit adjusted. The Loads Overload Timeout will be transferred to bypass line. Battery test has completed. You can see the all results via front panel End of Battery Test status menu. Test was aborted manually or by UPS since the criterias were not Batt. Test Aborted provided during battery test. Manuel Switch To Static switchs directions were changed manually to the bypass line via BYP UPS command menu.
  • Page 54 CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING No Battery No battery detected. Maint. BYP. Sw. On Maintenance bypass switch has been activated. Ambient Abnor. The ambient temperature is over limit. Check the ventilation of UPS Temp. room. Battery over‐current UPS battery charge current is out of the specified limits. Charge will be OFF until return to normal operating. Mains voltage is out of the specified limits, UPS will switched to battery Mains Voltage bad mode. Inverters temperature is out of limit, in case of 5 degrees more incremen Inverter Overtemp. Load will be transferred to Bypass line. Rectifier 's temperature is out of limit, in case of 5 degrees more PFC Overtemp. increment ,Load will be transferred to Bypass line. Charge / boost module temperature is out of the specified limits. If it is Chrg OverTemp. in charge mode, Charge will be stopped. If it is in boost mode, UPS will be stopped. Static Transfer Switches’ temperatures are out of limits. UPS will be STS Overtemp. stopped. 23 Outp.PL1 Cur. Limit. Short circuit protection is activated for output L1 phase. 24 Outp.PL2 Cur. Limit. Short circuit protection is activated for output L2 phase. 25 Outp.PL3 Cur. Limit. Short circuit protection is activated for output L3 phase. Bypass voltage value is out of limit while UPS was operating on the Bypass Voltage Bad bypass mode. UPS will switch to normal mode if temperature and load status are normal.If not ,UPS will stop.
  • Page 55 CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING Inverter voltage is out of limit. Load will be transferred to bypass line, 29 Inverter Voltage Bad when inverter voltage gets back to normal values,UPS will switch to normal mode again. Output load value is over %105, overloading counter will start to count, Overload If UPS is on normal mode, the charging will be stopped until load value gets back to normal. Maint. BYP. Sw. Off Maintenance bypass switch is deactivated. 32 Ambient Nor. Temp. UPS ambient temperature has got back to allowed limit values. Mains Voltage Nor. Mains voltage is in the limited values, UPS will switch to normal mode. Inverter temperature is in the limited values. If load and temperature 34 Inverter Nor. Temp. values are normal, UPS will switch to normal mode. Rectifier temperature is in the limited values. If load and temperature PFC Nor. Temp. values are normal, UPS will switch to normal mode. Charger/booster module temperature is in the allowed limits, charging Charger Nor. Temp. will be activated again. STS Nor. Temp. Temperature of Static transfer switches is in the allowed limit. Bypass Voltage Nor. Bypass voltage is within defined limits. Bypass Freq. Nor. Bypass frequency is within defined limits. UPS inverter or rectifier coil temperature has got back to normal Coil Normal temp. values. Inverter voltage is in the limited values, UPS will switch to normal Inverter Volt. Norm. mode. Normal Load Output load is under %100, If charging was OFF, It will be ON .
  • Page 56 CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING UPS has detected short circuit at bypass L3 thyristor. UPS will shut BYP Thyr.L3 Short C down. UPS has detected short circuit at inverter L1 thyristor. UPS will shut UPS Thyr.L1 Short C. down. UPS has detected short circuit at inverter L2 thyristor. UPS will shut UPS Thyr.L2 Short C. down. UPS has detected short circuit at inverter L3 thyristor. UPS will shut UPS Thyr.L3 Short C. down. UPS has detected that inverter L1 thyristor can not be activated. Load UPS Thyr.L1 Open C. will be transferred to bypass line. UPS has detected that inverter L2 thyristor can not be activated. Load UPS Thyr.L2 Open C. will be transferred to bypass line. UPS has detected that inverter L3 thyristor can not be activated. Load UPS Thyr.L3 Open C. will be transferred to bypass line. UPS has detected that bypass L1 thyristor can not be activated. Load BYP Thyr.L1 Open C. will be transferred to inverter line. UPS has detected that bypass L2 thyristor can not be activated. Load BYP Thyr.L2 Open C. will be transferred to inverter line. UPS has detected that bypass L3 thyristor can not be activated. Load BYP Thyr.L3 Open C. will be transferred to inverter line. One or more of UPSs which operate in paralel mode do not match in Parl. Phs. Rot. Err. phase sequence. Battery Start Starting through battery command has been given to UPS. One or more of UPSs which operate in paralel mode could not start to Parl. Start Error operate. Inverter Fault UPS couldn't prepare the inverter voltage.
  • Page 57 CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING UPS is operating in the bypass mode, load are energized through Bypass Mode bypass line. Maintenance Bypass UPS is operating in the bypass mode, load are energized through Mode bypass line. 2 or more UPS are operating in power sharing mode. Load is fed Parallel Mode through UPSs’ inverter lines. UPS has switched to battery test mode, loads are energized through Test Mode rectifier‐ battery‐ inverter line as source sharing. EKO Mod KGK eko moddan çalışıyor. Yükler bypass hattı üzerinden besleniyor. Switch to Inverter The direction of the static switches was varied manually on the rectifier Command through UPS commands menu. Output voltage is detected during the period of starting UPS . UPS has 68 Output Voltage Error been stopped. Abnormal stuation is detected during the moment of rectifier PFC Stop Cmd. operating.UPS has stopped itself. Manuel Start Start command is given via UPS command menu. Command Manuel Stop Stop command is given via UPS command menu. Command An error occurred while ramping up the battery bus, Batteries could Batt. Swtch. Failure not be activated. UPS Stopped UPS has been stopped. UPS has switched to bypass mode so many times i a short period, UPS Bypass Problem will be shut down.
  • Page 58 CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING Battery Err. Although connected to the UPS, batteries can not be charged. UPS which is operating in paralel mode has been given a command to Parallel Command change the status of static switches. Slave UPS which is operating in paralel mode can’t reach to master UPS No P.CAN Bus Comm. from CAN bus. If UPS is operating, will be shut down. UPS which is operating in paralel mode has been given a command to Ext. Start Command start up by another (master) UPS. UPS which is operating in paralel mode has been given a command to Ext. Stop Command stop by another (master) UPS. UPS which is operating in paralel mode has been given a command to Ext. Switch To BYP. transfer the load to bypass line. UPS which is operating in paralel mode has been given a command to Ext. Switch To UPS transfer the load to inverter line. Slave UPS which is operating in paralel mode has detected a failure of Parallel Comm. FE. input current sharing. Inverter voltage reached needed value after UPS is started up. UPS can Inverter OKEY feed the loads through inverter. Batt. Temp. Err. Battery temperature is out of defined limits, batteries can be damaged. Booster Overcurrent Overcurrent in Battery mode, UPS will be shut down. EPO key pressed EPO key button is pressed. Battery capacity has decreased below defined “ battery low limit” while Battery Low UPS was operating in battery mode. No P.485 Bus Comm. Parallel RS485 communication between the systems is not available. STS OverCurrent OverCurrent in Bypass line.
  • Page 59 CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING Unable to communicate with the fan control system. Only for UPSs that Fan Failure contain the fan control system. 97 Output DC Volt. Fault Over Inverter DC voltage. Loads will be transferred to the bypass line. Battery Temp. Nor. Battery temperature is normal. Output Signal ON UPS output switch is opened. Loads can be energized. Able to communicate with the fan control system. Only for UPSs that 100 Fans Active contain the fan control system. PFC Pbus 101 Positive DC Bus overvoltage. OverVoltage PFC Nbus 102 Negatif DC Bus overvoltage OverVoltage PFC PhL1 103 Short circuit protection is activated for rectifier L1 phase. OverCurrent PFC PhL2 104 Short circuit protection is activated for rectifier L2 phase. OverCurrent PFC PhL3 105 Short circuit protection is activated for rectifier L3 phase. OverCurrent Command to stop itself has been given to UPS which is operating in 106 Single Stop paralel mode separately from paralel system. 107 Master Changed UPS became master device in paralel system.
  • Page 60 CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING The error signal is detected on UPS through power source circuit 114 Pwr. Supply Fault debugger. Signal is detected from "generator mode input" of dry contact board. 115 Generator Mode UPS will switch to "generator mode". Alarms and Descriptions Decription of Alarm Alarm Over Temperature at the UPS units, Check the Status> Over Temperature Temperatures menu UPS is overloaded, reduce the load. Over Load Bypass line voltage or frequency is out of limits, can not be Bypass Bad bypassed. UPS Stopped The charging circuit problem is detected, batteries can not be Charge Failure charged. In the case of mains interruption, critical loads remain energized. Fan control board can not be reached, control will not be made. Fan Failure Output Fuse is turned OFF. Fuse Failure Stop command was given to the UPS, UPS will shut down at the end Shutting Down of the period. No battery detected. No Battery Maintenance bypass fuse is ON. M. Byp. Sig. Active UPS feeds the critical loads via bypass line. Static. Byp. Mode UPS is operating in the battery test mode.
  • Page 61 CHALLENGER SERIES 80‐120 KVA EXPLANATIONS OF LOGGING Inverter voltage can not be created. Inverter Fault UPS switched to battery mode. Battery Mode There is more than one UPS with the same ID number at the system Parallel. ID Conflict connected in parallel. Check ID numbers. In this case, the system can not be started. UPS cannot communicate with the master UPS of the parallel No Parallel Comm. system. The battery capacity has fallen below defined limit in battery mode. Low Battery UPS is operating in ECO mode. EKO Mode One or more thyristor is faulty. See the history logs for details. Thyristor Failure Bypass line phase sequence is not compatible with inverting the BYP. Phase Rot. Err. phase sequence. Number of perceived UPS at the parallel system is not the same as Par. UPSMissing number of set UPS. One or more other phase of UPS is energized as different from other Curr. Char. Err UPS. One of the power supplies that operates in paralel stopped. Power Supply Failure UPS switched to generator mode. Switching to generator mode Generator Mode command was given by dry contact board. AG‐SD‐36 Rev. No:0 Rev. Date:15.11.2012 Publish No:1...

  • Page 62: Technical Specifications

    CHALLENGER SERIES 80‐120 KVA TECHNICAL SPECIFICATIONS 6 Technical Specifications Technical Specifications Power 80KVA 100KVA 120KVA Active Power 64kW 80kW 96kW Input Input Voltage Range 220 ± %15 (L‐N) or 380 ± %15 (L‐L) 3P + N + PE Input Power Factor At Full Load > 0,99 Input Frequency Range 50Hz ± 10% / 60Hz ± 10% (Adjustable) Rectifier IGBT Rectifier Total Harmonic Distortion <%5 (THDi) Output 220/380 VAC (230/400 VAC adjustable) 3P + N ± 1% Static, ± 1% Output Voltage Range Dynamic At 0% ‐ 100% ‐ 0% load, maximum output tolerance %5, %1 Back to band Recovery <40ms Efficiency Up to %93 synchronous with the network at the range of 50Hz ±2% , mains when Output Frequency Range is out of range 50Hz ± 0,2%, battery mode 50Hz ± 0,2% Lineer <%3 Output THD (THDv) Non‐Lineer <%4 Crest Factor (CF)
  • Page 63 CHALLENGER SERIES 80‐120 KVA TECHNICAL SPECIFICATIONS Communication adapter option RS232 Standart, RS485 and SNMP Dry Contact Optional Protocol Megatec, SEC, TELNET Certificates Quality ISO 9001 Standard CE, TSE Safety TS EN 62040‐1‐1, IEC60950 EMC/LVD TS EN 62040‐2; A Class General Running Temperature At the range of 0 °C ~40 °C (for batteries 0 ~ 25 °C) Storage Temperature At the range of ‐15 °C ~ 45 °C (for batteries ‐10 ~ 60°C) Protection Class IP20 Chassis Anti‐Static Paint Protection Humidity 0‐95 % <1000m, Correction Factor 1. <2000m, Correction Factor >0,92, <3000m; Altitude Correction Factor >0,84 Acoustic Noise (1m) <70dBA 500Event Log. (Optional Status Record) Log Recording Parallel Operation Parallel power increase up to 8 pcs. EPO (Emergency Power Off) Standard Isolation Transformer Optional Net Weight...

  • Page 64: Contact Information

    CHALLENGER SERİSİ 80‐120 KVA CONTACT INFORMATION Contact Information www.makelsan.com.tr İstanbul Deri Organize Sanayi Bölgesi 2. Yol, I ‐5 Parsel, 34956 Tuzla/ İstanbul Tel: 0216 428 65 80 Faks: 0216 327 51 64 e‐mail: makelsan@makelsan.com.tr İzmir Branch: Hakapınar Mah. 1348 Sok. 2AE Keremoğlu İş Merkezi Yenişehir – İzmir Tel: 0232 469 47 00 Faks: 0232 449 47 00 e‐mail: izmir@makelsan.com.tr...
  • Page 66 İstanbul Deri Organize Sanayi Bölgesi 2. Yol, I ‐5 Parsel, 34956 Tuzla/ İstanbul Tel: 0216 428 65 80 Faks: 0216 327 51 64 e‐mail: makelsan@makelsan.com.tr İzmir Branch: Hakapınar Mah. 1348 Sok. 2AE Keremoğlu İş Merkezi Yenişehir – İzmir Tel: 0232 469 47 00 Faks: 0232 449 47 00 e‐mail: izmir@makelsan.com.tr...

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