Boxer-S Service Manual

BOXERS UPS SERVICE MANUAL
BOXER-S UPS SERIES SERVICE MANUAL

10-15-20 KVA
1
Publication Date: 02.11.2022 Revision No: 1
BOXER-S UPS SERIES SERVICE

MANUAL
10-15-20 KVA
2
About The Manual

This manual is created for Boxer-s ups 10-15-20 KVA UPS.
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.
3
CONTENTS
1. SAFETY……………….…………………………………………………………………………5
2. Functional Test ……………………………………………………………………………..6-13
3. Software Updating...........................................................................14-19
4. Logging…..…………………………………………………………………………………….20-23
5. Offsetting of Mainboard Replacement…..…………………………………………..24
4
1. SAFETY;
1. All loads connected to the device are switched off.

2. Press the EPO button of the device.
3. All fuses of the device are turned off.
4. DCBar of the device is discharged. (TS-SD-11 UPS Dc Busbar Discharging Instructions)
5. It is checked that the voltage is reduced to 0.0 V / DC - 1.0 V / DC by means of a
measuring instrument over DC busbar.
Make sure there is no voltage on the device!
5
2. Functional Test
Necessary equipments for functional testing;
RS232/USB Converter RS232 Cable
A10-7 Functional Test Board
i) PC Connection;
 USB / RS232 Converter is plugged into the USB port of the computer.
6
 Enter the device manager from the computer and the Ports (COM & LPT) section
opens.
 In the Ports (COM & LPT) section, the COM number of the transducer apparatus is
learned.
 COM information is entered into the Config text document (Exp COM4)
 One end of the RS232 cable is connected to the USB / RS232 Converter bracket.
 Connect the other end of the RS232 cable to the FD1 socket of the A10-7 board
 Note; the PC connection process is valid for every segment.
7
ii) IGBT Measurement;

IGBTs are vital components in the rectifier and inverter units of the BOXER-S series UPS. In
case they are needed to be tested please follow the procedures mentioned below.
IGBT modules can be tested rapidly, by using a standard multimeter, and the test consists
in verifying three things.
 The Gate terminals are insulated from the relative Emitters;

 The Diodes are in good condition.
 The IGBTs are in good condition.
A. First of all set on the multimeter to diode mode(Please press the Shift Button).
Pic1 Pic2
8
B. The positive probe of the multimeter should be touched to (DC+123) of the IGBT, the
COM probe of the multimeter to the number ph1,ph2&ph3(step by step) of the IGBT
and you should see 3.6 Volt on the multimeter display.
Ph1 Ph2 Ph3
C. The COM probe of the multimeter should be touched to (DC+123) of the IGBT, the
positive probe of the multimeter to the number Ph1,Ph2&Ph3(step by step) of the
IGBT and you should see 0.7-0.8 Volt on the multimeter display.
Ph1 Ph2 Ph3
9
D. The COM probe of the multimeter should be touched to (DC-123) of the IGBT, the positive
probe of the multimeter to the phases Ph1,Ph2&Ph3(step by step) of the IGBT and you
should see 3.6 Volt on the multimeter display.
Ph1 Ph2 Ph3
E. The positive probe of the multimeter should be touched to(DC-123) of the IGBT, the COM
probe of the multimeter to the phases Ph1,Ph2 & Ph3(step by step) of the IGBT and you
should see 0.7 – 0.8 Volt on the multimeter display.
Ph1 Ph2 Ph3
10
iii) IGBT Driver Test;

 External power cable phase’s is attached to SMPS AC(L) and Neutral to
SMPS AC(N)(220VAC).
 The device is energized.

 The BoxerS_v1TEST program in the BoxerS_v1TEST folder is opened.
 After activating the program, it is checked by clicking L1_H and L1_L

buttons on rectifier part and the signals on the driver cards are lit.
11


iv) By-Pass Board Testing;

 Click the BYP_L1, BYP_L2 and BYP_L3 buttons ın the STS section of the
program.
 Check that the pressed buttons turn red.
 It is checked that which are under the transformers on the by-pass board
on.
12
v) Power Board Testing;
 Click the INV_L1, INV_L2 and INV_L3 buttons in the STS section of the
program.
 Check that the pressed buttons turn red.
 İt is checked that which are under the transformers on the by-pass board
on.
a. Click the Relay section INV_RLY, INV_RLY and SOFT_RLY buttons in the STS
section of the program.
b. Check that the pressed buttons turn red.
c. It is checked that which are under the transformers on the by-pass board on.
13
3. Software Updating;
i) The necessary equipment for software installation.
RS232 cable USB \ RS232 Converter
ii) The female side of RS232 cable plugs into the USB / RS232 Converter and the
male side of plugs into the RS232 Service socket.
iii) The C2Prog program opens from the computer.

iv) Press the 'Configure Ports ..' button.
v) Press the Configure Ports button.
14
vi) The previously learned COM number is entered at the time of writing Serial Port
then press the OK buton.
vii) The J16 and J12 sockets should be short circuit on the mainboard of the ups.
PFC SOFTWARE INSTALLATION
viii) RS232 cable need to connet REC SERVİCE socket.
15
ix) The PFC software to be installed on the device is selected.

The Password = BOXERS2021
x) The following values are checked in the Programming Configuration section.
xi) Press to the Program buton.
xii) After the green field is filled, click on the OK button after the warning "You may
now close this window and reset the target".
Note; In this instance, the PFC software is installed and the processes are completed.
16
INVERTER SOFTWARE INSTALLATION

xiii) RS 232 cable need to connect INV service socket.
xiv) In the C2Prog program, press the select file button to select the inverter software
to be installed.
The Password = BOXERS2021
Check the following values, In the Programming Configuration section.
xv) Press to the program buton.
17
xvi) After the green area is filled, click on the OK button after the warning "You may
now close this window and reset the target"
xvii) In finally, please cut off the external power supply cable from device(220VAC).
ERRORS
1. NO RESPONSE
If there is a connection problem between the device and the computer, a "No
Response" warning is issued.
18
In this case
a. USB / RS232 converter must be checked for consistency.
b. RS232 Cable must be checked for stability.
c. Make sure that the connection between the device and the computer is established
correctly.
1. WRONG KEY
If the PFC software is installed in the PFC DSP, the "Wrong Key" warning is issued. In this case
a. Check that cable number 1 on the A09-1 board is in the correct position.
b. Check that pin 1 of J12 and J16 switches on board A09-1 are in the correct position.
19
4. Logging;
Logging when the device is in a faulty state;

1. If there is no power to display.
2. If power is coming to display.
1. If there is no power to display
A. All loads connected to the device are switched off.

B. Press the EPO button of the device.
C. All fuses of the device are turned off.
D. DCBar of the device is discharged. (TS-SD-11 UPS Dc Busbar Discharging Instructions)
E. It is checked that the voltage is reduced to 0.0 V / DC - 1.0 V / DC by means of a
measuring instrument over DC busbar.
Make sure there is no voltage on the device!
F. The phase-neutral Cable attached to the SMPS (Supply) Board is disconnected.
G. Phase is connected to the AC(L) pin of the SMPS Board and Neutral is connected to the
AC(N) pin(220VAC).
H. The device is energized.
20
2. If power is coming to display
I. If the RS 232 Converter is connected to the inverter;

“The log is taken by following the steps below(Logging Implementation)”
II. If the RS232 Converter is not connected to the inverter;
 First, UPS should be taken to mechanical by-pass mode!
 The converter cable(RS232 cable) should be plugged into the J7 socket on the
RS232 Option Board or Option Board Controller.
RS232 Option Board
Option Board Controller
 After completing this process, the BOXER-S log steps should be performed.
21
Logging Implementation
a. The necessary equipment for software installation.
RS232 cable USB \ RS232 Converter
b. The female side of RS232 cable plugs into the USB / RS232 Converter and the male
side of plugs into the RS232 Inv Service socket.
c. Enter the device manager from the computer and the Ports (COM & LPT) section
opens.
22
d. In the Ports (COM & LPT) section, the COM number of the transducer apparatus is
learned.
e. COM information is entered into the Config text document (Exp COM4).
f. The Log_r3 program opens from the computer.
g. BXS option is selected.

h. Press the 'read' button.
23
i. After the operations are completed, log Log_r3 is uploaded to the folder where the
program is located.
Note; If you can`t get log, please update the software of device`s!
5. Offsetting of Mainboard Replacement
After the replacement of mainboard, current need to offsetting.
Menu Set up Service Menu Control Current Offsets Press the ENT
Bottun.
24

Boxer-S Service Manual

Uploaded by

Copyright:

Available Formats

Boxer-S Service Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Boxer-S Service Manual

Uploaded by

Copyright:

Available Formats

BOXERS UPS SERVICE MANUAL

BOXER-S UPS SERIES SERVICE MANUAL

BOXER-S UPS SERIES SERVICE

About The Manual

Visit www.makelsan.com.tr for updates, Always use the latest manual.

1. All loads connected to the device are switched off.

Make sure there is no voltage on the device!

Necessary equipments for functional testing;

RS232/USB Converter RS232 Cable

A10-7 Functional Test Board

ii) IGBT Measurement;

 The Gate terminals are insulated from the relative Emitters;

Ph1 Ph2 Ph3

Ph1 Ph2 Ph3

Ph1 Ph2 Ph3

Ph1 Ph2 Ph3

iii) IGBT Driver Test;

 The device is energized.

 After activating the program, it is checked by clicking L1_H and L1_L

 After activating the program, it is checked by clicking L2_H and L2_L

 After activating the program, it is checked by clicking L3_H and L3_L

iv) By-Pass Board Testing;

v) Power Board Testing;

i) The necessary equipment for software installation.

RS232 cable USB \ RS232 Converter

iii) The C2Prog program opens from the computer.

PFC SOFTWARE INSTALLATION

viii) RS232 cable need to connet REC SERVİCE socket.

ix) The PFC software to be installed on the device is selected.

xi) Press to the Program buton.

INVERTER SOFTWARE INSTALLATION

Check the following values, In the Programming Configuration section.

xv) Press to the program buton.

a. USB / RS232 converter must be checked for consistency.

b. RS232 Cable must be checked for stability.

Logging when the device is in a faulty state;

1. If there is no power to display

A. All loads connected to the device are switched off.

Make sure there is no voltage on the device!

F. The phase-neutral Cable attached to the SMPS (Supply) Board is disconnected.

H. The device is energized.

2. If power is coming to display

I. If the RS 232 Converter is connected to the inverter;

RS232 Option Board

Option Board Controller

RS232 cable USB \ RS232 Converter

f. The Log_r3 program opens from the computer.

g. BXS option is selected.

5. Offsetting of Mainboard Replacement

After the replacement of mainboard, current need to offsetting.

You might also like