Challenger 10-250kva Serv Man - Ing

SERVICE MANUAL
CHALLENGER SERIES
10 - 250 KVA
AG-SD-36 Rev. No:0 Rev. Date:16.01.2014 Publish No:1
SERVICE MANUAL
CHALLENGER SERIES
10-250 KVA
AG-SD-36
Document Y.No:1 Rev:0
About The Manual
This manual is prepared for the users of Challenger 10-250 kVA.
Companion Manuals
For more info 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.
CHALLENGER SERIES 10-250 KVA CONTENTS
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 ......................................................................................................... 14
2.1.1. Static Transfer Switch............................................................................................... 14
2.1.2. Battery Temperature Regulation........................................................................... 15
2.2. UPSs Operation Modes..................................................................................................... 15
2.2.1. Normal (Online) Mode.............................................................................................. 15
2.2.2. Battery(stored) Mode............................................................................................... 16
2.2.3. Bypass Mode............................................................................................................... 16
2.2.4. Auto Restart Mode..................................................................................................... 16
2.2.5. Maintenance Mode .................................................................................................... 17
2.3. Battery Management......................................................................................................... 17
2.3.1. Normal Operation Mode........................................................................................... 17
2.3.2. Advanced Level Functions (Automatic Battery Test)......................................... 18
2.4. User Panel ........................................................................................................................... 18
2.4.1. Openning Screen........................................................................................................ 21
2.4.2. Main Menu................................................................................................................... 21
2.4.3. Navigating Through the Menus............................................................................... 21
2.4.4. Password Protected Menus ..................................................................................... 22
2.4.5. Control Menu.............................................................................................................. 22
2.4.6. Status Menu................................................................................................................. 23
2.4.7. Setup Menu ................................................................................................................. 25
2.4.8 Logging Menu................................................................................................................... 28
3. INSTALLATION...................................................................................................................................... 29
3.1. Single Mode Installation................................................................................................... 29
3.1.1. Warnings ..................................................................................................................... 29
3.1.2. Pre-installation check up......................................................................................... 29
3.1.3. Positioning.................................................................................................................. 30
3.1.3.1. Positioning of UPS.............................................................................................. 30
3.1.3.2. External Battery Configration......................................................................... 30
3.1.4 Transportation Type of Cabinets.................................................................................. 34
3.1.5 Main, Load and Battery Connections ........................................................................... 34
3.1.5.1 External Protection.................................................................................................. 35
3.1.5.2 Cable and Fuse Selection......................................................................................... 35
3.1.5.3 Connecting the Cables.............................................................................................. 35
3.1.5.4 Battery Connections.......................................................................................... 40
Battery Assembly for 28.............................................................................................................. 40
Battery Assembly for 28x2......................................................................................................... 41
Battery Assembly for 38.............................................................................................................. 41
Battery Assembly for 38x2.......................................................................................................... 42
Battery Assembly for 40............................................................................................................ 42
3.1.5.4.1 External Battery Installation Procedure and Connection...................... 44
3.1.5.5. Menu Setup After Battery Installation........................................................... 47
3.1.5.6 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......................................................................... 52
4.1.3.1 Switching from Online Mode to Battery Mode............................................. 52
4.1.3.2 Switching from Online Mode to Static Bypass Mode................................... 52
4.1.3.3 Switching from Static Bypass Mode to Online.............................................. 53
4.1.3.4 Switching from Online Mode to Maintenance Bypass Mode ..................... 54
4.1.4 Performing a Complete Shutdown......................................................................... 55
4.1.5 EPO (Emergency Power Off).................................................................................... 56
4.1.6 RS232 Serial Communication Installation and investigation........................... 56
Challenger Parallel Operation Guide..................................................................................................... 57
A. Check if the devices can be used in parallel mode. .................................................................. 57
B. Check the positioning of the devices. ............................................................................................ 57
C. Make the electrical connections ..................................................................................................... 57
D. Set the software for parallel operation. ....................................................................................... 59
E. Operation ................................................................................................................................................ 61
Master/Slave configuration ...................................................................................................................... 61
Parallel start-up........................................................................................................................... 61
Switching to static bypass ........................................................................................................... 63
Stopping/Removing a single UPS............................................................................................... 63
Stopping all UPS.......................................................................................................................... 64
Troubleshooting for Parallel Mode ........................................................................................................ 64
5 ELECTRONIC BOARDS......................................................................................................................... 67
Main Control Board........................................................................................................................ 67
PFC Input Board D09-3.V1R1....................................................................................................... 71
Battery Input Board........................................................................................................................ 75
Fuse Board ....................................................................................................................................... 78
Signal Flow Diagram........................................................................................................... 80
HV DC TO DC SMPS..................................................................................................................... 81
Signal Flow Diagram........................................................................................................... 85
Main Board Power Supply ............................................................................................................. 86
Front Panel Board........................................................................................................................... 90
IGBT Driver Board......................................................................................................................... 95
Signal Flow Diagram......................................................................................................... 101
By-pass Board................................................................................................................................ 102
IGBT Driver Connection Board................................................................................................... 109
Contactors ...................................................................................................................................... 113
Firmware Update for Challenger...........................................................................................................113
DRY CONTACT R335...................................................................................................................................115
Precautions..................................................................................................................................... 115
Installation ..................................................................................................................................... 115
Operation ....................................................................................................................................... 118
Relay info................................................................................................................................ 118
Isolated input info.................................................................................................................. 118
Pin functionality ............................................................................................................................ 119
Dry contact functions.......................................................................................................... 120
Connection examples..................................................................................................................... 121
LED DEFINITIONS ................................................................................................................ 122
6 EXPLANATIONS OF LOGGING .........................................................................................................133
Fault Alarms ......................................................................................................................... 141
SPARE PART LISTS............................................................................................................... 148
7 TECHNICAL SPECIFICATIONS .........................................................................................................154
Contact Information...................................................................................................................................156
CHALLENGER SERIES 10-250 KVA SAFETY AND WARNINGS
1. SAFETY AND WARNINGS
1.1. Warnings
This manual must be read before installing the UPS. The device can be installed and started only
by Makelsan staff.
Installation or start-up by unauthorized personal may cause damage to the device and serious
injury or death.
The UPS is designed to be used in continuous vertical fixed position applications.
Warning:
THE UPS MUST BE USED WITH GROUND CONNECTION.
Connect the ground cable before connecting the mains.
Ground currents may be as high as 0.4A
THE UPS MUST BE DISCONNECTED FROM THE MAINS AND BATTERIES BEFORE
SERVICING. ALSO WAIT FOR AT LEAST 5 MINUTES FOR THE DC BUS
CAPACITORS TO DISCHARGE AFTER POWER OFF.
Service and Maintenance
All servicing and maintenance is done internally. All parts in the device can be serviced and
replaced only by a trained technician.
preventative maintenance is recommended at least once a year from the installation by
authorized technical staff. (This service will be provided for a fee by our authorized
MAKELSAN staff.)
Battery Voltage may rise up to 700 V DC!
Battery terminal voltages can be at hazardous levels (700Vdc). Nobody except trained staff should
touch batteries.
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 delivered to
MAKELSAN authorized technicians or to the foundations which are authorized for collecting
waste batteries by the Ministry of Environment.
1.1. Warnings
by Makelsan staff.
injury or death.
Warning:
MAKELSAN staff.)
touch batteries.
1.1. Warnings
by Makelsan staff.
injury or death.
Warning:
MAKELSAN staff.)
touch batteries.
Fire extinguishing equipment must be kept nearby the UPS.
1.2. Clearance and Access
Clearance
There is no any air inlet or outlet grill on the left or right sides of our 10-250 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 at the front side of UPS. 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 10-250 kVA UPS. Therefore, enough area must be left for
operator.. 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 fromexcessive 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.
Be more careful of sudden movements, especially when batteries are inside of cabinet.
Move the UPS as rarely as possible.
CHALLENGER SERIES 10-250 KVA PRODUCT DESCRIPTION
AG-SD-36 Rev. No:0 Rev. Date:1511.2012 Publish No:1
2. PRODUCT DESCRIPTION
Front Cover View( 80-200kVA)
1 RS232 Serial Interface for Inverter
2 RS232 Serial Interface for Rectifier
3 Input Circuit Breaker
4 External Bypass Circuit Breaker
5 Output Circuitr Breaker
6 Optional Card Slots
CH80120EN04R0
Rear view(10-60kVA)
CH1060TR04R0
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
Electrical Connection
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 the loads after passed from 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.
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.
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.
If 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.
If Maintenance or repair are necessary, maintenance switch must be turned "ON" before the input
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. Battery Temperature Regulation
Optional temperature sensor is given with external battery cabinet. Battery temperature are
perceived by mentioned temperature sensor. UPS adjusts battery charge parameters according to
the information of the perceived temperature. These parameters can easily be adjusted via LCD or
TELNET interface by authorized staff of MAKELSAN.
In this case, We recommend you to order "External Battery Temperature Measurement Kit" to
detect the temperature.
2.2. UPSs Operation Modes
Challanger 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 Mode
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.
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.
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.
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.
2.2.5. Maintenance Mode
In maintenance mode, UPS equipped with a switch capable for not to be interrupted of the loads.
This switch was choosen to meet the full load.
2.3. Battery Management
Lead Acid Batteries are used with UPSs as internal.
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%.
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.
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.
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.
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
Menu Flow Chart
Control Menu
Status Menu
Setup Menu
Logging Menu
Service Menu
CONTROL
Start
Stop
Output Bypass
Output UPS
Quick Battery Test
Battery Status Test
Stop Battery Test
STATUS
Mains
Output
Bypass
Battery
Temperatures
Inverter
Alarms
Device
Information
SETUP
Date & Time
Battery Install Date
Auto Restart
Auto Battery Test
Screen
Warning Beep
Language
Communication
LOGGING
Log Code
Date
Time
Log Records
Information
MAINS
Voltage(phase-
neutral)
Frequency
Current
Voltage(phase-
phase)
Aktive Power
Apparent Power
Power Factor
Positive Bus
Negatif Bara
WARNINGS
Actual
Alarms
BATTERY
Voltage
Current
Temperature
Charge Percentage
Remaining Back up
(Autonomy) Time
Last Test Result
Next Test Date
INVERTER
Voltage
Current
Active Power
TEMPERATURE
Rectifier
Inverter
Ambient
Battery
Bypass
Choke
BYPASS
Frequency
Current
Voltage (phase-
neutral)
Voltage (phase-
phase)
DEVICE INFORMATION
Software Versions
Serial No
Appearant Power
Voltage
Frequency
Serial Arm x Battery
Quantities
Battery Capacity
OUTPUT
Frequency
Current
Voltage
Active Power
Reactive Power
Power Factor
Apparent Power
Load Percentage
Crest Factor
SERVICE*
*Detailed
service
menu can be
observed by
only
authorised
staff.
Main Screen
Manufacturer Device Name
Date - Time
Load Status as Percent
Battery Charge Status as Percent
Remaining Back up (Autonomy)
Time
UPS Mode Actual Alarms
Main Menu Titles
2.4.1. Openning Screen
When the front panel monitor is turned on,
firstly opening screen is observed.
Manufacturer Device Name, Date Time,
Load Status as Percent, Battery Charge Status
as Percent, Remaining Back up (Autonomy)
Time, UPS Mode Actual Alarms, Main Menu
Titles can be observed here.Last event (log) is
shown at the bottom left and active alarms
list that appears 2,5 second intervals are
shown at the bottom right. If no button is
pressed for 5 minutes, system returns to the
opening screen.
2.4.2. Main Menu
Press ENT button to switch to the main menu.
2.4.3. Navigating Through the Menus
Use UP and DOWN keys to move the cursor arrow.
Press enter to open a sub- menu. Press ESC to go
back to the previous menu. Control sub-menu is
shown on left.
Hold the UP or DOWN key to navigate between the
sub- menus.
Some menus have changeable options like
ON/OFF, durations or quantities. To change
some setups in such a menu, press ENTER
to choose the variable, use up and down
keys. To change the value, press ENTER to
set the new value, press ESC to cancel.
2.4.4. Password Protected Menus
Some menus such as the control menu are
password protected.Press UP and DOWN to
set each
digit and press ENTER to confirm.
User level password is: 0000 (zero-zero-
zero-zero)
2.4.5. Control Menu
In the control menu, you can do one of the following:
Start Start the UPS
Stop Stop the UPS
Switch 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 battery test
Battery status test, drains the 30% of battery energy and reports batteries which has more
capacity than 15-30% as Good, less capacity than 15% as Replace according to the test
results.
After UPS is started and every 24 hours, it makes a quick battery test ,if test counter value is zero
(0).
Note: Batteries must have been fully charged and kept in floating situation for at least one hour
before performing the quick battery test.
Status on the System> Battery > Remaining Time can be seen.
If Stop Battery Test is chosen from the menu, the UPS cancels the battery test and goes back to
the previous operating state.
2.4.6. Status Menu
Mains Output, Bypass, Battery, Temperatures, inverter, Alarms and UPS information can be seen
on this menu.
Mains
UP, I, Hz Voltage (phase-neutral), current and frequency of each phase.
UL, S, P Voltage(phase phase), reactive and active power of each phase.
PF, U, D Power factor, positive DC bus and negative DC Bus of each phase.
Output
UP, I, Hz Voltage(phase-neutral), current and frequency of each phase.
UL, S, P Voltage(phase phase), reactive and active power of each phase.
PF, L, CF Load percentage for each phase and crest factor.
Bypass
UP, I, Hz Voltage(phase-neutral), current and frequency of each phase.
UL Voltage of each phase (phase to phase).
Battery
Mode Battery Mode.
U, I, T Battery Voltage, Charge Current and Temperature.
Charge % Charge Percentage.
Battery Time The estimated battery run time with current load.
Last Test Result Test type, test number, test date and time. Battery capacity and condition.
Next Test Time Next test date
Time Timer countdown for the next test availability.
Temperature
C,C,C,C,C,C,C Rectifier, inverter, charger, ambient, battery and thyristor temperatures.
Inverter
U, I, P Voltage, current and frequency of each phase.
Alerts UPS alarms.
UPS Information
Software Version of inverter,rectifier,CPLD
and front panel; UPS's apparent power(kVA),
nominal output voltage (phase-neutral),
nominal output frequency (Hz); number of
batteries in parallel , serial and battery
capacity can be seen via version menu.
2.4.7. Setup Menu
The following adjustments can made on setup menu:
Date & Time
To set date and time, use up and down keys to
choose the variable you want to set.
Then use up and down keys to set the value,
and press ENTER.
Battery Replacement Date
Set the date of battery installation through this
menu.
Auto Restart
On the battery mode, UPS operates until
charging process completed. the device turns
off
at the end of battery discharge process. Auto-
restart can be used to restart the UPS
automatically when the mains comes back to
limits.
Turn on auto-restart and set the time to
define when the device will be started after
the mains is normal.
Auto Battery Test
This function can be turned on to start
the user independent battery tests.
Time interval sets when the test will be repeated.
Note: Auto Battery test is the equivalent of
battery quick test.
Screen
Change the screen contrast to make it more
visible on different environmental conditions.
Beep
Turn the beeper sound on/off.
Language
Set the menu language.
Communication
Set the protocol for the RS232 connection. The
options are SEC, Megatech and TELNET.
Economy Mode
Economy mode (ECO) and UPS switch to static
bypass mode at the specified days and hours.
Use this menu to setup the days and hours.
Service Menu
Service menu is password secured, and cannot be
accessed with the user password.
2.4.8 Logging Menu
Last 500 events of the device can be seen in this
menu.
When viewing an event, press enter to see detailed
info about the UPS. Use up and down keys to see
older/newer event logs.
CHALLENGER SERIES 10-250 KVA INSTALLATION
3. INSTALLATION
3.1. Single Mode Installation
In this section, the warnings which must be obeyed and the checking which must be performed
before starting-up the UPS are stated. Additionally, you can find informations about the points you
must pay attention during carrying the cabinets, positioning and connections.
3.1.1. Warnings
The UPS must be installed by a certified electrician.
Do not energize the UPS before proper installation.
Battery Hazard
Battery terminal voltage reaches up to 450 Vdc during operation.
Proper safety gear must be used to protect the skin and the eyes from electrical arcs.
Check the batteries for leakage before using them.
ESD-protected rubber gloves should be used.
Battery ingredients are hazardous. In case of contact with battery ingredients, rinse the skin with
water, and consult a physician if irritation occurs.
Remove any metal accessories (ring, watch, etc.) before working on the device.
UPS, needs a feeding which has 3-phases and four-wire ( +earth) on the input. Feeding type is
suitable for connection to IEC 60364-3. Optional 3-wire to 4-wire conversion transformers are
available.
If it is used in IT AC power distribution systems, a 4-pole circuit breaker must be used on the
input and refer to the relative IT Systems2 standart.
Detail of the subject is explained in more detail on the standart named IEC 60364-3.
3.1.2. Pre-installation check up
Before installing the device, the following checks should be carried , these are the first and most
important steps in the operation of the product correctly.
Check if any damage was done to the device during transportation. Report any damages instantly.
Make sure that the model power rating is right. Check the device label for the actual power rating.
3. INSTALLATION
3.1.1. Warnings
Battery Hazard
available.
3. INSTALLATION
3.1.1. Warnings
Battery Hazard
available.
3.1.3. Positioning
UPS and batteries are designed for indoor use; UPS must be placed in a places where has clean
and easy air flow.
3.1.3.1. Positioning of UPS
In Challenger 10-250 kVA series, air enters the device from the front side ventilation holes, goes
out from the rear side of UPS through fans. Air inlet and outlet ports should never be covered. It
should be positioned in a place where is far from the risk of liquid contact.
If the area is dusty, Optional filters must be used on dusty environments.
The using of these filters will be made according to the instructions on.
UPS is an energy-loss system due to its nature. Energy losses emerges as heat. You can see what
kind of a forced air-cooling is needed in the following table. This table can be used to calculate the
capacity of air conditioning which must be used in UPS ambiance.
UPS
Amount of BTU /h for
cooling
Bridge Load 100% (Non-lineer) estimated
BTU / h value for load
working
10KVA 2.663 3.196
15KVA 3.790 4.548
20KVA 3.892 4.670
30KVA 7.785 9.342
40KVA 8.058 9.670
60KVA 12.975 15.570
80 KVA 17500 21000
100 KVA 21900 26300
120 KVA 26300 31500
160KVA
37000
44000
200KVA
40000
48000
250 KVA
54700
65600
3.1.3.2. External Battery Configration
Batteries must be used in balanced and uniform temperature environments. temperature, is the
most important factor that directly affect to battery capacity and usage lifes. in general, battery
manufacturers recommend the batteries to be used between 20-25 C. In addition, Battery
manufacturers give the performance of their products in this temperature range. If temperature
exceeds this specific limits, battery life will decrease. If the temperature drops below this range,
the battery capacity is severely reduces. Therefore, the expected autonomy time will not be
sufficient during redundancy process. As a result, keep the batteries away from the points where a
heat source and serious air flow are located. Please observe the following points on connecting
external batteries by taking into account these issues:
Keep batteries away from main heat sources.
Keep batteries away from main air inlets.
Keep batteries 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 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 necessary safety writings and strips
Espacially, 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. This closeness will increase the
electrical operation safety.
THE TABLE OF CHALLENGER EXTERNAL BATTERY USAGE
Device Power (KVA) 10
Total number of Batt. 28 32 36 38 42 46 50
Ibat.max @ Vbat.max (A) 5,2 4,5 4,0 3,8 3,5 3,2 2,9
Ibat.max @ Vcutoff (A) 31 27 24 23 21 19 17
Recommended internal fuse (A) 40 32 32 32 25 25 20
Device Power (KVA) 15
Total number of Batt. 28 32 36 38 42 46 50
Ibat.max @ Vbat.max (A) 7,8 6,8 6,0 5,7 5,2 4,7 4,3
Ibat.max @ Vcutoff (A) 46 40 36 34 31 28 26
Recommended internal fuse (A) 63 50 40 40 40 32 32
CHALLENGER SERS HARC AK KABN KONFGRASYONU
Device Power (KVA) 20 30
Total number of Batt. 38 42 46 50 38 42 46 50
Ibat.max @ Vbat.max (A) 7,6 6,9 6,3 5,8 11,4 10,4 9,5 8,7
Ibat.max @ Vcutoff (A) 45 41 37 34 67 61 56 51
Recommended internal fuse (A) 50 50 50 40 80 80 63 63
Device Power (KVA) 40 60
Total number of Batt. 48 50 50
Ibat.max @ Vbat.max (A) 12,1 11,6 17.4
Ibat.max @ Vcutoff (A) 71 68 102
Recommended internal fuse (A) 80 80 125
Device Power (KVA) 80 100 120 160 200 250
Total number of Batt. 50 50 50 50 50 50
Ibat.max @ Vbat.max (A) 18,6 23,2 27,8 37,1 46,4 58,0
Ibat.max @ Vcutoff (A) 136 170 204 271 339 424
Recommended internal
fuse (A)
160 200 250 280 355 400
External battery cabinet and battery room applications are given below as an example.
The method of application may vary according to the customer.
Example Battery Chamber Application(80-250kVA)
CH80120EN08R0
CH80120EN09R0
External Battery Cabinet Application(80-250kVA)
3.1.4 Transportation Type of Cabinets
Carrying vehicles or handling accessories must have enough features and characteristics to carry
UPSs 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 the UPS as rarely as possible.
3.1.5 Main, Load and Battery Connections
Makelsan strictly recommends a distribution board for the UPS outputs. Proper fuses and
breakers must be used in such distribution board. A-B type fuses or magnetic breakers are
recommended if the load is suitable.
3.1.5.1 External Protection
To protect the AC inputs, thermal magnetic breakers or V type breakers must be installed on the
distribution board.
Over current protecting must be installed on mains input distribution board and fuses must be
chosen 135% higher rated than the ones given in the table below. Fuses must be C-type.
Ground leakages flow to the ground through the EMI filters on the input and the output of the UPS.
Makelsan recommends the use of 700mA rated relays for handling leakage currents.
Leakage current relays that set at the input of UPS are shown below;
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
3.1.5.2 Cable and Fuse Selection
Cable designs must be suitable to mentioned currents and voltages; additionally, local guidelines
on this topic must be considered.
UPS
Power
(KVA)
Nominal Currents (A)
Input currents@max charge
current (3P+N)
Output Currents @100% Load
(3P+N)
380V 400V 415V 380V 400V 415V
10 17,1 16,2 15,7 15,4 14,6 14,1
15 25,6 24,4 23,5 23,1 21,9 21,1
20 34,2 32,5 31,3 30,8 29,2 28,2
30 51,3 48,7 47 46,2 43,9 42,3
40 68,4 65 62,6 61,6 58,5 56,4
60 102 97 94 93 88 85
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
160 273,6 259,9 250,5 246,2 233,9 225,5
200 342,0 324,9 313,1 307,8 292,4 281,8
250 427,5 406,1 391,4 384,7 365,5 352,3
Non-linear loads (computer-type loads) may affect design of cable cross-sectional. The Neutral
currents may be bigger than the phase currents, even it may rise up to 1,5 times of phase current.
Protection Ground cable must be connected to directly each cabinet and ground line easily.
Typical ground line cable cross-sections for 80 kVA should be 50mm2, for 100 kVA should be
70mm2 and for 120 kVA should be 95mm2.
3.1.5.3 Connecting the Cables
All electrical connections of the UPS are made from the rear side of the device.
ATTENTION! 3 pole-circuit breakers (switch) are used for the input and output of UPS,
Neutral line is not be interrupted.
80-250kVA Cable Connection
1 Input Terminals
2 Output Terminals
CH80120EN10R0
1 Input Terminals
2 Output Terminals
CH80120EN10R0
1 Input Terminals
2 Output Terminals
CH80120EN10R0
1 Input Terminals
2 Output Terminals
1. Make sure that the network and loads are
isolated through cables by turning off the all
breakers on the distrubution board.
2. Connect the ground cable.
10-60kVA 80-250kVA
3. Make sure that the circuit breakers are off. The use of these circuit breakers are
explained on the next sections.
4. Connect the input cables.;
R to INPUT L1,
S to INPUT L2,
T to INPUT L3,
N(Neutral) to INPUT N.
80-250kVA
10-60kVA
5. Check the phase sequence.
6. Repeat steps 4-5 for output cables.
Use the cable clips to stabilize the cables when 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 on UPS or
other devices of installaton may be hazardous. Wrong works and grounding may damage UPS and
another system on the installation
3.1.5.4 Battery Connections
You can find explanations about installation procedures and connections of internal and external
batteries in this section.
Battery Hazard
The battery terminal voltage can reach up to 700 Vdc.
Preserve your eyes and skin against possible arcs.
Check for leaks before connecting the batteries.
Batteries have harmful content. In case of contact wash with plenty of water If irritation persists,
consult a doctor.
Remove the metal accessories such as ring ,watch before working with batteries
Battery Assembly for 28
Battery Hazard
consult a doctor.
Battery Hazard
consult a doctor.
Battery Assembly for 28x2
3.1.5.4.1 External Battery Installation Procedure and Connection
You can see detailed information about how to be positioned of external batteries under the title
of external batteries positioning above. In this section, Information about connecting batteries to
UPS was given
Avoid short circuiting batteries .Exploding batteries can damage you and
your environment!
Battery terminal may rise up to 700 Vdc
1. If any switch breaker exist on the battery cabinet, switch Off them.
2. Remove the battery fuse in the battery cabinet.
3. Remove the battery fuse on the UPS.
4. Make sure that the batteries are connected properly in series and parallel.
5. Connect the negative battery terminal to BAT cable, also connect the positive battery terminal to
the +BAT cable in the UPS.
6. Check the polarity of the battery connection once again.
7. Replace the battery fuse on the UPS.
8. Replace the battery fuse in the battery cabinet.
9. Replace the battery fuse on the UPS
10. If any switch breaker exist on the battery cabinet, switch ON them.
11. Please check that whether there is appropriate battery voltage on the input terminals of the
battery of UPS by measurement tool.
UPS was given
your environment!
UPS was given
your environment!
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. The selection should be such that the cable will allow at most 0,5 Vdc decreasing.
External Battery Temperature Measurement Kit which is sold as optional is recommended
to purchase for optimization according to battery temperatures on the external battery cabinets
applications. Otherwise, your batteries will not be optimized according to temperatures.
80-250kVA External Battery Connection
10-60kVA External Battery Connection
3.1.5.5. Menu Setup After Battery Installation
Menu setup shall be adjusted in the following statements after installation is done.
1. Turn on CB1
2. From the user panel, go to Service menu> Setup and adjust battery settings.
Settings are: number of batteries in series, number of parallels and battery
capacity.
3. Switch off CB1 and look at UPS operation conditions.
3.1.5.6 Control and Communication Cable Connections
MAKELSAN UPS have standard or optional connections of advanced external battery cabinet,
environmental monitoring, control panels and various intelligent monitoring.
Connections on the side of UPS :
One RS232 serial communication connector (RS232/Rectifier Service)
One RS232 serial communication connector (RS232/Inverter Service)
Two optional card slot
Connections on the UPS:
One paralleling connection connector
3.2 Parallel Installation
The product which you have bought can be operated in parallel; however, this feature is offered as
an option. Please contact your dealer for parallel operation.
Parallel application should be made by authorized personal of Makelsan !
1. Turn on CB1
capacity.
1. Turn on CB1
capacity.
In case of need for redundancy or more power, Challenger series UPS can be operated in parallel
up to quantity 8 (eight). A schematic diagram which shows two UPS connected in parallel can be
seen below.
Inputs and outputs of more than one UPS are connected to each other; but definitely each battery
group is different from another, batteries can not be used in common. The following points should
be considered while placement of UPS in parallel system and their electrical connections are made:
UPSs connected in parallel must have the same power rating 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-U2--UN), (V1-V2--VN), (W1-W2--WN).
Each UPS must have their own battery set, batteries cannot be used for more than one device at
the same time.
The length of all cables which are connected to distribution panel must be the same for the equal
current sharing.
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.
80-250kVA Paralel Connection Socket
10-60kVA Paralel Connection Socket
CHALLENGER SERIES 10-250 KVA OPERATION
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
UPS has three circuit breakers that can be reached from the front panel, these are used for AC input,
maintenance bypass and output connections respectively.
Three-phase AC voltage is applied through CB1 to input of UPS.
AC input voltage is applied directly to loads through CB2. In this way, maintenance purposed
switching is done properly. By auxiliary short circuit info located in CB3, mains makes the bypass
static switches activated while UPS operates. The system will be switched to maintenance mode
smoothly.
CB3 is used to connect or separate AC voltage that comes from static switches to the loads on UPS.
Active Breakers Operation Mode Explanation
CB1, CB3 Normal Mode UPS operates in normal mode..
CB1, CB3 Static Bypass Mode
UPS is overloaded, loads will be transferred to
static bypass line temporarily.
CB2 Test Mode
UPS is ON, but loads will be fed through
mechanical bypass line.
CB2 Maintenance Mode
UPS is shut down for maintenance; loads will be
fed through mechanical bypass line.
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
3. Start the UPS using the front panel.
Main menu> Control > Password > Start
4. Wait for the operation of the rectifier. Rectifier LED on the mimic diagram will flash for a
while, and then remain lit.
5. Wait for the operation of the battery charge. Battery charge LED on the mimic diagram will
be lit continuously.
6. Wait for the switching of UPS to static bypass mode. Static bypass LED on the mimic
diagram will light up.
7. Check the UPS has switched to normal operation mode, via mimic diagram LEDs and LCD
panel. Verify that batteries are switched via front panel indicator and "Status > Battery" menu.
8. Turn output circuit braker (CB3) ON.
9. Turn the maintenance bypass braker (CB2) OFF.
10. The loads which are connected to UPS can be turned on.
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. 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 battery mode.
Turn CB1 back ON again if everything is ok.
4.1.3.2 Switching from Online Mode to Static Bypass Mode
Use the front panel to switch the device to static bypass mode. Check the mimic panel to make sure
that the device has switched to bypass mode.
Main menu> Control > Switch to Bypass
NOTE: UPS will not switch to bypass mode if the inverter voltage is out of limits or there is and
overload or overtemperature situation.
4.1.3.3 Switching from Static Bypass Mode to Online
Use the front panel to switch the device to online mode. Check the mimic panel to make sure that the
device has switched to online mode.
Main menu > Control > Switch to UPS
NOTE: The UPS will not switch to normal mode if the inverter voltage is out of limits, or there is and
over load or over temperature situation.
4.1.3.4 Switching from Online Mode to Maintenance Bypass Mode
WARNING: Make sure that the inverter output is synchronous with the maintenance bypass line
before switching to maintenance bypass mode. Otherwise there is a possibility of cutting off the load
power for a short while.
Use the front panel to switch the device to static bypass mode. Check the mimic panel to make sure
that the device has switched to bypass mode.
Main Menu > Control > Output BYPASS
1. Turn CB2 ON.
Stop the UPS by using front panel.
Main menu > Control > Stop
2. Turn CB1 and CB3 OFF.
WARNING:
Wait at least 5 minutes before opening up the device after it is completely turned
off for safety
4.1.4 Performing a Complete Shutdown
Turn off the loads connected to the device.
Use the front panel to turn the device OFF
Main Menu> Control> Password> Stop
WARNING:
off for safety
WARNING:
off for safety
WARNING: Make sure that there are no critical loads on the UPS output before performing a
complete shutdown.
4.1.5 EPO (Emergency Power Off)
UPS turns off rectifier, amplifier and inverter respectively when the EPO button is pressed. UPS is
completely separated from the system, if the shutdown option of output circuit breaker is setted.
10-60kVA 80-250kVA
4.1.6 RS232 Serial Communication Installation and investigation
Challenger 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.
complete shutdown.
10-60kVA 80-250kVA
complete shutdown.
10-60kVA 80-250kVA
Challenger Parallel Operation Guide
Please read the following instructions before you use the devices in parallel mode.
A. Check if the devices can be used in parallel mode.
1. Be sure that all devices are from the same series and rated the same power.
2. Go to the version screen using menu keys, and check if all devices have the same firmware.
Main screen > Setup > Version
B. Check the positioning of the devices.
3. Keep the devices as close to each other as possible. The distance between must not exceed
10 meters.
C. Make the electrical connections
4. Make sure that the devices are turned OFF and have been kept off for at least 5 minutes
before you make any electrical connections.
5. Connect the devices in parallel through the electrical panel. Refer to parallel connection
example for detailed connection drawing.
6. Connect each device to ground using seperate cables.
7. Make sure that the phases are in the right order.
(U1-U2--UN), (V1-V2--VN), (W1-W2--WN).
Check the connections using a multimeter in diode mode;
First turn the maintenance switch OFF and see if the inputs of the devices are
connected to each other.
Then turn the maintenance switch ON and check the connection between the input
of the first device and the output of the second device.
8. Use seperate sets of batteries for each device. Do NOT use the same set of batteries on
more than one device at the same time.
9. Connect the communication cable and secure the connections.
10. Check the termination resistors on the connection cable.
Remove the UPS top panel and reach the main board.
Find the J9 socket on the main board, and check the resistance between pin 2 and
pin 3 using a multimeter. (60)
Check the resistance between pin 4 and pin 5. (60)
Close the replace the UPS top panel. Turn on the device.
D. Set the software for parallel operation.
In parallel operation, Challenger series UPS use the Master/Slave configuration. Master
authorization is temporary for a UPS, one of the slaves may become the master depending on
the conditions.
11. Go to the Service menu and enter the Parallel Operation screen.
Main screen > Setup > Service Menu > Parallel Operation
12. Change MODE to Parallel using the menu keys.
13. Set a different ID number for each device and then authorize one of the devices as
MASTER.
14. Check the number of running devices (ACT) on the right lower side of the screen. If the
number is not correct, make sure that each device has its own ID number.
MASTER.
MASTER.
E. Operation
Master/Slave configuration
Open the status menu to see if any device is a master or a slave.
Open the status menu to see if any device is a master or a slave. The letter on the lower left
corner of the LCD screen is M or S in parallel mode.
Parallel start-up
Read the following to start the parallel system.
Turn on the UPS breakers on the distribution board, then turn on the main input
breaker.
E. Operation
Parallel start-up
breaker.
E. Operation
Parallel start-up
breaker.
Start one of the UPS using the front panel, and all the other UPS will start automatically.
Turn on the output breakers on the distribution board, then turn on the main output breaker.
The loads will be equally distributed on all devices.
Switching to static bypass
If any one of the devices is manually switched to static bypass mode, the others will
automatically switch to static bypass mode.
To switch all the devices to online mode, select switch to UPS on any device.
Stopping/Removing a single UPS
In a parallel Challenger system, any one of the devices can be removed off the system without
affecting the others. To remove a UPS off the parallel system for maintenance, follow the steps
below:
Stop the desired UPS using the control menu.
If the Master device is stopped, the UPS with the smallest ID no will become the new
Master device.
Turn off the UPS input breaker (CB1)
Turn off the UPS output breaker (CB3) and the maintenance breaker (CB2)
Turn off the UPS breakers on the distribution board.
below:
Master device.
below:
Master device.
Stopping all UPS
To stop all the UPS in a parallel system, go to Setup >Service Menu >Control >Stop All UPS.
Note: Pressing the EPO button on any UPS will stop all UPS
Troubleshooting for Parallel Mode
Possible alarms regarding parallel mode, and their solutions are:
Alarm Explanation Necessary Action
Parl. ID Collision
Two or more parallel
devices have been assigned
to the same ID number.
Check the parallel ID numbers and make sure
that each device have their own unique ID.
Main menu > setup > service menu > parallel
operation.
No Parallel Comm.
No parallel communication
between devices. Master
device is unavailable or
cannot be reached.
Make sure that one of the devices is
authorized as MASTER. Check the parallel
connection cable.
Stopping all UPS
Parl. ID Collision
operation.
No Parallel Comm.
cannot be reached.
connection cable.
Stopping all UPS
Parl. ID Collision
operation.
No Parallel Comm.
cannot be reached.
connection cable.
Parl.Missing Dev.
One or more devices cannot
be reached on parallel
mode.
Check the parallel connection cable. Check if
ACT = NODE on parallel setup screen. If not,
correct NODE.
Par. Communication
FE
Parallel communication
frame error.
Check the parallel connection cable and
termination resistors.
Please contact MAKELSAN technical service for further questions.
CHALLENGER CARD MATRIX
BOARD
CODE
BOARD EXPLANATIONS
1
0
K
V
A

C
H
A
L
L
E
N
G
E
R
1
5
K
V
A

C
H
A
L
L
E
N
G
E
R
2
0
K
V
A

C
H
A
L
L
E
N
G
E
R
3
0
K
V
A

C
H
A
L
L
E
N
G
E
R
4
0
K
V
A

C
H
A
L
L
E
N
G
E
R
6
0
K
V
A

C
H
A
L
L
E
N
G
E
R
8
0
K
V
A

C
H
A
L
L
E
N
G
E
R
1
0
0
K
V
A

C
H
A
L
L
E
N
G
E
R
1
2
0
K
V
A

C
H
A
L
L
E
N
G
E
R
1
6
0
K
V
A

C
H
A
L
L
E
N
G
E
R
2
0
0
K
V
A

C
H
A
L
L
E
N
G
E
R
2
5
0
K
V
A

C
H
A
L
L
E
N
G
E
R
A09-1.V1R1 MAIN CONTROL BOARD (10-80KVA) 1 1 1 1 1 1 1
A09-1.V2 MAIN CONTROL BOARD (100-120KVA) 1 1
A09-1.V3 MAIN CONTROL BOARD (160-200KVA) 1 1
A09-1.V7 MAIN CONTROL BOARD (250KVA) 1
A09-2.V3 MAIN BOARD POWER SUPPLY 1 1 1 1 1 1 1 1 1 1 1 1
A10-1.V2 RELAY BOARD 1 1 1 1 1 1
A10-1.V3 RELAY BOARD 1 1 1 1 1 1
A10-3.V1 CONTACTOR POWER SUPPLY 2 2 2 2 2 2
A10-4.V1 LP EMI FILTER 2 2 2 2 2 2
A10-5.V1R1 HP EMI FILTER 2 2 2 2 2 2
A11-3.V1 SMPS PARALELLING MODULE 1 1 1 1 1 1
C09-1.V1R1 IGBT DRIVER CONTROL BOARDV1 (SINGLE IGBT) 7 7 7 7 7 7 7 7 7
C09-1.V4R1 IGBT DRIVER CONTROL BOARD V4 (DOUBLE IGBT) 7 7
C09-1.V5 IGBT DRIVER CONTROL BOARD V5 (DOUBLE IGBT) 7
C09-2.V1R1 IGBT DRIVER POWER BOARD 7 7 7 7 7 7 7 7 7 7 7 7
C09-5.V1R1 IGBT DRIVER CONNECTION BOARD (Standart) 1 1 1 1 1 1 1 1 1
C10-2.V1R1 IGBT DRIVER CONNECTION BOARD (Mini) 1 1 1
C09-3.V1 BY-PASS CARD (LOW POWER) 1 1 1 1 1 1
C09-4.V2R2 BATTERY IMPUT BOARD 1 1 1 1 1 1
C09-12.V2 BY-PASS BOARD (HIGH POWER) 1 1 1 1 1 1
D09-1.V1R1 4x20 LCD FRONT PANEL 1 1 1 1 1 1
A09-4.V2R1 FUSE BOARD 1 1 1 1 1 1 2 2 2 2 2 2
A09-3.V1R1 HV DC TO DC SMPS 1 1 1 1 1 1 2 2 2 2 2 2
D09-3.V1R1 PFC INPUT BOARD 1 1 1 1 1 1
A11-5.V1 150V CONTACTOR POWER SUPPLY 1
A12-1.V1 BATTERY EMI FILTER 1 1 1 1 1 1 1 1 1 1 1 1
D10-1.V1 DC BUS CHARGER 1 1 1 1 1 1
A10-9.V1 320x240 GLCD FRONT PANEL 1 1 1 1 1 1
A12-3.V1 GRAPHIC LCD PANEL INDICATOR 1 1 1 1 1 1
A12-7.V1 CHARACTER LCD PANEL INDICATOR 1 1 1 1 1 1
C10-6.V1 DIGITAL TEMPERATURE MEASURING PROBE CARD 1 1 1 1 1 1 1 1 1
C10-7.V1 DIGITAL TEMPERATURE CONTROL CARD 1 1 1 1 1 1 1 1 1
A09-4.V4 FUSE BOARD (110-220 SELECTABLE) 1 1 1 1 1 1 2 2 2 2 2 2
A09-3.V3 HV DC TO DC SMPS (110-220 SELECTABLE) 1 1 1 1 1 1 2 2 2 2 2 2
D09-3.V2R1 PFC INPUT BOARD (120VAC) 1 1 1 1
CHALLENGER SERIES 10-250 KVA TECHNICAL SPECIFICATIONS
5 ELECTRONIC BOARDS
Main Control Board
This board controls all the operations of the UPS. Not only the basic functions like start / stop, it
also monitors the changes that occur in UPS operational modes, evaluation of the sampled
parameters of the UPS and according to that produces various control signals changing the UPS
parameters.
TEST
1. Purpose
To make sure A09-1.V1 main board properly process.
2. Execution
Before the test, precaution should be performed for electrostatic protection. Without defined
direction IPC-A-610D article 3(Protecting the AssemblyEOS/ESD and Other Handling
Considerations) taken as a reference, ESD safety requirements should be provided.
2.1. Required Test Equipments
Short circuit protected, constant current and voltage adjusted, series, parallel or
individually runs and constant 5V double channel Linear DC Power Supply
Measuring device for stated conditions
200x1,3 Mp digital microscope
Before the test
Insert J3 jumper
Below 30 and 40kVA powers
There is no application can be performed.
Above 30 and 40kVA powers
Number 1 and 2 of J73, J79,J80, J81, J82 and J83 will be short circuited.
60 KVA:
Number 1 and 2 of J71, J73, J76, J77, J78, J79, J80, J81 J82 and J83 will be short circuited.
Electrical Tests
1. Power supply set to series as 15V.
2. Power supply is passed +5V by 5V-5A series parameter, J59 socket is connected to zero, J10 is
connected to +5V.
3. Number 7 of J34 is -15V,number 4 is zero, number 1 is +15V , 15V DC is connected.
4. 310mA should be seen on the series ampermeter when you switched on UPS.(If the board is
programmed, the value can be above.)
5. LED should be ON on the board.
6. Measuring device zero probe is connected to GND, positive probe is connected to number 3 of
U62. Average value should be -15V.
U61. Average value should be +15V.
U62. The value should be -12V %3.
U61. The value should be +12V %3.
C254. The value should be 1,9V %3.
C247. The value should be +3,3V %3.
U60. The value should be between 3,04 and 3,01.
15. U36 reference should be checked by observing voltage range between 2,04 and 2,06 on the C123.
16. U36 analog inputs should be checked.
B7 = 1,535V %2 A0 = 1,535V %2
B5 = 1,535V %2 A2 = 1,535V %2
B3 = 1,535V %2 A4 = 1,535V %2
B1 = 1,535V %2 A6 = 1,535V %2
B6 = 1,535V %2 A1 = 1,535V %2
B4 = 1,535V %2 A3 = 1,535V %2
B2 = 1,535V %2 A5 = 1,535V %2
B0 = 0V A7 = 1,535V %2
17. U37 reference should be checked by observing voltage range between 2,04 and 2,06 on the C124.
18. U37 analog input should be checked.
B7 = 1,535V %2 A0 = 1,535V %2
B5 = 1,535V %2 A2 = 1,535V %2
B3 = 1,535V %2 A4 = 1,535V %2
B1 = 1,535V %2 A6 = 1,535V %2
B6 = 1,535V %2 A1 = 1,535V %2
B4 = 1,535V %2 A3 = 1,535V %2
B2 = 1,535V %2 A5 = 1,535V %2
B0 = 1,535V %2 A7 = 1,535V %2
19. Measuring device zero probe touches to D96 cathode.
Number 2 of C41 should be observed as 13V
Number 2 of C42 should be observed as 13V.
Number 2 of C45 should be observed as 5V+%2.
Number 1 of R27 should be observed as 5V+%2.
After completing the pretest of the board, current firmware is installed. The board is labeled as tested after
running all the functions and stored in available conditions.
PFC Input Board D09-3.V1R1
PFC input board is capable of :
Having input filtering( 10mf-400v capacitors)
Reading input voltages( Phase-Neutral)
Reading input phase currents by LEM
Loading the DC busbar with watt resistance and relays.
Activating /deactivating input and neutral contactors which means by signals for relays
activation is performed by main board from incoming voltage and current information
TEST
3. Purpose
To make sure D09-3.V1R1 PFC input board properly runs by performing quality control for
D09-3.V1R1 PFC input board.
4. Execution
4.1. Required Test Equipments
Topward 6303D or similar DC wer Supply
Fluke 45 or similar
Dinolite or similar microscope
Required sockets for testing
Front panel and main board
4.2. Before the test
4.3. Physical Control of Board
2.3.1 Circuit components and pcb should be checked by physically and microscobe. IPC-A-
610D CLASS II citeria and assembly directions should be validated.
4.4. Electrical Tests
2.4.1 J55,J39,J11,J13,J15,J44,J46,J48,J4,J5,J6 sockets on the board are tested for short
circuit against their own pins and GND. Only number 4 pin of J11, J13,J15 sockets with GND
should be shorted.
2.4.2 In order to test relays, J39 and J4 sockets should be inserted.
2.4.3 DC power supply first channel is set for 12V and second channel is set for 24V.
2.4.4 To test relays K1 and K3, measuring device is set to OHM step
One point is connected to MH15 and other is connected to MH16. Any value should
not be seen after the measurement.
One point is connected to MH18 and other is connected to MH19. Any value should
not be seen after the measurement.
By setting up 12V DC power supply, number 5 pin of J39socket is connected to
positive(+) and number 4 is connected to negative(-). After the connection, D3 ve D4
LEDs are ON.
In order to see 188R value, the measuring device is set to OHM again and same
procedures are done with MH15 and MH16, MH18 and MH19 and (line has 4 resistances
-47R10W total value- and tolerance variable within 5)
2.4.5 Controlling K2 relay is provided by DC power supply, first channel is 12Vdc and
second is set to 24Vdc.
For the 12Vdc, number 5 pin of J 39socket is connected to positive(+) and number 1 is
connected to negative(-). After the connection, D1 LED is ON.
Without disconnecting 12Vdc, the power supply is set to 24Vdc, number 3 pin of
J4socket is connected to positive(+) and number 1 is connected to negative(-). After
completing connections, number 1 of J5 socket is connected to black probe of measuring
device and number 3 is connected to red probe. As a result, 24Vdc voltage can be seen
exactly as applied to J4 socket.
When separating 12Vdc which is applied from J39 socket, the relay is tripped to J5
applied voltage from J4.
2.4.6 Controlling K4 relay is provided by DC power supply, first channel is 12Vdc and
second is set to 24Vdc.
For the 12Vdc, number 5 pin of J39 socket is connected to positive (+) and number 2 is
connected to negative (-). After the connection, D12 LED is ON.
Without disconnecting 12Vdc, the power supply is set to 24Vdc, number 3 pin of
J4socket is connected to positive (+) and number 1 is connected to negative (-). After
completing connections, number 1 of J6 socket is connected to black probe of measuring
device and number 3 is connected to red probe. As a result, 24Vdc voltage can be seen
exactly as applied to J4 socket.
When separating 12Vdc which is applied from J39 socket, relay is tripped to J6 by
applied voltage fromJ4.
2.4.7 After the procedures above mentioned are performed, current sensors are inserted
according to power of the device.
2.4.8 10-20-30-40 KVA systems should have LA100P, 60kVA and above should have
LA200P.
2.4.9 Once the current sensors are inserted, current set to 3A for DC power supply first
channel.
2.4.10 Main board and front panel connection, J58 socket is completed for the test.
2.4.11 To control T1 current sensor, the cable with peeled ends is passed 1 cycle inside
inside the current sensor. Current sensor and main board connection, J11 socket
connection is performed. 3A should be passed from power supply. Front panel which is
connected to main board, menu should be set up by ENTER>STATUS>MAINS and then
R phase can be seen as 3A. As a result, current sensor can be confirmed if it is durable.
2.4.12 To control T2 current sensor, the cable with peeled ends is passed 1 cycle inside the
current sensor. Current sensor and main board connection, J13 socket connection is
performed. 3A should be passed from power supply. Front panel which is connected to
main board, menu should be set up by ENTER>STATUS>MAINS and then S phase can be
seen as 3A. As a result, current sensor can be confirmed if it is durable.
2.4.13 To control T3 current sensor, the cable with peeled ends is passed 1 cycle inside the
current sensor. Current sensor and main board connection, J15 socket connection is
performed. 3A should be passed from power supply. Front panel which is connected to
main board, menu should be set up by ENTER>STATUS>MAINS and then T phase can be
seen as 3A. As a result, current sensor can be confirmed if it is durable.
2.4.14 After all the steps is performed, and then testing can be done. All the boards should
be stored with ESD precautions.
Battery Input Board
This board where battery connection is performed and battery capacitors are located. In the board:
Battery voltage can be read before and after battery contactors. (Before J41 contactor and
after J57 contactor).
Battery charging and discharging is read by LEM. (J21)
The bus is loaded by battery relays and watt resistance. (Battery has + and resistance)
The Battery contactor is pulled and released.
The signal of pulling the contactor is done by main board. (J41)
TEST
Purpose
C09-4.V2 board should be tested by functionality.
Execution
Required Test Equipments
Testing Board Physically
Circuit components and pcb should be tested by physically and microscope and IPC-A-610D
CLASS II criteria and assembly directions should be validated.
Bar-coding order should be controlled and validated.
Electrical Tests
1. Power supply is set to INDEP (Two channels is set individually.) First channel is set to
12Vdc and second channel is set to 24Vdc.
! Directions of C4 and C6 components should be paid attention.
2. Number 1 of J7 sockets should be applied to GND-2 and number 3 should be applied to
+24Vdc.
3. Number 5 of J41 should be applied to 12Vdc.
4. Number 1 of J41 socket should be connected to GND-1; D2 is ON which means K2 relay
should be triggered. Number 3 of J8 should be measured by +24Vdc.( against to number
1 of J8)
5. Number 2 of J41socket is connected to GND-1, number 3 of J1 socket is measured by
+12Vdc.(against number 1 of J1)
6. Number 3 of J41 socket is connected to GND-1; number3 of J1 socket is measured by
+12Vdc.(against number 1 of J1)
7. Current sensor should be tested in both direction current pass. Before starting the test,
number 1 of J21 should be applied by (+15), number 3 should be applied by (-15),
number 4 should be applied to GND.
During the current sensor test, current should be passed and current of number 2 of J21
socket should be read by 1 over 2000. The reading should be performed by both
directions.
After completing the test, the board should be labeled and stored in available conditions.
Fuse Board
This is the initial supply for electronic boards. In the board:
There are R , S, T and neutral (J2)
Battery + - and bus voltage as input (J1). All are connected in one point by diodes as + and
(J3)
Only grid voltage enters, if grid voltage R: 220V, S:220V, T: 220V , output voltage is 535V
DC(J3)
If the battery is connected, there is output voltage from J3 according to number of batteries.
If there is bus voltage ,the output is 750V DC
The high voltage goes to HF3-R302B board.
TEST
Purpose
A09-4.V2 AC_CONFIG board should be tested and the purpose should be evalauted.
Execution
Before the Preparation
The fuses where is located at F1,F2,F3,F4,F6 fuses holder should be placed as defined limits
in GENERAL MATERIAL LIST.
Physical Control of the Board
Circuit components and pcb should be checked by physically and microscope. IPC-A-610D CLASS II
criteria and assembly directions should be validated.
Electrical Tests
The board should be tested and confirmed for short and open circuits by measuring device.
After completing the test, the board should be labeled and stored in available conditions.
Signal Flow Diagram
HV DC TO DC SMPS
High voltage coming from HF3-R302E card goes to J3 socket and leaves as 48V DC from J1 and J2.
TEST
Purpose
A09-3.V1 HV_DCDC board should be tested by functionality.
Execution
3 channel isolated 1Ghz or any capable oscilloscope
Electrical Tests
DC 0-900V supply is connected to J3.
R60 resistance is connected to DC voltmeter.
In second channel of oscilloscope, negative side of probe is connected to number 3 of Q3
and positive side is connected to number 1 by isolated probe.
In third channel of oscilloscope with isolated probe, negative side of probe is connected to
number 3 of Q1, positive side is connected to number 1. Volt/Div=10V Offset= -20 are all
set. Trigger is set to channel 2 and the slope step should be pos/time
Number 1 of J4 socket is applied to zero, number 2 is applied to 15Vdc.
Under these conditions, the oscilloscope can be seen as follows.
Two signals should be seen as 85-%5 KHz frequency. Voltage should not be spiked in both
signal fluctuating edges. Signal peaks should not be passed 18V.
In third channel of oscilloscope with isolated probe, negative side of probe is connected to
number 3 of Q1; positive side is connected to number 2. Volt/Div=200V Offset= -600 are all
set. Trigger is set to channel 2 and the slope step should be pos/time
Number 1 of J1 socket is connected to negative side of measuring device, number 2 is
connected to positive side of measuring device.
Positive side of the other measuring device is connected to jumper on F1, negative side is
connected to jumper on F2.
DC supply is increased by 20 in V steps. Current is not withdrawn from DC supply, output
voltage is increasing gradually.
Sgnals can be observed in the oscilloscope. The signals in the channel 2 are stable, signals
in the channel 1 can be seen as increased gradually in the following picture.
If incoming voltage is 250V, output voltage, 48V is regulated and signal changes can be
observed during the regulation in the following picture.
Input voltage is continued to be increased in this point. When it reaches to 550V,output
voltage becomes 48V%2. Signals in the oscilloscope can be seen in the following picture.
J1 socket can be loaded with 100 23W (0,5A) resistance. Signals in the oscilloscope can be
seen in the following picture.
Please pay attention that voltage spikes should not be happened on the signals. The peak
signal in the channel 1 should not pass 20V, the peak signal in the channel 2 should not pass
600V.
15V supply should be from J4 socket.
0-900V DC Supply is increased by 50V. Once it reaches 250V DC, output voltage should be
27V DC%2, input should not be passed 200A from DC supply and D15 LED becomes ON.
The measuring device on R60 is seen as 12V % 2 or above.
Incoming voltage set to 550V. It is loaded by resistance 24 100W (2A) from J1 socket. The
signals can be seen in the following picture. Voltage spikes should be occurred and output
voltage should be observed as 48V %2 and above.
Input voltage is set to 700V. It is loaded by resistance 24 100W (2A) from J1 socket.
Output voltage should be observed as 48V %2 and above.
Wait for a moment as DC supply is turned off. After unloading the capacitors in the circuits,
DC supply can be turned on again, the circuit can be observed under the load.
Turn off the DC supply and remove the components in the board.
After completing the test by running all the functions, the board should be labeled and stored in
available conditions.
Signal Flow Diagram
Main Board Power Supply
This board provides 48V DC which supplies the main board and current transformers.
TEST
Purpose
A09-2.V1 MAINBOARD POWER SUPPLY board should be tested by functionality.
Execution
Electrical Tests
Power supply is set to series mode. Each channel is set to +24V and as a total of 48V.
48V is applied from J2 socket.
Available fuse is chosen for F1 fuse holder which is defined in GENERAL MATERIAL LIST
48V is applied by turning on the power supply. By observing, the current is not withdrawn
from power supply.
Number 1 of J3 socket is the ground of measuring device, number 2 is the active point of
measuring device. DC24V% 2 is measured.
3A is withdrawn from number 1 and 2 of J3 socket by 8 71Wload. Number 1 and 2 points
are measured as DC24V%3.
3A is withdrawn from number 1 and 2 of J1 socket by 8 71Wload. Number 1 and 2 points
are measured as DC24V%3.
Number 4 of J3 socket is the ground of measuring device, number 1 is the active point of the
measuring device. Number 2 of F8 fuse is applied to +24Vdc from the 0-24V point of power
supply. Approximately 20mA is withdrawn and D19 LED is ON. Number 1 and 4 from J34
socket has 15Vdc%2 .
If number 1 and 4 of J34 socket are loaded as 15 15W, DC 15V %3 can be measured.
Number 4 of J3 socket is the ground of measuring device, number 7 is the active point of the
measuring device. Number 2 of F8 fuse is applied to +24Vdc from the 0-24V point of power
supply. Approximately 20mA is withdrawn and D19 LED is ON. Number 4 and 7 from J34
socket has -15Vdc %2.
If number 4 and 7 of J34 socket are loaded as 15 15W, DC -15V %3 can be measured.
Available fuse is chosen for F8 fuse holder which is defined in GENERAL MATERIAL LIST
If number 1 - 4 and number 3-4 of J59 socket are loaded as 1,67 15W, DC 15V %2 can be
measured.
Number 2 of F6 fuse is applied to DC +24V from 0-24V point of power supply. After the
procedure, D21 LED is ON. Number 3-4 of J59 is measured as ground of measuring device,
number 10-11 is measured as active point of the device.
If number 1 - 4 and number 3-4 of J59 socket are loaded as 1,67 15W, DC 5V %2 can be
measured.
The fuse is inserted in F6 fuse holder as defined in GENERAL MATERIAL LIST
number 8 is measured as active point of the device. DC 7V%2 is measured.
If number 3 - 4 and number 8 of J59 socket are loaded as 3,5 14W, DC 7V %3 can be
measured.
The fuse is inserted in F5 fuse holder as defined in GENERAL MATERIAL LIST
number 6-7 is measured as active point of the device. DC 12V%2 is measured.
If number 3 - 4 and number 6-7 of J59 socket are loaded as 6 24W, DC 12V %3 can be
measured.
The fuse is inserted in F3,F4,F7 fuse holder as defined in GENERAL MATERIAL LIST.
Signal Flow Diagram
Signal Flow Diagram
Signal Flow Diagram
Front Panel Board
This board takes all the information from the main controller board.Front panel has buttons on the
right side which can provide the all required information, start up and stop functions for the
system. In adiition, there is 3V battery behind the panel for saving the date and time.
TEST
Purpose
D09-1.V1 FRONT PANEL board should be tested by functionality.
Execution
Topward 6303D or similar DC power supply
Fluke 45 or similar measuring device
Dinolite or similar digital microscope
MPLAB ICD 2
Computer
Membrane,CR2032 3 volt battery.
Preparation before the test
1 Before LCD is installed to PCB, 1x16 header is inserted in the following picture.
2 LCD screws are installed as the following picture.
3 Once LCD is installed and fixed to PCB with level of straightness, screws can be installed.
4 As you can see fromthe pictures, LCD and PCB are prepared for the test.
Electrical Tests
Front Tests
1 Measuring device is set to short circuit mode. J58, J5, J6, J1 sockets pins should be
checked and see there is short circuit between pins. J4 socket also checked for short
circuit between pin 2 and 4.
2 Between GND and other pins should be short circuited.(Pin 3 of J58 socket, pin 1 of J1,
pin 2 and 4 of J4 and GND should be short circuited) and other pins should not be short
circuited with GND.
3 Power supply is set to +5Vdc. Pin 3 of J58 to GND and pin 4 to +5Vdc is connected in
order to observe board feeding.
4 The current withdraws not greater than 0.05A from power supply.( Before installing
the software)
5 Measuring device is to DC voltage. The zero is attached to the ground and other is
attached to positive (+) side of C46 and is obtained 3,3Vdc.
6 The next step is to check feedings. The measuring device zero point is attached GND
and the other is attached where the point shall be observed.
U1 number 3 has to be 5Vdc.
U4 number 7 has to be 5Vdc.
U3 number 8 has to be 3,3Vdc.
C19 positive point has to be 5Vdc
Measuring device negative side(-) and pin2 of J5 is connected, positive side and
pin 3 are connected and 5Vdc observed.
Measuring device negative side(-) and pin2 of J5 is connected, positive side and
pin 1 are connected and 3,3Vdc observed.
Measuring device zero side and GND, the other side and pin10 of J6 and 3,3Vdc
observed.
Measuring device negative side and pin1 of J1(C21 side), the other side and
pin2 is connected and 5Vdc observed.
Measuring device negative side and pin2 of J4, the other side and pin1 is
connected and 3,3Vdc observed.
Measuring device zero side and GND, the other side and pin10 of Q3 is
connected and 3,3Vdc observed.
7. DSB feeding should be checked. Measuring device is set to DC and following
measurements are performed.
Points between C26 should be 3,3Vdc.
8. Negative side (-) of measuring device and negative side of the battery is touched. DSP
sides of C7, C8, C10 is touched to positive side of measuring device and observed as
2,5Vdc.
9. After completing feeding checks in D09-1 board, the software can be installed to the
board.
MPLAB ICD 2 is connected to the computer.
Power supply is set to +5Vdc and pin 3 of J58 to GND and pin 4 to +5Vdc are
connected in order to feed the board.
Red(number 1) side of flat cable in the MPLAB ICD 2 software device is
connected to pin1 of J14 on the D09-1 board.
10. Applications has to be performed in MPLAP software in the followings
PIC has to be programmed is chosen fromConfigure > Select Device
Programer > Select Program > 2.MPLAB ICD 2 is chosen.
File > mport > programfile location > UIFT.hex is chosen.
Programmer> program is chosen and loading operation is performed into the
board.
Turn off the board power and remove MPLAB ICD 2.
11. After installing the program, the following statements should be controlled.
Characters should be observed in the LCD screen.
U3 integration D4 LED should be flashing.
Number 3 of Q3 should be observed as 13V with %10 tolerance.
Oscilloscope shall be set for performing CH1 part. Time/DIV 50ns and Volt/DIV
1V are all set. Offset should be zero and trigger1 should be chosen.
In the side of Y1 crystal at the Y2 crystal, 10Mhz frequency should be observed.
Peak value should not be passed 3,3Vdc as follows in the picture.
In the oscilloscope, Time/DIV is set to 1s and measures number 1 of Q3 as 312
kHz. Peak value should not be passed 3,3Vdc.
Number 1 of Q1 is measured as 40 kHz.
Once all the phases are performed above, CR2032 3Vdc battery and membrane
are installed.
Menus can be seen in the board from the membrane and see if the buttons
operate.
During the standby mode, the following direction should be performed on the
LCD screen
- Set date and time by clicking
ENTER>SETTINGS>DATE&TIME>PASSWORD(0000)
- De-energize the board and energize again. Check if the date and time
is remained as similar as adjusted.
12. Once the controls are completed, the test can be ended with boards as applicable.
IGBT Driver Board
The Pulse Width Modulation signals obtained from the main controller board unit are transmitted
to this board. These transmitted signals are transformed to suitable pulse width modulation signals
for IGBTs.
In order to protect the IGBTs against over current fast monitoring and control is provided. This is
accomplished by IGBT control logic available inside the hybrids over this board. In this part the
transistors collector-emitter voltage is continuously monitored and controlled.
There are two drivers in the system. One of them is for the rectifier unit and the other one is for the
inverter unit.
The fault pin is not used for CH2 devices.
WARNING: Driver board differs depending on the IGBT used on the device. Check the version
number before installing the board.
TEST
Purpose
Execution
Adjusted DUTY ratio function generator
Thermal camera(preferably able to transfer image to the computers
Preparation before the Test
Every output with pogo pin has 75nF capacitive loads, C09-1.V4 board.
Electrical Tests
1. Power Supply sets to INDEP (Two channels should be adjusted separately.) First channel is
set to 15Vdc and 500mA.
2. Output of function generator should be set by 16 kHz %50 Duty and able to produce square
wave signal. Adjusted signal should start from 0V and peak value should be 3,3V. The
adjusted signal is called as PWM-1, The complement of this signal is called as PWM-2.
3. In the beginning, function generator and power supply should be OFF. Power supply
always turned on first and then function generator is turned on. For switching off, vice
versa should be applied, function generator is first and then power supply.
Note: Function generator should not be switched on/off from power switch. Switch
should be connected to output J2 socket at the positive side.
4. C09-1.V4 board J2 socket connection should be performed as in the following table.
1 N/C
2 GND-Pwm
3 PWM-1
4 N/C
5 N/C
6 N/C
7 N/C
8 PWM-2
9 GND-Pwm
10 N/C
11 +15Vdc
12 GND-Power
5. C09-2.V1 board should be assembled into C09-1.V4 and not be affected from vibration by
strengthening the connection.
6. PWM signals and feeding voltage in the Table 1 should be applied to the C09-1.V4 board.
(First feeding voltage and PWM signals should be applied.)
7. D9,D14,D15 LED on the C09-1.V4 board and D2 LED on the C09-2.V1are all ON.
8. The signal should be as follows at the pin 4 of the U3 integration
9. The signal should be seen as follows at the pin4 of the U4 and U6 integration.(against GND-
Power )
10. The signals at the pin 5 and pin 6 in the transformer T1.
11. Pin 3 of the U1 integration should be +15.5Vdc, pin 2 should be observed as 19.5Vdc.
(against GND-High)
12. Pin 3 of the U5 integration should be +11.5Vdc, pin 2 should be observed as 8Vdc. (against
GND-High)
GND-Low)
GND-Low)
15. Pin 2 of the J2 header should be seen as +8.5Vdc.(against GND-Pwm)
16. The board should be tested for low voltage.
a) The feeding voltage of the board should be initiated from 0V and the board should
be run in the 14.2V level.
b) The feeding voltage of the board should be decreased from 15V and board should be
stop running at the level of 12V.
GND AREAS
Signal Flow Diagram
By-pass Board
By-pass board is controlled by the main board. This is the board that drives by-pass thyristor and
by-pass inverter thyristor. By-pass voltage and current and also inverter voltage and current
readings can be done by the by-pass board.
By pass board for 10 - 60kVA
By-pass board for 80-250kVA
As shown above, the reason for smaller size of by-pass board for larger UPS is that thyristors are
located outside of the board.
Purpose
Execution
Adjusted DUTY ratio function generator
Thermal camera(preferably able to transfer image to the computers
Preparation before the Test
Required thyristor and connection cables should be there for gate outputs
Electrical Tests
1) Power Supply sets to INDEP (Two channels should be adjusted separately.) First channel is
set to 12Vdc
2) Output of function generator should be set by 16 kHz %50 Duty and able to produce square
wave signal. Adjusted signal should start from 0V and peak value should be 3,3V. (See
Picture1)
Picture 1
3) In the beginning, function generator and power supply should be OFF. Power supply always
turned on first and then function generator is turned on. For switching off, vice versa should
be applied, function generator is first and then power supply.
Note: Function generator should not be switched on/off frompower switch. Switch should
be connected to output J2 socket at the positive side.
4) The feeding voltage is applies as follows: pin 4-5 of J38 socket is connected to +12V, pin 6-7 is
connected to GND.
5) Number 3 of U2 regulator integration should be measured as +12V.(against GND)
6) Number 2 of U2 regulator integration should be measured as +5V.(against GND)
7) Thyristor J3 and J4 connection points should be connected the board before the test.
8) Adjusted PWM as in the second article is applied to number 1 of J38 socket by function
generator.
9) D2 LED is ON after these steps.
10) The signal should be seen in the number 4 of U1 integration as shown below (against
GND)(See Picture 2)
Picture 2
11) The signal should be seen as below in the number 2 of Q2 transistor. (See Picture 3)
Picture 3
12) The signals should be measured in the order of J3 and J4. Pin 1 of sockets are negative(-) and
pin 2 of sockets are positive. Probes of the oscilloscope should be polarized according to this
statement. (See Picture 4)
Picture 4
generator.
16) The signal should be seen in the number 8 of U1 integration as above. (against GND) (See
Picture 2)
17) The signal should be seen in the number 2 of Q4 transistor as above. (See Picture 3)
20) Adjusted PWMas in the second article is applied to number 3 of J38 socket by function
generator.
22) The signal should be seen in the number 8 of the U1 integration. (against GND) (See Picture 2)
23) The signal should be seen in the number 2 of Q7 transistor as above.(against GND) (See
Picture 3)
24) The signals should be measured in the order of J11 and J23. Pin 1 of sockets are negative(-)
and pin 2 of sockets are positive. Probes of the oscilloscope should be polarized according to
this statement. (See Picture 4)
25)Thyristor J1 and J25 connection points should be connected the board before the test.
generator.
Picture 3)
32)Adjusted PWM as in the second article is applied to number 9 of J38 socket by function
generator.
Picture 3)
38)Adjusted PWM as in the second article is applied to number 10 of J38 socket by function
generator.
40) The signal should be seen in the number 10 of the U3 integration. (against GND) (See Picture
2)
Picture 3)
43) Once all the procedures are completed, the board should be inspected by thermal camera and
check if there is any anormal
44) Two way current flow should be performed by current sensors. Before starting the test, the
pin 1 of input socket should be connected by +15V and pin 3 is connected to -15V and pin 4 is
connected to GND.
Signal Flow Diagram: zole Trafo means Isolated Transformer
IGBT Driver Connection Board
IGBT driver connection board provides the connection from PWM and driver supplies in mainboard to
drivers.
TEST
Purpose
A09-2.V1 MAINBOARD POWER SUPPLY board should be tested by functionality.
Execution
Preperation Before the Test
Test circuit should be prepared according to Appendix-1.
Electrical Tests
1) Power Supply sets to INDEP (Two channels should be adjusted separately.) First channel is
set to 12Vdc.
2) Test circuit should be connected to the tested board.
In the test circuit, the socket referred as J36 should be connected to the J36 socket in the
board by the cables.
In the test circuit, the socket referred as J37 should be connected to the J37 socket in the
board by the cables.
Appropriate sockets for Jx in the Appendix-1 should be attached to J1,J2,J3,J4,J5,J6,J7,J8
socket.
3) +12V should be applied from CN1 connector in the test circuit.(pin 1 is (-) and pin 2 is
(+)polarite)
4) By pressing the buttons in the order, LEDS should be ON in the test circuit. Which button
lights up the which LED is indicated in the following list.
For example: By pressing SW1 button, D2 LED should be ON in the J4 socket.
Button LED Button LED
SW1 J4-D2 SW17 J5-D2
SW9 J1,J2,J3,J4-D1 SW25 J5,J6,J7,J8-D1
After completing the test by running all the
functions, the board should be labeled and stored in available conditions.
Appendix-1 Test Circuit Diagram and Jx connector structure
R14 2.2K/0.25W/%5 2 1
SW1 SW PUSHBUTTON
SW2 SW PUSHBUTTON
R11 2.2K/0.25W/%5
2 1
SW3 SW PUSHBUTTON
SW4 SW PUSHBUTTON
SW5 SW PUSHBUTTON
R15 0R/0.25W/%5
2 1
SW6 SW PUSHBUTTON
SW7 SW PUSHBUTTON
SW8 SW PUSHBUTTON
R16 0R/0.25W/%5
2 1
SW9 SW PUSHBUTTON
SW10 SW PUSHBUTTON
SW11 SW PUSHBUTTON
SW13 SW PUSHBUTTON
SW12 SW PUSHBUTTON
SW15 SW PUSHBUTTON
SW14 SW PUSHBUTTON
SW16 SW PUSHBUTTON
R12 2.2K/0.25W/%5
2 1
R13 2.2K/0.25W/%5
2 1
Jx
1X12/2.54-180H
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
D1 3 MM ROUND-GREEN 2 1
D2 3 MM ROUND-GREEN
2 1
D3 3 MM ROUND-GREEN
2 1
SW17 SW PUSHBUTTON
SW18 SW PUSHBUTTON
SW19 SW PUSHBUTTON
SW20 SW PUSHBUTTON
SW21 SW PUSHBUTTON
SW22 SW PUSHBUTTON
SW23 SW PUSHBUTTON
SW24 SW PUSHBUTTON
SW25 SW PUSHBUTTON
SW26 SW PUSHBUTTON
SW27 SW PUSHBUTTON
SW29 SW PUSHBUTTON
SW28 SW PUSHBUTTON
SW31 SW PUSHBUTTON
SW30 SW PUSHBUTTON
SW32 SW PUSHBUTTON
CN1
MINI-TUNIK-02
1
1
2
2
D4 3 MM ROUND-GREEN
2 1
J37
3012-26T00SBA
1
1
2
2
3
3
4
4
5
5
6
6
7
7
14
14
13
13
12
12
11
11
10
10
9
9
8
8
16
16
18
18
20
20
22
22
24
24
26
26
15
15
17
17
19
19
21
21
23
23
25
25
J36
3012-26T00SBA
1
1
2
2
3
3
4
4
5
5
6
6
7
7
14
14
13
13
12
12
11
11
10
10
9
9
8
8
16
16
18
18
20
20
22
22
24
24
26
26
15
15
17
17
19
19
21
21
23
23
25
25
D5 3 MM ROUND-GREEN
2 1
GND
GND
+
-
D6 3 MM ROUND-GREEN
2 1
12V
GND
SW10 J1,J2,J3,J4-D1 SW26 J5,J6,J7,J8-D1
SW11 J1-D4 SW27 J5-D3
SW12 J4-D3 SW28 J6-D3
SW13 J2-D3 SW29 J8-D3
SW14 J1-D3 SW30 J7-D4
SW15 J7-D3 SW31 J3-D3
SW16 J1,J2,J3,J4-D6 SW32 J5,J6,J7,J8-D6
Contactors
There are three(3) contactors in the UPS. (Without paralel contactors)
1. Input Contactor(R,S,T) has 3 poles and one is switched off. It is performed to read auxilary
swtich information for three poles phase current or normally switched off 4 poles is used.
2. Neutral Contactor takes incoming neutral connects to contactor output T phase if the grid
blackouts. The purpose of the bus is information. If there is no auxilary switch, then third sleeve
can be used for auxilary switch and be controlled by the relay in PFC input board and main
control board.
3. Battery Contactor provides battery + and - connected or seperated. It has 4 poles contactor.
Controls can be be done by the relay on the battery input board and incoming signal from main
control board .
Firmware Update for Challenger
1. The firmware is uploaded to the Challenger DSPs via C2000prog software. Please install the
software to your PC.
2. Turn off the input and output breakers (CB1 & CB3) and wait for at least 5 minutes until the DC
bus voltage goes down to 0V.
3. Remove the top panel of the UPS, and see the RED DSP switches. Remember to take ESD
precaution before touching the boards.
4. There are four notches on both switches. Turn notch 1 ON on both of them, so that the DSPs are
ready for programming.
5. Check the DSP version no, it can be either 332 or 335. Example: F28332PGFA
6. Turn the input breaker ON, and plug the serial cable into the rectifier service slot on the rear
side of the UPS.
NOTE: The LCD display will be blank during programming, that is perfectly normal.
7. Plug the other side of the serial cable to your PC, and run the C2000prog software.
8. Write down your PC serial port in the software tab. Example:COM7
9. Click on Select file, Open the rectifier folder and choose the file that suits your DSP
verison.(332 or 335)
10. C2000prog will ask for the password on first programming; PASS: MAKELSAN2010
11. Click on program and wait until the programming has finished.
NOTE: On the mainboard, D7 D8 are RECTIFIER programming LEDs and D4-D3 are
INVERTER programming LEDs. Those will blink during programming.
12. C2000prog software will indicate that the programming is successful.
13. Remove the serial cable from the Rectifier service slot, and plug it into the inverter service slot.
14. Repeat steps 9-11 for the inverter.
15. Remove the serial cable off the UPS.
16. Turn CB1 OFF and dont forget to switch back the RED programming switches (notch 1) back to
OFF.
17. Turn the input breaker (CB1) on and check the firmware version.
Go to Setup >Version on device user menu, and check the first line.
iN29_PN67_C12_U22.
NOTE: Please Confirm to MAKELSAN that the Firmware is exactly as written here before
starting the UPS. A failure during the update may cause serious damage to the device.
18. Replace the top cover of the UPS
DRY CONTACT R335
Precautions
Stop the ups and wait for at least 5 minutes before installing the module.
Dangerous voltages may be present on relay outputs during use.
Avoid contact to the PCB surface before taking electrostatic precautions.
Installation
The module is installed on the left side slot on the rear side of the machine.
OFF.
iN29_PN67_C12_U22.
DRY CONTACT R335
Precautions
Installation
OFF.
iN29_PN67_C12_U22.
DRY CONTACT R335
Precautions
Installation
1. Unscrew and remove the left hand side slot cover, reach the female CAN socket. (attached to the slot
cover)
2. Detach the cable from the socket cover using a cutter, and insert the female socket into the male J3
socket on the dry contact module.
3. Carefully insert the module into the slot, and screw to make sure that it is stable.
4. Insert the signal cables into the sockets while pressing on the connector with a screwdriver.
Operation
Relay outputs are isolated from the UPS and ground.
If the contacts are going to be used for load switching, it should be made sure that the relays are
capable of handling the load.
Operating voltage for the isolated inputs is between 3.3 24 Volts and the input impedance is 3
kohms.
Polarity must be checked before applying any voltage to the inputs.
The 12V/150mA power supply on the module is also isolated from the UPS.
Relay info
Rated Switching NO 5A 250VAC
Rated Switching NC 2A 250VAC
Max. Switching Current NO 10A
Max. Switching Current NC 3A
Max. Switching Voltage NO 250VAC - 110VDC
Max. Switching Voltage NC 250VAC - 110VDC
Cable Cross-section min. 0,25mm, max. 0,5mm
Isolated input info
Min. Input Voltage 3.3 Vdc
Max. Input Voltage 24 Vdc
Min. Drawn current 1 mA
Max. Drawn current 8 mA
Operation
kohms.
Relay info
Isolated input info
Operation
kohms.
Relay info
Isolated input info
Input Impedance 3 K
Cable Cross-section min. 0,25mm, max.0,5mm
Pin functionality
The module has 25 I/O pins as seen on figure above. Refer to the following table for pin functionality
info.
Pin Function Pin Function
1 12 Vdc Out (+) 14 Output-2(battery mode) NO
2 12 Vdc Out (-) 15 Output-2(battery mode) COM
3 Input-1(start) (+) 16 Output-2(battery mode) NC
4 Input-1(start) (-) 17 Output-3(bypass mode) NO
5 Input-2(stop) (+) 18 Output-3(bypass mode) COM
6 Input-2(stop) (-) 19 Output-3(bypass mode) NC
7 Input-3(bypass mod) (+) 20 Output-4(common fault) NO
8 Input-3(bypass mod) (-) 21 Output-4(common fault) COM
9 Input-4(ups mode) (+) 22 Output-4(common fault) NC
10 Input-4(ups mode) (-) 23 Output-5(battery fault) NO
11 Output-1(low battery) NO 24 Output-5(battery fault) COM
12 Output-1(low battery) COM 25 Output-5(battery fault) NC
13 Output-1(low battery) NC
Pins 11-25 belong to output relays and their default function is shown on the table. Different functions
can be assigned to these relays; please refer to Challenger installation manual (UDD-SD-01 UDD-SD-
03) for setup.
Dry contact functions
Over Temp. Test in Progress
Over Load Replace Batterys
Bypass Bad Inverter Bad
UPS Shutdown Battery Mode
Charger Fail Parl. ID Collision
Fan Fail No Parallel Comm.
Fuse Fail Low Battery
Shutdown Pending ECO Mode
No Battery Tyristor Fault
M.Byp.Breaker On Byp.Phs.Rot.Err.
S. Byp.Mode Parl.Missing Dev.
Connection examples
Output relays can be connected in various ways to meet with control necessities.
AND and OR configurations can be set with the relays by connecting them in series or parallel as
seen in the figure above.
LED DEFINITIONS
6 EXPLANATIONS OF LOGGING
UPS will beep when any problem is detected. You can see the first information about the situation on
the front monitor panel. This may not be enough most of the time. In this case, you can see the
following warnings by using log screen.
Warning Warning Description
1
RS232 Start
Command
UPS was started by RS232 communication software.
2 RS232 Stop Command UPS was stopped by RS232 communication software.
3 Auto Restart
After the batteries discharge totally, UPS restarted itself automatically
after the mean time which adjusted that follows the mains getting back
to normal values.
4 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 has operated at overload more than time limit adjusted. The Loads
will be transferred to bypass line.
11 End of Battery Test
Battery test has completed. You can see the all results via front panel
status menu.
12 Batt. Test Aborted
Test was aborted manually or by UPS since the criterias were not
provided during battery test.
13
Manuel Switch To
BYP
Static switchs directions were changed manually to the bypass line via
UPS command menu.
14 No Battery No battery detected.
15 Maint. BYP. Sw. On Maintenance bypass switch has been activated.
16
Ambient Abnor.
Temp.
The ambient temperature is over limit. Check the ventilation of UPS
room.
17 Battery over-current
UPS battery charge current is out of the specified limits. Charge will be
OFF until return to normal operating.
18 Mains Voltage bad
Mains voltage is out of the specified limits, UPS will switched to battery
mode.
19 Inverter Overtemp.
Inverters temperature is out of limit, in case of 5 degrees more increment,
Load will be transferred to Bypass line.
20
PFC Overtemp.
Rectifier 's temperature is out of limit, in case of 5 degrees more
increment ,Load will be transferred to Bypass line.
21 Chrg OverTemp.
Charge / boost module temperature is out of the specified limits. If it is
in 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.
26 Bypass Voltage Bad
Bypass voltage value is out of limit while UPS was operating on the
bypass mode. UPS will switch to normal mode if temperature and load
status are normal.If not ,UPS will stop.
27 Bypass Freq. Bad
Bypass frequency value is out of limit while UPS was operating on the
bypass mode. UPS will switch to normal mode if temperature and load
status are normal.If not ,UPS will stop.
28 Coil Overtemp Over temperature is observed for UPS inverter and rectifier coils.
29 Inverter Voltage Bad
Inverter voltage is out of limit. Load will be transferred to bypass line,
when inverter voltage gets back to normal values,UPS will switch to
normal mode again.
30 Overload
Output load value is over %105, overloading counter will start to count,
If UPS is on normal mode, the charging will be stopped until load value
gets back to normal.
31 Maint. BYP. Sw. Off Maintenance bypass switch is deactivated.
32 Ambient Nor. Temp. UPS ambient temperature has got back to allowed limit values.
33 Mains Voltage Nor. Mains voltage is in the limited values, UPS will switch to normal mode.
34 Inverter Nor. Temp.
Inverter temperature is in the limited values. If load and temperature
values are normal, UPS will switch to normal mode.
35 PFC Nor. Temp.
Rectifier temperature is in the limited values. If load and temperature
values are normal, UPS will switch to normal mode.
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 back to normal
values.
41 Inverter Volt. Norm.
Inverter voltage is in the limited values, UPS will switch to normal
mode.
42 Normal Load Output load is under %100, If charging was OFF, It will be ON .
43 BYP Thyr.L1 Short C.
UPS has detected short circuit at bypass L1 thyristor. UPS will shut
down.
44 BYP Thyr.L2 Short C.
down.
45 BYP Thyr.L3 Short C
down.
46 UPS Thyr.L1 Short C.
UPS has detected short circuit at inverter L1 thyristor. UPS will shut
down.
down.
down.
49 UPS Thyr.L1 Open C.
UPS has detected that inverter L1 thyristor can not be activated. Load
52 BYP Thyr.L1 Open C.
UPS has detected that bypass L1 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 UPS.
57 Parl. Start Error
One or more of UPSs which operate in paralel mode could not start to
operate.
58 Inverter Fault UPS couldn't prepare the inverter voltage.
59 Output Off Static transfer switches all disabled. The loads can not be energized.
60 Normal Mode
UPS is operating in the normal mode, load are energized through
rectifier inverter line.
61 Battery Mode
UPS is operating in the battery mode, load are energized through
battery inverter line.
62 Bypass Mode
UPS is operating in the bypass mode, load are energized through
bypass line.
63
Maintenance Bypass
Mode
UPS is operating in the bypass mode, load are energized through
bypass line.
64 Parallel Mode
2 or more UPS are operating in power sharing mode. Load is fed
through UPSs inverter lines.
65 Test Mode
UPS has switched to battery test mode, loads are energized through
rectifier- battery- inverter line as source sharing.
66 EKO Mod KGK eko moddan alyor. Ykler bypass hatt zerinden besleniyor.
67
Switch to Inverter
Command
The direction of the static switches was varied manually on the rectifier
through UPS commands menu.
68 Output Voltage Error
Output voltage is detected during the period of starting UPS . UPS has
been stopped.
69 PFC Stop Cmd.
Abnormal stuation is detected during the moment of rectifier
operating.UPS has stopped itself.
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 Changed Device-related parameters were changed on the service menu
76 Batterys Changed
Battery replacement date has been changed. Battery statistics will be
reset.
77
Battery Contactor
OFF
Battery mechanical switch on the service menu was deactivated.
Batteries are not active.
78 Battery Contactor ON
Battery mechanical switch on the service menu was activated. Batteries
are active.
79 Battery Err. Although connected to the UPS, batteries can not be charged.
80 Parallel Command
UPS which is operating in paralel mode has been given a command to
change the status of static switches.
81 No P.CAN Bus Comm.
Slave UPS which is operating in paralel mode cant reach to master UPS
from CAN bus. If UPS is operating, will be shut down.
82 Ext. Start Command
start up by another (master) UPS.
83 Ext. Stop Command
stop by another (master) UPS.
84 Ext. Switch To BYP.
transfer the load to bypass line.
85 Ext. Switch To UPS
transfer the load to inverter line.
86 Parallel Comm. FE.
Slave UPS which is operating in paralel mode has 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 has decreased below defined battery low limit while
UPS was operating in battery mode.
92 No P.485 Bus Comm. Parallel RS485 communication between the systems is not available.
93 STS OverCurrent OverCurrent in Bypass line.
94 Output Signal OFF UPS output breaker is turned off. Loads can not be energized.
95 BYP. Phase Rot. Err. Reverse phase sequence was detected in mains at the UPS run time.
96 Fan Failure
Unable to communicate with the fan control system. Only for UPSs that
contain the fan control system.
97 Output DC Volt. Fault Over Inverter DC voltage. Loads will be transferred to the bypass line.
98 Battery Temp. Nor. Battery temperature is normal.
99 Output Signal ON UPS output switch is opened. Loads can be energized.
100 Fans Active
Able to communicate with the fan control system. Only for UPSs that
contain the fan control system.
101
PFC Pbus
OverVoltage
Positive DC Bus overvoltage.
102
PFC Nbus
OverVoltage
Negatif DC Bus overvoltage
103
PFC PhL1
OverCurrent
Short circuit protection is activated for rectifier L1 phase.
104
PFC PhL2
OverCurrent
105
PFC PhL3
OverCurrent
106 Single Stop
Command to stop itself has been given 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 has been exceeded in the maintenance
bypass mode. UPS is shut down.
111 RMS output Failure The value of output voltage is out of the limits. UPS will be shut down.
112 Stop All Units Stop all units command was given via front panel.
113 Float Charge Mode
UPS charge mode has switched to the standby mode at the constant
voltage fromconstant current mode.
114 Pwr. Supply Fault
The error signal is detected on UPS through power source circuit
debugger.
115 Generator Mode
Signal is detected from "generator mode input" of dry contact board.
UPS will switch to "generator mode".
Alarms and Descriptions
Alarm
Decription of Alarm
1 Over Temperature
Over Temperature at the UPS units, Check the Status>
Temperatures menu
2 Over Load
UPS is overloaded, reduce the load.
3 Bypass Bad
Bypass line voltage or frequency is out of limits, can not be
bypassed.
4 UPS Stopped
5 Charge Failure
The charging circuit problem is detected, batteries can not be
charged. In the case of mains interruption, critical loads remain
energized.
6 Fan Failure
Fan control board can not be reached, control will not be made.
7 Fuse Failure
Output Fuse 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 found to be
insufficient. Critical loads remain energized, In the case of mains
interruption.
Fault Alarms
SOLUTIONS
1) Ups input voltage should be checked
2) Input voltage should be checked from front panel menu.
3) L1 and L2 IGBTs should be checked.
4) Resistance on the PFC board (D09-3V1) should be checked.
14 Inverter Fault
Inverter voltage can not be created.
15 Battery Mode
UPS switched to battery mode.
16 Parallel. ID Conflict
There is more than one UPS with the same ID number at the system
connected in parallel. Check ID numbers. In this case, the systemcan
not be started.
17 No Parallel Comm.
UPS cannot communicate with the master UPS of the parallel
system.
18 Low Battery
The battery capacity has fallen below defined limit in battery mode.
19 EKO Mode
UPS is operating in ECO mode.
20 Thyristor Failure
One or more thyristor is faulty. See the history logs 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 systemis 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 Generator Mode
UPS switched to generator mode. Switching to generator mode
command was given by dry contact board.
Soft Start Fail = UPS DC busbar is not charged to desired level.
5) Relays which engage with resistances on the PFC board should be checked.
6) Transistors which engage with resistances on the main board (A09-1V1) should be checked.
SOLUTION:
1) Phase 1 and 2 should be reversed in the input voltage .
SOLUTIONS:
1) L1 L2 L3 voltages should be checked from Status Menu.
2) Input CB01 breaker should be checked(On or Off)
3) Input breaker should be checked.
SOLUTION
1) In certain limits, loads should be transferred to by-pass.
SOLUTIONS
1) Battery configuration should be checked from service menu.
2) Battery fuses should be checked.
3) Battery voltage should be checked from status menu.
4) Battery (+) and () directions should be checked.
By-Pass Phase Rot. Error =During the start-up, phases in the input voltage is connected in a
wrong way.
End Of Discharge = During the battery mode, batteries are under voltage limits.
Overland Timeout =Overloading is above certain time
No Battery = No battery installed.
REASONS
1. UPS inverter fan is broken or less than certain cycle.
2. Cooling channels for invertor might be dirty or congested.
3. UPS hot air delivery pipe might be congested or misplaced.
SOLUTIONS:
1) If the temperature is 5 degree more 5 ,load would be transferred to by pass.If the load is even
higher than by pass tolerances,UPS shut downs.
2) If the load is even higher than by pass tolerances, UPS shut downs.
FAULT REASONS
1. If temperature and load is in the normal range, UPS is turned to normal or, otherwise UPS shut
downs.
2. UPS limit range can be increase from service menu.
SOLUTIONS
1) Please check if any black out is occurred.
2) From the status menu, L1 L2 L3 voltages should be checked if they are in the defined limits.
3) CB1 input breaker should be checked. If the breaker is OFF, please check PFC and inputs .
4) Neutral line connected to UPS should be checked.
INVERTER OVERTEMP If the temperature is 5 degree more for inverter , load would be
transferred to by pass. If the load is even higher than by pass tolerances, UPS shut downs.
Mains Voltage Bad = Input voltage is out of defined limits. UPS wii be turned to battery mode.
Bypass Voltage Bad =KGK by-pass modunda alrken by-pass voltaj limitler dna kt.
Maint. Byp. Sw. ON
REASONS
1) Maintenance by-pass switch are turned on by clients or Makelsan authorized personnel.
2) Maintenance by-pass switch aux. contact might be out of order.
3) ) Maintenance by-pass switch aux. contact information might be disappear, please check cables.
SOLUTION
1) Main board should be changed.
REASON:
1. After PFC Phl1 overcurrent warnings such as UPS stopped ve UPS startup.
SOLUTIONS
1) Rectifier IGBTs and coils should be checked.
2) If IGBT is out of order, drivers should be changed.
SOLUTIONS
1. Due to abnormal condition,UPS shut downs.
2. Input contactors,breakers,rectifier IGBT should be checked.
SPI Comm. Error = Processors are not communicated on the mainboard.
PFC PhL1 OverCurrent =Rectifier Phl1 is determined as error. UPS shut downs.
Pfc Stop Cmd.=During the rectifier runs, abnormal situation is determined.
UPS Thyr.L1 Open C Inverter L1 thyristor is not initiated.
REASON
1. Invertor L1 thyristor is determined as unperformed
SOLUTIONS :
1) The load will be fed if it is under by pass voltage limit. If not, UPS shut downs.
2) Please check by pass board.
3) By pass thyristor signal cables should be checked.
4) By pass thyristor should be checked.
5) Main board control should be performed.
REASON
1. UPS by pass determined L1 thyristor not to activated.
SOLUTIONS
1) By pass thyristor control should be performed.
2) By pass thyristor signal cables should be checked.
3) By-pass board should be checked.
REASON
1. Rectifier temperature is above limits.
SOLUTIONS
1) Rectifier fan should be controlled.
2) UPS placement should be checked.
3) Fan cycle should be checked.
4)Rectifier sensor should be checked.
BYP Thyr.L1 Open C. By pass thyristor is iniated.
Pfc Overtemp.
SOLUTIONS
1) Please check fans and control cycles.
2) Cooling channels should be checked.
SOLUTIONS
1) J41, J7 connection cables should be checked..
2) From the status menu, DC busbar should be checked.
3) From the service menu,battery configuration should be checked.
4) Battery contactor feeding should be checked if it comes from 24V battery board
5) Check if the battery contactor is durable.
6) Transistor on the main board should be checked.
REASON
1. Static transfer switch temperature is above limits.
SOLUTIONS
3) Please check fans and control cycles.
1) Cooling channels should be checked.
REASON
In the situation of the overloading, timing for loads is determined according to type of loads.
Charger Overtemp.
Battery Switch Fail : DC busbar fail is occurred and batteries are not connected to the system.
STS Overtemp.
Overload Timeout
After the timing is reached, the error message is shown as above.
SOLUTION
In the situation of overloading, UPS normal mode change to by pass. After running 1minute, if there
is normal temperature and loading, it will turn to normal mode again.
These values are: %101 -> %125 20min -> 10min
%125 -> %150 10min -> 1 min
%150 -> %170 1min -> 20sec
REASONS
1. Overcurrent is passed from battery IGBT during the battery mode. UPS shuts down.
2. Short circuit occurring in the output or many non linear loads are activated at the same time
might cause this situation.
3. Static transfer switch temperature is above limits. UPS shuts down.
SOLUTIONS
1) Balance contactor should be checked.
2) Aux. contact of balance contactor and cables should be checked.
3) Check the load.
4) PFC driver and IGBT should be checked.
SOLUTIONS
5) Balance contactor should be checked.
6) Aux. contact of balance contactor and cables should be checked.
7) Check the load.
8) PFC driver and IGBT should be checked.
Booster overCurrent: Over current during the battery mode.
Pbus overVoltage : Positive DC busbar over voltaged. UPS shuts down.
Pfc Nbus overVoltage :Negative DC busbar overvoltaged. UPS shuts down .
SPARE PART LISTS
SUPPLY
DEFIINITION
PIECE STOCK
CODE
PURCHASING
CODE
PRODUCER PICTURE
FRONT PANEL 1 D09-1.V1R0 MAKELSAN
PFC BOARD 1 D09-3.V1R1 MAKELSAN
DC2DC BOARD FOR
DRIVER
7 C09-2.V1R0 MAKELSAN
IGBT DRIVER
BOARD
7 C09-1.V1 MAKELSAN
IGBT CONNECTION
BOARD
1 C09-5.V1 MAKELSAN
BY-PASS BOARD 1 C09-3.V1R0 MAKELSAN
SUPPLY
DEFIINITION
PIECE STOCK
CODE
PURCHASING
CODE
PRODUCER PICTURE
BATTERY INPUT
BOARD
1 C09-4.V2R1 MAKELSAN
MAIN POWER
SUPPLY BOARD
1 A09-2.V1R0 MAKELSAN
HIGH VOLTAGE
BOARD
( HV DC TO DC
SMPS)
AC TO DC BOARD 1 A09-4.V2R1 MAKELSAN
DSP BASED MAIN
CONTROL
IGBT 200A 1200V 6 FF200R12RT4 INFINEON
SUPPLY
DEFIINITION
PIECE STOCK
CODE
PURCHASING
CODE
PRODUCER PICTURE
IGBT 300A
1200V
1 F300R12RT4 INFINEON
TRISTOR 95A
1200V
6 MCC95-
12IO8B
IXYS
SNUBBER 7 NA KP220K-
TL1000V (KP-
3C)
2.2uF
ALCON
BUSBAR
CAPACITOR
20 NA B43310-
A5228-M
2200uF
450V
EPCOS
INPUT
OUTPUT
CAPACITOR
3/6 NA B32332-I71
50uF
420V
EPCOS
INPUT OUT
CAPACITOR
3/6 NA E62.L95-
104G10
100 uF
420V
ELECTRONI
CON
SUPPLY
DEFIINITION
PIECE STOCK
CODE
PURCHASING
CODE
PRODUCER PICTURE
AC FAN 220V 2 6C-230HBS B-SONIC
DC FAN 24V 2 NA DV6224 EBMPAPST
CONTACTOR 25A
24VDC 3POLE
1 NC1-2510BD CHINT
CONTACTOR 80A
24VDC 3POLE
1 NA NC1-8011BD CHINT
CONTACTOR 65A
24VDC 4POLE
1 NC1-6504BD CHINT
SUPPLY
DEFIINITION
PIECE STOCK
CODE
PURCHASING
CODE
PRODUCER PICTURE
CONTACTOR 25A
24VDC 3POLE
1 VTC25/10KD
24VDC
VIKO
CONTACTOR 80A
24VDC 3POLE
1 VTC80/11KD
24VDC
VIKO
CONTACTOR 65A
24VDC 4POLE
1 VTC65/00KD-4
24VDC
VIKO
BUSBAR CAPACITOR 20 NA K01450222
2200uF
450V
KENDEL
CIRCUIT BREAKER
125A - 18kA
3 ABE-203B
125A
LS
SUPPLY
DEFIINITIO
N
PIECE STOCK
CODE
PURCHASING
CODE
PRODUCER PICTURE
60KVA
CHOKE COIL
(PFC)
(25mm)
3 MKLCH10802
62
MAKELSAN
60KVA
CHOKE COIL
(INV)
(25mm)
3 MKLCH16802
60
MAKELSAN
60KVA
CHOKE COIL
(BOST)
(25mm)
1 MKLCH08802
61
MAKELSAN
EMI FILTER 2 NA C46 ULUS
7 TECHNICAL SPECIFICATIONS
Technical Specifications
Power 80KVA 100KVA 120KVA
Active Power 64kW 80kW 96kW
Input
Input Voltage Range 220 %15 (L-N) or 380 %15 (L-L) 3P + N + PE
Input Power Factor At Full Load > 0,99
Input Frequency Range 50Hz 10% / 60Hz 10% (Adjustable)
Rectifier IGBT Rectifier
Total Harmonic Distortion
(THDi)
<%5
Output
Output Voltage Range
220/380 VAC (230/400 VAC adjustable) 3P + N 1% Static, 1%
Dynamic
Recovery
At 0%- 100%- 0% load, maximum output tolerance %5, %1 Back to band
<40ms
Efficiency Up to %93
Output Frequency Range
synchronous with the network at the range of 50Hz 2%, mains 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 the
output voltage, Overload that will occur at the output (out of the periods
specified), Overheating that will cause failure related to over temperature,
high voltage which will occur at DC Bus voltage, low voltage which will
occur at DC Bus voltage, short circuit at the output.
Battery
Quantity (12V DC VRLA)
50
Charge Value ( C )
Nominal 0.1 C, adjustable.
Battery Power
25% of the device power
Communnication
Communication RS232 Standart, RS485 and SNMP adapter option
Dry Contact Optional
Protocol Megatec, SEC, TELNET
Certificates
Quality ISO 9001
Standard CE, TSE
Safety TS EN 62040-1-1, IEC60950
EMC/LVD TS EN 62040-2; A Class
General
Running Temperature At the range of 0 C ~40 C (for batteries 0 ~ 25 C)
Storage Temperature At the range of -15 C ~ 45 C (for batteries -10 ~ 60C)
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) <70dBA
Log Recording 500Event Log. (Optional Status Record)
Parallel Operation Parallel power increase up to 8 pcs.
EPO (Emergency Power Off) Standard
Isolation Transformer Optional
Net Weight 300 kg 320 kg 350 kg
Dimensions (W x D x H)mm 880 x 770 x 1660 mm
Contact Information
www.makelsan.com.tr
stanbul Deri Organize Sanayi Blgesi 2. Yol, I -5 Parsel,
34956 Tuzla/ stanbul
Tel: 0216 428 65 80 Faks: 0216 327 51 64 e-mail: makelsan@makelsan.com.tr
zmir Branch: Hakapnar Mah. 1348 Sok. 2AE Keremolu Merkezi Yeniehir zmir
Tel: 0232 469 47 00 Faks: 0232 449 47 00 e-mail: izmir@makelsan.com.tr
Ankara Branch: Mustafa Kemal Mah. 2157 Sok. No:4/6 ankaya / ANKARA
Tel: 0312 219 82 35 / 37 Faks: 0312 219 82 36 e-mail: ankara@makelsan.com.tr

Challenger 10-250kva Serv Man - Ing

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Challenger 10-250kva Serv Man - Ing

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SERVICE MANUAL

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