MAKELSAN Challenger Series User manual

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USERMANUAL
CHALLENGERSERIES
10‐60KVA
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AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 4
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USERMANUAL
CHALLENGERSERIES
10‐60KVA
AG–SD‐35
DocumentP.No:2Rev:1

CHALLENGERSERIES10‐60KVA  ABOUTTHEMANUAL
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AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 5
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AbouttheManual
ThisManualispreparedfortheusersofChallanger10‐60kVA.
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CompanionManuals
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Formoreinfoaboutthisdeviceanditsoptions,pleasevisitwww.makelsan.com.tr
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Updates
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Visitwww.makelsan.com.trforupdates.Alwaysusethelatestmanual.
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CHALLENGERSERIES10‐60KVA  CONTENTS
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AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 6
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Contents
1.SafetyandWarnings....................................................................................................................................................8
1.1Warnings...................................................................................................................................................................8
1.2ClearanceandAccess...........................................................................................................................................9
1.3Storage........................................................................................................................................................................9
1.4Shipment...................................................................................................................................................................9
2.ProductDescription..................................................................................................................................................10
2.1GeneralInformation..........................................................................................................................................15
2.1.1StaticTransferSwitch..............................................................................................................................15
2.1.2BatteryTemperatureRegulation.........................................................................................................16
2.2UPS’sOperationModes....................................................................................................................................16
2.2.1Normal(Online)Mode...........................................................................................................................16
2.2.2Battery(stored)Mode...............................................................................................................................17
2.2.3BypassMode.................................................................................................................................................17
2.2.4AutoRestartMode.....................................................................................................................................17
2.2.5MaintenanceMode.....................................................................................................................................18
2.3BatteryManagement.........................................................................................................................................18
2.3.1.NormalOperationMode.........................................................................................................................18
2.3.2AdvancedLevelFunctions(AutomaticBatteryTest).................................................................19
2.4UserPanel..............................................................................................................................................................20
2.4.1OpeningScreen...........................................................................................................................................23
2.4.2MainMenu.....................................................................................................................................................23
2.4.3NavigationThroughtheMenus............................................................................................................23
2.4.5Password‐protectedmenus...................................................................................................................24
2.4.6ControlMenu................................................................................................................................................24
2.4.7StatusMenu..................................................................................................................................................25
2.4.8SetupMenu...................................................................................................................................................26
2.4.9LoggingMenu...............................................................................................................................................28
3.Installation....................................................................................................................................................................29
3.1SingleModeInstallation...................................................................................................................................29
3.1.1Pre‐installationcheckup........................................................................................................................29
3.1.2Positioning....................................................................................................................................................30

CHALLENGERSERIES10‐60KVA  CONTENTS

AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 7
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3.1.2.1PositioningTheUPS..........................................................................................................................30
3.1.2.2InternalBatteryConfiguration.....................................................................................................31
3.1.2.3ExternalBatteryConfiguration....................................................................................................36
3.1.3TransportationTypeofCabinets.........................................................................................................38
3.1.4Main,LoadandBatteryConnections...................................................................................................39
3.1.4.1ExternalProtection...........................................................................................................................39
3.1.4.2Cablingandfuseconfiguration.....................................................................................................39
3.1.4.3Cableconnections..............................................................................................................................40
3.1.4.4Batteryconnections.........................................................................................................................44
3.1.4.4.1InternalBatteryInstallationProcedureandConnection.........................................44
3.1.4.4.2.ExternalBatteryInstallationProcedureandConnection........................................45
3.1.4.5ControlandCommunicationCableConnections..................................................................47
3.2ParallelInstallation............................................................................................................................................47
4.Operation.......................................................................................................................................................................50
4.1OperationProcedure.........................................................................................................................................50
4.1.1CircuitBreakers..........................................................................................................................................50
4.1.2FirstStart‐Up................................................................................................................................................51
4.1.3TestingofTypesofUPSOperation......................................................................................................54
4.1.3.1.SwitchingfromOnlineModetoBatteryMode.....................................................................54
4.1.3.2SwitchingfromOnlineModetoStaticBypassMode..........................................................55
4.1.3.3SwitchingfromStaticBypassModetoOnline.......................................................................55
4.1.3.4SwitchingfromOnlineModetoMaintenanceBypassMode............................................56
4.1.4PerfomingaCompleteShutDown......................................................................................................58
4.1.5EPO(EmergencyPowerOff)..................................................................................................................58
4.1.6RS232SerialCommunicationInstallationandInvestigation..................................................59
5.ExplanationsofLogging..........................................................................................................................................60
6.TechnicalSpecifications..........................................................................................................................................69
7.CONTACTINFORMATIONS....................................................................................................................................71

CHALL
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eymust
u
thorized

CHALLENGERSERIES10‐60KVA  SAFETYANDWARNINGS
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AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 9
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1.2ClearanceandAccess
Clearance
There is no any air inlet or outlet grill on the left or right sides of our 10-60 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 for UPS's front side and 1,2 meter at the back side. 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 10-60 kVA UPS. Therefore, enough area must be left for
operator. Also, UPS can be intervened in the back of it for service and maintenance. Because of
this reason , enough area for personal must be left at the rear side of UPS. 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.

Cabinetisequippedwithfour‐wheel.Inthisway,itcanbeplacedbymovingeasily.These
wheelsareusedonlysmoothsurfaces.

TherearwheelsofUPSmustbelockedafterpositioningproperly.Therearsidewheelsare
fixed.

Bemorecarefulofsuddenmovements,especiallywhenbatteriesareinsideofcabinet.

MovetheUPSasrarelyaspossible.
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CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION

AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 10
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2.ProductDescription
GeneralView
CH1060TR02R0

CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION

AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 11
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Frontview
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1 4x20KarakterLCDEkran
2 VentilationInlets
3 MimicDiagram
4 MenuKeys
5 EPO(EmergencyPowerOff)Button





CH1060EN03R0

CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION

AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 12
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Rearview

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
CH1060EN04R0









CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION

AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 13
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




1 Rectifier/Charger‐InverterCoolingFans
2 WindingHotAirEvacuationChannel
3 Mains(Input)Breaker
4 Mains(Input)ConnectionTerminal
5 GroundConnection
6 Input‐Output‐BatteryCableFixingTerminals
7 OutputConnectionTerminals
8 BatteryRapidFusesandBatteryConnection
Terminals
9 OutputCircuitBreaker
10 External(Maintanance)BypassBreaker
11 RS232TerminalforCommunicationSocketofRectifier
12 RS232TerminalforCommunicationSocketofInverter
13 Optionalcardslots
14 Optionalcardslots
15 OptionalParallelPortTerminal
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

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
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CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION

AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 14
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ElectricalConnection
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

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CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION

AG–SD‐35Rev.No:1Rev.Date:25.09.2013PublicationNo:2 15
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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loadsafter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.
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Systemprovidestheloadstobefedsmoothandseamlessbymainsorinverter.Inorderto
managehisprocessatminimumrisk,UPSsychronizestheinverteroutputandstatic(mains)
bypassasphaseandfrequency.Therefore,Inverterfrequencycanbeconsideredasmains.It
isthesameasmainsfrequencyaslongasitiswithinfrequencylimit.
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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.
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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.

CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION
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Incaseofanyneedformaintenanceorrepairing,maintanencecirciutbreakermustbeturned
ONbeforetheinputoroutputcircuitbreakersturnedON.Then,firstUPS’soutputmustbe
turnedOFF,secondlyinputcircuitbreakermustbeturnedOFF.
NOTE:Inthemeantime,theloadsareunprotectedagainstthepower‐off,damage,twistetc.
problems.
2.1.2BatteryTemperatureRegulation
10‐60kVAUPSshavetheirownplaceforinternalbatteries.Thesebatterytemperatureare
perceivedby"temperaturesensor”.UPSadjustsbatterychargeparametersaccordingtothe
informationofthedetectedtemperature.TheseparameterscaneasilybeadjustedviaLCDor
TELNETinterfacebyauthorizedstaffofMAKELSAN.
Temperaturesensorisgivenasoptionalwithexternalbatterycabinets.UPSregulatescharge
parametersinthesamewaybythissensor.Inthiscase,Werecommend you to order
"BatteryMonitoringKit"todetectthetemperature.
2.2UPS’sOperationModes
ChallenegerseriesUPS'son‐lineandhasadoubleloopstructure.Ourproductsoperatein
thefollowingmodes:
 OnlineMode
 BatteryMode
 BypassMode
 AutoRestart
 MaintenanceMode
2.2.1Normal(Online)Mode
Inthismode,UPSsuppliestheloadthroughtheinverters.RectifierunitissuppliedbytheAC
mains.InverterandbatterychargerunitsareenergizedbythegeneratedDCsupply.
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CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION
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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.InordertoprovideproperDCBusvlotage,batteryvoltagewillbe
boosted.
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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.
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2.2.4AutoRestartMode
UPSsuppliesitscriticalloadsuptoendofdischargevoltagelevelduetoanymainsfailure.
UPSfeedscriticalloadsuntillendofbatterydischargevoltagelevelcausedbyanymains
failure.Upswilloperateuntilbatterieschargingprocesscompletingafterthatwillbe
switchedoff.UPScanoperatebyitselfinspecifiedtimeaftermainsturnedbacktonormal
mode.Inthiscase,UPSkeepsoperatingproperaslongasUPSvoltagebeinginaccordance
criterias.ForChallengerSeriesUPS,thisfeatureisnotactivatedasfactoryinitialsetups.

CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION
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2.2.5MaintenanceMode
Inmaintenancemode,theloadsareswitchedtothemaintenancebypass line with a
breaker,sothattheUPScanbeservicedwithoutcuttingoffthepowerflowtotheloads.
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2.3BatteryManagement
Lead–AcidBatteriesareusedwithUPSsasinternalwithvariableconfigurations.
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%.
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CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION
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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.
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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.
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CH1060EN05R0
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1 RectifierindicatorLED
FlasheswhiletheDCbusisrampingup.IlluminateswhenRectifierworks.
2 AC/DCmodule(Rectifier)
3 BoostmodeindicatorLED
Illuminatesinbatterymode.FlasheswhenUPSisstartedupthroughbatteries.
4 BatterychargeindicatorLED
Illuminateswhilethebatteriesarecharging.
5 Batterymodule
6 DC/ACmodule(Inverter)
7 MainsbypassindicatorLED
Illuminateswhiletheloadsarefedthroughbypassline.

CHALLENGERSERIES10‐60KVA  PRODUCTDESCRIPTION
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8 InverterstaticswitchindicatorLED
Illuminateswhentheloadisfedbytheinverter
9 Alarm/WarningindicatorLED
10‐
13 Menukeys
14 EPO(EmergencyPowerOff)Button
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