MAKELSAN BOXER SERIES User Manual
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MAKELSAN BOXER SERIES User Manual

10 - 20 kva
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USER MANUAL
BOXER SERIES
10 - 20 KVA

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Summary of Contents for MAKELSAN BOXER SERIES

  • Page 1 USER MANUAL BOXER SERIES 10 - 20 KVA...
  • Page 2 USER MANUAL BOXER SERIES 10 - 20 KVA AG–SD-109 Rev:0...
  • Page 3 Companion Manuals For further 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. Shipment Carrying vehicles or handling accessories must have enough features and characteristics to carry UPS’s weight.

  • Page 4: Table Of Contents

    BOXER SERIES 10-20 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 General Information .............................. 9 2.1.1 Static Transfer Switch ..........................
  • Page 5 BOXER SERIES 10-20 KVA CONTENTS 3.1.3.3 Placing External Batteries ....................... 24 3.1.4 Transportation Type of Cabinets ......................26 3.1.5 Mains, Load and Battery Connections ....................26 3.1.5.1 External Protections .......................... 26 3.1.5.2 Cable and Fuse Configuration ......................27 3.1.5.3 Cable Connections ..........................27 3.1.5.4 Connecting Batteries ..........................

  • 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 10-20 KVA SAFETY AND WARNINGS 1.2 Clearance and Access Clearance There exist no air inlet or outlet grilles on the sides of 10-20 kVA UPS. All air is taken through front and evacuated through fan grids on the back side. There must be 1 m clearance at least at front side and 1.2 m clearance at least at rear side of UPS.
  • Page 8 BOXER SERIES 10-20 KVA SAFETY AND WARNINGS The cabinet is equipped with four wheels. By this means, it can be easily moved and placed. These wheels must only be used on smooth surfaces. After the UPS has been placed on an appropriate position, front wheels must be locked. Back wheels are fixed.

  • Page 9: Product Description

    BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION 2 PRODUCT DESCRIPTION General View AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...
  • Page 10 BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION Front View LCD Display Fresh Air Vacuum Grid EPO (Emergency Power Off) Button Menu Navigation Keys Mimic Diagram Back View AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...
  • Page 11 BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION Rectifier/Charger-Inverter Cooling Fans Bus Bar Charging Button Optional External Bypass Switch Maintenance Bypass Switch Mains Switch Mains Connecting Terminal Ground Connection AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...
  • Page 12 BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION Input-Output-Battery Cable Fixing Connectors Output Connecting Terminal Battery Fast Circuit Breakers and Connecting Terminals Battery Commissioning Switch Output Switch Thyristor Hot Air Evacuation Channel Optional Cold Start(Starting through battery) Switch Winding Hot Air Evacuation Channel...
  • Page 13 BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...

  • Page 14: General Information

    PRODUCT DESCRIPTION 2.1 General Information General operation topology of Boxer Series UPS 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 15: Battery Temperature Regulation

    “External Battery Temperature Sensor Kit” for temperature detection of the UPS. 2.2 UPS’s Operation Modes Boxer SERIES UPS's on-line and has a double loop structure. Our products operate in the following modes:  Normal (Online) Mode  Battery Mode ...

  • Page 16: Automatic Restart 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 17: Advanced Level Functions (Automatic Battery Test)

    BOXER SERIES 10-20 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 18: User Panel

    BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION 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. Rectifier indicator LED It constantly illuminates when rectifier works. AC/DC module (Rectifier)
  • Page 19 BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION Menu Flow Chart Control Menu Status Menu Setup Menu Logging Menu LOGGING STATUS CONTROL SETUP Log Code Mains Start Date & Time Date Output Stop Battery Install Date Time Bypass Switch to Bypass Auto Restart...

  • Page 20: Opening Screen

    BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION 2.4.1 Opening Screen When the front panel monitor is turned on, firstly opening screen is observed. Model name, charge status, load status and remaining back-up time are displayed. In case of any alarm case, alarms are shown as scrolling text in the first line.

  • Page 21: Password Protected Menus

    BOXER SERIES 10-20 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 22: Setup Menu

    BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION The mains, output, bypass, battery, inverter, DC bus and alarms can be displayed on this menu. Mains VP, A Hz Voltage (phase-neutral), current and frequency of each phase. KW, KVA, PF Active power, reactive power and power factor of each phase.
  • Page 23 BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION Date & Time To set date and time, use up and down keys to choose the variable you want to set and press ENT. Set the value via arrow buttons and press ENT button again.
  • Page 24 BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION Change the screen contrast setting to make it more visible on different environmental conditions. 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.

  • Page 25: Logging Menu

    BOXER SERIES 10-20 KVA PRODUCT DESCRIPTION Inverter, rectifier, CPLD, front panel software version and UPS serial no, device apparent power (KVA), nominal output voltage (phase-neutral), nominal output frequency (Hz); parallel battery handle number x series battery handle number and battery capacity set on the UPS can be accessed through the version menu.

  • Page 26: 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.

  • Page 27: Pre-Installation Check Up

    BOXER SERIES10-20 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 28: Configuration Of Internal Batteries

    BOXER SERIES10-20 KVA INSTALLATION 3.1.3.2 Configuration of Internal Batteries The 10-20 kVA UPS can be configured through 64 4,5Ah, 7Ah or 9Ah standard batteries as seen in the following table: BOXER INTERNAL BATTERY USAGE TABLE Device Power (KVA) Series Battery Number Battery Group Total Battery Number I_bat.max @V_bat_cutoff(A)

  • Page 29: Placing External Batteries

    BOXER SERIES10-20 KVA INSTALLATION 3.1.3.3 Placing 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 30 BOXER SERIES10-20 KVA INSTALLATION  Battery rooms should be properly ventilated.  Shelves will be accessible in touch if batteries are in battery room. Therefore, please keep restricted accessing to battery rooms. Use necessary safety writings and strips. Especially, 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.

  • Page 31: Transportation Type Of Cabinets

    BOXER SERIES10-20 KVA INSTALLATION 3.1.4 Transportation Type of Cabinets Pay attention that carrying vehicles or handling accessories must have enough features and characteristics to carry the weight of the UPS. UPS and optional battery cabinets are designed to be carried by a forklift or similar vehicles. In addition, the UPS can be carried through its own wheels in short distances.

  • Page 32: Cable And Fuse Configuration

    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 BOXER SERIES10-20 KVA INSTALLATION ATTENTION! 3 pole-circuit breakers (switch) are used for the input and output of the UPS, Neutral line is not interrupted. Please, follow the steps below for electrical connections: 1. Take all the breakers in the distribution boards open circuit (OFF) position and make sure that loads and the mains are isolated from cables 2.
  • Page 34 BOXER SERIES10-20 KVA INSTALLATION 3. Connect the ground cable. 4. Make sure that all the circuit breakers are in the open circuit (OFF) position. The use of these circuit breakers are explained in the next sections. AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...
  • Page 35 BOXER SERIES10-20 KVA INSTALLATION 5. Connect the input cables:  R phase to INPUT L1,  S phase to INPUT L2,  T phase to INPUT L3,  N(Neutral) to Input N. 6. Check the phase sequence. 7.Repeat steps 4-5 for output cables. 8.

  • Page 36: Connecting Batteries

    BOXER SERIES10-20 KVA INSTALLATION Make sure that the loads in the output of the UPS prepared are isolated during the connection if they are not ready to be connected yet. Before the UPS is started, make sure that cable connections have been made in accordance with the warnings in boards.

  • Page 37: External Battery Installation Procedure And Connection

    BOXER SERIES10-20 KVA INSTALLATION See the chapter of options for control of external batteries. 3.1.5.4.2 External Battery Installation Procedure and Connection You can find details about how to configure the external batteries under “External Batteries Configuration” title above. The information about connection of external batteries and UPS is given in this section.
  • Page 38 BOXER SERIES10-20 KVA INSTALLATION 2. If there is, switch breakers on the battery cabinet to the position of open circuit (OFF). 3. Remove the battery fuse on the battery cabinet. 4. Remove battery fuse on the UPS. 5. Make sure of serial and parallel connections of external battery packs are correct. 6.

  • Page 39: Control And Communication Cable Connections

    BOXER SERIES10-20 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 rear side of the UPS:  One RS232 serial communication bus (Standard), ...

  • 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: AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev.
  • Page 41 BOXER SERIES10-20 KVA INSTALLATION Input and output of more than one device are connected to each other; but definitely each battery group is different from another, batteries cannot be used in common. The following points should be considered while placement of devices in parallel system and their electrical connections are made: ...
  • Page 42  For equal current sharing, all cables with which the devices are connected to the board must be equal in length and cross section. Parallel Settings Connect the parallel cable as shown in figure below. Only use the cables provided by MAKELSAN. AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...
  • Page 43 BOXER SERIES10-20 KVA INSTALLATION Software settings on the user panel should be made by authorized personnel. AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...

  • Page 44: Operation

    BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING 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 rear side.
  • Page 45 BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING 3. Switch the input breaker (CB1) to closed circuit (ON) position. If there exists optional external bypass, switch the external bypass breaker (CB5) to closed circuit (ON) position. 4. Start the UPS using the front panel.

  • Page 46: Testing The Operation Modes Of The Ups

    BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING 7. Switch output circuit breaker (CB3) to closed circuit (ON) position. 8. You can turn on the loads connected to the device. 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.

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

    BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING 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. 4.1.3.3 Switching from Static Bypass Mode to Normal Mode Switch the device to UPS mode via user panel.
  • Page 48 BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING Main Menu>Control> Switch to BYPASS 1. Take CB2 to closed circuit (ON) position. 2. Stop the UPS using the front panel. Main Menu>Control >Password>Stop AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...

  • Page 49: Performing A Complete Shutdown

    BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING 3. Switch CB1, CB3 and CB4 to open circuit (OFF) position. FOR SAFETY, WAIT 5 MINUTES AT LEAST BEFORE OPENING UP THE DEVICE AFTER YOU HAVE SWITCHED THE DEVICE TO THE MAINTENANCE BYPASS MODE.

  • Page 50: 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 51: Explanations Of Logging

    BOXER SERIES 10-20 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 52 BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING 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. Current Bypass voltage value is out of limit while UPS was operating on Bypass Voltage Bad the bypass mode.
  • Page 53 BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING BYPASS Thyristor UPS has detected short circuit at bypass L2 thyristor. UPS will L2 Short Circuit shut down. BYPASSThyristorL3 UPS has detected short circuit at bypass L3 thyristor. UPS will Short Circuit shut down.
  • Page 54 BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING Test UPS has switched to battery test mode, loads are energized Mode through rectifier- battery- inverter line as source sharing. Switch to Inverter Switching to inverter mode command has been given via front Mode panel.
  • Page 55 BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING Sequence Error time. Output DC Voltage Inverter DC voltage limit has been exceeded. Loads will be Error transferred to the bypass line. One or more phases of slave devices’ output is not connected to Output Offset Error master device in parallel systems.
  • Page 56 BOXER SERIES 10-20 KVA EXPLANATIONS OF LOGGING AG-SD-109 Publishing Date: 13.10.2015 Revision No: 0 Rev. Date:...

  • Page 57: Table Of Technical Specifications

    BOXER SERIES 10-20 KVA TABLE OF TECHNICAL SPECIFICATIONS 6 TABLE of TECHNICAL SPECIFICATIONS Technical Specifications 10kVA 15kVA 20kVA Power 12kW 16kW Active Power INPUT Input Voltage Range 220/380 VAC - %15 + %18 3P + N + PE Input Power Factor At Full Load >...
  • Page 58 BOXER SERIES 10-20 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: Contact Information

    BOXER SERIES 10-20 KVA GUARANTEE 7 CONTACT 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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