WÄRTSILÄ JOVYSTAR COMPACT S BAX 5452 Operating Manual

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BAX 5452

Operating manual

Wärtsilä

JOVYSTAR COMPACT S

30/40/50 kVA

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Index

Date

Name

Alternation note

2015-11-11

D. Busboom

First edition

2016-01-28

D. Busboom

16/047

2016-11-02

D. Busboom

16/494

2016-11-30

D. Busboom

16/539

2017-01-10

D. Busboom

17/008

2017-01-24

D. Busboom

17/037

2017-06-26

D. Busboom

17/196

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Contents

1 Introduction 5

1.1 General instructions 5

1.2 Overview of warning information 6

2 Description of the System 7

2.1 Functional description 8

2.1.1 Rectifier 8

2.1.2 Inverter 8

2.1.3 Battery 8

2.1.4 Static bypass 8

2.1.5 Internal, manual bypass 8

2.2 Operating states 9

2.2.1 Normal operation 9

2.2.2 Inverter fault 10

2.2.3 Rectifier fault 10

2.2.4 Mains failure 11

2.2.5 Manual bypass 11

3 Installation 12

3.1 Handling of the UPS 12

3.2 Positioning and Installation 13

3.2.1 Base Plan, Static Load and Weights 13

3.2.2 Overall Dimensions, Clearances and Ventilation 14

3.2.3 Environmental Installation Conditions 16

3.3 Electrical connections, cross sections, fuses 17

3.3.1 Fuses and cross sections for cable connections to the UPS 17

3.3.2 Connections to the UPS 18

3.3.3 UPS-Options (Optional equipment) 19

3.3.4 Mounting and connecting the battery 20

4 Operation 23

4.1 Front Panel 23

4.1.1 Function Buttons 24

4.1.2 Mimic Panel / LED 25

4.1.3 LED-Bar 26

4.2 Menu structure 27

4.2.1 Measures 28

4.2.2 Alarms 30

4.2.3 Special 31

4.2.4 Info 34

4.3 Alarm messages and status reports in the display 37

4.3.1 Description of status reports 37

4.3.2 Description of alarm messages 38

5 Commissioning and decommissioning procedures 44

5.1 Commissioning 44

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5.1.1 Problems during commissioning 45

5.2 Decommissioning 45

5.3 Commissioning from the internal, manual bypass 46

5.4 Decommissioning in the internal manual bypass 46

6 Servicing 47

6.1 Maintenance 47

6.1.1 Visual inspection 47

6.1.2 Functional test 47

6.1.3 Battery inspection 47

6.2 Repairs 48

6.2.1 Spare parts list 48

7 Dismantling and cleaning up 48

8 Appendix 49

8.1 Technical data 49

8.2 Other technical documents 50

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1 Introduction

Congratulations on purchasing a UPS unit from our JOVYSTAR series. The static UPS you have chosen incorporates the latest state of technology in power electronics and digital signal processing. It provides an ideal solution to the problems of supplying power to electronic data processing systems. Our JOVYSTAR UPS systems are true online systems that protect your consumers. The production of this equipment is subject to stringent quality assurance. As a result, the UPS offers the perfect solution to your power supply needs. The reliability of this product is our top priority and the result of more than 70 years of experience in secure power supply technology.

1.1 General instructions

Please read these instructions carefully

This operating manual includes safety requirements, instructions for installation as well as working instructions to help you guarantee the maximum performance and operating readiness the UPS offers. The manufacturer accepts no liability for damage to persons or equipment caused by disregarding instructions given in this manual.

Please store these instructions in a safe place

They contain important rules for the safe use of this UPS and information for contacting the manufacturer's service department in the event of any questions or problems concerning the UPS and its correct operation.

Storing or recycling packaging material

The packaging material for the UPS has been designed with great care to protect it against damage during transportation. This material is also useful should you ever need to return the UPS for inspection. Damage that arises during transportation is not covered by the warranty terms.

Validity

This operating manual reflects the technical status of the UPS at the time of printing. Its contents are not part of any contract but are for information purposes only. Wärtsilä JOVYATLAS EUROATLAS GmbH reserves the right to make substantive and technical changes relative to the content of this Operating Manual without prior notification. Wärtsilä JOVYATLAS EUROATLAS GmbH cannot be held liable for any errors or inaccuracies in this operating manual, in view of the fact that there is no obligation to provide regular updates to it.

Limited warranty

Our goods and services are subject to the general terms of delivery for products of the electronics industry as well as our general sales conditions. We reserve the right to make changes to this operating manual at any time – in particular the technical data, operating instructions, dimensions and weights stipulated in it. We ask that any claims in respect of delivered goods be submitted within eight days of receipt of goods, enclosing the relevant packing note. Claims made at a later time cannot be considered.

Wärtsilä JOVYATLAS EUROATLAS GmbH will cancel without notice all obligations entered into by Wärtsilä JOVYATLAS EUROATLAS GmbH and its agents, such as warranties and service agreements, if replacement parts other than original Wärtsilä JOVYATLAS EUROATLAS GmbH parts or other than parts purchased from Wärtsilä JOVYATLAS EUROATLAS GmbH are used for servicing and repair.

Any disclosure, reproduction and/or copying of this operating manual, by electronic or mechanical means, in whole or in part, requires the express prior written consent of Wärtsilä JOVYATLAS EUROATLAS GmbH.

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1.2 Overview of warning information

Proper operation and maintenance as well as adherence to the safety requirements are required to protect personnel and to ensure continuous readiness for use. All personnel installing/dismantling, commissioning, operating and maintaining this equipment must be familiar with and observe these safety regulations. Only trained and qualified personnel may carry out the described work and they must use the proper, intact tools, equipment, test equipment and materials. Important instructions are indicated by the terms "CAUTION", "ATTENTION" and "NOTE" and by indented text passages.

CAUTION:

This symbol identifies all working and operational procedures requiring absolute compliance to avoid any danger to personnel.

ATTENTION:

This symbol identifies all working and operational procedures requiring absolute compliance to prevent any damage or disruption to the uninterruptible power supply (UPS) or any of its components.

NOTE:

This symbol identifies technical requirements and additional information requiring the operator's attention.

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2 Description of the System

Ensuring a reliable power supply is one of many major issues when using electronic data processing and process control systems. The main causes of many interruptions to power supply are:

 Spikes produced by switching devices on the mains distribution  High frequency superposition caused by welding machines, fluorescent lights, photocopiers and more  Voltage variations due to fast load variations in big inductive consumers (lifts, transformers, machinery,

etc.)

 Voltage failures due to disturbances in the mains supply  Frequency variations caused by the use of separate power supply units

The range of disturbances extends from data corruption to memory leaks and from hardware failure to production stoppages. Therefore, the quality of the power supply is key to the reliability of electronic data processing equipment. The perfect solution for a secure, uninterrupted power supply for critical consumers is thus the UPS (Uninterruptible Power Supply). The UPS:

 Generates a constant supply voltage and frequency  Reduces mains disturbances and feedback  Guarantees an uninterruptible power supply to connected consumers for a specified period during a

mains failure

In comparison with conventional power sources such as the mains power supply or generators*, the cutting edge technology featured in UPS systems in the JOVYSTAR series brings the following outstanding advantages:

 Minimum mains feedback caused by active IGBT rectifiers  Three sources of intelligence through two DSPs (Digital Signal Processor) and µC (microprocessor)  Extended communication interfaces

 RS232/USB serial interfaces for reading UPS data (standard)  SNMP adapter for remote monitoring, data exchange via a LAN connection (option)  MODBUS adapter for remote monitoring, data transfer using MODBUS protocol via RS485

interface (option)

 Parallel slot for parallel redundancy systems, UPS systems communicate data with one another

via CAN bus protocol (option)

 Relay card with alarm messages for industrial remote monitoring via floating contacts (option)

*NOTE:

Operation of a UPS or other electronic consumers using a generator assumes that before installing the complete system the planner has established whether the generator can be used in conjunction with power electronics. Some generators are designed such that operation with power electronics consumers is not possible due to the additional loading with harmonics, power factor and commutation notches. In some cases faults may occur such as voltage unbalance, a tendency to oscillate and the shutting down of the generator. It may help to ask the generator manufacturer about this and, if necessary change the regulator on the generator or incorporate damper windings in the generator from the outset.

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2.1 Functional description

The block diagram shows the functional design of a JOVYSTAR UPS. It comprises the component groups "rectifier", "battery", "inverter", "static switch". The "RCB", "SBCB", "MBCB", "BCB" and "OCB" switches are used to start and shut down the UPS as well as to switch over to the bypass. Additionally, for maintenance purposes the battery can be disconnected from the UPS.

Block diagram of a JOVYSTAR UPS

Key to the block diagram

 Mains/Bypass → UPS supply  RCB → Rectifier Circuit Breaker  SBCB → Static Bypass Circuit Breaker  MBCB → Manual Bypass Circuit Breaker  BCB → Battery Circuit Breaker  OCB → Output Circuit Breaker  Output → Output for the connection of consumers

2.1.1 Rectifier

The rectifier converts the three-phase mains voltage into a regulated DC voltage to supply the inverter and charge the batteries. The rectifier comprises the control electronics for charging the battery and IGBT components for adjusting the power factor.

2.1.2 Inverter

The inverter converts the DC voltage from the rectifier or the battery into a stabilised AC voltage regulated by pulse width modulation. Due to the fast regulation, the UPS generates an excellent sine -wave voltage with extremely low distortion that even permits loads with high crest factors. The inverter output is also designed to be short-circuit proof (electronic short-circuit protection).

2.1.3 Battery

The battery works in standby parallel operation, which means that the inverter, charger and battery are permanently connected in parallel. To obtain the maximum lifetime of the battery it is protected by floating operation according to DIN 41773.

2.1.4 Static bypass

Static bypass switches the load without interruption between the inverter and bypass mains input. It comprises a thyristor bridge for the inverter and another for the bypass. For online operation the inverter output is switched to the UPS output. In the event of an overload at the output or failure of the inverter, the UPS output continues to be powered without interruption via the bypass.

2.1.5 Internal, manual bypass

Manual bypass is used to bypass parts of the UPS. In the event of maintenance or repair, the load is supplied directly from the mains.

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2.2 Operating states

2.2.1 Normal operation

Normal operation is divided into two further operating modes. For sensitive loads, online operation via the inverter provides a stable AC voltage. For loads that are less susceptible to mains fluctuations, eco mode offers a better efficiency rating.

Online operation

 The mains feeds the rectifier.  The rectifier provides the DC voltage for the inverter and charges the batteries.  The inverter supplies the load at the output with the necessary energy via the static switch.  If there is any threat of a deep battery discharge, the system automatically switches to the static bypass

without interruption.

Online operation: load supplied via the inverter

Offline operation:

 The mains feeds the rectifier.  The rectifier provides the DC voltage for the inverter and charges the batteries.  The bypass supplies the load at the output with the necessary energy via the static switch.  In the event of a mains failure the system automatically switches to the inverter without interruption.

Offline operation: load supplied via the static bypass

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2.2.2 Inverter fault

 The mains feeds the rectifier.  The rectifier provides the DC voltage for the inverter and charges the batteries.  The load at the output is transferred to the bypass without interruption via the static switch.

Inverter fault: load supplied via the bypass

2.2.3 Rectifier fault

 The mains feeds the rectifier.  The battery provides the DC voltage for the inverter (for the duration of the stored energy time).  The inverter supplies the load at the output with the necessary energy via the static switch.  If there is any threat of a deep battery discharge, the system automatically switches to the static bypass

without interruption.

Rectifier fault: load supplied via the inverter according to the stored energy time of the batteries

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2.2.4 Mains failure

 The battery provides the DC voltage for the inverter (for the duration of the stored energy time).  The inverter supplies the load at the output with the necessary energy via the static switch.  If there is any threat of a deep battery discharge, the system automatically shuts down completely and

the load is no longer supplied with power.

Mains failure: load supplied via the inverter according to the stored energy time of the batteries

2.2.5 Manual bypass

 The load is supplied by the mains via the manual bypass.  Any necessary maintenance or repairs to the UPS can be carried out safely.

Manual bypass load supplied via the manual bypass

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3 Installation

Remove the packaging immediately after receiving the UPS and check the system for transport damages. The transport company must be informed immediately after receipt of the UPS in the event of any damage caused during transportation. If the UPS is not installed immediately it must be stored in an upright position as indicated onthe packaging and kept in a dry, well ventilated room. If the UPS is not stored in the original packaging, it must be protected from dust and moisture.

3.1 Handling of the UPS

The UPS is packed on a pallet. It is handled from the transport vehicle to the installation (or storage) place via a fork lift.

The device has a heavy weight

 Avoid turnover during the transport of the UPS.  Cabinets must always be handled in upright position.  During loading and unloading operations, always respect the indications regarding

the device barycentre marked on the package.

Before positioning the UPS, in order to avoid risks of turnover, it’s recommended to move the system on the wood pallet on which the UPS is fixed. Before the positioning in the final location, remove the UPS from the pallet. To handle the UPS remove the lower front, rear and side panels and insert the forks of a fork lift. The UPS can be handled both from the front and from the side according to the available spaces, as shown by the following picture.

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3.2 Positioning and Installation

The UPS must be installed indoor, in a clean and dry room, preferably without dust or humidity infiltrations. For the environmental conditions in the place of installation, in compliance with the current legislation, please refer to the “Overall dimensions, minimum distances from the walls and ventilation” section.

Special environmental conditions

It is necessary to implement specific protective measures in case of unusual environmental conditions:

 harmful smoke, dust, abrasive dust;  humidity, vapour, salt air, bad weather or dripping;  explosive dust and gas mixture;  extreme temperature variations;  bad ventilation;  conductive or radiant heat from other sources;  fungus, insects, vermin.

3.2.1 Base Plan, Static Load and Weights

Power (kVA)

L1 – mm

502

P1 – mm

943

The supporting base of the UPS must be designed to carry the UPS weight and to ensure its steady and safe support. Its carrying capacity must be adequate to the static loads indicated in the table below.

Power (kVA)

Weight w/o batteries (kg)

140

150

190

Static load w/o batteries (kg/m^2)

500

510

550

Weight with batteries (kg)

310

335

425

Static load with batteries (kg/m^2)

1110

1135

1225

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3.2.2 Overall Dimensions, Clearances and Ventilation

Leistung (kVA)

L – mm

505

D – mm

940

H – mm

1505

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The UPS must be so installed as to ensure its serviceability and to allow a correct air flow as much as possible. With regard to the minimum distances from the walls, for all of the UPS sizes the same installation conditions apply as indicated in the table below.

Power (kVA)

L – mm

505

H – mm

1505

X (min.) - mm

Y (min.) – mm

500

A (min.) – mm

500*

*Only required at installed battery inside the UPS (Battery exchange)!

The table below shows the air volume required for an optimal ventilation and cooling of the UPS.

Power (kVA)

Air volume (m3/h)

900

1100

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3.2.3 Environmental Installation Conditions

The air is classified by the EN 60721-3-3 standard (Classification of environmental parameters and their severities – Stationary use at weather-protected locations) based on climatic and biological conditions as well as on mechanically and chemically active substances. Therefore the place of installation must meet specific requirements to ensure compliance with the conditions for which the UPS was designed.

Climatic conditions according to the technical specification

Environmental parameter

Minimum operating temperature (°C)

– 10

Maximum operating temperature (°C)

+ 40

Minimum relative humidity (%)

Maximum relative humidity (%)

Condensation

Rainfall with wind (rain, snow, hail, etc.)

Water with an origin other than rain

Ice formation

The UPS is designed to be installed in an environment that meets the following classifications.

Climatic conditions

In accordance with the technical specification

Biological conditions

3B1 (EN 60721-3-3)

Chemically active substances

3C2 (EN 60721-3-3)

Mechanically active substances

3S2 (EN 60721-3-3)

In the event that the environmental conditions of the installation room do not comply with the specified requirements, additional precautions must be taken to reduce excessive values to the specified limits.

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3.3 Electrical connections, cross sections, fuses

The electrical connection of the UPS unit is the task of the electrician providing the electrical installation services. This task is not carried out by the UPS manufacturer. For this reason, the following recommendations are only an indication, as the UPS manufacturer isnot responsible for the electrical installation.

In all cases we recommend carrying out the installation and the electrical connections to the UPS in accordance with local regulations and standards. Take particular care during electrical installation to ensure a clockwise rotating phase sequence. In the event that strong electromagnetic fields are emitted, we recommend the use of shielded cables between the UPS and the load. In accordance with EN 62040-1, mains backfeed protection has to be provided for the UPS, preventing a current flow from the output of the UPS back into the mains at a single fault of the system. Therefore it is necessary to install a separator in the power supply for the bypass, which the bypass current path separates automatically in case of a failure of the bypass mains.

ATTENTION:

Even when the mains voltage is switched off there is a dangerously high battery voltage inside the device. All installations and connections may therefore only be carried out by qualified electricians. Before commencing work, electricians must read this manual carefully to familiarize themselves with the special features of this UPS unit. The UPS output still carries voltage even in the event of a mains failure. For this reason, the installer must clearly label the outlets and sockets on the UPS unit in accordance with EN 62040!

ATTENTION:

The input line between the mains and the UPS unit must be protected against short circuits! The use of FI safety switches before the UPS unit is not recommended.

3.3.1 Fuses and cross sections for cable connections to the UPS

Should larger cable cross-sections be required for the installation than the maximum cross-section of the UPS terminals, a socket or a terminal box can be installed near the UPS. From there to the UPS, a cable laying with a smaller cross-section can be possible (better laying conditions such as installation type, cable length, ...).

Details der elektrischen Anschlüsse

Leistung (kVA)

Input fuses [A]

Rectifier

100

Bypass

100

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3.3.2 Connections to the UPS

30/40kVA

50kVA

Max. 25mm²

4 - 4,5Nm

Max. 25mm²

4 - 4,5Nm

Max. 35mm²

2,8 - 3Nm

Max. 4mm² 0,5 - 0,8Nm

Bolt M6

8,3 - 11,1Nm

Max. 35mm²

4 - 4,5Nm

Max. 35mm²

4 - 4,5Nm

Max. 35mm²

2,8 - 3Nm

Max. 4mm²

0,5 - 0,8Nm

Bolt M6

8,3 - 11,1Nm

PE BOLT M8, 9 Nm

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3.3.3 UPS-Options (Optional equipment)

Following UPS-Options are described in the operating manual BAX 4834:

 Relay card  SNMP adapter  PROFIBUS  MODBUS  Battery symmetry supervision  Parallel redundant systems

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3.3.4 Mounting and connecting the battery

3.3.4.1 Battery 7/9/11Ah 12V installation

1) Remove the 4 screws to open the left/right lateral cover and access the battery trays (total trays are 4 and each contain three rows of 10 batteries, see picture).

Trays 7/9/11Ah 12V battery lateral view

One raw 7/9/11Ah 12V battery top view

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2) Install the batteries received in a separate packages and install it in accordance with the picture 11 and picture

12.

7/9/11Ah 12V battery connection tray top view

7/9/11Ah 12V battery connection tray front view

3) After the connection re-insert the battery trays on the internal of UPS.

4) Put back and fix the left/right cover with the four screws.

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4 Operation

4.1 Front Panel

The front panel of the UPS, consisting of four rows alphanumeric display plus 5 function keys, allows the complete monitoring of the UPS status. The mimic flow helps to understand the operating status of the UPS.

UPS front panel

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4.1.1 Function Buttons

The front panel of the UPS is provided with 5 buttons whose functions are indicated in the following table:

Button

Assigned functions

 Scrolls up the menus  Increases the values by one unit  Selects a value

 Scrolls down the menus  Decreases the values by one unit  Selects a value

 Selects a menu  Confirms changes

 Silences the buzzer (activated due to an alarm or a failure)

 Returns to the previous menu

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4.1.2 Mimic Panel / LED

UPS mimic panel

LED 1

GREEN

AC line on rectifier input within tolerance

GREEN

AC mains failure / Wrong phase rotation

LED 2

GREEN

AC bypass line within tolerance

GREEN

Wrong phase rotation

OFF

AC bypass line out of tolerance / failure

LED 3

GREEN

Rectifier off or faulty

RED

DC voltage out of tolerance

GREEN

Rectifier on and DC voltage within tolerance

LED 4

GREEN

Circuit breaker BCB closed and battery charging

GREEN

Battery discharging or under TEST

ORANGE

Circuit breaker BCB open

RED

Battery fault (following a battery test)

OFF

Battery not available

LED 5

GREEN

Inverter voltage within tolerance and static switch closed

GREEN

Inverter overload or short-circuit

OFF

Inverter off or voltage out of tolerance

LED 6

ORANGE

Re-transfer blocked

ORANGE

Static bypass switch closed

OFF

Static bypass switch open

LED 7

GREEN

Output circuit breaker OCB closed

OFF

Output circuit breaker OCB open

LED 8

ORANGE

Manual bypass switch MBCB closed

OFF

Manual bypass switch MBCB open

LED 9

RED

Emergency power off (EPO) activated

OFF

Normal operation

LED 10

ORANGE

Maintenance request (slow blinking)

ORANGE

Critical alarm (fast blinking)

OFF

Normal operation

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4.1.3 LED-Bar

LED bar

LED 11

GREEN

AC line on rectifier input within tolerance

GREEN

Wrong phase rotation (fast blinking)

GREEN

Unbalanced AC voltage (slow blinking)

OFF

AC mains failure

LED 12

GREEN

Circuit breaker BCB closed and battery charging

ORANGE

Battery discharging or under TEST (fast blinking)

ORANGE

Circuit breaker BCB open (slow blinking)

RED

End of battery autonomy / Battery fault

LED 13

GREEN

Inverter voltage within tolerance and static switch closed

ORANGE

Inverter overload or short-circuit

RED

Inverter critical alarm

OFF

Inverter off

LED 14

GREEN

AC bypass line within tolerance

RED

Wrong phase rotation (fast blinking)

RED

AC bypass line out of tolerance / failure

LED 15

GREEN

Programmed maintenance required (slow blinking)

GREEN

Critical alarm (fast blinking)

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4.2 Menu structure

The following figure shows the complete structure in a clear format. The main menu is divided into four areas: "Measures", "Alarms", "Special" and "Info" This means the required information/reports and measures can be displayed quickly and various settings made. Details of the options available are given in the sections below.

JOVYSTAR

MEASURES

INPUT

OUTPUT

BYPASS

INVERTER

AC / DC

BATTERY

ALARMS

UPS STATUS

HISTORY

SPECIAL

RESET

CLOCK SETTINGS

SELECT LANGUAGE

UPS TEST

BATTERY SETTING

BATTERY TEST

NEW BATTERY

INSTALL

RESET HISTORY

MODBUS

RESET RUNNING

HOURS

INFO

SERIAL NUMBER

DEVICE TYPE

PARALLEL

MODBUS

FIRMWARE

RELEASE

SERVICE

RUNNING HOURS

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4.2.1 Measures

The measured data of the UPS are saved in the main menu under “Measures”. It can be displayed the input, output and bypass values, as well as data about the assemblies rectifier, inverter and battery.

„UPS-NAME“

MEASURES

„UPS-NAME“

ALARMS

Password-entry is required!

„UPS-NAME“

SPECIAL

„UPS-NAME“

INFO

Sub menu

Display

Voltage is based on N-connector

MEASURES

INPUT

INPUT VOLT/CURR

xxx yyy zzz V

INPUT FREQUENCY

xx.x Hz

INPUT POWER

xxx kVA

INPUT

EXIT

Main menu

„UPS-NAME“

xxx kVA

RES

Voltage is based on N-connector

MEASURES

OUTPUT

OUTPUT VOLT/CURR

xxx yyy zzz V

OUTPUT FREQUENCY

xx.x Hz

OUTPUT POWER

xxx kW

OUTPUT POWER

yyy kVA

LOAD

xxx yyy zzz %

RES

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Sub menu

Display

Voltage is based on N-connector

MEASURES

BYPASS

BYPASS VOLTAGE

xxx yyy zzz V

BYPASS

EXIT

Main menu

BYPASS FREQUENCY

xx.x Hz

RESET

Voltage is based on N-connector

MEASURES

INVERTER

INVERTER VOLT/CURR

xxx yyy zzz V

INVERTER

EXIT

INVERTER FREQUENCY

xx.x Hz

RESET

MEASURES

AC / DC

AC / DC VOLTAGE

xxx V

AC / DC

EXIT

RESET

MEASURES

BATTERY

BATTERY VOLT/CURR

xxx V xxx A

BATTERY AUTONOMY

xxx Min yyy %

BATTERY TYPE

xx.x Ah

RESET

BATTERY

EXIT

MEASURES

EXIT

OUTPUT

EXIT

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4.2.2 Alarms

The menu “Alarms” displays the status of the UPS and the alarms. All active alarms and status reports will be displayed in the sub menu „UPS Status“. If a fault occurs, the status menu automatically appears and presents the relevant report on the display. In addition, an acoustic signal will sound, which can be disabled by pressing the buzzer button. Occurred and removed faults are saved and can be displayed in the sub menu „History“ at any time.

(See also list of status reports)

(See also list of alarms)

Star (*) next to fault code means:

Fault was removed at the specified time

„UPS-NAME“

MEASURES

„UPS-NAME“

ALARMS

Password-entry is required!

„UPS-NAME“

SPECIAL

„UPS-NAME“

INFO

Sub menu

Display

ALARMS

UPS STATUS

USV STATUS

(First status report)

Main menu

„UPS-NAME“

xxx kVA

USV STATUS

(Last status report)

RESET

Fault was detected at the specified time

ALARMS

HISTORY

HISTORY: xxx/yyyy Code Date/Time

HISTORY

HISTORY: xxx/yyyy Code* DATE/TIME

RESET

ALARMS

EXIT

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4.2.3 Special

Different settings to the UPS can be made in the „Special“-menu. For that a password entry is necessary, to prevent a change of the system data by unauthorized persons. Then the following settings can be made: Reset of the UPS, set Date/Time, select language, perform an UPS test, enter battery data, perform a battery test, install new battery, delete history, set modbus address and reset running time.

UPS automatically switches from Inverter

mode to bypass mode and returns

Caution: In bypass fault, an

immediately inverter operating during

the test phase cannot be guaranteed! A

failure of the load is possible!

Change language of the display output

Set date and time

„UPS-NAME“

MEASURES

„UPS-NAME“

ALARMS

Password-entry is required!

„UPS-NAME“

SPECIAL

„UPS-NAME“

INFO

Sub menu

Display

Main menu

„UPS-NAME“

xxx kVA

RESET

SPECIAL

CLOCK SETTINGS

CURSOR-Keys: Selection of a digit (0-9)

RETURN: Confirmation of a digit

RESET: Cancel current selection of digit

and back to previous digit

CLOCK SETTINGS

DD-MM-YY hh:mm

SPECIAL

SELECT LANGUAGE

CURSOR-Keys: Selection of the language

RETURN: Confirmation of the language

More languages

2 – DEUTSCH, 3 – F RANCAIS, 4 – ENGLISH, 5 – PORTUGUES, 6 – ESPANOL, 7 – POLSKI, 8 – TURKCE

SELECT LANGUAGE

1 – ITALIANO

Note: Lower interventions are made in

the system

(Input wrong password: Exit) CURSOR-Keys: change digit

RETURN: Confirmation of a digit

ENTER PASSWORD

123

Reset of the UPS: Active fault conditions

are reset

SPECIAL

RESET

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

RESET DEVICE?

YES / NO

RESET

SPECIAL

UPS TEST

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

UPS TEST

YES / NO

RESET

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Caution: The test can affect the supply

of the load if the battery is not fully

charged

Short discharge test of the battery;

„Battery fault“ appears, if battery not O.K.

Set the battery properties:

Capacity, charging current, autonomy time

Sub menu

Display

Main menu

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

CONFIRM AUTON BATT?

YES / NO

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

SAVE BATT SETTINGS?

YES / NO

BATT SETTINGS SAVED

SPECIAL

BATTERY SETTING

CURSOR-Keys: Selection of a digit (0-9)

RETURN: Confirmation of a digit

RESET: Cancel current selection of digit

and back to previous digit

BAT CAPACITY SETTING

xxx.x Ah

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

CONFIRM BATT CAP.?

YES / NO

CURSOR-Keys: Selection of a digit (0-9)

RETURN: Confirmation of a digit

RESET: Cancel current selection of digit

and back to previous digit

BAT RECHAR CURR SET

xx.x A

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

CONFIRM RECHAR CURR?

YES / NO

CURSOR-Keys: Selection of a digit (0-9)

RETURN: Confirmation of a digit

RESET: Cancel current selection of digit

and back to previous digit

AUTONOMY BAT SETTING

xxxx min

RESET

(4x)

(2x)

(4x)

SPECIAL

BATTERY TEST

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

BATTERY TEST?

YES / NO

RESET

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Reset running time to zero

Set modbus address

Delete history

Sub menu

Display

Main menu

SPECIAL

RESET RUNNING HOURS

SPECIAL

EXIT

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

RESET HISTORY?

YES / NO

SPECIAL

RESET HISTORY

SPECIAL

MODBUS

CURSOR-Keys: Selection of a digit (0-9)

RETURN: Confirmation of a digit

RESET: Cancel current selection of digit

and back to previous digit (Address range: 1… 247)

MODBUS ADDRESS

xxx

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

RESET RUNNING HOURS?

YES / NO

RESET

Set autonomy time of the new installed

battery to 100 %

CURSOR-Keys: Selection YES/NO

RETURN: Confirmation YES/NO

SPECIAL

NEW BATTERY INSTALL

NEW BATTERY INSTAL?

YES / NO

RESET

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4.2.4 Info

The menu „Info“ include all relevant information of the UPS as the serial numbers (Device and job number), the device type (Online-/Eco mode and single or parallel system), the device data at a parallel system (Only active, if available), the modbus address, the versions of the installed firmware, the service remark (Only active, if available) and the running time.

„UPS-NAME“

MEASURES

„UPS-NAME“

ALARMS

Password-entry is required!

„UPS-NAME“

SPECIAL

„UPS-NAME“

INFO

Sub menu

Display

Main menu

„UPS-NAME“

xxx kVA

RESET

INFO

DEVICE TYPE

Display the device serial number

UPS SERIAL NUMBER

xxxxxxxxxx

Display the job number

OEM SERIAL-NUMBER

xxxxxxxxxx

SERIAL-NUMBER

EXIT

INFO

SERIAL NUMBER

Possibility: On Line/Eco mode

DEVICE TYPE

UPS – ON LINE

Possibility: Single/Parallel

DEVICE TYPE

SINGLE

RESET

DEVICE TYPE

EXIT

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CAN bus statistic static switch:

Number of received data and number of

correctly received data in percent

All UPS devices send data;

All UPS devices receive data

Sub menu

Display

Main menu

Parallel menu only visible, if the UPS

belongs to a parallel system!

POWER: All UPS devices supply the load

REDUNDANT+X: X = Number of the UPS

devices in the parallel-standby mode

Digit = Device number in the parallel

system; M = Master, S = Slave;

? = No communication exists on the data

bus in the parallel system;

[ ] = Identify position/configuration of the

current UPS in the parallel system

Position of the current UPS in the parallel

system/Number of UPS devices in the

parallel system

PARALLEL

x / y

Possibility: Master/Slave

Only a master possible, or faults in the data

communication bus

PARALLEL

MASTER

PARALLEL

EXIT

INFO

PARALLEL

1- S 2- M 3-[S] 4- ?

PARALLEL

REDUNDANT+X

PARALLEL

CAN STATISTICS SSW

MSG RX: xxxxx xxx.x%

RESET

CAN bus inverter:

Number of received data and number of

correctly received data in percent

Only the master sends data;

Only the slaves receive data

PARALLEL

CAN STATISTICS INV

SYNC RX: xxxxx xxx.x%

CAN bus inverter:

Number of received data and number of

correctly received data in percent

All UPS devices send data;

All UPS devices receive data

PARALLEL

CAN STATISTIK INV

MSG RX: xxxxx xxx.x%

Display the modbus address

INFO

MODBUS

Settable address range: 1… 247

MODBUS

ADDRESS: xxx

RESET

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See contact details/inform Technical

Support Service

Service menu only visible, if a service

remark is active

Sub menu

Display

Main menu

See contact data/Notify the service

INFO

SERVICE

FIRMWARE RELEASE

EXIT

SERVICE

---------- Sliding text ----------

SERVICE

EXIT

INFO

RUNNING HOURS

xxxxxx

RUNNING HOURS

EXIT

Microcontroller of the static switch

FIRMWARE RELEASE

uC S: vv.xx.yy.zz

RESET

INFO

EXIT

Digital signal processor of the inverter

Digital signal processor of the rectifier

INFO

FIRMWARE RELEASE

DSP1 R: vv.xx.yy.zz

FIRMWARE RELEASE

DSP2 I: vv.xx.yy.zz

RESET

MODBUS

EXIT

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4.3 Alarm messages and status reports in the display

The status reports describe the operating condition of individual components, whereas alarm messages indicate special states or faults described in detail below. The descriptions of alarm messages additionally show possible causes and recommend initial actions that may be taken to resolve the problem.

4.3.1 Description of status reports

Status

RECTIFIER OK

Description

The rectifier section is working properly

Operating condition

The rectifier supplies the inverter and keeps the battery charged

Status

BATTERY OK

Description

The battery is connected to the UPS

Operating condition

The battery is kept charged by the rectifier and is ready to feed the inverter

Status

INVERTER OK

Description

The inverter voltage and frequency are within the allowed range

Operating condition

The inverter is ready to feed the load

Status

INVERTER FEEDS LOAD (Only in Online-mode)

Description

The inverter feeds the load

Operating condition

The load is fed via the static inverter switch

Status

INVERTER BYPASS SYNCHRONIZATION

Description

The inverter is synchronized with the bypass

Operating condition

The synchronization between the inverter and the bypass is locked, and the static switch can change over from one source to the other.

Status

BYPASS OK

Description

The bypass voltage and frequency are within the allowed range

Operating condition

The bypass line is ready for changeover in case of inverter failure

Status

BYPASS FEEDS LOAD (Only in ECO-mode)

Description

Load fed by the bypass line

Operating condition

The load is fed by the bypass via the static switch, waiting for the inverter to restart

Status

BOOST CHARGE

Description

The battery is in BOOST charge

Operating condition

The rectifier is charging the battery with a higher voltage. The return to FLOATING charge mode is automatic.

Status

MASTER INVERTER SYNCHRONIZATION

Description

The inverter is synchronized with the MASTER UPS

Operating condition

This status is only present on the SLAVE UPS units, and shows that the inverter is synchronized with the signal sent by the MASTER UPS

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4.3.2 Description of alarm messages

Alarm

MAINS FAILURE

Description

The voltage or frequency of the input line is out of tolerance.

Possible causes

Mains instability or failure. Wrong phase rotation.

Solutions

1. Check the connections to the mains.

2. Check the stability of mains voltage.

3. If the alarm persists, contact our Technical Support Service.

Alarm

INPUT PHASE ROTATION NOT CORRECT

Description

The phase rotation on the rectifier input line is wrong.

Possible causes

Wrong connection of power cables.

Solutions

1. Check the phase rotation.

2. If the alarm persists, contact our Technical Support Service.

Alarm

RECTIFIER OFF

Description

The rectifier has been temporarily disconnected and the inverter is fed by the battery.

Possible causes

Instability of the AC line voltage or frequency. Possible fault in the rectifier control circuit.

Solutions

1. Check the parameters of the AC line voltage.

2. Restart the device.

3. If the alarm persists, contact our Technical Support Service.

Alarm

RECTIFIER FAILURE

Description

The rectifier has been disconnected due to an internal fault.

Possible causes

Possible fault in the rectifier control circuit.

Solutions

1. Check which alarms are present and carry out the indicated procedures.

2. Restart the device.

3. If the alarm persists, contact our Technical Support Service.

Alarm

WRONG DC VOLTAGE

Description

The measured DC voltage is out of tolerance.

Possible causes

The battery has reached the discharge voltage due to a power failure. Measuring circuit failure.

Solutions

1. Check the actual value of the measured DC voltage.

2. In case of mains failure, wait for the AC voltage to be restored.

3. Check which alarms are present and carry out the indicated procedures.

4. Restart the device.

5. If the alarm persists, contact our Technical Support Service.

Alarm

BATTERY IN TEST

Description

The rectifier voltage is reduced to start a short controlled discharge of the battery.

Possible causes

A battery test has been started automaticall y (if set), or manually by the user.

Solutions

1. Wait for the test to end, and check possible battery faults.

Alarm

BCB OPEN

Description

The battery isolator is open.

Possible causes

Battery isolator open.

Solutions

1. Check the status of the battery isolator.

2. Check the functionality of the auxiliary contact of the isolator.

3. Check the connection between the auxiliary contact of the isolator and the auxiliary terminals of the UPS (if provided).

4. If the alarm persists, contact our Technical Support Service.

Alarm

BATTERY DISCHARGING

Description

The battery is discharging.

Possible causes

The battery is discharging due to a mains failure. Rectifier failure.

Solutions

1. Check which alarms are present and carry out the indicated procedures.

2. If the alarm persists, contact our Technical Support Service.

Alarm

BATTERY AUTONOMY END

Description

The battery has reached the pre-alarm discharge level.

Possible causes

The battery is discharging due to a mains failure. Rectifier failure.

Solutions

1. Check which alarms are present and carry out the indicated procedures.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A10

BATTERY FAULT

Description

Fault following a battery test.

Possible causes

Battery fault.

Solutions

1. Check the battery.

2. Reset the system.

3. If the alarm persists, contact our Technical Support Service.

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Alarm

A11

SHORT-CIRCUIT

Description

The current sensor has detected a short-circuit at the output.

Possible causes Load problem.

Measuring circuit failure.

Solutions

1. Check the loads connected to the UPS output.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A12

SHORT-CIRCUIT TIMEOUT STOP

Description

Inverter shutdown due to an extended short-circuit during a power failure, or due to an over current on the inverter bridge input.

Possible causes

Short-circuit on the loads during a power failure. Inverter bridge fault. Temporary current peak.

Solutions

1. Reset the system.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A13

INVERTER OUT OF TOLERANCE

Description

The inverter voltage or frequency is out of tolerance.

Possible causes

Inverter shutdown due to an alarm. Inverter failure.

Solutions

1. Check which alarms are present and carry out the indicated procedures.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A14

BYPASS PHASE ROTATION NOT CORRECT

Description

The phase rotation of the bypass line is wrong.

Possible causes

Wrong connection of power cables.

Solutions

1. Check the phase rotation.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A15

BYPASS FAILURE

Description

The voltage or frequency of the bypass line is out of tolerance.

Possible causes

Bypass line instability or failure. Wrong phase rotation.

Solutions

1. Check the connections to the mains.

2. Check the stability of mains voltage.

3. If the alarm persists, contact our Technical Support Service.

Alarm

A16

BYPASS FEEDS LOAD (Only in Online-mode)

Description

The load is fed by the bypass line.

Possible causes

Temporary changeover due to inverter failure.

Solutions

1. Verify the inverter status and check whether other alarms are present.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A17

RE-TRANSFER BLOCKED

Description

The load is blocked on the bypass line.

Possible causes

Very frequent changeovers due to load in-rush currents. Static switch problems.

Solutions

1. Reset the system.

2. Check the in-rush currents of the loads.

3. If the alarm persists, contact our Technical Support Service.

Alarm

A18

MBCB CLOSED

Description

The manual bypass isolator is closed.

Possible causes

Manual bypass isolator closed.

Solutions

1. Check the status of the manual bypass isolator.

2. Check the functionality of the auxiliary contact of the isolator.

3. If the alarm persists, contact our Technical Support Service.

Alarm

A19

OCB OPEN

Description

The output isolator is open.

Possible causes

Output isolator open.

Solutions

1. Check the status of the output isolator.

2. Check the functionality of the auxiliary contact of the isolator.

3. If the alarm persists, contact our Technical Support Service.

Alarm

A20

OVERLOAD

Description

The current sensor has detected an overload at the output. If the alarm persists, the thermal image protection will be activated (alarm A21).

Possible causes

Output overload. Measuring circuit failure.

Solutions

1. Check the loads connected to the UPS output.

2. Contact our Technical Support Service.

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Alarm

A21

THERMAL IMAGE

Description

The thermal image protection has been activated after an extended inverter overload. The inverter is shut down for 30 minutes and then restarted.

Possible causes Output overload.

Measuring circuit failure.

Solutions

1. Check the loads connected to the UPS output.

2. Should you need to restore the inverter supply immediately, reset the system.

3. If the alarm persists, contact our Technical Support Service.

Alarm

A22

BYPASS SWITCH

Description

The „Normal/Bypass“ selector has been operated.

Possible causes

Maintenance operation.

Solutions

1. Check the selector position.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A23

EPO (Electronic Power Off)

Description

The system is blocked due to the activation of the electronic power off button.

Possible causes

Activation of the (local or remote) electronic power off button.

Solutions

1. Release the electronic power off button and reset the alarm.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A24

HIGH INVERTER / DC FUSE TEMPERATURE

Description

High temperature of the heat sink on the inverter bridge or tripping of the DC fuses which protect the inverter bridge.

Possible causes

Fault of the heat sink cooling fans. The room temperature or cooling air temperature is too high. Tripping of the DC protection fuses.

Solutions

1. Check the fans operation.

2. Clean the ventilation grids and the air filters, if any.

3. Check the air conditioning system (if present).

4. Check the status of the DC fuses on the inverter bridge input.

5. If the alarm persists, contact our Technical Support Service.

Alarm

A25

INVERTER OFF

Description

The inverter is blocked due an operation failure.

Possible causes

Various.

Solutions

1. Reset the system.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A26

COMMUNICATION LOSS

Description

Internal error.

Possible causes

Microcontroller communication problems.

Solutions

1. If the alarm persists, contact our Technical Support Service.

Alarm

A27

EEPROM ERROR

Description

The controller has detected an error in the parameters stored in E2PROM.

Possible causes

Wrong parameters entered during programming.

Solutions

1. Contact our Technical Support Service.

Alarm

A28

CRITICAL FAULT

Description

An alarm has been activated which causes the shutdown of part of the UPS (rectifier, inverter, static switch).

Possible causes

System failure.

Solutions

1. Check which alarms are present and carry out the indicated procedures.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A29

SCHEDULED MAINTENANCE REQUIRED

Description

It is necessary to carry out maintenance work.

Possible causes

The time limit since the last maintenance work has elapsed.

Solutions

1. It is necessary to carry out maintenance work.

Alarm

A30

COMMON ALARM

Description

Common alarm.

Possible causes

At least one alarm is present.

Solutions

1. Check which alarms are present and carry out the indicated procedures.

Alarm

A31

BUS MBCB CLOSED

Description

The manual bypass isolator is closed.

Possible causes

Manual bypass isolator closed.

Solutions

1. Check the status of the manual bypass isolator.

2. Check the functionality of the auxiliary contact of the isolator.

3. If the alarm persists, contact our Technical Support Service.

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Alarm

A32

BUS EPO (Electronic Power Off)

Description

The system is blocked due to the activation of the electronic power off button.

Possible causes

Activation of the (local or remote) electronic power off button.

Solutions

1. Release the electronic power off button and reset the alarm.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A33

ASYMMETRIC LOAD

Description

The positive and negative voltages measured on the DC capacitors towards the middle point are different.

Possible causes

Possible failure on the measuring circuit. Possible fault of DC capacitors.

Solutions

1. Reset the system.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A34

SERVICE REQUIRED

Description

A UPS check is necessary.

Possible causes

Possible UPS fault.

Solutions

1. If the alarm persists, contact our Technical Support Service.

Alarm

A35

BATTERY IN DIESEL MODE

Description

The UPS is supplied by the diesel generator.

Possible causes

The auxiliary contact which activates the diesel generator connected to the UPS is closed, and imposes this operating mode.

Solutions

1. Wait for the diesel generator to stop as soon as the mains voltage is restored.

2. Check the connection of the auxiliary contact which signals the diesel generator start, to terminals XD1/XD2.

3. If the alarm persists, contact our Technical Support Service.

Alarm

A36

FAST SHUTDOWN

Description

Inverter shutdown due to the operation of the protection sensor as a result of sudden DC voltage variations.

Possible causes

Battery fault.

Solutions

1. Check the battery.

2. Reset the system.

3. If the alarm persists, contact our Technical Support Service.

Alarm

A38

INVERTER FEEDS LOAD (Only in ECO-mode)

Description

The load is fed by the inverter. This alarm is active for UPS systems in „ECO“ mode, where the preferential supply is from the bypass line.

Possible causes

Temporary changeover due to bypass line failure.

Solutions

1. Verify the status of the bypass line and check whether other alarms are present.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A39

INVERTER LOOP ERROR

Description

The control is not able to regulate the inverter voltage precisely.

Possible causes

Regulation system failure.

Solutions

1. Reset the system.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A40

SSI FAULT

Description

The system has detected a failure in the static inverter switch.

Possible causes

Possible problems on the loads. Static switch fault.

Solutions

1. Check the absorption of the loads and the presence of DC components, if any, on AC current.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A41

RECTIFIER VOLTAGE LOOP ERROR

Description

The control is not able to regulate the rectifier output voltage precisely.

Possible causes

Regulation system failure.

Solutions

1. Reset the system.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A43

RECTIFIER CURRENT LOOP ERROR

Description

The control is not able to regulate the rectifier output current precisely.

Possible causes

Regulation system failure.

Solutions

1. Reset the system.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A44

DESATURATION

Description

The inverter is blocked due to the operation of the desaturation sensor of the IGBT drivers.

Possible causes

Inverter bridge fault.

Solutions

1. Reset the system.

2. If the alarm persists, contact our Technical Support Service.

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Alarm

A45

HIGH SSW TEMPERATURE

Description

High temperature of the static switch heat sink.

Possible causes

Fault of the heat sink cooling fans. The room temperature or cooling air temperature is too high.

Solutions

1. Check the fans operation.

2. Clean the ventilation grids and the air filters, if any.

3. Check the air conditioning system (if present).

4. If the alarm persists, contact our Technical Support Service.

Alarm

A46

REDUNDANCY LOSS

Description

This alarm is only active on parallel systems. Continuity is not ensured in the event of a fault on one of the UPS units.

Possible causes

The total load is higher than the maximum expected value. Possible failure on the measuring circuit.

Solutions

1. Check the load fed by the system.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A47

WRONG TRANSMISSION OF EEPROM PARAMETERS

Description

Internal error.

Possible causes

Microcontroller communication problems.

Solutions

1. Contact our Technical Support Service.

Alarm

A48

FAILED RECEPTION OF EEPROM PARAMETERS

Description

Internal error.

Possible causes

Microcontroller communication problems.

Solutions

1. Contact our Technical Support Service.

Alarm

A49

TEST MODE DISCREPANCY

Description

Internal error.

Possible causes

Microcontroller communication problems.

Solutions

1. Contact our Technical Support Service.

Alarm

A50

STATIC SWITCH BLOCKED

Description

The static switch is blocked. The load is no longer supplied.

Possible causes

Loads failure. Possible UPS fault.

Solutions

1. Check the loads for possible failures.

2. Reset the system.

3. If the alarm persists, contact our Technical Support Service.

Alarm

A51

BATTERY TEMPERATURE OUT OF TOLERANCE

Description

The battery temperature is out of tolerance. This alarm is only active when the temperature probe is installed and enabled on the battery.

Possible causes

Anomalous temperature in the battery cabinet. Possible failure on the measuring circuit.

Solutions

1. Check the temperature on the batteries and remove the cause of the alarm, if any.

2. If the alarm persists, contact our Technical Support Service.

Alarm

A52

DC COMP ERROR

Description

Internal error.

Possible causes

Microcontroller communication problems.

Solutions

1. Contact our Technical Support Service.

Alarm

A53

FIRMWARE CONFIGURATION ERROR

Description

The controller has detected an incompatibility in the control software.

Possible causes

The software update was not performed properly.

Solutions

1. Contact our Technical Support Service.

Alarm

A54

PARALLEL CAN COMMUNICATION ERROR

Description

Internal error.

Possible causes

Microcontroller communication problems.

Solutions

1. Contact our Technical Support Service.

Alarm

A55

PARALLEL CABLE DISCONNECTED

Description

Parallel cable doesn’t communicate.

Possible causes

Parallel cable disconnected or damaged.

Solutions

1. Check the connection of all cable.

2. Contact our Technical Support Service.

Alarm

A56

MAINS BALANCE

Description

Rectifier stop at unbalanced mains

Possible causes

The voltages of the three phases are deviate from each other about 7 %.

Solutions

1. Check the input voltages/- cable from the mains.

2. Contact our Technical Support Service.

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Alarm

A63

STARTING SEQUENCE BLOCKED

Description

During the UPS start-up a failure prevented the proper execution of the sequence.

Possible causes

Control devices in wrong position or operated improperly. Possible internal fault.

Solutions

1. Make sure the position of the control devices (isolators, selectors) is as specified in the procedures (see „Installation and start-up“ section).

2. If the alarm persists, contact our Technical Support Service.

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5 Commissioning and decommissioning procedures

The procedures explain what to do when starting up, shutting down and switching between normal operation/bypass operation of the UPS. The sequence of actions must be adhered to exactly. Not adhering to the sequence may lead to serious faults and/or destruction of the UPS. In the event of queries, please contact our Technical Support Service (see contact details).

5.1 Commissioning

Certain important points should be checked in advance in order to prevent faults during commissioning:

 All wiring and connections have been connected properly  The battery is connected with the poles correctly positioned and the battery voltage is in order  The voltages and phase rotation of the mains connections are correct  The "EPO" (Emergency Power Off) switch on the control panel, if installed, has not been pressed

No.

Panel display

Action

UPS status

---

Close RCB

All LEDs go on. Start of the control logic and activation of the panel.

BOOT LOADING

All LEDs go off.

EEPROM READING

All LEDs go off. EEPROM data are read.

PLEASE WAIT

UPS START UP

PLEASE WAIT

UPS startup. LED #1 lights if input voltage is correct.

RECTIFIER START UP

PLEASE WAIT

The rectifier starts and increases the intermediate circuit voltage. LED #3 lights green if the intermediate circuit voltage is correct.

INVERTER START

PLEASE WAIT

The inverter starts and increases the output voltage. LED #5 lights green, static switch inverter is closed

BYPASS START UP

CLOSE SBCB

Close SBCB

BYPASS START UP

PLEASE WAIT

The control logic checks the bypass parameters. LED #2 lights green if the bypass voltage is correct.

BATTERIE START UP

CLOSE BCB

Close BCB

Attention: Optional „Battery symmetry supervision“ is to reset additionally through the reset push button switch.

BATTERIE START UP

PLEASE WAIT

The control logic checks if the BCB is closed. LED #4 lights green if the battery is correct.

UPS START UP

CLOSE OCB

Close OCB

START UP END

PLEASE WAIT

The control logic checks the output parameters. LED #7 lights green if the output parameters are correct.

UPS NAME

xxx kVA

After termination of the startup procedure appears the standard display.

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5.1.1 Problems during commissioning

This paragraph contains essential information should an alarm occur during the start-up procedure. If the problem cannot be solved using this information, please contact our Technical Support Service.

1. No information in the display after closing the RCB

 Check the phase sequence from the mains  Check whether the input voltage and frequency are within tolerances  Check rectifier fuses F1-F2-F3

2. If the UPS stops the start sequence after step number 1 and one or more alarms occur

 Check displayed alarms and rectify the cause  Restart the UPS by closing the RCB

3. If the UPS does not start again after step number 2 and the alarm displays A15 – Bypass failure

 Check whether the SBCB is closed  Check the fuses of the static bypass switch integrated in the UPS  Check the phase sequence of the bypass mains  Check whether the bypass voltage and frequency are within tolerances

4. If the UPS does not start again after step number 3 and the alarm displays A7 – BCB open

 Check the BCB and the battery fuses  Inspect the connections between the auxiliary contact of the BCB and terminals Bac1-Bac2 of the

UPS

5.2 Decommissioning

Decommissioning the UPS leads directly to an interruption in the power supply to the consumer. The following steps should therefore only be carried out if necessary/wished.

No.

Action

Panel display

UPS Status

Open OCB

A30 COMMON-ALARM

The supply of the load is interrupted. LED #7 goes off.

Open BCB

A30 COMMON-ALARM

The battery is disconnected from the rectifier. LED #4 flashes red.

Open SBCB

A30 COMMON-ALARM

The static Bypass is disconnected. LED #2 goes off.

Open RCB

A30 COMMON-ALARM

Rectifier and inverter switched off. All LEDs go off.

---

End of switch off procedure.

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5.3 Commissioning from the internal, manual bypass

This switchover procedure starts the UPS from the internal manual bypass. Before doing so, the following two preconditions must be checked.

 The bypass switch is in the bypass position  The MBCB is closed.

No.

Panel display

Action

UPS Status

---

Close RCB

All LEDs go on. Start of the control logic and activation of the panel.

EEPROM READING

All LEDs go off. EEPROM data are read.

USV START UP

PLEASE WAIT

All LEDs go off. LED #1 lights green, LED #8 lights orange.

RECTIFIER START UP

PLEASE WAIT

The rectifier starts and increases the intermediate circuit voltage. LED #3 lights green if the intermediate circuit voltage is correct.

START UP FROM MBCB

CLOSE SBCB

Close SBCB

BYPASS START UP

PLEASE WAIT

LED #2 lights green. The control logic checks the bypass parameters. LED #6 lights green, static switch bypass is closed.

START UP FROM MBCB

CLOSE BCB

Close BCB

LED #4 lights green. Attention: Optional „Battery symmetry supervision“ is to reset additionally through the reset push button switch.

START UP FROM MBCB

CLOSE OCB

Close OCB

LED #7 lights green. Die Last is supplied through the static- and manual bypass.

START UP FROM MBCB

OPEN MBCB

Open MBCB

LED #8 goes off. The load is supplied through the manual bypass only.

INVERTER START

PLEASE WAIT

The inverter starts and increases the output voltage. The control logic checks the synchronization with the bypass.

START UP FROM MBCB

MOVE BYP-SWITCH

Bypass switch to

„Normal“

LED #5 lights green. LED #6 goes off. The inverter supplies the load.

START UP END

PLEASE WAIT

The control logic checks the output parameters. LED #7 lights green if the output parameters are correct.

UPS NAME

xxx kVA

The UPS is in normal mode again.

5.4 Decommissioning in the internal manual bypass

Once the procedure has been carried out successfully the consumer is switched to the internal manual bypass without interruption.

Attention: The input voltage from the mains is still live at the input terminals of the UPS. To ensure that the UPS is completely voltage free, the input voltage must additionally be disconnected from the UPS.

No.

Action

Panel display

UPS Status

Bypass switch to

position „Bypass“

A30 COMMON-ALARM

Static switch inverter opens, static switch bypass closes. LED #5 goes off, LED #6 lights orange.

Close MBCB

A30 COMMON -ALARM

LED #8 lights orange. The load is supplied through the manual- and static bypass.

Open OCB

A30 COMMON -ALARM

Led #7 goes off. The load is supplied through the manual bypass only.

Open BCB

A30 COMMON -ALARM

LED #4 flashes red. The battery is disconnected from the rectifier.

Open SBCB

A30 COMMON -ALARM

LED #2 goes off. The static bypass is opened.

Open RCB

A30 COMMON -ALARM

LED #1 and LED #3 go off. Rectifier and inverter are switched off.

---

The display goes off, the UPS is disconnected.

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6 Servicing

6.1 Maintenance

To maintain constant availability and operational reliability, we recommend that you carry out regular visual and functional tests on the UPS as well as inspecting the battery charge status. A log should be kept for verification.

CAUTION:

Maintenance work must sometimes be performed when the UPS is connected to the power supply. Always observe the safety regulations and secure the work area!

6.1.1 Visual inspection

During visual inspections, check for:

 Unusual noises or odours  Mechanical damage or foreign bodies in the unit  Conductive dirt or dust deposits inside the unit  Accumulations of dust that affect heat dissipation  Fault messages shown in the display.

The intervals between visual inspections depend first and foremost on the conditions in the location where the devices are installed.

6.1.2 Functional test

The functional testing of the UPS should be performed every six months and involves the following tasks:

 Activate the manual bypass  Disconnect the UPS and check the following functions when restarting the system:

 Displays (fault messages)  Correct start of the rectifier and inverter  Function of the static switch  Check the output voltages of the rectifier and inverter as well as of the static switch

6.1.3 Battery inspection

If the UPS is out of operation for a prolonged period, maintenance-free batteries must be recharged at threemonthly intervals. Please observe the battery manufacturer's instructions!

CAUTION:

Acid vapours emitted in the battery compartment can cause burns upon contact with body parts and when inhaled. The applicable protective measures must be complied with in accordance with the safety regulations of VDE 0510, Part 2.

The following items must be measured and logged every three months:

 Battery voltage between B+/N and B-/N  If possible, the voltage of the block batteries, otherwise of the battery racks

The voltage of all block batteries must be measured and logged on an annual basis. The firmness of all screw connections must be checked annually. All checks must be performed in accordance with DIN IEC 60896-21. Special checks, such as those in accordance with DIN VDE 0108, must also be observed. Additional testing by means of automatic testing equipment is not permitted except with the written approval of the battery manufacturer.

NOTE:

If the battery voltage is not within the stated range and/or the battery cannot be charged successfully, please inform our Technical Support Service and if necessary have the battery replaced by our specialists.

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6.2 Repairs

Despite the use of predominantly wear-free components, we recommend that you should store spare parts that are relevant to the operation of the UPS unit. This will assist the permanent operational readiness of your UPS. When ordering spare parts, please quote the designation (code) and order/device number.

6.2.1 Spare parts list

The spare parts list will be submitted.

7 Dismantling and cleaning up

After the decommissioning and dismantling of the UPS system from the connected power supply, the UPS and batteries must be cleaned up in accordance with the statutory provisions. We take free of charge our UPS unit and batteries from the operator and recycle them appropriately.

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8 Appendix

The following pages contain technical documents, including drawings and technical specifications for the UPS unit.

8.1 Technical data

JOVYSTAR COMPACT S

Online UPS-Type

30 kVA

40 kVA

50 kVA

Output

Output apparent power (cos φ = 0,9)

30 kVA

40 kVA

50 kVA

Output active power (cos φ = 1)

27 kW

36 kW

45 kW

Rated output voltage

- Tolerance static, symmetric load

- Tolerance static, asymmetric load

- Tolerance dynamic load (20 % → 100 % → 20 %)

- Correction time after load step

3 x 380/220 V / 3 x 400/230 V / 3 x 415/240 V

±1 % ±2 % ±5 %

< 20 ms

Rated output frequency

- Tolerance at free running quartz oscillator

- Tolerance at inverter-synchronization with mains

50/60 Hz

±0,001 Hz

±2 Hz

Rated output current (cos φ = 0,9)

44 A

58 A

73 A

Rated output current (cos φ = 1,0)

39 A

52 A

65 A

THDU (according to IEC EN 62040-3)

- Linear load

- Non linear load

< 1 % < 5 %

Input rectifier

Input voltage

3 x 400/230 V +15 % -20 %

Input frequency

50/60 Hz ±10 %

Input current (at 100 % load, without battery charging)

42 A

56 A

70 A

Input current (at 100 % load, max. battery current)

54 A

66 A

88 A

Input power factor (at 100 % load)

> 0,99

Input current THD (at 100 % load)

< 3 %

Input Bypass

Input voltage

3 x 380/220 V / 3 x 400/230 V / 3 x 415/240 V ±10 %

Input frequency

50/60 Hz ±5 %

Battery

Number of battery cells

2 x 180

Compensation charging voltage

2 x 409 V (2,27 V/Z)

Cut-off voltage

2 x 310 V (1,72 V/Z)

Max. battery charging current (at 100 % load)

10 A

8 A

Battery charging characteristic

IU (DIN 41773)

Overload capability/Output short circuit characteristic

Overload capability inverter

< 125 % for 10 min

125 % to 150 % for 30 s

> 150 % for 100 ms

Overload capability static bypass

150 % continuously

1000 % for 1 cycle

Short circuit characteristic (Bypass is available)

Immediate transfer to the bypass

Short circuit characteristic (Bypass is not available)

1. Current limitation to 500 ms

2. Current limitation from 500 ms to 5 s

78 A 66 A

104 A

87 A

130 A

109,5 A

Design

Dimensions (W x H x D)

505 x 1505 x 940 mm

Weight (without battery)

140 kg

150 kg

190 kg

Weight (with battery)

500 kg

510 kg

550 kg

Paint

RAL 9005

Noise level

< 52 dB

< 57 dB

International protection

IP 20

Conformity according IEC 62040

EMV-class

UPS classification

VFI SS 111

Other data

Efficiency normal mode (at 100 % load)

> 93 %

Efficiency battery mode (at 100 % load)

> 96 %

Efficiency eco-mode (Offline-mode)

> 98 %

Max. crest factor without power reduction

3 : 1

Heat dissipation (at 100 % load and rated input voltage)

2 kW

2,7 kW

3,4 kW

Requirements to the installation position

Max. installation altitude without power reduction

< 1000 m

Power reduction for installation altitude according to IEC EN 62040-3

0,5 % every 100 m above

1000 m up to 2000 m

Required air cooling volume

900 m³/h

1100 m³/h

UPS operating ambient temperature

0 to +40 °C

UPS storage temperature

-10 to +70 °C

Battery ambient -/storage temperature (recommended battery ambient temperature, see also battery operating instruction)

0 to +25 °C

+20 °C

Relative humidity (non condensing)

< 95 %

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8.2 Other technical documents

We provide you through our website on the product page of the UPS the following documents available to download:

 Battery data sheets  Battery operating instructions  Material safety data sheet  CE – Compliance Declaration

Download at:

http://www.jovyatlas.com/ja/Waertsilae-JOVYSTAR-COMPACT,120-93-2 http://www.jovyatlas.com/Batteries

Page 51

Operating Manual

Wärtsilä

JOVYSTAR COMPACT M

60kVA – 160kVA

BAX 5480

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Index

Date

Name

Remarks

2015-12-12

Chr. Fechteler

1 2016-05-24

D. Busboom

16/285

2016-12-01

D. Busboom

16/540

2017-01-10

D. Busboom

17/008

2017-01-24

D. Busboom

17/037

2017-08-24

D. Busboom

17/274

2017-10-16

D. Busboom

17/364

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Wärtsilä JOVYSTAR COMPACT M BAX 5480 - 3 -

Table of Contents

1 Conventions Used ............................................................................................................................ 5

2 Documentation Notes ....................................................................................................................... 6

3 Contact ............................................................................................................................................. 6

4 Factory Warranty .............................................................................................................................. 7

5 Limitation of Liability ......................................................................................................................... 9

6 Scope ............................................................................................................................................... 9

7 Safety Rules and Warnings ............................................................................................................ 10

7.1 Use of the UPS ...................................................................................................................... 10

7.2 Special Safety Warnings ....................................................................................................... 10

7.3 Environmental Protection ...................................................................................................... 16

8 Installation ...................................................................................................................................... 16

8.1 Receipt of the UPS ................................................................................................................ 16

8.2 Handling of the UPS .............................................................................................................. 17

8.3 Positioning and Installation .................................................................................................... 18

8.4 Positioning and Connection of the Batteries ......................................................................... 22

9 Electrical connection ...................................................................................................................... 23

9.1 Connection of the Power Cables ........................................................................................... 24

9.2 Backfeed Protection Device .................................................................................................. 25

9.3 Terminal Boards .................................................................................................................... 26

9.4 Battery ................................................................................................................................... 27

9.5 Connection of the Auxiliary Cables ....................................................................................... 33

9.6 Serial interfaces and external connections ............................................................................ 34

9.7 Relay Card Connection (Optional)......................................................................................... 36

9.8 UPS-Options (Optional equipment) ....................................................................................... 37

10 Startup and Shutdown ............................................................................................................... 38

10.1 Preliminary checks ................................................................................................................ 38

10.2 Start-Up Procedure ................................................................................................................ 39

10.3 Basic Troubleshooting ........................................................................................................... 41

10.4 Switching to Manual Bypass.................................................................................................. 42

10.5 Restart from Manual Bypass ................................................................................................. 43

11 General UPS Description .......................................................................................................... 44

11.1 Typology ................................................................................................................................ 44

11.2 System Description ................................................................................................................ 44

11.3 Operating Status .................................................................................................................... 46

11.4 Control and Operation Devices ............................................................................................. 50

12 Front Panel ................................................................................................................................ 52

12.1 Function Buttons .................................................................................................................... 53

12.2 Mimic Panel / LED ................................................................................................................. 54

12.3 LED-Bar ................................................................................................................................. 55

13 Handling the Operating Panel ................................................................................................... 56

13.1 Main Menus ........................................................................................................................... 56

13.2 Measures Display .................................................................................................................. 57

13.3 Basic Diagnostics .................................................................................................................. 59

14 Settings and Advanced Operations ........................................................................................... 63

14.1 Setting Date and Time ........................................................................................................... 65

14.2 Display language setting ....................................................................................................... 65

14.3 New Battery Installation ......................................................................................................... 65

14.4 Battery Configuration ............................................................................................................. 65

14.5 Setting Modbus Parameters .................................................................................................. 67

14.6 UPS Test ............................................................................................................................... 67

14.7 Battery Test ........................................................................................................................... 68

14.8 System Reset ........................................................................................................................ 68

14.9 Reset Alarm history ............................................................................................................... 69

15 System Information .................................................................................................................... 70

15.1 Parallel Operation Information ............................................................................................... 71

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15.2 Service Information ................................................................................................................ 73

16 Faults and Alarms ...................................................................................................................... 74

16.1 Operating Status Definition .................................................................................................... 75

16.2 Troubleshooting ..................................................................................................................... 76

17 Technical Data ........................................................................................................................... 84

18 Service and Download ............................................................................................................... 85

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Wärtsilä JOVYSTAR COMPACT M BAX 5480 - 5 -

Thank you for choosing a Wärtsilä JOVYATLAS product. This section of the manual contains indications regarding the symbols used in the UPS documentation as well as basic information about the product, including the factory warranty terms.

1 Conventions Used

The following symbols have been used to indicate potential dangers and to highlight useful information, so as to minimize the risks to persons and property.

HAZARD

“HAZARD” statements contain characteristics and basic instructions for the safety of persons. Non-compliance with such indications may cause serious injury or death.

WARNING

“WARNING” statements contain characteristics and basic instructions for the safety of persons. Non-compliance with such indications may cause injury.

CAUTION

“CAUTION” statements contain characteristics and important instructions for the safety of things. Non-compliance with such indications may cause damage to materials.

NOTE

“NOTE” statements contain characteristics and important instructions for the use of the device and for its optimal operation.

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2 Documentation Notes

Storing documentation

This manual and any other supporting technical documentation relating to the product must be stored and made accessible to personnel in the immediate vicinity of the UPS.

Further information

In the event that the information provided in this manual is not sufficiently exhaustive, please contact the manufacturer of the device, whose details are available in the “Contacts” section.

3 Contact

For any information about the UPS systems manufactured by JOVYATLAS, please contact:

Wärtsilä JOVYATLAS EUROATLAS GmbH Fennenweg 4 26844 Jemgum, Germany Tel. +49 – 4958 9394 - 0 Fax +49 – 4958 9394 - 10 service.jovyatlas.de@wartsila.com

http://www.jovyatlas.de

For help with technical problems or for information concerning device use and maintenance, please contact the technical help service by phoning the above-indicated telephone number, specifying the following data:

 Type of device and its nominal power  Serial number  Error code, if applicable.

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4 Factory Warranty

The factory warranty provided by Wärtsilä JOVYATLAS EUROATLAS GmbH is subject to the terms indicated below.

Validity

a) The present warranty terms only apply to the UPS systems manufactured by JOVYATLAS and

to their storage batteries, when supplied by JOVYATLAS.

Duration

a) The factory warranty provided by Wärtsilä JOVYATLAS EUROATLAS GmbH has a validity of

12 (twelve) months from the startup date of the UPS. The warranty expires at the latest 18 (eighteen) months from the purchasing date (invoicing).

General conditions

a) The execution of one or more repairs within the warranty time will not alter the original expiry of

the warranty.

b) If a unit is faulty and/or damaged within the time frame covered by the warranty, it will be

repaired or replaced with an equivalent or similar product.

Costs

a) The warranty covers all the costs resulting from repairs and/or spares to restore the correct

operation of the product covered by our factory warranty.

b) All other costs, particularly shipping costs, travel and accommodation costs for the service

personnel of Wärtsilä JOVYATLAS EUROATLAS GmbH for on-site repairs, as well as costs for the customer’s own employees, will not be covered by the factory warranty and will be charged to the end customer.

c) In case of service performed following a call made by mistake, or in case our technicians incur

extra time and/or costs due to the site inaccessibility or due to work interruptions required by the customer, such costs will be invoiced.

Modes required

a) In the event of a fault covered by the warranty, the customer shall notify Wärtsilä JOVYATLAS

EUROATLAS GmbH in writing of the occurred fault, providing a short description of the fault.

b) The customer shall also provide documents showing the validity of the warranty

(receipt/purchasing invoice with serial number of the product – report indicating the start-up date).

Service at the installation site

a) During preventive maintenance visits or emergency service, access shall be ensured to the

installation site, and the device shall be made available in order to ensure maintenance or repair with no waiting time.

b) During the intervention, the customer’s representative must attend service operations at the

installation site, so that he/she may operate the control devices outside the equipment.

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c) In case entry permits are necessary in order to enter the installation site, Wärtsilä JOVYATLAS

EUROATLAS GmbH must be notified of the time necessary to obtain the documentation required, if any.

d) In case of customer’s non-compliance, Wärtsilä JOVYATLAS EUROATLAS GmbH reserves the

right to refuse warranty service. Wärtsilä JOVYATLAS EUROATLAS GmbH will not accept any product returned for repair or replacement without prior agreement.

Exclusions

a) Our warranty does not cover the products which are faulty or damaged due to:

 Transport,  Installation or start-up defects caused by the customer’s non-compliance with the

installation and use instructions provided by Wärtsilä JOVYATLAS EUROATLAS GmbH

 Tampering, alterations or repair attempts made without the specific written approval by

Wärtsilä JOVYATLAS EUROATLAS GmbH

 Damage caused by work done by personnel not authorized by Wärtsilä JOVYATLAS

EUROATLAS GmbH

 Damage to the device caused by improper use, negligence, voluntary damage or use of the

device beyond the allowed limits;

 Damage caused by external factors such as dirt, fire, flooding, failed operation of the air

conditioning system, etc.;

 Non-compliance with applicable safety standards;  Force majeure (e.g. lightning, surges, natural disasters, fire, acts of war, riots, etc.);  Fall or displacement due to incorrect installation;  Ordinary wear caused by proper and continuous use of the device.

b) Protective devices inside the units (fuses and dischargers) are also excluded from the warranty,

unless the failure is due to component faults.

Responsibility

a) In no event shall Wärtsilä JOVYATLAS EUROATLAS GmbH be liable for direct or indirect

damage, or any damage whatsoever connected with the execution of warranty services (e.g. possible voltage interruptions during the repair period or assembly and dismantling costs), except for the cases provided for by mandatory laws.

b) The present warranty terms do not affect the purchaser’s mandatory rights as by law.

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5 Limitation of Liability

All the information contained in the present documentation is the exclusive property of Wärtsilä JOVYATLAS EUROATLAS GmbH. Written consent by Wärtsilä JOVYATLAS EUROATLAS GmbH is required in order to wholly or partially publish or disclose this information.

 The present manual constitutes an integral part of the product technical support

documentation. Read the warnings with attention, as they give important instructions concerning safe usage.

 The equipment must be destined exclusively for the use for which it was expressly

designed. Any other use is considered improper and therefore hazardous. The manufacturer cannot be held responsible for possible damage arising from improper, erroneous or unreasonable usage.

 JOVYATLAS assumes responsibility for the equipment in its original configuration.  Any intervention that alters the structure or the operating cycle of the equipment must be

carried out and authorized directly by JOVYATLAS.

 JOVYATLAS will not be held responsible for the consequences arising from the use of non-

original spare parts.

 JOVYATLAS reserves the right to make technical modifications to the present manual and

to the equipment without prior warning. Whenever typographical or other errors are found, the corrections will be included in new versions of the manual.

 JOVYATLAS assumes responsibility for the information given in the original version of the

manual in German language.

6 Scope

The instructions contained in the operating manual are applicable to the UPS systems listed below.

JOVYATLAS JOVYSTAR COMPACT m 60kVA - 160kVA

Storing documentation

This manual and any other supporting technical documentation relating to the product must be stored and made accessible to personnel in the immediate vicinity of the UPS.

Further information

In the event that the information provided in this manual is not sufficiently exhaustive, please contact the manufacturer of the device, whose details are available in the “Contacts” section.

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7 Safety Rules and Warnings

7.1 Use of the UPS

Congratulations on choosing a product from JOVYATLAS for the safety of your equipment. To obtain the best performance from your JOVYSTAR COMPACT m 60 - 160 kVA UPS system (Uninterruptible Power Supply), we suggest that you take your time to read the following manual. The purpose of this manual is to give a short description of the parts composing the UPS and to guide the installer or the user through the installation of the unit in its using environment. The installer or the user must read and correctly perform the instructions included in the present manual, with particular reference to the requirements regarding safety, in compliance with the current regulations.

Read the technical documentation

Before installing and using the device, make sure you have read and understood all the instructions contained in the present manual and in the technical supporting documentation.

Check the technical characteristics

Before carrying out any installation or start-up operation on the UPS, make sure its technical characteristics are compatible with the AC supply line and with the output loads.

7.2 Special Safety Warnings

7.2.1 General warnings

The UPS is provided with various stickers with indications regarding specific dangers. These stickers must be always well visible and replaced in case they are damaged. The present documentation must be always available in proximity to the device. In case of loss we recommend to request a copy to the manufacturer, whose details are available in the “Contacts” section.

7.2.2 Personnel

Any operation on the UPS must be carried out by qualified personnel. By qualified and trained person we mean someone skilled in assembling, installing, starting up and checking the correct operation of the product, who is qualified to perform his/her job and has entirely read and understood this manual, especially the part regarding safety. Such training and qualification shall be considered as such, only when certified by the manufacturer.

7.2.3 Transport and handling

Avoid bending or deforming the components and altering the insulation distances while transporting and handling the product.

Undistributed weight

The weight of the UPS is not uniformly distributed. Pay attention when lifting.

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Please inspect the device before installing it. In case any damage is noticed from the conditions of the package and/or from the outside appearance of the equipment, contact the shipping company or your dealer immediately. The damage statement must be made within 6 days from receipt of the product and must be notified to the shipping carrier directly. Should the product need to be returned to the manufacturer, please use the original package.

Injury hazard due to mechanical damage

Mechanical damage to the electrical components constitutes a serious danger to persons and property. In case of doubt regarding the non-integrity of the package or of the product contained therein, contact the manufacturer before carrying out the installation and/or the start-up.

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7.2.4 Installation

The product must be installed in strict compliance with the instructions contained in the technical backup documentation, including the present safety instructions. In particular, the following points must be taken into account:

 The product must be placed on a base suitable to carry its weight and to ensure its vertical

position;

 The UPS must be installed in a room with restricted access, according to standard CEI

EN62040-1;

 Never install the equipment near liquids or in an excessively damp environment;  Never let a liquid or foreign body penetrate inside the device;  Never block the ventilation grates;  Never expose the device to direct sunlight or place it near a source of heat.

Special environmental conditions

The UPS is designed for normal climatic and environmental operating conditions as defined in the technical specification: altitude, ambient operating temperature, relative humidity and environmental transport and storage conditions. It is necessary to implement specific protective measures in case of unusual conditions:

Use authorized personnel only

All transport, installation and start-up operations must be carried out by qualified and trained personnel. The installation of the UPS must be carried out by authorized personnel, in compliance with national and local regulations.

Do not modify the device

Do not modify the device in any way: this may result in damage to the equipment itself as well as to objects and persons. Maintenance and repair must be carried out by authorized personnel only. Contact the manufacturer for details of the nearest service centre.

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7.2.5 Electrical connection

The UPS connection to the AC power must be carried out in compliance with the current regulations. Make sure the indications specified on the identification plate correspond to the AC power system and to the actual electrical consumption of all of the equipment connected.

Check the conformity to the Standards

The UPS must be installed in compliance with the standards in force in the country of installation.

IT system

The UPS is also designed to be connected to an IT power distribution system.

All the electrical connections must be carried out by authorized personnel. Before connecting the device make sure that:

 the connection cable to the AC line is properly protected;  the nominal voltages, the frequency and the phase rotation of the AC supply are respected;  the polarities of the DC cables coming from the battery have been checked;  no leakage current to earth is present.

The device is connected to the following voltage supplies:

 DC battery voltage;  AC mains voltage;  AC bypass voltage.

Injury hazard due to electric shock!

The device is subject to high voltages, thus all safety instructions must be scrupulously adhered to before performing any operation on the UPS:

 Isolate the battery via DC circuit breakers before connecting it to the UPS;  Connect the ground cable to the relevant bar before carrying out any other

connection inside the device.

Injury hazard due to electric shock!

If primary power isolators are installed in an area other than the UPS one, you must stick the following warning label on the UPS. “ISOLATE THE UNINTERRUPTIBLE POWER SUPPLY (UPS) BEFORE WORKING ON THIS CIRCUIT”

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7.2.6 Operation

The installations to which the UPS systems belong must comply with all the current safety standards (technical equipment and accident-prevention regulations). The device can be started, operated and disconnected only by authorized personnel. The settings can only be changed using the original interface software.

Injury hazard due to electric shock!

During operation, the UPS converts power characterized by high voltages and currents.

 All the doors and the covers must remain closed.

Injury hazard due to contact with toxic substances

The battery supplied with the UPS contains small amounts of toxic materials. To avoid accidents, the directives listed below must be observed:

 Never operate the UPS if the ambient temperature and relative humidity are higher

than the levels specified in the technical documentation.

 Never burn the battery (risk of explosion).  Do not attempt to open the battery (the electrolyte is dangerous for the eyes and

skin).

Comply with all applicable regulations for the disposal of the battery.

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7.2.7 Maintenance

Service and repairs must be carried out by skilled and authorized personnel. Before carrying out any maintenance operation, the UPS must be disconnected from AC and DC supply sources. The device is provided with internal isolators which allow to isolate the internal power circuits. However the voltages of the supply sources are present on the terminals. To isolate the device completely, provide external circuit breakers on the lines. The device contains dangerous voltages even after shutdown and disconnection from the supply sources, due to the internal capacitors which discharge slowly. Thus we recommend to wait at least 5 minutes before opening the device doors.

Injury hazard due to electric shock!

Any operation must be carried out only when voltage is absent and in compliance with safety directives.

 Make sure the battery circuit breaker that may be placed near the battery has been

opened.

 Isolate the device completely by operating the external circuit breakers.  Wait at least 5 minutes in order to allow the capacitors to discharge.

After switching off and disconnecting the device there still might be very hot components (magnetic parts, heat sinks); therefore we recommend to use protective gloves.

High temperature of components

It is strongly recommended to use protective gloves due to the high temperatures that may be reached during the operation.

7.2.8 Storage

If the product is stored prior to installation, it should remain stored in its original package in a dry place with a temperature ranging from -10°C to +45°C.

Special environmental conditions

It is necessary to implement specific protective measures in case of unusual environmental conditions:

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7.3 Environmental Protection

7.3.1 Recycling of packing materials

Packing materials must be recycled or disposed of in compliance with applicable local and national laws and regulations.

7.3.2 Device disposal

At the end of their product life, the materials composing the device must be recycled or disposed of in compliance with the current local and national laws and regulations.

8 Installation

8.1 Receipt of the UPS

Danger to persons due to transport damages

8.1.1 Storage

The package normally ensures protection from humidity and possible damages during transport. Do not store the UPS outdoor.

Risk of damage due to inappropriate storage

 For the environmental storage conditions, refer to the indications given for the

installation of the device.

 The device must only be stored in rooms protected from dust and humidity.  The device cannot be stored outdoor.

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8.2 Handling of the UPS

The UPS is packed on a pallet. It is handled from the transport vehicle to the installation (or storage) place via a fork lift.

The device has a heavy weight

 Avoid turnover during the transport of the UPS.  Cabinets must always be handled in upright position.  During loading and unloading operations, always respect the indications regarding

the device barycentre marked on the package.

Picture 2 – Handling of the UPS

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8.3 Positioning and Installation

Special environmental conditions

It is necessary to implement specific protective measures in case of unusual environmental conditions:

8.3.1 Base Plan, Static Load and Weights

Picture 3 – Base plan The supporting base of the UPS must be designed to carry the UPS weight and to ensure its steady and safe support. Its carrying capacity must be adequate to the static loads indicated in the table below.

Power (kVA)

100

125

160

Weight w/o batteries (kg)

250

300

320

360

380

Static load w/o batteries (kg/m^2)

490

590

630

710

750

Weight with batteries (kg)

800

850 - -

Static load with batteries (kg/m^2)

1570

1670

- - -

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8.3.2 Overall Dimensions, Clearances and Ventilation

Picture 4 – Overall dimensions

Picture 5 – Clearances

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- UPS with internal batteries

A (mm)

B (mm)

C (mm)

D (mm)

Recommended clearances

1200

600

Minimum clearances

1200

600

400

- UPS with external battery cabinet

A (mm)

B (mm)

C (mm)

D (mm)

Recommended clearances

1200

400

600

Minimum clearances

1200 0 400

The table below shows the air volume required for an optimal ventilation and cooling of the UPS.

Power (kVA)

100

125

160

Air volume (m3/h)

1000

1200

1500

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8.3.3 Environmental Installation Conditions

Climatic conditions according to the technical specification

Environmental parameter

Minimum operating temperature (°C)

– 10

Maximum operating temperature (°C)

+ 40

Minimum relative humidity (%)

Maximum relative humidity (%)

Condensation

Rainfall with wind (rain, snow, hail, etc.)

Water with an origin other than rain

Ice formation

The UPS is designed to be installed in an environment that meets the following classifications.

Climatic conditions

In accordance with the technical specification

Biological conditions

3B1 (EN 60721-3-3)

Chemically active substances

3C2 (EN 60721-3-3)

Mechanically active substances

3S2 (EN 60721-3-3)

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8.4 Positioning and Connection of the Batteries

Risk of electric shock

A battery can present a risk for electrical shock and high short circuit current. The following precautions should be observed when working on batteries:

a) Remove watches, rings or other metal objects;

b) Use tools with insulated handles;

c) Wear rubber gloves and boots;

d) Do not lay tools or metal parts on top of batteries;

e) Disconnect the charging source prior connecting or disconnecting battery terminals;

f) Determine if battery is inadvertently grounded. If inadvertently grounded, remove source

from ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock can be reduced if such grounds are removed during installation and maintenance (applicable to equipment and remote battery supplies not having a grounded supply circuit).

Follow the installation instructions

For battery installation please respect EN62040-1-2 strictly and follow the installation manual of the UPS. To obtain the battery life indicated by the battery manufacturer, the operating temperature must remain between 0 and 25 °C. However, although the battery can operate up to 40°C, there will be a significant reduction of the battery life. To avoid the formation of any kind of potentially explosive hydrogen and oxygen mixture, suitable ventilation must be provided where the battery is installed (see EN62040-1-2 annex N). For the materials installed in France, the rule stated by NFC 15-100 article 554.2 must be applied: the volume of the renewed air has to be at least 0,05 NI m3 per hour, where N is the number of the elements inside the battery and I is maximum current of the rectifier.

The batteries can either be internal or external; it is recommended to install them when the UPS is capable of charging them. Please remember that, if the battery is not charged for periods over 2-3 months it can be subject to irreparable damage.

Auxiliary contact of the external battery switch

For a correct operation of the UPS it is advisable to connect the auxiliary contact of the external battery switch to the terminals X10-9/10.

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9 Electrical connection

The electrical connection is part of the work which is normally provided by the company that carries out the product installation. For this reason, the UPS manufacturer shall not be held responsible for any damages due to wrong connections.

Use qualified personnel only

All the operations related to the electric connection must be carried out by qualified and trained personnel.

Work in compliance with the local standards

The installation of the UPS must be carried out in compliance with national and local regulations.

Connection of ground cable

The grounding of the UPS via the relevant terminal is mandatory. It is strongly recommended to connect the ground terminal as first terminal.

The electrical connection is part of the work which is normally provided by the company that carries out the electrical installation and not by the UPS manufacturer. For this reason, the following recommendations are only an indication, as the UPS manufacturer is not responsible for the electrical installation. In any case we recommend to carry out the installation and the electrical input and output connections in compliance with the local standards. Cables must be selected bearing in mind technical, financial and safety aspects. The selection and the sizing of cables from a technical viewpoint depend on the voltage, on the current absorbed by the UPS, on the bypass line and on the batteries, on the ambient temperature and on the voltage drop. Finally, the kind of cable laying must be taken into particular consideration. For more explanations regarding the selection and the sizing of cables, please refer to the relevant IEC standards, in particular to IEC 64-8 standard. “Short-circuit currents” (very high currents with a short duration) and “overload currents” (relatively high currents with a long duration) are among the main causes of cable damage. The protection systems normally used to protect the cables are: thermal magnetic circuit breakers or fuses. Protection circuit breakers must be selected according to the maximum short-circuit current (max Isc) that is needed to determine the breaking power of automatic circuit breakers, and to the minimum current (min Isc) that is needed to determine the maximum length of the line protected. The protection against short-circuit must operate on the line before any thermal and electrothermal effects of the overcurrents may damage the cable and relevant connections. During the electrical installation take particular care to respect the phase rotation. The terminal boards are placed on the front of the UPS. To access the terminals remove the front panel, removing the fixing bolts.

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Mains connection

The connection to the mains must be carried out with protection fuses between the mains and the UPS. The use of differential protection devices in the line supplying the UPS is unadvisable. The leakage current to ground due to the RFI filters is rather high and it can cause spurious tripping of the protection device. According to CEI EN62040-1 standard, in order to take into account the UPS’ leakage current, residual current devices having adjustable threshold can be used.

Mains connection

Include an appropriate and readily accessible disconnecting device in the electrical line connecting the UPS to the mains.

9.1 Connection of the Power Cables

For the electric connection of the UPS, connect the following cables:

 DC supply from the battery (if the battery is external);  AC supply from the rectifier and bypass supply mains;  AC output to the loads.

Injury hazard due to electric shock!

Very high voltages are present at the ends of the cables coming from the battery:

 Isolate the battery via DC circuit breakers before connecting it to the UPS;  Connect the ground cable to the relevant bar before carrying out any other

connection inside the device.

Risk of damages to the device due to insufficient insulation

 The cables must be protected from short-circuits and leakage currents to earth;  The connection points must be hermetically sealed to prevent the air from being

sucked through the cable passage.

Risk of damages to the device due to incorrect wiring

To connect the device, follow the electrical drawing scrupulously and respect the polarity of cables.

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Details of the electrical connections

Power (kVA)

100

125

160

Input fuses [A]

Rectifier

125

160

200

250

315

Bypass

125

160

200

250

315

Power connections

Type

Screw terminals

Conductor max. cross section [mm2]

Max. number of conductors

Tightening torque [Nm]

4 ÷ 4,5

7 ÷ 8

15 ÷ 20

Bolt M10 (19 Nm)

Rated current (at full load and battery recharging)

Power (kVA)

100

125

160

Rectifier input [A]

(1)

109

140

170

214

267

Bypass input / Output [A]

(1) (2)

115

144

180

231

Battery [A]

100

133

166

208

266

(1)

Values referred to 400Vac rated voltage

(2)

For the overload values refer to the Technical Specification

9.2 Backfeed Protection Device

The UPS is provided (as option) with voltage-free contacts, which can be used to operate the shunt trip coil (undervoltage release type) of the external sectioning device; the external device is not part of the UPS supply and is provided and installed at customer care. The following table shows the main electrical characteristics of the external sectioning device.

Backfeed protection device

Power (kVA)

100

125

160

Maximum operating voltage (Vac)

690

Minimum rated current (A)

125

160

200

250

315

Category

AC-1

A backfeed contactor can also be installed inside the UPS as an option.

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9.3 Terminal Boards

The UPS is provided with terminal boards for the connection of power cables and of auxiliary connections.

Picture 6 – Terminal board 60 – 80kVA

Picture 7a – Terminal board 100 kVA

Picture 7b – Terminal board 125 - 160 kVA

UPS OUTPUT

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9.4 Battery

CAUTION

A battery can present a risk for electrical shock and high short circuit current. The following precautions should be observed when working on batteries:

a) Remove watches, rings or other metal objects;

b) Use tools with insulated handles;

c) Wear rubber gloves and boots;

d) Do not lay tools or metal parts on top of batteries;

e) Disconnect the charging source prior connecting or disconnecting battery terminals;

f) Determine if battery is inadvertently grounded. If inadvertently grounded, remove source

Batteries installation

For battery installation please respect the prescriptions of the EN62040-1 standard, paragraph

4.5. To obtain the battery life indicated by the battery manufacturer, the operating temperature must remain between 0 and 25 °C. However, although the battery can operate up to 40 °C , there will be a significant reduction of the battery life. To avoid the formation of any kind of potentially explosive hydrogen and oxygen mixture, suitable ventilation must be provided where the battery are installed (see EN62040-1 annex N).

The batteries can be internal or external, however, it is recommended to install them when the UPS is capable of charging them. Please remember that, if the battery is not charged for periods over 2-3 months they can be subject to irreparable damage.

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Internal batteries

The UPS can have internal batteries.

 Servicing of batteries should performed by qualified personnel only.  Replace the batteries with the same number of block and capacity.  Replace only with original type.  CAUTION: do not dispose of batteries in fire. The battery may explode.  CAUTION: do not open or mutilate batteries. Released electrolyte is harmful to the

skin and eyes. It may be toxic.

 CAUTION: do not dump the exhausted batteries in the environment.

9.4.1 Battery connection and positioning

Battery voltage

After the battery installation, before closing BCB, check the battery voltage on the BCB circuit breaker.

In case of not directly supplied cabling, please connect the cables to the battery breaker (BCB) as shown in the below picture.

Picture 8 – Cabling of BCB fuse holder

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9.4.1.1 Battery 7/9/11Ah 12V installation – 60-80 kVA

1) Remove the six screws to open the left/right lateral cover and access the battery trays (total trays are 6 and each contain three rows of 10 batteries, see picture 9 & 10).

Picture 9 - Trays 7/9/11Ah 12V battery lateral view

Picture 10 – One raw 7/9/11Ah 12V battery top view

Screw to fix the tray

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2) Install the batteries received in a separate packages and install it in accordance with the picture 11 and picture 12.

Picture 11- 7/9/11Ah 12V battery connection tray top view

Picture 12- 7/9/11Ah 12V battery connection tray front view

3) After the connection re-insert the battery trays on the internal of UPS.

4) Put back and fix the left/right cover with the four screws.

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9.4.1.2 Battery 12/14Ah 12V battery installation – 60-80 kVA

1) Remove the six screws to open the left/right lateral cover and access the battery trays (total trays are 6 and each contain two rows of 7 batteries and one rows of 6 batteries, see picture 13 & 14).

Picture 13 - Trays 12/14Ah 12V battery lateral view

Picture 14 – One raw 12/14Ah 12V battery top view

Screw to fix the tray

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2) Install the batteries received in a separate packages and install it in accordance with the picture 15 and picture 16.

Picture 15- 12/14Ah 12V battery connection tray top view

Picture 16-12/14Ah 12V battery connection tray front view

3) After the connection re-insert the battery trays on the internal of UPS.

4) Put back and fix the left/right cover with the four screws.

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9.5 Connection of the Auxiliary Cables

The UPS systems can be connected to external controls/components specifically designed to improve the safety and reliability of the device. External manual bypass (MBCB); External Normal/Bypass selector switch; External output switch (OCB); Remote emergency power off button (EPO); Auxiliary battery contact (BCB). Diesel generator The auxiliary cables are connected to a dedicated terminal board. Wires up to 4 mm2 can be connected to the terminals.

Auxiliary contacts of OCB - MBCB - BCB

The auxiliary contacts of the external switches MBCB, BCB and OCB (if provided) must be mandatorily connected to the UPS.

Picture 17 – Auxiliary terminals 60÷160 kVA

9.5.1 External manual bypass

Auxiliary contact of the external Manual Bypass Switch (if provided) on terminals X10-1/2. A normally open contact is required; when the contact is closed (see Manual Bypass procedure), the microprocessor will acquire the status of the contact and shut down the inverter.

9.5.2 Normal/Bypass selector

Auxiliary contact of the external NORMAL/BYPASS selector on terminals X10-3/4. When the contact is closed the UPS will UPS will transfer the load from inverter to bypass.

9.5.3 UPS output switch

Auxiliary contact of the external UPS output switch (if provided) on terminals X10-5/6. This auxiliary contact is necessary to indicate the position of the isolator (open-closed).. In case the external switch is not provided short-circuit the terminals 5-6.

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9.5.4 Remote emergency power off (EPO)

Auxiliary EPO contact on terminals X10-7/8. The voltage supply to the loads can be interrupted from a remote location by using this contact (i.e. for safety requirements). A normally closed contact is required; when this contact is open the static inverter and by-pass switches are opened so that the output supply is interrupted. In case the external EPO command is not provided short-circuit the terminals 7-8.

9.5.5 Battery auxiliary contact

Battery auxiliary contact on terminals X10-9/10. This auxiliary contact is necessary to indicate the position of the isolator (open-closed).

9.5.6 Diesel Generator auxiliary contact

Auxiliary contact from the Diesel Generator on terminals X10-11/12. A normally open contact must be used; the contact must close when the diesel generator is operating. The microprocessor will acquire the status of the contact and, upon the rectifier start-up, it will enable the "Diesel Mode" operation, that is the operation at reduced DC voltage in order to reduce the power drawn from the AC line.

9.6 Serial interfaces and external connections

The UPS is provided with serial interfaces and external connection facilities for the communication of the operating status and parameters.

Picture 18 – Position of the serial interfaces

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 RS232/USB: it is used for connection to the proprietary programming and control software.  SRC-2 (OPTIONAL): relay card, used for the remote signalizations of status and alarms.  PARALLEL (OPTIONAL): it is used for communication between paralleled UPS units.  MODBUS (OPTIONAL): it is used for the transmission of data to the outside via MODBUS

RTU protocol (RS485).

 THERMAL PROBE (OPTION): it is used to acquire the temperature of the battery

cabinet/room in order to adjust the charging voltage automatically.

 SNMP (OPTIONAL): it is used for the external transmission of data via LAN.  NORMAL/BYPASS SELECTOR

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9.7 Relay Card Connection (Optional)

The UPS, in its full configuration, is provided with a relay card for repeating alarms and operating statuses remotely. The electric connection is carried out directly on the terminals located on the front of the interfaces slot SRC-2.

Picture 19 – Relay card terminals

Relay

Alarms/ Status

Status

LED

Pins

Status in normal operation

Name

Status in normal operation

RL 1

Alarm = A30 COMMON ALARM

Not energized if alarm is present

2 - 3

Closed

DL 1

ON 1 - 2

Open

RL 2

Alarm = A1 MAINS FAULT

Not energized if alarm is present

5 - 6

Closed

DL 2

ON 4 - 5

Open

RL 3

Alarm = A9 BATTERY AUT END

Not energized if alarm is present

8 – 9

Closed

DL 3

ON 7 - 8

Open

RL 4

Alarm = A13 INV OUT OF TOL

Not energized if alarm is present

11 – 12

Closed

DL 4

ON 10 – 11

Open

RL 5

NORMAL MODE Alarm = A16 BYPASS

-> LOAD

Not energized if alarm is present 13 – 14

Closed

DL 5

14 - 15

Open

RL 5

ECO MODE

Status = S7 BYPASS

-> LOAD

Energized if status is present 14 - 15

Closed

13 - 14

Open

Relay output characteristics:

250 Vac voltage 1 A current 30 Vdc voltage 1 A current resistive load

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9.8 UPS-Options (Optional equipment)

Following UPS-Options are described in the operating manual BAX 4834:

 SNMP adapter  PROFIBUS  MODBUS  Battery symmetry supervision  Parallel redundant systems

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10 Startup and Shutdown

Read the technical documentation

Before installing and using the device, make sure you have read and understood all the instructions contained in the present manual and in the technical supporting documentation.

Further information

In the event that the information provided in this manual is not sufficiently exhaustive, please contact the manufacturer of the device, whose details are available in the “Contacts” section.

External isolators

All the procedures that follow make reference to the external isolator BCB and are only valid if such device is installed (externally) and its auxiliary contacts properly wired to the UPS terminals.

10.1 Preliminary checks

Before starting up the unit, make sure that:

 all installation and electric connection works have been performed professionally;  all power and control cables have been properly and tightly connected to the relevant

terminal boards;

 the ground cable is properly connected;  the battery polarity is correct and the voltage is within the operating values;  the phase rotation of the line is correct and the voltage is within tolerance with the operating

values.

 the emergency power off “EPO” push-button, if installed, is not pressed (if not, press it back

to the rest position).

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10.2 Start-Up Procedure

EPO push-button and phase rotation

Before switching the UPS on, make sure that:

1) the emergency power off “EPO” push-button, if installed, is not pressed. If not, press it back to the rest position;

2) the input and output phase rotation is correct.

Circuit breaker BCB

Do not close the battery breaker BCB before it’s required by the front panel. Serious damages to the UPS internal parts and/or to the battery may occur.

Wiring of the auxiliary contacts

Carry out a proper electrical installation by wiring the auxiliary contacts of the external manual bypass, output and battery isolators to the dedicated terminals on board the UPS. This will allow the control logic to acquire the status of the switches and guide the operator during the start-up and manual bypass procedures.

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No.

LCD

Action

Checks

Blank

CLOSE RCB

After operating switch RCB the pre-charging phase of the capacitive bank will start. The control logic will be started and the front panel is activated.

BOOT LOADER

“BOOT” phase where the UPS firmware can be updated following the appropriate procedure. All the LED’s on the front panel are on.

EEPROM READING

Reading of the configuration parameters stored in the EEPROM. All the LED’s on the front panel are off.

EEPROM PARAM. SENDING

Sending of the configuration parameters stored in the EEPROM. All the LED’s on the front panel are off.

PLEASE WAIT

UPS START UP PLEAS WAIT

UPS start-up. LED #1 is on - input voltage present.

RECTIFIER START UP PLEASE WAIT

The IGBT rectifier bridge starts to modulate; VDC voltage reaches the nominal value. LED #3 is lit green: DC voltage present.

INVERTER START UP PLEASE WAIT

The modulation of the inverter bridge is started. The AC output voltage reaches the nominal value. After a few seconds the static inverter switch is closed. LED #5 is lit green: static switch SSI closed.

BYPASS START UP CLOSE SBCB

CLOSE SBCB

BYPASS START UP PLEASE WAIT

The control logic checks that all the bypass parameters (voltage, phase rotation, frequency) are correct. LED #2 is lit green: bypass voltage present

BATTERY START UP CLOSE BCB

CLOSE BCB

BATTERY START UP PLEASE WAIT

The control logic checks the closing of the circuit breaker to go to the following step. Led #4 lit green.

UPS START UP END CLOSE OCB

CLOSE OCB

START UP END PLEASE WAIT

The control logic checks that all the output parameters (voltage, current, frequency) are correct. LED #7 is lit green: output voltage present.

End

UPS NAME NOMINAL POWER

The default screen is displayed after a short time with the UPS name and the nominal power.

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10.3 Basic Troubleshooting

This paragraph provides the basic information if any problems occur during the start-up procedure. In case the problem cannot be solved, contact the service department.

1) After closing RCB the LCD display is still blank

 Check the phase rotation of supply voltage.  Make sure the input voltage and frequency are within tolerance.  Check the rectifier protection fuses F1-F2-F3; they are inside the unit.

2) After step #1 the UPS stops the starting sequence and shows one or more alarm messages

 Check the alarms indicated on the display and remove their causes.  Close RCB and try to restart the UPS.

3) After step #2 the unit shows the alarm A15 – Byp fault

 Make sure the switch SBCB is closed.  Check the protection fuses of the static bypass switch; they are inside the unit.  Check the phase rotation of the bypass voltage.  Make sure voltage and frequency are within tolerance.

4) After step #3 the unit shows the alarm A7 – BCB open

 Make sure you have closed the battery circuit breaker; the circuit breaker or the fuse holder

is external to the UPS system.

 Check the battery fuses.  Check the interconnection between the auxiliary contact of the battery circuit breaker (in the

external cabinet) and the terminals X10-9/10.

Shutdown Procedure

No.

Action

LCD

Checks

Open OCB

A30 GENERAL ALARM

The supply to the load is interrupted. LED #7 off.

Open BCB

A30 GENERAL ALARM

The battery is disconnected from the rectifier. Led #4 red flashing.

Open SBCB

A30 GENERAL ALARM

The bypass supply is disconnected. LED #2 off.

Open RCB

A30 GENERAL ALARM

Rectifier and inverter shutdown.

BLANK

End of shutdown procedure.

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10.4 Switching to Manual Bypass

The load is transferred to Manual Bypass with no interruption of supply to the loads. In this configuration, the system can be restarted via the return procedure from load on manual bypass, without the need to de-energize the loads.

Manual bypass

To perform the switching procedure correctly, make sure no alarms are present on the system. During Manual Bypass the load is supplied directly by the input mains, therefore continuous supply cannot be guaranteed to the loads.

No.

Action

LCD

Checks

Move the bypass selector SW to BYPASS

A30 GENERAL ALARM

The load is transferred to the bypass line. LED #5 off, LED #6 lit orange.

Close MBCB

A30 GENERAL ALARM

The inverter is switched off. The load is supplied by the input mains through the manual bypass switch. The static bypass switch is still closed. Led #8 lit orange.

Open BCB

A30 GENERAL ALARM

The battery is disconnected from the DC bus bar. Led #4 red flashing.

Open RCB

A30 GENERAL ALARM

The supply input is opened; the rectifier shuts down. LED #1 off.

Open OCB

A30 GENERAL ALARM

The load remains fed by the manual bypass switch. LED #8 off.

Open SBCB

A30 GENERAL ALARM

The bypass line is disconnected. The display goes out.

7 BLANK

The load is supplied directly by the mains through the manual bypass switch. The UPS is isolated.

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10.5 Restart from Manual Bypass

Before restarting the UPS from manual by-pass, make sure the “Bypass_SW" selector is in BYPASS position and the MBCB isolator is closed.

No.

LCD

ACTION

Checks

BLANK

Close RCB

BOOT LOADING

“BOOT” phase where the UPS firmware can be updated following the appropriate procedure. All the LED’s on the front panel are on.

EEPROM READING

Reading of the configuration parameters stored in the EEPROM. All the LED’s on the front panel are off.

UPS START UP WAIT PLEASE

The rectifier is supplied and the DC voltage reaches the nominal value. All the LED’s on the front panel are on. The microprocessor checks that all the start-up conditions are good for restart. Led #1 lit green. Led #8 lit orange.

RECTIFIER START UP WAIT PLEASE

The IGBT rectifier bridge starts to modulate; VDC voltage reaches the nominal value. LED #3 is lit green: DC voltage present.

START UP FROM MBCB CLOSE SBCB

Close SBCB

BYPASS START UP WAIT PLEASE

The microprocessor checks that all the bypass parameters (voltage, phase rotation, frequency) are within tolerance. Led #2 lit green. The static bypass switch is closed. LED #6 lit orange.

START UP FROM MBCB CLOSE BCB

Close BCB

Closing of the battery circuit breaker. Led #4 lit green.

START UP FROM MBCB CLOSE OCB

Close OCB

The load is fed by the static bypass switch. Circuit breaker MBCB is still closed. Led #7 lit green.

START UP FROM MBCB OPEN MBCB

Open MBCB

The load is fed by the static bypass switch and the inverter can be started. LED #8 off.

INVERTER START WAIT PLEASE

The modulation of the inverter bridge is started. The AC voltage reaches the nominal value. The microprocessor checks the synchronization with the bypass line.

START UP FROM MBCB MOVE BYP SWITCH

Move the selector “NORMAL-BYPASS” to NORMAL The load is transferred to the inverter. Led #5 lit green.

START UP END WAIT PLEASE

The microprocessor checks that all the output parameters (voltage, current, frequency) are within the tolerance limits.

UPS MODEL OUTPUT VOLTAGE

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11 General UPS Description

11.1 Typology

The UPS described in this manual is on-line, double conversion; the inverter included in the UPS always supplies energy to the load, whether mains is available or not (according to the battery autonomy time). This configuration guarantees the best service to the User, as it supplies clean power uninterruptedly, ensuring voltage and frequency stabilization at nominal value. Thanks to the double conversion, it makes the load completely immune from micro-interruptions and from excessive mains variations, and prevents damage to critical loads (Computer - Instrumentation - Scientific equipment etc.).

Output voltage present

The line connected to the UPS output is energized even during mains failure, therefore in compliance with the prescriptions of IEC EN62040-1-2, the installer will have to identify the line or the plugs supplied by the UPS making the User aware of this fact.

Picture 20 – Block diagram

The UPS uses IGBT technology with a high switching frequency in order to allow a low distortion of the current re-injected into the supply line, as well as high quality and stability of output voltage. The components used assure high reliability, very high efficiency and maintenance easiness.

11.2 System Description

11.2.1 Rectifier

It converts the three-phase voltage of the AC mains into continuous DC voltage. It uses a three-phase fully-controlled IGBT bridge with a low harmonic absorption.

current absorbed by mains (THDi) to less than 3%. This ensures that the rectifier does not distort the supply mains, with regard to the other loads. It also avoids cable overheating due to the harmonics circulation. The rectifier is so sized as to supply the inverter at full load and the battery at the maximum charging current.

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11.2.2 Inverter

It converts the direct voltage coming from the rectifier or from the DC battery into alternating AC voltage stabilized in amplitude and frequency. The inverter uses IGBT technology with a high switching frequency of approximately 8 kHz.

hat, thanks to its processing capability, generates an excellent output sine-wave. Moreover, the fully digital control of the output sine-wave allows to achieve high performances, among which a very low voltage distortion even in presence of high-distorting loads.

11.2.3 Battery and battery charger

The battery is installed outside the UPS. It is generally housed in an external battery cabinet. The battery charger logic is completely integrated in the rectifier’s control electronics. The battery is charged, according to the DIN 41773 Standard, every time it has been partially or completely discharged. When its full capacity is restored, it is disconnected from the DC bus by means of a static switch, in order to save energy, reduce the stress due to the AC ripple thus increasing the lifetime. This operating mode is called Green Conversion. It is however periodically charged but the prevailing state is of complete rest.

11.2.4 Static bypass

The Static Bypass allows to transfer the load between Inverter and Emergency Mains, and vice-versa, in a very short time, and uses SCR’s as power commutation elements.

11.2.5 Manual bypass

The Manual Bypass is used to cut off the UPS completely, supplying the load directly from the input mains in case of maintenance or serious failure.

Follow the procedures contained in the manual

The sequence of manual bypass switching and return must be carried out with respect to the procedure indicated in the installation and start-up section. The manufacturer cannot accept responsibility for damages arising from incorrect operation.

External manual bypass

In the UPS system the manual bypass isolator is optional and installed outside the unit.

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11.3 Operating Status

The UPS has five different operating modes, as described below:

 Normal operation  Green Conversion  Bypass operation  Battery operation  Manual bypass

11.3.1 Normal operation

During normal operation all the circuit breakers/isolators are closed, except for MBCB (maintenance bypass). The rectifier is supplied by the AC three-phase input voltage which, on its turn, feeds the inverter and compensates mains voltage as well as load variations, keeping the DC voltage constant. At the same time, it provides to charge the battery. The inverter converts the DC voltage into an AC sine-wave with stabilized voltage and frequency, and also supplies the load via its static switch SSI.

Picture 21 – Normal operation

11.3.2 Green Conversion

During the operation in Green Conversion mode the battery is disconnected from the DC bus by means of a static switch (see picture) and the rectifier works at reduced DC voltage; a control algorithm provides to periodically re-connect the battery for recharge purposes (intermittent charging).

Picture 22 – Green Conversion

When the Green Conversion algorithm is active the rectifier operates at reduced DC voltage and supplies the inverter alone, since the battery is disconnected from the DC bus.

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The battery charge is controlled by a specific algorithm. In case no mains outage events have occurred, and so no battery discharges have occurred too, the control logic provides to start a charging cycle once every 25 days. The battery-charger restores the capacity lost due to the selfdischarge and remains in floating charge for additional 12 hours. As this time has elapsed the battery static switch is opened and the battery is disconnected from the DC bus. In case a discharge event occurs, the control logic provides to calculate the capacity which has been lost during the discharge; as the mains is restored a charging cycle is started, which is extended for an additional time that depends on the percentage of lost capacity, referred to the rated value.

 Lost capacity < 10%  Additional charge for 12 hours  Lost capacity between 10% and 20%  Additional charge for 48 hours  Lost capacity > 20%  Additional charge for 96 hours

Such values complies with the recommendations of the main battery manufacturers.

Set the right battery capacity

The UPS front panel allows the setting of the battery parameters, including the rated capacity. Considering the importance that such value assumes for the correct execution of the charge control algorithm, it is highly recommended to verify the correctness of the programmed value.

11.3.3 Bypass operation

The load can be switched to bypass either automatically or manually. The manual changeover is due to the BYPASS SWITCH which forces the load to bypass. In case of failure of the bypass line, the load is switched back to inverter without interruption.

Picture 23 – Load supplied by bypass

11.3.4 Battery operation

In case of power failure or rectifier fault, the battery feeds the inverter without interruption. The battery voltage drops based on the amplitude of the discharging current. The voltage drop has no effect on the output voltage, which is kept constant by changing the PWM modulation. An alarm is activated when the battery is near the minimum discharge value. In case the supply is restored before the battery is completely discharged, the system will be switched back to normal operation automatically. In the opposite case, the inverter shuts down and the load is switched to the bypass line (bypass operation). If the bypass line is not available or is out of tolerance, the loads supply is interrupted as soon as the battery reaches the discharge limit threshold (black-out). As soon as the supply is restored, the rectifier will recharge the battery. In the standard configuration, the loads are supplied again via static switch SSB when mains is available again. The inverter is restarted when the battery has partially restored its capacity.

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The system restart from the black-out condition can be customized based on the requirements of the plant, in three different modes:

 Bypass  loads are supplied as soon as the bypass line is available (factory

configuration).

 Inverter  loads are supplied by the inverter (even if the bypass line is available)

when the battery voltage has reached a programmed threshold, after

the rectifier restart.  Man. Inverter  the output supply is NOT restored automatically. The system requires

a confirmation to restart which can only be done manually by the user via the front panel.

Picture 24 – Battery operation

11.3.5 Manual bypass

The manual bypass operation is necessary whenever the UPS functionality is tested, or during maintenance or repair work.

Picture 25 – Manual bypass for functional checks

Follow the procedures contained in the manual

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Wiring of the auxiliary contacts

Carry out a proper electrical installation by wiring the auxiliary contacts of the manual bypass and output isolators to the dedicated terminals on board the UPS. This will allow the control logic to acquire the status of the switches and guide the operator during the start-up and manual bypass procedures.

For further information refer to the section "Installation and start-up".

During the manual bypass due to repair or maintenance, the UPS is completely shut down and the load is directly supplied by the bypass line.

Picture 26 – Manual bypass for repair or maintenance works

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11.4 Control and Operation Devices

The control and operation devices of the UPS are indicated below:

 Isolator on rectifier input (RCB)  Isolator on bypass input (SBCB)  Isolator on UPS output (OCB)  Manual bypass isolator (MBCB)  Battery Isolator / Circuit breaker (BCB) - External, inside the battery cabinet  Emergency power off button (EPO)  Normal/Bypass selector  LCD control panel

Check the personnel training

The use of the operation and control devices of the UPS is intended for authorized personnel only. We recommend to check the training of the personnel responsible for the use and maintenance of the system.

11.4.1 Isolators

The isolators provided on the UPS are used to isolate the power components of the device from the AC supply line, from the storage battery and from the load.

Voltage present on terminals

The isolators do not isolate the UPS completely, since AC voltage is still present on the UPS input terminals. Before carrying out any maintenance on the unit:

 Isolate the device completely by operating the external circuit breakers;  Wait at least 5 minutes in order to allow the capacitors to discharge.

11.4.2 Emergency Power Off Command (EPO)

The emergency power off command is used to disconnect the UPS output immediately, interrupting the loads supply. It also shuts down the inverter.

Operate the command only in case of real emergency

The components of the system are subject to a high stress when the emergency power off command is operated under load presence.

Use the emergency power off button only in case of real emergency.

WÄRTSILÄ JOVYSTAR COMPACT S BAX 5452 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual