MAKELSAN AG-SD-36 User manual
USERMANUAL
CHALLENGERSERIES
80‐120KVA
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
USERMANUAL
CHALLENGERSERIES
80‐120KVA
AG‐SD‐36
Document Y.No:1 Rev:0
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
AboutTheManual
ThismanualispreparedfortheusersofChallenger80‐120kVA.
CompanionManuals
Formoreinfoaboutthisdeviceanditsoptions,pleasevisitwww.makelsan.com.tr.
Updates
Please, visit www.makelsan.com.tr for updates. Always use the latest manuals.
CHALLENGERSERIES80‐120KVA CONTENTS
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
Contents
1.SAFETYANDWARNINGS.......................................................................................................................6
1.1.Warnings ............................................................................................................................... 6
1.2.ClearanceandAccess .......................................................................................................... 7
1.3.Storage ................................................................................................................................... 7
1.4.Shipment ............................................................................................................................... 7
2.ProductDescription...............................................................................................................................8
2.1.GeneralInformation ......................................................................................................... 14
2.1.1.StaticTransferSwitch ............................................................................................... 14
2.1.2.BatteryTemperatureRegulation ........................................................................... 15
2.2.UPS’sOperationModes ..................................................................................................... 15
2.2.1.Normal(Online)Mode .............................................................................................. 15
2.2.2.Battery(stored)Mode ............................................................................................... 16
2.2.3.BypassMode ............................................................................................................... 16
2.2.4.AutoRestartMode ..................................................................................................... 16
2.2.5.MaintenanceMode .................................................................................................... 17
2.3.BatteryManagement ......................................................................................................... 17
2.3.1.NormalOperationMode ........................................................................................... 17
2.3.2.AdvancedLevelFunctions(AutomaticBatteryTest) ......................................... 18
2.4.UserPanel ........................................................................................................................... 18
2.4.1.OpenningScreen ........................................................................................................ 21
2.4.2.MainMenu ................................................................................................................... 21
2.4.3.NavigatingThroughtheMenus ............................................................................... 21
2.4.4.PasswordProtectedMenus ..................................................................................... 22
2.4.5.ControlMenu .............................................................................................................. 22
2.4.6.StatusMenu ................................................................................................................ 23
2.4.7.SetupMenu ................................................................................................................. 25
2.4.8LoggingMenu ................................................................................................................... 28
3.Installation.............................................................................................................................................29
3.1.SingleModeInstallation ................................................................................................... 29
3.1.1.Warnings ..................................................................................................................... 29
3.1.2.Pre‐installationcheckup ......................................................................................... 29
CHALLENGERSERIES80‐120KVA CONTENTS
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
3.1.3.Positioning .................................................................................................................. 30
3.1.3.1.PositioningofUPS .............................................................................................. 30
3.1.3.2.ExternalBatteryConfigration ......................................................................... 30
3.1.4TransportationTypeofCabinets .................................................................................. 32
3.1.5Main,LoadandBatteryConnections ........................................................................... 32
3.1.5.1ExternalProtection .................................................................................................. 33
3.1.5.2CableandFuseSelection ......................................................................................... 33
3.1.5.3ConnectingtheCables .............................................................................................. 33
3.1.5.4BatteryConnections .......................................................................................... 36
3.1.5.4.1ExternalBatteryInstallationProcedureandConnection ...................... 37
3.1.5.5ControlandCommunicationCableConnections ......................................... 39
3.2ParallelInstallation .......................................................................................................... 39
4OPERATION............................................................................................................................................42
4.1OperationProcedure ........................................................................................................ 42
4.1.1CircuitBreakers ............................................................................................................... 42
4.1.2FirstStart‐Up .............................................................................................................. 43
4.1.3TestingofTypesofUPSOperation ......................................................................... 46
4.1.3.1SwitchingfromOnlineModetoBatteryMode ............................................. 46
4.1.3.2SwitchingfromOnlineModetoStaticBypassMode ................................... 47
4.1.3.3SwitchingfromStaticBypassModetoOnline .............................................. 47
4.1.3.4SwitchingfromOnlineModetoMaintenanceBypassMode ..................... 48
4.1.4PerformingaCompleteShutdown ......................................................................... 50
4.1.5EPO(EmergencyPowerOff) .................................................................................... 51
4.1.6RS232SerialCommunicationInstallationandinvestigation ........................... 51
5ExplanationsofLogging.....................................................................................................................52
6TechnicalSpecifications....................................................................................................................61
ContactInformation.....................................................................................................................................63
1
1.1
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CHALLENGERSERIES80‐120KVA SAFETYANDWARNINGS
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
FireextinguishingequipmentmustbekeptnearbytheUPS.
1.2. ClearanceandAccess
Clearance
Thereisnoanyairinletoroutletgrillontheleftorrightsidesofour80‐120kVAUPS.Allairgoes
intoUPSfromthefrontandisevacuatedfromtherearthroughfans.Theremustbespacesat
least1meteratthefrontsideofUPS.Shouldnotbepermanentortemporaryusewithinthelimits
specified.Otherwise,theUPSperformancewilldecrease.
Access
OperatorreachesUPSviafrontpanelon80‐120kVAUPS.Therefore,enoughareamustbeleftfor
operator..Thereisnolimittothesidesofthedevice.
1.3. Storage
UPSshouldbekeptinaroomorareawhereisprotectedfromexcessivemoistureandheatbefore
commissioning.
WARNING:
Unusedbatteriesmustbechargedatregularintervals.Thistimeintervalisdeterminedbythe
batterysupplier.Chargingcanbeperformedperiodicallybyconnectingtoapropermainsfora
while.
1.4. Shipment
CarryingvehiclesmusthaveenoughfeaturesandcharacteristicstocarryUPS.
Bemorecarefulofsuddenmovements,especiallywhenbatteriesareinsideofcabinet.
MovetheUPSasrarelyaspossible.
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:1511.2012PublishNo:1
2. ProductDescription
GeneralView
CH80120EN02R0
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
FrontView
CH80120EN03R0
1 320x240 6” Grafik LCD
2 VentilationInlets
3 MimicDiagram
4 MenuKeys
5 EPO(EmergencyPowerOff)Button
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
FrontCoverView
1 RS232SerialInterfaceforInverter
2 RS232SerialInterfaceforRectifier
3 InputCircuitBreaker
4 ExternalBypassCircuitBreaker
5 OutputCircuitrBreaker
6 OptionalCardSlots
CH80120EN04R0
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
FrontInsideView
1 MaintenanceCircuitBreaker
2 ExternalBypassCircuitBreaker
3 InputConnectiionTerminals
4 OutputConnectionTerminals
5 EarthGroundConnection
6 BatteryRapidFusesandBatteryConnectionTerminals
7 OutputCircuitBreaker
CH80120EN05R0
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
TopView
1
V
entilationOutletsforinductors
2
V
entilationOutletsforpfc,chargerandinverter
3
P
arallelInterface
CH80120EN06R0
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
ElectricalConnection
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
2.1. GeneralInformation
GeneraloperationtopologyofChallengerSeriesUPScanberecognizedasfollows.
TheUPSisconnectedtothemainsvoltagethroughtheCB1breaker.AsDCbusisrampedup,the
rectifierstartstooperateandconvertstheACmainstoDCVoltage.Whenthemainsvoltageisnot
available,theDC/DCboosterpumpsthebatteryvoltagetothenecessarylevel.DCDCbusvoltage
isthenconvertedtomainssynchronizedACvoltagebytheinverter.Thisisahighqualityvoltage.
GeneratedACpowerisappliedtheloadsafterpassed from static semi‐conductor switches and
output(load)breakers.
2.1.1. StaticTransferSwitch
Someblocksarenamedas“staticswitches”ascanbeseenabove.Theseblocksconsistofinverse
parallelconnectedthyristors.Theseswitches,whichareunderthecontrolofthemainboard
controlunit(DSP),providescontrollingofsupplyingtheloadsthrougheithermainsorinverters.
Theloadsaresuppliedthroughinverterduringthenormaloperatingmode.Therefore,Inverter
staticswitchesareactiveifthereisnoproblemwiththesystem.
UsercanswitchtheUPSbetweenmainsandinverterbyusingfrontpanel.Whiletheloadsarefed
directlybymainswiththeorderofuser,incaseofeitherpowerofformainsvaluesoutof
tolerances,theUPSwillstarttosupplytheloadsthroughbatterymode.
Iftheuserwants,canprovidemainstofeedloadcontinuouslybyswitchingonthemaintenance
bypasswithoutmakingadjustmentonthefrontpanel.Lateron,theusercanmaketheinputand
outputswitchfusesshortcircuit.
Ifuserwants,canprovidemainstofeedloadcontinuouslybyswitchingonthemaintenance
bypasswithoutmakingadjustmentonthefrontpanel.Lateron,theusercanmaketheinputand
outputswitchfusesshortcircuit.
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
IfMaintenanceorrepairarenecessary,maintenanceswitchmustbeturned"ON"beforetheinput
and output breakers are switched 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. BatteryTemperatureRegulation
Optionaltemperaturesensorisgivenwithexternalbatterycabinet.Batterytemperatureare
perceivedbymentionedtemperaturesensor.UPSadjustsbatterychargeparametersaccordingto
theinformationoftheperceivedtemperature.TheseparameterscaneasilybeadjustedviaLCDor
TELNETinterfacebyauthorizedstaffofMAKELSAN.
Inthiscase,Werecommendyoutoorder"ExternalBatteryTemperatureMeasurementKit"to
detectthetemperature.
2.2. UPS’sOperationModes
ChallangerseriesUPS'son‐lineandhasadoubleloopstructure.Ourproductsoperateinthe
followingmodes:
OnlineMode
BatteryMode
BypassMode
AutorestartMode
MaintenanceMode
2.2.1. Normal(Online)Mode
Inthismode,UPSsuppliestheloadthroughtheinverters.RectifierunitissuppliedbytheAC
mains.InverterandbatterychargerunitsareenergizedbythegeneratedDCsupply.
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
2.2.2. Battery(stored)Mode
UPSrunsonbatterymodewhenthemainsvoltageisbad.BatteryVoltage is boosted for the
sufficientDcbusvoltage.
2.2.3. BypassMode
Inanoverloadcondition,orifthereisaproblemwiththedoubleconversion,theloadsarefedby
thebypassline.
UPSswitchestoACsupplyfrominverterforthatbystaticswitches. Inverter must be
synchronized with the mains supply for these transitions to beseamless.This transitionsmight
take15msdependingonthetypeofloadifinverteroutputisnotsynchronizedwiththemains.
2.2.4. AutoRestartMode
UPSsuppliesitscriticalloadsuptoendofdischargevoltagelevelduetoanymainsfailure.UPS
feedscriticalloadsuntillendofbatterydischargevoltagelevelcausedbyanymainsfailure.Ups
willoperateuntilbatterieschargingprocesscompletingafterthatwillbeswitchedoff.UPScan
operatebyitselfinspecifiedtimeaftermainsturnedbacktonormalmode.Inthiscase,UPSkeeps
operatingproperaslongasUPSvoltagebeinginaccordancecriterias.ForChallengerSeriesUPS,
thisfeatureisnotactivatedasfactoryinitialsetups.
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
2.2.5. MaintenanceMode
Inmaintenancemode,UPSequippedwithaswitchcapablefornottobeinterruptedoftheloads.
Thisswitchwaschoosentomeetthefullload.
2.3. BatteryManagement
Lead–AcidBatteriesareusedwithUPSsasinternal.
2.3.1. NormalOperationMode
ConstantChargeCurrent
Currentislimitedto0.1Cuntillthefloatreachesto chargevoltage.(adjustablebetween0.05C‐
0.25C.)Theappliedcurrentcannotexceedmaximumchargepower.
FloatCharge
Dependingonthebatterydischargecurrentthethirdpercentenergyofthebatteryischargedat
thislevel.Thankstothislevel,batteriesarekeptreadyforuseatthehighestcapacity.Forlead‐
acidbatteries,thisvoltagevariesbetweenvalues2.2‐2.35V/cellThisvoltagemaydifferslightly
withtemperatureadaptation.OptionofsettingthiscoefficientisprovidedwithourUPS.Ifthe
temperaturesensorisused,itisrecommendedtouse.
DeepDischargeProtection
Whilethesystemoperatesonbatterymode,ifbatteryvoltagehasdroppedbelowthedischarge
levelUPSshutsdownandstopsabsorbingenergyfromthebatteries.Thisvaluevariesbetween
1.6‐1.75V/cellforLead‐Acidbatteries,andforNi‐Cdbatteriesbetween0.9‐1.1V/cell.
LowBatteryWarning
Whilethesystemoperatesinbattery(stored)mode,accordingtoactualloadsifthebattery
capacitydropsbelowits40%value,itwillgiveaudibleandvisiblealarms.Thispercentagevalue
isadjustableforuserbetween20%‐70%.
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
2.3.2. AdvancedLevelFunctions(AutomaticBatteryTest)
Theautobatterytestdischarges30%ofthebatteryenergyinauserdefinedperiod(defaultis90
days).Thisperiodcanbeadjustedbetween30‐360days.Testreportsthebatteryconditionas
“goodorreplace”.Resultsofthelatesttestcanbeseenonthebatteryscreenfromthestatus
menu.
WARNING:Ifthetestresultis“replace”,thenthebatteriesarecompletelydrainedduringthe
test.Thissituationmaycausetheloadremainedunpoweredincaseofmainsvoltageisoutofthe
limitsormainspoweroff.
Thistestcanbestartedbycommandfromfrontpanelmonitor,viaTELNETinterface,viaRS232
smartcommunicationorviaMAKNET(SNMP,seetheoptions).
Itischeckedthatifthebatteriescansupplytheminimumback‐uptimeneededincaseofthefirst
power‐offbyusingtheresultsofallthesetests.Checkingthetestresultswitharegularperiodis
recommended.
2.4. UserPanel
Userpanelconsistsofmimicdiagram,LCDscreen,EPObuttonandmenukeys.TheUPScanbe
controlledviathispanel.
CH80120EN07R0
CHALLENGERSERIES80‐120KVA PRODUCTDESCRIPTION
AG‐SD‐36Rev.No:0Rev.Date:15.11.2012PublishNo:1
1 RectifierindicatorLED
FlasheswhiletheDCbusisrampingup.IlluminateswhenRectifierworks.
2 AC/DCmodule(Rectifier)
3 BoostmodeindicatorLED
Illuminatesinbatterymode.FlasheswhenUPSisstartedupthroughbatteries.
4 BatterychargeindicatorLED
Illuminateswhilethebatteriesarecharging.
5 Batterymodule
6 DC/ACmodule(Inverter)
7 MainsbypassindicatorLED
Illuminateswhiletheloadsarefedthroughbypassline.
8 InverterstaticswitchindicatorLED
Illuminateswhentheloadisfedbytheinverter
9 Alarm/WarningindicatorLED
10‐
13 Menukeys
14 EPO(EmergencyPowerOff)Button
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