MAKELSAN Challenger Series User Manual Download

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USER

MANUAL

CHALLENGER

SERIES

‐

KVA

Summary of Contents for Challenger Series

Page 1: ...USER MANUAL CHALLENGER SERIES 10 60 KVA ...

Page 2: ......

Page 3: ...AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 4 USER MANUAL CHALLENGER SERIES 10 60 KVA AG SD 35 Document P No 2 Rev 1 ...

Page 4: ...9 2013 Publication No 2 5 About the Manual This Manual is prepared for the users of Challanger 10 60 kVA Companion Manuals For more info about this device and its options please visit www makelsan com tr Updates Visit www makelsan com tr for updates Always use the latest manual ...

Page 5: ...rmal 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 St...

Page 6: ...y 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 S...

Page 7: ...TO DISCHAR ance is done technician ce is recom l staff T taff y rise up to can be at ha not be throw aste batterie uthorized te ies by the M ent must be Publication ngs talling the U zed persona ntinuous ve WITH GROU e before con as high as 0 CONNECTED O WAIT FOR RGE AFTER e internally mmended a This servic o 450V DC azardous lev wn into fire es must def echnicians o Ministry of E e kept nearb n N...

Page 8: ...tenance 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 perfo...

Page 9: ...CHALLENGER SERIES 10 60 KVA PRODUCT DESCRIPTION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 10 2 Product Description General View CH1060TR02R0 ...

Page 10: ...10 60 KVA PRODUCT DESCRIPTION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 11 Front view 1 4x20 Karakter LCD Ekran 2 Ventilation Inlets 3 Mimic Diagram 4 Menu Keys 5 EPO Emergency Power Off Button CH1060EN03R0 ...

Page 11: ...CHALLENGER SERIES 10 60 KVA PRODUCT DESCRIPTION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 12 Rear view CH1060EN04R0 ...

Page 12: ...nnection 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 Optiona...

Page 13: ...CHALLENGER SERIES 10 60 KVA PRODUCT DESCRIPTION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 14 Electrical Connection ...

Page 14: ...l 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 System provides the loads to be fed smooth and seamless by mains or inverter In order to manage his process at minimum risk UPS ...

Page 15: ...sts 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 tem...

Page 16: ...ized 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 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 U...

Page 17: ...ery 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 sy...

Page 18: ... 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...

Page 19: ...1060EN05R0 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 whil...

Page 20: ...DESCRIPTION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 21 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 ...

Page 21: ...erter DC Bus Warnings SETUP Date Time Battery Install Date Auto Restart Auto Battery Test Screen Warning Beep Language Communication Service Menu Versiyon LOGGING Log Code Date Time Log Records MAINS Voltage Current Frequency Active Power Reactive Power Apparent Power WARNINGS Actual Alarms BATTERY Current Temperature Voltage Charge Percentage Test Type Number Test Time and Date Capacity Battery S...

Page 22: ...ge TER to se C to cancel S 10 60 KVA Rev Date 25 een n is on when t being used me charge an d remaining arming cond wn on the fi pressed for to the open m opening sc es enter Through th wn keys to m enter to op go back t sub menu is nus may h Keep pressi he next scree ave changea ations or uch a menu variable up the value a et the new A 5 09 2013 P n the display d It shows nd load g runtime dition...

Page 23: ...ll the b st have been the battery t tery timer are left est is chose state A 5 09 2013 P menus ontrol menu s up and d nd press EN 000 you can do Start Stop t Switc Switc Start Start Stop t e 10 of ba ess capacity battery energ n fully charg tests r to find ou n from the m Publication N u are down NTER o one of the f the UPS the UPS ch to static B ch to online m the quick ba the deep ba the battery...

Page 24: ...eac oltage curre oltage of eac harge curren est type test ext test date ectifier inver oltage curre to DC DC PS alarms Publication N ns re ent and frequ apparent po nd apparent ent and frequ apparent po nd apparent ch phase ph ent and frequ ch phase faz nt temperatu t number tes timer count rter charger ent and frequ to N voltage No 2 uency of each ower ande po t power uency of each ower and po po...

Page 25: ...star mains come auto restart hen the devi s is normal self test tion can be t ndependent erval sets wh ted ttery self tes y quick test the screen n different en S 10 60 KVA Rev Date 25 of the follow use up and le you want own keys to et the batte eries are inst device turn discharge A t the UPS au es back to li and set the ce will be st turned on to t battery tes hen the test st is the equi contra...

Page 26: ... the serv ccessed to in el software apparent po oltage phas equency Hz rm x numbe ery capacity S 10 60 KVA Rev Date 25 nd on off ge r the RS23 gatech and T O and UPS s specified da up the days sword secur he user pas vice menu is nverter rect version and ower KVA e neutral i z number o er of serial b adjusted for A 5 09 2013 P 32 connecti TELNET switch to sta ays and hou and hours red and can swor...

Page 27: ... 5 Rev No 1 gging Men events of th ng menu wing a log p nfo about th hat particul be seen on t nd down k s S 10 60 KVA Rev Date 25 nu he device ca press enter he UPS All r ar event sta the menu eys to see A 5 09 2013 P an be seen i to see recorded atus setup older newe Publication N n er No 2 PRODU UCT DESCRI IPTION 28 ...

Page 28: ...roper i d aches up to 7 used to prot age before u es should be ardous In c hysician if ir ies ring wa h has 3 pha IEC 60364 distribution ve IT System ained in mor k up e following on of the pro was done to t odel power Publication be followed a ditionally y yle for cabin d by a certif installation 700 Vdc dur tect the skin using them used case of conta rritation occ atch etc be ses and fou 3 Optio...

Page 29: ...om the front side ventilation holes goes out from the fans on the rear side of the device Care must be taken in order not to cover the air enterance and exit spots If the area is dusty Optional filters must be used on dusty environments During operation there is a remarkable amount of heat loss to room air so an air conditioning system must be used to keep the temperature in limits UPS Amount of B...

Page 30: ...ble shows the recommended battery configurations Fast and semi conductor protection type of fuse is used for batteries The following general battery safety precautions and warnings should be observed at all times Do not dispose of battery in fire Do not attempt open the batteries Eye protection should be worn to prevent injury from electrical arcs Remove rings watches necklaces bracelets and all o...

Page 31: ...CHALLENGER SERIES 10 60 KVA INSTALLATION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 32 The batteries positioning shapes can be seen at the following table 38x2 Battery Set ...

Page 32: ...CHALLENGER SERIES 10 60 KVA INSTALLATION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 33 CH1060EN07R0 CH1060EN08R0 ...

Page 33: ...CHALLENGER SERIES 10 60 KVA INSTALLATION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 34 40x2 Battery Set 51 54 52 ...

Page 34: ...CHALLENGER SERIES 10 60 KVA INSTALLATION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 35 CH1060EN10R0 CH1060EN11R0 ...

Page 35: ...y rooms and cabinets If it is possible please use breaker switch without fuse for the bateery cabinet Keep battery cabinets and shelves high above the ground UPS should be protected against floods or liquid contacts 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 room Use necessar...

Page 36: ...6 3 5 8 11 4 10 4 9 5 8 7 I_bat_max V_cut_off A 45 41 37 34 67 61 56 51 Recommended fuse for external cabinet A 50 50 50 40 80 80 63 63 UPS Rating KVA 40 60 Total number of Batt 48 50 50 I_char_max V_bat_max A 12 1 11 6 17 4 I_bat_max V_cut_off A 71 68 102 Recommended fuse for external cabinet A 80 80 125 External battery cabinet and battery room applications are given below as an example The appl...

Page 37: ...cessories must have enough features and characteristics to carry UPS s weight Cabinet is equipped with four wheel Thanks to this feature it can be moved easily These wheels must be used only on smooth surfaces The front side wheels of UPS must be locked after positioning properly The back side wheels are fixed Be more careful of sudden movements especially when batteries are inside of cabinet Move...

Page 38: ...0mA rated relays for handling leakage currents Those relays must also be Resistant to both positive and negative DC pulses And not sensitive to transient currents Must be sensitive to currents which is average between 0 3 1 A 3 1 4 2 Cabling and fuse configuration Full load input and output currents must be reviewed for proper cabling and fuse selection UPS Rating KVA Rated Currents A Input curren...

Page 39: ...V 1 Rev Date nnections ctions of the nput and ou ENTION 3 ut of UPS utral line is 0 VA 25 09 2013 e UPS are ma utput connec 3 pole circu not be inte Input Term Output Te Publication ade from th ctions uit breaker errupted minals rminals n No 2 e rear side o rs switch of the device are used INSTAL e Remove th for the in LLATION 40 he metal put and ...

Page 40: ...lication No 2 41 Follow the steps below to electrical connections 1 Make sure that the network and loads are isolated through cables by turning off the all breakers on the distrubution board 1 Unscrew and remove the metal board on the rear side of the device CH1060EN16R0 CH1060EN15R0 ...

Page 41: ...INSTALLATION AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 42 2 Connect the ground cable 3 Make sure that the circuit breakers are off The use of these circuit breakers are explained on the operation section CH1060EN17R0 ...

Page 42: ...en the connections are done WARNING Make sure that the loads are isolated from the UPS output if they are not ready to be connected WARNING Make sure that the cables are connected properly before UPS is started Additionaly check if there is galvanic isolation transformers at input of UPS and consider the local directions WARNING Check the grounding before starting the UPS Wrong works or grounding ...

Page 43: ...ace the meta VA 25 09 2013 ns ut installatio on zard e can reach n against pos ecting the b tent In case ies such as r Installatio rocedure to connect t ery fuse he batteries labeled cabl labeled cabl ty of the batt cuiting batt ent al may rise al rear cover Publication on procedur up to 700 V ssible arcs atteries of contact w ring watch b n Procedu the internal are connect e inside the le inside ...

Page 44: ...y termina breaker exi battery fuse battery fuse 1R0 VA 25 09 2013 re is monit ion for exter Installatio on about ho ng above In uiting batte al may rise u st on the ba in the batte on the UPS Publication tored by the rnal battery on Procedu ow to be pos this section eries Explo up to 700 V ttery cabine ery cabinet n No 2 e NTC conn y monitoring ure and Co sitioned of e Informatio ding batter Vdc e...

Page 45: ...tery voltage on the input terminals of the battery of UPS by measurement tool The external battery cable selection is determined by the application Recommended fuses are given for UPS and battery cabinet The lowest diameter cable that can be connected to those fuses is recommended to be used Please refer to standard called EN 50525 2 31 VDE 0100 430 in this subject Bu konuda EN 50525 2 31 VDE 0100...

Page 46: ...ntity 8 seen below VA 25 09 2013 nection diag unication C dart or opti onitoring co ide of UPS unication co unication co on connecto ave bought e contact yo ion should dancy or m eight A sc w Publication gram is give Cable Con onal connec ontrol panel nnector RS nnector RS or can be ope our dealer fo be made by more power chematic dia n No 2 n below nections ctions of adv ls and variou S232 Rectif...

Page 47: ...ing and must be the same series Devices must be running on the same firmware if not old firmwares must be updated Devices must be located as close as possible to each other max 6 x 110 cm paralleling cables Each device must have its own neutral cable Each device must have its own ground connection UPS must be connected in paralel on the distribution panel and phases must be connected correctly U1 ...

Page 48: ...No 1 Rev Date 25 09 2013 Publication No 2 49 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 personel CH1060EN24R0 CH1060EN25R0 ...

Page 49: ...h CB2 In this way maintenance purposed switching is done properly If UPS is actived while it is working thanks to auxilary short circuit info located in CB3 mains makes the bypass static switches actived The system will be switched to maintenance mode smoothly CB3 is used to connect or seperate AC voltage that come from static switches to the loads on UPS Active Brakers Operation Mode Explanation ...

Page 50: ...N AG SD 35 Rev No 1 Rev Date 25 09 2013 Publication No 2 51 4 1 2 First Start Up WARNING Wait for at least 5 seconds between each step 1 Turn the Maintenance CB2 bypass breaker ON 2 Turn the input CB1 breaker ON CH1060EN26R0 CH1060EN27R0 ...

Page 51: ...tio ED on the m while and th the operatio tery charge ll be lit cont he switching de Static b ram will ligh UPS has sw mode via m nel KVA 25 09 2013 the front ol Passw on of the mimic diagr hen remain l on of the b LED on the tinuously g of UPS to ypass LED ht up witched to mimic diagra Publication panel word rectifier ram will lit battery e mimic o static on the normal m LEDs n No 2 O CH1060TR28 ...

Page 52: ...35 Rev No 1 Rev Date 25 09 2013 Publication No 2 53 8 Verify that batteries are switched via front panel indicator and Status Battery menu 9 Turn output circuit braker CB3 ON 10 Turn the maintenance bypass braker CB3 OFF CH1060EN32R0 CH1060EN33R0 ...

Page 53: ...situation check UPS total and phase loads The UPS gives audio alerts in an overload condition without feeding critical AC loads 4 1 3 Testing of Types of UPS Operation After first start up check device operation by switching between the following modes manually 4 1 3 1 Switching from Online Mode to Battery Mode Turn CB1 OFF This action cuts off the mains voltage and the UPS starts operating on bat...

Page 54: ... 09 2013 nline Mode witch the dev switched to Switch to By ch to bypass mperature sit atic Bypass witch the de ched to onlin Switch to switch to no temperature Publication e to Static B vice to static bypass mod ypass s mode if the tuation s Mode to evice to onlin ne mode UPS ormal mode e situation n No 2 Bypass Mo c bypass mo de e inverter vo Online ne mode Ch e if the inver ode de Check th oltag...

Page 55: ...devi u Control n CB2 ON N38R0 KVA 25 09 2013 line Mode that the inv o maintenan wer for a sho switch the de ice has swit Output BY Publication to Mainte erter output nce bypass m ort while evice to stat tched to byp YPASS n No 2 nance Byp t is synchro mode Other tic bypass m pass mode pass Mode nous with th wise there i mode Check O he maintena is a possibili the mimic p CH1060T OPERATION 56 ance ...

Page 56: ...for s RIES 10 60 K 1 Rev Date the UPS by in menu C n CB1 CB3 a least 5 min safety KVA 25 09 2013 using front Control Sto and CB4 OFF nutes before Publication panel op F e opening u n No 2 up the devic ce after it is CH1 O s complete 1060EN39R0 OPERATION 57 ly turned 0 N 7 ...

Page 57: ...sure that mplete shut gency Pow rectifier am etely separa KVA 25 09 2013 te Shut Do nnected to t to turn the t there are tdown wer Off mplifier and ated from th Publication wn the device e device OF no critical inverter res e system if n No 2 FF by follow loads on th spectively w the shutdow wing Main he UPS outp when the EP wn option of O n Menu put before p O button is f output circ OPERATION 58...

Page 58: ...rial Communication Installation and Investigation Challanger series has an RS 232 interface which supports SEC and TELNET protocol as standart This interface is fully isolated and safe UPS can be monitored remotely via a computer PC or SNMP by using this protocol This connection works with all kinds of options ...

Page 59: ...UPS Startup The main board of the UPS is energized 5 Soft Start Fail UPS could not ramp the DC bus up 6 Quick Battery Test Quick battery test has began 7 Deep Battery Test Battery capacity test has began 8 Battery Self Test Periodical battery test has began 9 End Of Discharge Batteries voltage has gone below cut off voltage value while UPS was operating on the battery mode 10 Overload Timeout UPS ...

Page 60: ...n charge mode Charge will be stopped If it is in boost mode UPS will be stopped 22 STS Overtemp Static Transfer Switches temperatures are out of limits UPS will be stopped 23 Outp PL1 Cur Limit Short circuit protection is activated for output L1 phase 24 Outp PL2 Cur Limit Short circuit protection is activated for output L2 phase 25 Outp PL3 Cur Limit Short circuit protection is activated for outp...

Page 61: ...to normal 36 Charger Nor Temp Charger booster module temperature is in the allowed limits charging will be activated again 37 STS Nor Temp Temperature of Static transfer switches is in the allowed limit 38 Bypass Voltage Nor Bypass voltage is within defined limits 39 Bypass Freq Nor Bypass frequency is within defined limits 40 Coil Normal temp UPS inverter or rectifier coil temperature has got bac...

Page 62: ...PS has detected that bypass L2 thyristor can not be activated Load will be transferred to inverter line 54 BYP Thyr L3 Open C UPS has detected that bypass L3 thyristor can not be activated Load will be transferred to inverter line 55 Parl Phs Rot Err One or more of UPSs which operate in paralel mode do not match in phase sequence 56 Battery Start Starting through battery command has been given to ...

Page 63: ... 70 Manuel Start Command Start command is given via UPS command menu 71 Manuel Stop Command Stop command is given via UPS command menu 72 Batt Swtch Failure An error occurred while ramping up the battery bus Batteries could not be activated 73 UPS Stopped UPS has been stopped 74 Bypass Problem UPS has switched to bypass mode so many times i a short period UPS will be shut down 75 Parameters Change...

Page 64: ... detected a failure of input current sharing 87 Inverter OKEY Inverter voltage reached needed value after UPS is started up UPS can feed the loads through inverter 88 Batt Temp Err Battery temperature is out of defined limits batteries can be damaged 89 Booster Overcurrent Overcurrent in Battery mode UPS will be shut down 90 EPO key pressed EPO key button is pressed 91 Battery Low Battery capacity...

Page 65: ...n to UPS which is operating in paralel mode separately from paralel system 107 Master Changed UPS became master device in paralel system 108 Par Bus ID Collision ID value of one or more UPS is the same as each other in parallel system 109 Output Offset Err One or more phase of slave UPS output is not connected to master UPS in Parallel systems 110 Bypass Short Circuit Short circuit current limit h...

Page 66: ...se is turned OFF 8 Shutting Down Stop command was given to the UPS UPS will shut down at the end of the period 9 No Battery No battery detected 10 M Byp Sig Active Maintenance bypass fuse is ON 11 Static Byp Mode UPS feeds the critical loads via bypass line 12 Test is progressing UPS is operating in the battery test mode 13 Replace the batteries At the end of the battery test battery capacity was ...

Page 67: ...ogs for details 21 BYP Phase Rot Err Bypass line phase sequence is not compatible with inverting the phase sequence 22 Par UPSMissing Number of perceived UPS at the parallel system is not the same as number of set UPS 23 Curr Char Err One or more other phase of UPS is energized as different from other UPS 24 Power Supply Failure One of the power supplies that operates in paralel stopped 25 Generat...

Page 68: ...ns when is out of range 50Hz 0 2 battery mode 50Hz 0 2 Output THD THDv Lineer 3 Non Lineer 4 Crest Factor CF 3 1 Overload Capacity At 125 load 10 min at 150 load 1 min Protections The input voltage is out of tolerance input frequency is out of tolerance input phase failure output voltage is out of tolerance output frequency is out of tolerance output phase failure DC component that can occur at th...

Page 69: ...erature At the range of 15 C 45 C for batteries 10 60 C Protection Class IP20 Chassis Anti Static Paint Protection Humidity 0 95 Altitude 1000m Correction Factor 1 2000m Correction Factor 0 92 3000m Correction Factor 0 84 Acoustic Noise 1m 60dBA 65dBA Log Recording 500Event Log Optional Status Record Parallel Operation Parallel power increase up to 8 pcs EPO Emergency Power Off Standard Isolation ...

Page 70: ...FORMATIONS www makelsan com tr İstanbul Deri Organize Sanayi Bölgesi 2 Yol I 5 Parsel 34956 Tuzla İstanbul Tel 0216 428 65 80 Faks 0216 327 51 64 e mail makelsan makelsan com tr İzmir Şube Hakapınar Mah 1348 Sok 2AE Keremoğlu İş Merkezi Yenişehir İzmir Tel 0232 469 47 00 Faks 0232 449 47 00 e mail izmir makelsan com tr ...

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Page 72: ...esi 2 Yol I 5 Parsel 34956 Tuzla İstanbul Tel 0216 428 65 80 Faks 0216 327 51 64 e mail makelsan makelsan com tr İzmir Şube Hakapınar Mah 1348 Sok 2AE Keremoğlu İş Merkezi Yenişehir İzmir Tel 0232 469 47 00 Faks 0232 449 47 00 e mail izmir makelsan com tr ...

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