MAKELSAN LEVELUPS Series, LEVELUPS T3 SERIES User Manual
USER MANUAL
LEVELUPS SERIES
10 - 20 KVA
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
USER MANUAL
LEVELUPS SERIES
10 - 20 KVA
AG–SD-83
Rev. No:0 Rev. Date: 15.09.2014 Publication No:1
LEVELUPS SERIES 10-60 KVA ABOUT THE MANUAL
AG-SD-83 Rev. No:0 Rev. Date: 15.09.2014 Publication No:1
About the Manual
This Manual is prepared for the users of LevelUps Series10-20 kVA.
Companion Manuals
For more info about this device and its options, please visit www.makelsan.com.tr
Updates
Visit www.makelsan.com.tr for updates. Always use the latest manual.
Shipment
Carrying vehicles or handling accessories must have enough features and characteristics to carry
UPS’s weight.
DO NOT LIFT HEAVY DUTY WEIGHT WITHOUT HELP
1 Person
<18 kg (<40 lb)
2 People
18-32 kg (40-70 lb)
3 People
32-55 kg (70-120 lb)
Carrying vehicles or handling accessories
>55 kg (>120 lb)
Be more careful of sudden movements, especially when batteries are inside of cabinet.
LEVELUPS SERIES 10-60 KVA CONTENTS
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
CONTENTS
1 SAFETY AND WARNINGS ............................................................................................................................................ 4
1.1 Warnings .................................................................................................................................................................... 4
1.2 Clearance and Access ............................................................................................................................................ 5
1.3 Storage ........................................................................................................................................................................ 5
1.4 Shipment .................................................................................................................................................................... 5
GeneralView ......................................................................................................................................................................... 7
2.1 General Information ........................................................................................................................................... 12
2.1.1 Static Transfer Switch ............................................................................................................................... 12
2.1.2 Battery Temperature Regulation .......................................................................................................... 13
2.2 UPS’s Operation Modes ..................................................................................................................................... 13
2.2.1 Normal (Online) mode .............................................................................................................................. 13
2.2.2 Battery (Stored) Mode .............................................................................................................................. 13
2.2.3 Bypass Mode ................................................................................................................................................. 14
2.2.4 Auto Restart Mode ...................................................................................................................................... 14
2.2.5 Maintenance Mode ..................................................................................................................................... 14
2.3 Battery Management ......................................................................................................................................... 14
2.3.1 Normal Operation Mode ........................................................................................................................... 14
2.3.2 Advanced Functions (Battery tests) Auto Battery Test ............................................................... 15
2.4 User Panel ............................................................................................................................................................... 16
2.4.1 Opening Screen ............................................................................................................................................ 18
2.4.2 Main Menu Screen ....................................................................................................................................... 18
2.4.3Navigation through the menu ................................................................................................................. 18
2.4.4 Password-protected menus .................................................................................................................... 19
2.4.5 Control Menu ................................................................................................................................................ 19
2.4.6 Status Menu ................................................................................................................................................... 20
2.4.7 Setup Menu .................................................................................................................................................... 21
2.4.8 Logging Menu ................................................................................................................................................ 24
3 INSTALLATION ............................................................................................................................................................. 25
3.1 Single Module Installation ............................................................................................................................... 25
3.1.1 Warnings ......................................................................................................................................................... 25
3.1.2 Pre-installation check up ......................................................................................................................... 26
3.1.3 Positioning ..................................................................................................................................................... 26
LEVELUPS SERIES 10-60 KVA CONTENTS
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
3.1.3.1 Positioning The UPS ............................................................................................................................... 26
3.1.3.2 Internal Battery Configuration .......................................................................................................... 27
3.1.3.3 External Battery Configuration ......................................................................................................... 28
3.1.4 Transportation Type of Cabinets .......................................................................................................... 30
3.1.5 Main,Load and Battery Connections ................................................................................................... 30
3.1.5.1 External Protection ................................................................................................................................ 30
3.1.5.2 Cabling and fuse configuration .......................................................................................................... 31
3.1.5.3 Cable connections ................................................................................................................................... 32
3.1.5.4 Battery connections ............................................................................................................................... 35
3.1.5.4.1 Internal Battery connection ............................................................................................................ 35
3.1.5.4.2 External Battery Installation Procedure and Connection ................................................... 37
3.1.5.5 Control and Communication Cable Connections ....................................................................... 39
3.2 Parallel Installation ............................................................................................................................................ 39
3.2.1 Parallel Settings ........................................................................................................................................... 42
4 OPERATION ................................................................................................................................................................... 43
4.1 Operation Procedure ......................................................................................................................................... 43
4.1.1 Circuit Breakers ........................................................................................................................................... 43
4.1.2 First start-up ................................................................................................................................................. 44
4.1.3 UPS Operation Modes Testing ............................................................................................................... 46
4.1.3.1 Switching from Online Mode to Battery Mode ............................................................................ 46
4.1.3.2 Switching from Online Mode to Static Bypass Mode ................................................................ 46
4.1.3.3 Switching from Static Bypass Mode to Online ............................................................................ 47
4.1.3.4 Switching from Online Mode to Maintenance Bypass Mode ................................................. 47
4.1.4 Performing a Complete Shutdown ....................................................................................................... 50
4.1.5 EPO(Emergency Power OFF) ................................................................................................................. 51
4.1.6 RS232 Serial Communication Installation and Investigation ................................................... 51
5 EXPLANATIONS of LOGGING .................................................................................................................................. 52
6 Table of Technical Specifications .......................................................................................................................... 56
7 CONTACT INFORMATIONS ..................................................................................................................................... 58
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
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 authorized personnel.
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-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 personnel. (This service will
be provided for a fee by our authorized MAKELSAN personnel.)
Battery Voltage may rise up to 450V DC!
Battery terminal voltages can be at hazardous levels (450Vdc). Nobody except trained personnel
should touch batteries.
Batteries must not be thrown into fire. The damaged batteries and batteries with completed life
cycle must not be thrown to nature. For the collection and disposal batteries must delivered to
MAKELSAN authorized technicians or to the foundations which are authorized for collecting
waste batteries by the Ministry of Environment.
Fire extinguishing equipment must be kept nearby the UPS.
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
1.2 Clearance and Access
Clearance
There is no any air inlet or outlet grill on the left or right sides of our 10-20 kVA UPS. All air goes
in to UPS from the front and is evacuated from the rear through fans. There must be spaces at
least 1 meter for UPS's front side and 1,2 meter at the back side. Should not be permanent or
temporary use within the limits specified. Otherwise, the UPS performance will decrease.
Access
Operator reaches UPS via front panel on 10-20 kVA UPS. Therefore, enough area must be left for
operator. Also, UPS can be intervened in the back of it for service and maintenance. Because of
this reason, enough area for personal must be left at the rear side of UPS.
1.3 Storage
UPS should be kept in a room or area where is protected from excessive moisture and heat
before commissioning. UPS and battery cabinets must be kept in the original packaging.
WARNING:
Unused batteries must be charged at regular intervals. This time interval
are 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 be equipped properly and have features and characteristics
sufficient to carry UPS.
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
The UPS device shipment must be done on pallets.
The 10-20kVA UPS are delivered on the pallet sized 87x55x140 mm (WxDxH). The height of
device together with pallet is approximately 200mm. The pallet measurements are given
below..
Cabinet is equipped with four-wheel. In this way, it can be placed by moving easily. These wheels
are to be used on smooth surfaces only.
The front wheels of UPS must be locked after positioning properly. The rear side wheels are
fixed.
Be more careful of sudden movements, especially when batteries are inside of cabinet.
Move the UPS as rarely as possible
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
2 PRODUCT DESCRIPTION
General View
AG-SD-76 Yayın No:1 Yayın Tarihi:18.08.2014 Rev. No:0
490mm
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
Front View
1
LCD Display
2
Fresh Air Grids
3
EPO button
4
Menu Keys
5
Mimic Diagram
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
Rear View
1
Hot air evacuation channel
2
DC Bus Ramping up Button
3
External Bypass Switch
4
Maintenance Bypass Switch
5
Mains Switch
6
Mains Connection Terminals
7
Ground Connection
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
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8
External Bypass Fuse
9
Output Connectors Terminals
10
Battery Fast Fuses and Connection Terminals
11
Output Breaker
12
Battery Start-up Fuses
13
Thyristor Hot Air Discharge Channel
14
Cold Start Switch
15
RS232 Terminal for Communication Software
16
Optional Card Slots
17
The external temperature sensor output
18
Optional Parallel Port Terminal
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
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Electrical Connection
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
2.1 General Information
General operation topology of LevelUps Series 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. Rectifier converts the AC mains to DC voltage and charges the
batteries. When the mains voltage is not available, the necessary the DC bus voltage is generated
with use of the battery voltage. 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 to loads
through the static semi-conductor switches and output (load) breakers.
When maintenance or repair is needed, before the Input (CB1) and Output switches (CB3) are
put to the open circuit (OFF) position, the device must be switched to static bypass mode (please
see 4.1.3.2). Consequently the maintenance switch (CB2) is put to the position closed circuit
(ON). After that first Output breaker (CB3), then Input switches (CB1) are turned OFF
respectively.
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. Controlled by the main board control unit (DSP) these switches
provide feeding of the loads through either mains or inverters. The loads are supplied through
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
inverter during the normal operating mode. Therefore, Inverter static switches are active if
there are no problems with the system.
System provides the loads to be fed smooth and seamless by mains or inverter. In order to
manage this process at minimum risk, UPS synchronizes the inverter output and static (mains)
bypass as phase and frequency. Therefore, Inverter frequency can be considered same with
mains as long as it is within frequency limit.
User can switch between mains and inverter by using front panel. When the inverter is ready,
while the loads are fed through the bypass line, in case of either power failure or if mains values
are out of tolerances, the loads automatically will be fed through the inverter.
The user can activate the maintenance bypass and all the loads will be fed through the mains
without manipulations from the main panel. After that the input and the output fuses can be
turned to the OFF position.
NOT: When the inverter is not ready the loads are fed through the bypass line. Loads are not
protected against the mains failure, power spikes and other mains problems.
2.1.2 Battery Temperature Regulation
In the external battery cabinets the battery temperature is measured and detected by
"temperature sensor”. UPS adjusts battery charge parameters according to the detected
temperature. These parameters can be easily adjusted via LCD or TELNET interface by
authorized personnel of MAKELSAN. UPS adjusts battery charge parameters according to the
temperature detected by the sensor.
2.2 UPS’s Operation Modes
LevelUps series is on-line double conversion device. Our products operate in the following
modes:
Online Mode
Battery Mode
Bypass Mode
Auto Restart
Maintenance Mode
2.2.1 Normal (Online) mode
In this mode, UPS feeds the load through the inverters. Rectifier unit is fed by the AC mains
power. Inverter and battery charge units are fed by DC supply generated by rectifier unit.
2.2.2 Battery (Stored) Mode
When the mains voltage is bad the UPS runs on battery mode. UPS feeds the critical load through
the inverter; the energy is obtained from batteries.
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
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2.2.3 Bypass Mode
In case when UPS is overloaded or if inverter cannot generate a quality AC output due to any
problem and if bypass voltage and frequency values are within the limits, the loads will be fed
from the static bypass source (mains). UPS without interruption switches from inverter to AC
source (mains) via static transfer switches. The inverter source and mains must be synchronized
in order to manage smooth switching. If inverter output and mains are not synchronized,
switching may take up to 15 msec, varying according to load type.
2.2.4 Auto Restart Mode
In case of any failure of the mains, UPS will continue feeding the critical loads until the batteries
will reach the end of discharge voltage level. UPS will be working until the batteries are drained
and then will shutdown. When mains are restored to normal conditions UPS automatically will
start its operation, in the period determined by the user. UPS continues to operate in normal
(online) mode as long as the mains values are within desired limits. For LevelUps Series, this
feature is not activated in the initial factory set-up.
2.2.5 Maintenance Mode
On the maintenance mode loads are switched to the maintenance bypass line with a breaker, so
that the UPS can be serviced without cutting off the power to loads. The breaker is in full
conformity with capacity of loads.
2.3 Battery Management
Lead-acid batteries are used.
2.3.1 Normal Operation Mode
Constant Charge Current
Constant current at 1/10 rate of the battery capacity is applied to battery, until it reaches the
float voltage.
Float Charge
Depending on the battery discharge current the 1/3 of the battery energy is charged at this level.
With this level of charging batteries are kept ready for use at maximum 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, we
recommend using the temperature sensor.
Deep Discharge Protection
While the system is operating in the battery mode, if battery voltage has dropped below the
discharge level UPS shuts down and stops taking energy from the batteries. This value varies
between 1.6-1.75 V/cell for Lead-Acid batteries, and between 0.9-1.1 V / cell for Ni-Cd batteries.
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
Low Battery Warning
While the system operates on battery (stored) mode, according to actual loads, if the battery
capacity drops below 40% of its value, device will give audible and visible alarms. This value is
adjustable and can be set by user between 20%-70%.
2.3.2 Advanced Functions (Battery tests) Auto Battery Test
The auto battery test discharges 10% of the battery energy in a user defined period. Default is 90
days. Test reports the battery condition as good, weak 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 batteries are
completely drained during the test. This may cause the interruption
in the power supply to the critical loads in case of the mains failure.
This test command can be given from front panel monitor, via TELNET interface, via RS232
smart communication or via UPSMAN (SNMP, see the options).
The purpose of the battery test is to check if the batteries can supply the minimum back-up time
needed in case of mains failure. We recommend checking the test results on the regular basis.
LEVELUPS SERIES 10-20 KVA PRODUCT DESCRIPTION
AG-SD-83 / Publication Date: 15.09.2014 / Rev. No: 0 / Rev. Date:
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
Battery discharge LED
Illuminates on 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
Static Bypass Switch 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
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