MAKELSAN BOXER SERIES User Manual
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MAKELSAN BOXER SERIES User Manual

80 - 120 kva
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USER MANUAL
BOXER SERIES
80 - 120 KVA

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  • Page 1 USER MANUAL BOXER SERIES 80 - 120 KVA...
  • Page 2 USER MANUAL BOXER SERIES 80-120 KVA AG–SD-37 Document P. No:1 Rev:1...
  • Page 3 About The Manual This manual is prepared for the users of 80-120 kVA Boxer UPS. Companion Manuals For more information 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.

  • Page 4: Table Of Contents

    BOXER SERIES80-120 KVA CONTENTS CONTENTS 1 SAFETY and WARNINGS ............................1 1.1 Warnings ..................................1 1.2 Clearance and Access ............................2 1.3 Storage ..................................2 1.4 Shipment ..................................2 2 PRODUCT DESCRIPTION ............................. 4 2.1.1 Static Transfer Switch ..........................11 2.1.2 Battery Temperature Regulation ......................
  • Page 5 BOXER SERIES80-120 KVA CONTENTS 3.1.4 Transportation Type of Cabinets ......................27 3.1.5 Mains, Load and Battery Connections ....................27 3.1.5.1 External Protections .......................... 27 3.1.5.2 Cable and Fuse Configuration ......................28 3.1.5.3 Cable Connections ..........................29 3.1.5.4 Connecting Batteries .......................... 32 3.1.5.4.12 External Battery Installation Procedure and Connection ........

  • Page 6: Safety And Warnings

    Batteries certainly must not be thrown into fire. Regarding the topic of batteries which are dead and defected: The waste batteries must definitely not be thrown to nature. They must be delivered to MAKELSAN authorized technicians or to the foundations which are authorized for collecting waste batteries by the Ministry of Environment.

  • Page 7: Clearance And Access

    BOXER SERIES 80-120 KVA SAFETY AND WARNINGS 1.2 Clearance and Access Clearance There exist no air inlet or outlet grilles on the sides of 80-120 kVA UPS. All air is taken through front and evacuated through fan grids on the upper side. There must be 1 m clearance at least at front side of UPS.
  • Page 8 BOXER SERIES 80-120 KVA SAFETY AND WARNINGS Move the UPS as rarely as possible. AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...

  • Page 9: Product Description

    BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION 2 PRODUCT DESCRIPTION General View 776 mm 886 mm AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...
  • Page 10 BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Front View 320x240 6” Graphic LCD Fresh Air Vacuum Grid Mimic Diagram Menu Navigation Keys EPO (Emergency Power Off) Button AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...
  • Page 11 BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Front Cover View Soft Start Button RS232 Serial Communication Socket for Inverter Mains Circuit Breaker External Bypass Circuit Breaker Output Circuit Breaker Battery Circuit Breaker Optional Card Slots AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...
  • Page 12 BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Front Internal View Mains Circuit Breaker External Bypass Circuit Breaker Mains Connecting Terminal Output Connecting Terminal Ground Connection Battery Fast Circuit Breakers and Connecting Terminals Output Circuit Breaker Battery Circuit Breaker AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...
  • Page 13 BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Top View Thyristor Hot Air Evacuation Channel Rectifier, Charger, Inverter Hot Air Evacuation Channel Parallel Connecting Socket AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...
  • Page 14 BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Electrical Connections AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...
  • Page 15 PRODUCT DESCRIPTION 2.1 General Information General operation topology of Boxer Series devices can be recognized as follows: The UPS is connected to the mains voltage through the CB1 breaker. After this energy has filled DC bus condensers, the rectifier operates. The rectifier converts the AC mains energy to DC voltage and charges the batteries in a controlled manner.

  • Page 16: Static Transfer Switch

    UPS adjusts charge parameters according to the information of the detected temperature.. 2.2 UPS’s Operation Modes Boxer series UPS devices have a structure of online and double loop. Our products operate in the following modes:  Normal Mode ...

  • Page 17: Bypass Mode

    UPS automatically starts to operate in a period to be determined. In this case, the UPS continues to operate in normal mode as long as the mains values are in desired criteria. In the Boxer SERIES UPS, this feature is not activated in factory settings. 2.2.5 Maintenance Mode The UPS is equipped with a specific protection switch in order to keep the loads powered during maintenance.

  • Page 18: Advanced Level Functions (Automatic Battery Test)

    BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION 2.3.1 Advanced Level Functions (Automatic Battery Test) The auto battery test automatically discharges 10% of the battery existing capacity in a certain period defined (default is 90 days). The period between two tests can be adjusted by user between 30-360 days.

  • Page 19: User Panel

    BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION 2.4 User Panel User panel consists of mimic diagram, LCD screen, EPO button and menu keys. The device can be controlled via this panel. Rectifier indicator LED It flashes while DC bus is being charged. It constantly illuminates when rectifier works.
  • Page 20 BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Menu Flow Chart MAIN SCREEN Manufacturer–Device Name Control Menu Date - Time Status Menu Load Status as Percent Setup Menu Battery Charge Status as Percent Logging Menu Remaining back up (Autonomy) Time Service Menu Device Mode –...

  • Page 21: Opening Screen

    BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION 2.4.1 Opening Screen When the front panel monitor is turned on, firstly opening screen is observed. Manufacturer – Model Name, Date – Time, Load Status as Percent, Battery Charge Status as Percent, Remaining Back up (Autonomy) Time, UPS Mode –...

  • Page 22: Password Protected Menus

    BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION 2.4.4 Password Protected Menus Some menus such as the control menu are password protected. To enter password choose each digit with UP/DOWN buttons and confirm with ENT button. User level password is: 0000 2.4.5 Control Menu The followings can be done in the control menu: ...

  • Page 23: Status Menu

    BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Battery tests are performed by directing the power to the mains, independently from the loads. If the mains values gets out of limits during the test, test is cancelled. Following Status> Battery menu, how many minutes left to start the test can be observed.

  • Page 24: Setup Menu

    BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Last Test Result Capacity and status according to the last test results Next Test Date Next test date, time and remaining time for test Temperature ° ° ° ° ° Rectifier, inverter, charger, ambient, battery and thyristor temperatures.
  • Page 25 BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Battery Installation Date When new batteries are installed, set the battery install date via this menu. Automatic Restart In battery mode, the device operates until batteries discharge and then shuts down. Auto-restart can be used to restart the UPS automatically when the mains gets back into limit values.
  • Page 26 BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION Beeper Turn the beeper sound on/off. Language Set the menu language. Communication Set the protocol for the RS232 connection. The options are SEC and Telnet. AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...

  • Page 27: Logging Menu

    BOXER SERIES 80-120 KVA PRODUCT DESCRIPTION 2.4.8 Logging Menu The last 500 logs can be observed in the logging menu. While observing any of the logs, if ENT button is pressed, all details regarding the moment of the event (status, setup etc.) can be seen.

  • Page 28: Installation

    Additionally, you can find information concerning the points you must pay attention to during carrying style for cabinets, positioning and connections. 3.1.1 Warnings The UPS must be installed by the personnel approved by MAKELSAN. Warranty is not valid for the devices installed by unauthorized personnel. Battery Hazard! In some models, during operation of battery and the UPS together, there may exist battery terminal voltages reaching up to 450 VDC.

  • Page 29: Pre-Installation Check Up

    BOXER SERIES80-120 KVA INSTALLATION 3.1.2 Pre-Installation Check Up Before installing the UPS product, the following checks should be carried on. These are the first and important steps in the operation of the product correctly.  Definitely check whether or not any damage was done to internal and external structures of the UPS, accessories and batteries during transportation or shipment.

  • Page 30: 2Placing External Batteries

    BOXER SERIES80-120 KVA INSTALLATION 3.1.3.2Placing External Batteries Batteries should be mounted in an environment where the temperature is consistent and even over the whole battery. Temperature is a major factor directly affecting the battery life and capacity. In general, battery manufacturers recommend that batteries be used in 20-25 °C. Furthermore, battery manufacturer companies indicate the performance of batteries according to the said temperature range.
  • Page 31 BOXER SERIES80-120 KVA INSTALLATION Example Battery Chamber Application External Battery Cabinet Application AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...

  • Page 32: Transportation Type Of Cabinets

    Ground leakages flow to the ground through the EMI filters on the input and the output of the UPS. Accordingly, MAKELSAN recommends a residual current relay over 300mA. The residual current relays to be placed in the UPS input must also be: ...

  • Page 33: Cable And Fuse Configuration

    BOXER SERIES80-120 KVA INSTALLATION 3.1.5.2 Cable and Fuse Configuration Cable designs must be compatible to current and voltage values stated herein, additionally local instructions must be obeyed about these topics. Rated Currents (A) Mains Currents at Maximum Mains Currents at Maximum UPS Rating (KVA) Battery Charge (3 phase + Battery Charge (3 phase +...

  • Page 34: Cable Connections

    BOXER SERIES80-120 KVA INSTALLATION 3.1.5.3 Cable Connections UPS input, output and battery connection inlets are made from the front side of the UPS. ATTENTION! 3 pole-circuit breakers (switch) are used for the input and output of the UPS, Neutral line is not interrupted. Input Terminals Output Terminals Please, follow the steps below for electrical connections:...
  • Page 35 BOXER SERIES80-120 KVA INSTALLATION 2. Connect the ground cable. 3. Make sure that all the circuit breakers are placed to the open circuit (OFF) position. The use of these circuit breakers is explained in the next sections. BREAKER “OFF” POSITION BREAKER “OFF”...
  • Page 36 BOXER SERIES80-120 KVA INSTALLATION 4. Connect the input cables:  R phase to input L1,  S phase to input L2,  T phase to input L3,  N(Neutral) to input N. 5.Check the phase sequence. 6.Repeat steps 4 and 5 for output connections. Use the cable clips to stabilize the cables when the connections are done.

  • Page 37: Connecting Batteries

    BOXER SERIES80-120 KVA INSTALLATION 3.1.5.4 Connecting Batteries You can find details about external batteries installation procedure and connections in this section. 3.1.5.4.12 External Battery Installation Procedure and Connection You can find details about how to configure the external batteries under “External Batteries Configuration”...
  • Page 38 BOXER SERIES80-120 KVA INSTALLATION 10. Replace battery fuse on battery cabinet. 11.If there is, switch the breakers on the battery cabinet to the position of “ON”. 12Check if there is appropriate battery voltages to the battery input terminals of the UPS by means of a proper measuring device.

  • Page 39: Control And Communication Cable Connections

    BOXER SERIES80-120 KVA INSTALLATION 3.1.5.5 Control and Communication Cable Connections MAKELSAN UPS products have standard or optional connections of advanced external battery cabinet, environmental monitoring, control panels and various intelligent monitoring. Connections at the front side of the UPS: ...

  • Page 40: Parallel Setup

    Parallel application should be made by authorized personnel assigned by MAKELSAN! In case of need of redundancy or more power, Boxer SERIES devices can be operated as parallel up to the amount of 8. A principle scheme which shows a system in which two UPS are connected in parallel is given below: Input and output of more than one device are connected to each other;...
  • Page 41 BOXER SERIES80-120 KVA INSTALLATION AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...
  • Page 42 BOXER SERIES80-120 KVA INSTALLATION Parallel Settings Connect the parallel cable as shown in figure below. Only use the cables provided by MAKELSAN. Software settings on the user panel should be made by authorized personnel. AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...

  • Page 43: Operation

    BOXER SERIES 80-120 KVA OPERATION 4 OPERATION 4.1 Operation Procedure You can find information 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 The UPS has four circuit breakers accessible from the front side. These are used for the AC input, maintenance bypass, output and the battery connections respectively.

  • Page 44: First Start-Up

    BOXER SERIES 80-120 KVA OPERATION 4.1.2 First Start-Up NOTICE: Wait at least 5 seconds between each step. 1. Switch all the breakers to open circuit (OFF) position. 2. Push the Soft Start button (SW1) for minimum 10 seconds. 3. Switch the input breaker (CB1) and external bypass switches (CB5) to closed circuit (ON) position.
  • Page 45 BOXER SERIES 80-120 KVA OPERATION 5. Check the device has switched to normal operation mode, via front panel display LEDs and LCD panel. 6. Switch battery circuit breaker (CB4) to ON position. 7. Switch output circuit breaker (CB3) to ON position.

  • Page 46: Testing The Operation Modes Of The Ups

    BOXER SERIES 80-120 KVA OPERATION 4.1.3 Testing the Operation Modes of the UPS After first start switch between operating modes for control of operation 4.1.3.1 Switching from Normal Mode to Battery Mode Switch off CB1.This action cuts off the mains voltage and the UPS starts operating on battery mode.

  • Page 47: Switching From Normal Mode To Static Bypass Mode

    BOXER SERIES 80-120 KVA OPERATION 4.1.3.2 Switching from Normal Mode to Static Bypass Mode Switch the UPS to bypass mode via user panel. Check if static bypass led has flashed in mimic diagram. Main Menu>Control> Switch to BYPASS Note: The UPS will not switch to bypass mode if the mains is out of limits or phases are wrongly connected.

  • Page 48: Switching From Normal Mode To Maintenance Bypass Mode

    BOXER SERIES 80-120 KVA OPERATION 4.1.3.4 Switching from Normal Mode to Maintenance Bypass Mode 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.
  • Page 49 BOXER SERIES 80-120 KVA OPERATION 1. Switch on CB2. (ON) 2. Stop the UPS using the front panel. Main Menu>Control >Password>Stop AG-SD-37/ Publication Date: 19.10.2012/Rev. No:1/Rev. Date:16.11.2012...

  • Page 50: Performing A Complete Shutdown

    BOXER SERIES 80-120 KVA OPERATION 3. Switch off CB1, CB3 and CB4(OFF). NOTICE: FOR SAFETY, WAIT 5 MINUTES AT LEAST BEFORE OPENING UP THE DEVICE AFTER YOU HAVE SWITCHED THE DEVICE TO THE MAINTENANCE BYPASS MODE. 4.1.4 Performing a Complete Shutdown 1.

  • Page 51: Epo(Emergency Power Off)

    4.1.6 RS232 Serial Communication Installation and Examination Boxer series has an RS-232 interface which supports SEC and TELNET protocol as standard. This interface is fully isolated and safe. The status of UPS can be monitored remotely via a PC or SNMP by using this protocol.

  • Page 52: Explanations Of Logging

    BOXER SERIES 80-120 KVA EXPLANATIONS OF LOGGING 5 EXPLANATIONS of LOGGING The UPS will beep when any problem is detected. You can see the first information about the situation on the mimic status membrane. This may not be enough most of the time. In this case, you can see the following warnings by making use of log screen.
  • Page 53 BOXER SERIES 80-120 KVA EXPLANATIONS OF LOGGING Output FL1 Over Short circuit protection is activated for output L1 phase. Current Output FL2 Over Short circuit protection is activated for output L2 phase. Current Output FL3 Over Short circuit protection is activated for output L3 phase.
  • Page 54 BOXER SERIES 80-120 KVA EXPLANATIONS OF LOGGING BYPASS UPS has detected short circuit at bypass L1 thyristor. UPS will shut Thyristor L1 down. Short Circuit BYPASS UPS has detected short circuit at bypass L2 thyristor. UPS will shut Thyristor L2 down.
  • Page 55 BOXER SERIES 80-120 KVA EXPLANATIONS OF LOGGING UPS is operating in the maintenance bypass mode, loads are Maintenance energized through maintenance bypass line. Bypass Mode 2 or more UPS are operating in power sharing mode. Load is fed Parallel Mode through UPSs’...
  • Page 56 BOXER SERIES 80-120 KVA EXPLANATIONS OF LOGGING Battery capacity has decreased below defined battery low limit Low Battery while UPS was operating in battery mode. No Parallel 485 No RS485 communication between the parallel systems is Communication available. STS Over Current Time of over load in Bypass line is up.

  • Page 57: Table Of Technical Specifications

    BOXER SERIES 80-120 KVA TABLE OF TECHNICAL SPECIFICATIONS 6 TABLE of TECHNICAL SPECIFICATIONS Technical Specifications 80kVA 100kVA 120kVA Power 64kW 80kW 96kW Active Power INPUT Input Voltage Range 220/380 VAC - %15 + %18 3P + N + PE Input Power Factor At Full Load >...
  • Page 58 BOXER SERIES 80-120 KVA TABLE OF TECHNICAL SPECIFICATIONS BATTERY Quantity (12V DC VRLA) 62 (consists of 2 independent 31 battery groups) Charge Value ( C ) Nominal 0.1 C, selectable. Battery Power 25% of the device power COMMUNICATION Communication Port...

  • Page 59: 7Contact Information

    BOXER SERIES 80-120 KVA GUARANTEE 7CONTACT INFORMATION www.makelsan.com.tr Headquarter: İstanbul Deri Organize Sanayi Bölgesi 2. Yol I -5 Parsel 34956 Tuzla/ İstanbul : 0216 428 65 80 : 0216 327 51 64 E-mail makelsan@makelsan.com.tr İzmir Office : Halkapınar Mah. 1348 Sok. 2AE Keremoğlu İş Merkezi Yenişehir – İzmir...
  • Page 60 Headquarter: İstanbul Deri Organize Sanayi Bölgesi 2. Yol I -5 Parsel 34956 Tuzla/ İstanbul : 0216 428 65 80 : 0216 327 51 64 E-mail makelsan@makelsan.com.tr İzmir Office : Halkapınar Mah. 1348 Sok. 2AE Keremoğlu İş Merkezi Yenişehir – İzmir...

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