MAKELSAN BOXER SERIES, User Manual

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: ...elsan 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 carr...

Page 4: ...3 Bypass Mode 12 2 2 4 Automatic Restart Mode 12 2 2 5 Maintenance Mode 12 2 3 Battery Management 12 2 3 1 Advanced Level Functions Automatic Battery Test 13 2 4 User Panel 14 2 4 1 Opening Screen 16...

Page 5: ...ns 34 3 2 Parallel Setup 35 4 OPERATION 38 4 1 Operation Procedure 38 4 1 1 Circuit Breakers 38 4 1 2 First Start Up 39 4 1 3 Testing the Operation Modes of the UPS 41 4 1 3 1 Switching from Normal Mo...

Page 6: ...ALSO FOR SERVICE AND MAINTENANCE WAIT FOR AT LEAST 5 MINUTES FOR THE DC BUS CAPACITORS TO DISCHARGE AFTER POWER OFF Service Maintenance All service and maintenance operations are performed internally...

Page 7: ...f 80 120 kVA Therefore enough area must be left for operator No limitation exists for the rear and sides of the device 1 3 Storage The UPS should be kept in a room or area where is protected from exce...

Page 8: ...BOXER SERIES 80 120 KVA SAFETY AND WARNINGS AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 3 Move the UPS as rarely as possible...

Page 9: ...BOXER SERIES 80 120 KVA PRODUCT DESCRIPTION AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 4 2 PRODUCT DESCRIPTION General View 776 mm 886 mm 1657mm...

Page 10: ...VA PRODUCT DESCRIPTION AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 5 Front View 1 320x240 6 Graphic LCD 2 Fresh Air Vacuum Grid 3 Mimic Diagram 4 Menu Navigation Keys 5 EPO Emerg...

Page 11: ...Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 6 Front Cover View 1 Soft Start Button 2 RS232 Serial Communication Socket for Inverter 3 Mains Circuit Breaker 4 External Bypass Circuit Breaker 5 Output...

Page 12: ...1 Rev Date 16 11 2012 7 Front Internal View 1 Mains Circuit Breaker 2 External Bypass Circuit Breaker 3 Mains Connecting Terminal 4 Output Connecting Terminal 5 Ground Connection 6 Battery Fast Circu...

Page 13: ...A PRODUCT DESCRIPTION AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 8 Top View 1 Thyristor Hot Air Evacuation Channel 2 Rectifier Charger Inverter Hot Air Evacuation Channel 3 Para...

Page 14: ...BOXER SERIES 80 120 KVA PRODUCT DESCRIPTION AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 9 Electrical Connections...

Page 15: ...ains sufficient level DC bus voltage is created using battery voltage DC bus voltage is converted to mains synchronized AC voltage by the inverter This is a high quality voltage Generated AC power is...

Page 16: ...ceptable within frequency limit User can switch between mains and inverter using the front panel Loads operating from the mains with user instruction will automatically undertake the load in the event...

Page 17: ...e The UPS is equipped with a specific protection switch in order to keep the loads powered during maintenance This switch is designed so as to handle UPS loads completely 2 3 Battery Management Consta...

Page 18: ...status good or replace is determined At the end of this test if batteries are reported as replace then the batteries are completely drained after the test In this case loads can remain unpowered in ca...

Page 19: ...illuminates when rectifier works 2 AC DC module Rectifier 3 Boost mode LED It illuminates in battery mode and flashes when UPS is started up through batteries 4 Battery charge indicator LED It illumi...

Page 20: ...stall Date Auto Restart Auto Battery Test Screen Warning Beep Language Communication LOGGING Log Code Date Time Log Records Information MAINS Frequency Current Voltage Apparent Power Active Power Powe...

Page 21: ...wn row If no button is pressed for 5 minutes system returns to the opening screen 2 4 2 Main Menu To switch from opening screen to the main menu press ENT button 2 4 3 Navigating Through the Menus Pre...

Page 22: ...ch 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 batte...

Page 23: ...u You can see information about the mains output bypass line battery temperatures inverter alarms and device information on this menu Mains UP F I UL Frequency current and voltage phase neutral of eac...

Page 24: ...tive power of each phase Alarms Alarms Actual UPS alarms Device Information ____ ____ ___ ___ Inverter rectifier CPLD front panel software version UPS serial no KVA V Hz Apparent power instantaneous o...

Page 25: ...restart can be used to restart the UPS automatically when the mains gets back into limit values Open close auto restart via the option of ON OFF and determine how much time after the device will be st...

Page 26: ...ESCRIPTION AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 21 Beeper Turn the beeper sound on off Language Set the menu language Communication Set the protocol for the RS232 connecti...

Page 27: ...ast 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 Older actual logs c...

Page 28: ...be taken in order to protect eyes against electrical arcs that can result from contacts ESD protected rubber gloves should be used Batteries discharging or leaking electro liquid must not be used if a...

Page 29: ...n area with cool air flow 3 1 3 1 Positioning the UPS For the Boxer 80 120 KVA Series fresh and cool air enters the device from the front side and goes out through the fans on the top side of the devi...

Page 30: ...tteries away from the humid places Hereby batteries can be prevented from terminal oxidations and possible leakage currents Please use aR or gR semi conductor type fuse at the battery rooms and cabine...

Page 31: ...BOXER SERIES80 120 KVA INSTALLATION AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 26 Example Battery Chamber Application External Battery Cabinet Application...

Page 32: ...the load is suitable 3 1 5 1 External Protections To protect the AC inputs thermal magnetic breakers or V automat breakers must be independently installed on the distribution board Herein the cable i...

Page 33: ...rrents at Maximum Battery Charge 3 phase neutral 380V 400V 415V 380V 400V 415V 80 137 6 128 0 127 0 123 2 116 8 112 8 100 172 0 160 0 158 7 154 0 146 0 141 0 120 206 4 192 0 190 5 184 8 175 2 169 2 No...

Page 34: ...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 1 Input Terminals 2 Output Terminals Please follow the...

Page 35: ...Date 16 11 2012 30 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...

Page 36: ...cables when the connections are done Make sure that the loads in the output of the UPS are isolated during the connection if they are not ready to be connected yet Before the UPS is started make sure...

Page 37: ...on the UPS to the position of open circuit OFF 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 batte...

Page 38: ...cable selection is determined by application Fuses which are recommended for the UPS and battery cabinet are given To connect to these type fuses the lowest diameter cables are suggested Please refer...

Page 39: ...LSAN 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...

Page 40: ...other 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 The devices which are connect...

Page 41: ...BOXER SERIES80 120 KVA INSTALLATION AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 36...

Page 42: ...Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 37 Parallel Settings Connect the parallel cable as shown in figure below Only use the cables provided by MAKELSAN Software settings on the user...

Page 43: ...ugh CB2 In this way maintenance purposed switching is done properly WARNING If the CB3 switch is in the off circuit ON position and the UPS is running in online mode the UPS must be switched to the st...

Page 44: ...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 exter...

Page 45: ...anel 6 Switch battery circuit breaker CB4 to ON position 7 Switch output circuit breaker CB3 to ON position 8 You can turn on the loads connected to the device After all these steps check that load is...

Page 46: ...sting 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 th...

Page 47: ...gram 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 Mo...

Page 48: ...ssibility of cutting off the load power for a short while NOTICE When device is fed through the maintenance bypass mode no separateneutral connection is used so the neutral connections must not be dis...

Page 49: ...BOXER SERIES 80 120 KVA OPERATION AG SD 37 Publication Date 19 10 2012 Rev No 1 Rev Date 16 11 2012 44 1 Switch on CB2 ON 2 Stop the UPS using the front panel Main Menu Control Password Stop...

Page 50: ...ff 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 T...

Page 51: ...PERFORMING A COMPLETE SHUTDOWN 4 1 5 EPO Emergency Power OFF By pressing the EPO button the UPS turns the rectifier booster and the inverter off respectively If the output breaker turn off option is a...

Page 52: ...Batteries voltage has gone below cut off voltage value while UPS was operating on the battery mode 10 Overload Timeout UPS has operated at overload more than time limit adjusted The Loads will be tra...

Page 53: ...ing counter will start to count If UPS is on normal mode charging will be stopped until load value gets back to normal 28 Maintenance BYPASS Switch Off Maintenance bypass switch is deactivated 29 Norm...

Page 54: ...UPS has detected that inverter L3 thyristor cannot be activated Load will be transferred to bypass line 49 BYPASS Thyristor L1 Open Circuit UPS has detected that bypass L1 thyristor cannot be activate...

Page 55: ...replacement date has been changed Battery statistics will be reset 72 Load Impact Transfer The load which cannot be handled by inverter is activated Loads will be transferred to bypass line 73 Parall...

Page 56: ...ture is within limits 90 PFC Pbus Over Voltage Positive bus voltage limit excess 91 PFC Nbus Over Voltage Negative bus voltage limit excess 92 PFC FL1 Over Current Short circuit protection is activate...

Page 57: ...Efficiency Up to 93 Output Frequency Range In 50Hz 0 5 range synchronous with the network 50Hz 0 2 battery mode Output Harmonic Distortion THDv Linear Load 2 Non Linear Load 6 Crest Factor CF 3 1 Over...

Page 58: ...y ISO 9001 Safety EN 62040 1 1 EN 60950 EMC LVD EN 62040 2 GENERAL Running Temperature 0 C 40 C range for batteries 0 25 C Storage Temperature 15 C 45 C range for batteries 10 60 C Protection Class IP...

Page 59: ...lgesi 2 Yol I 5 Parsel 34956 Tuzla stanbul Tel 0216 428 65 80 Fax 0216 327 51 64 E mail makelsan makelsan com tr zmir Office Halkap nar Mah 1348 Sok 2AE Keremo lu Merkezi Yeni ehir zmir Tel 0232 469...

Page 60: ...6 Tuzla stanbul Tel 0216 428 65 80 Fax 0216 327 51 64 E mail makelsan makelsan com tr zmir Office Halkap nar Mah 1348 Sok 2AE Keremo lu Merkezi Yeni ehir zmir Tel 0232 469 47 00 Fax 0232 449 47 00 E m...