WÄRTSILÄ JOVYCUBE 160 User manual

Operating manual
WÄRTSILÄ
JOVYCUBE 160
BA 5157_en

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Index
Date Name Revision
0 09.03.2016 J. Schulte First edition
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Contents
1 Introduction 5
1.1 General instructions 5
1.2 Overvie of arning information 6
2 Description of the system 7
2.1 Functional description 8
2.1.1 UPS module 8
2.1.2 Static bypass module 9
2.1.3 UPS system 9
2.1.4 Battery 9
2.1.5 Internal, manual bypass 9
2.2 Operating states 10
2.2.1 ormal operation 10
2.2.2 Module error 10
2.2.3 Mains failure 11
2.2.4 Manual bypass 11
2.2.5 Smart bypass 12
3 Installation 13
3.1 Installation 13
3.2 Electrical connections, cross sections, fuses 13
3.2.1 Fuses and cross sections for cable connections to the UPS 14
3.2.2 Connections to the UPS 14
3.2.3 Mounting and connecting the battery 14
4 Operation 15
4.1 Soft are overvie 15
4.2 Touchscreen Display 16
4.3 Controller T4S 16
4.4 Startup/Login 17
4.5 Standard functions 17
4.5.1 [1] AC Input 18
4.5.2 [2] Battery 18
4.5.3 [3] UPS Module 18
4.5.4 [4] AC Output 20
4.6 Toolbar 20
4.6.1 Events 20
4.6.2 Connections 21
4.6.3 Files 21
4.6.4 Parameters 23
5 Start-up and shutdown procedures 27
5.1 Functions of the LEDs on the module 27
5.2 Po er capacity utilisation per phase 27
5.3 Operating principle of the LEDs on the SBP module 28
5.4 Start-up 29

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5.4.1 Problems during start-up 29
5.5 Shutdo n 30
5.6 Start-up from the internal manual bypass 30
5.7 Shutdo n to the internal manual bypass 31
5.8 Start-up of an additional 20kVA CUBE module 31
5.9 Replacing a smart bypass module 32
6 Servicing 33
6.1 Replacing a module 33
6.1.1 Removal 33
6.1.2 Erase missing module from the controller 33
6.1.3 Installation 33
6.1.4 Replacing a fan/resetting the interval 33
6.2 Maintenance 34
6.2.1 Visual inspection 34
6.2.2 Function test 34
6.2.3 Battery inspection 34
6.3 Repairs 35
6.3.1 Spare parts list 35
7 Troubleshooting 36
8 Technical data 42
8.1 20kVA CUBE module 42
8.2 Input data 42
8.3 Output data 42
8.4 Smart Bypass 43
8.5 Battery data 43
8.6 Touchscreen 43
8.7 Controller T4S 43
8.8 Ambient conditions and standards 44
9 Appendix 44

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1 Introduction
Congratulations on purchasing a UPS unit from our WÄRTSILÄ JOVYCUBE series. The static UPS
you have chosen incorporates the latest state of technology in po er electronics and digital signal
processing. It provides an ideal solution to the problems of supplying po er to electronic data processing
systems.
Our JOVYCUBE UPS systems are true online systems (UPS classification VFI SS 111 in accordance
ith IEC 62040-3) 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 po er supply needs.
The reliability of this product is our top priority and the result of more than 65 years of experience in
secure po er supply technology.
1.1 General instructions
Please read these instructions carefully
This operating manual includes safety requirements, instructions for installation as ell as orking
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 non-adherence to
instructions given in this manual.
Please keep 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 (see back page) in the event of any questions or problems
concerning the UPS and its correct operation.
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 ithout prior notification. Wärtsilä JOVYATLAS
EUROATLAS GmbH cannot be held liable for any errors or inaccuracies in this operating manual, in
vie of the fact that no obligation to provide regular updates to it exists.
Limited warranty
Our goods and services are subject to the general terms of delivery for products of the electronics
industry as ell as our general sales conditions. We reserve the right to make changes to this operating
manual – in particular the technical data, operating instructions and eights and measures stipulated in
it – at any time. We ask that any claims in respect of delivered goods be submitted ithin eight days of
receipt of goods, enclosing the relevant packing note. Claims made at a later time cannot be considered.
Wärtsilä JOVYATLAS EUROATLAS GmbH ill cancel ithout notice all obligations entered into by
Wärtsilä JOVYATLAS EUROATLAS GmbH and its agents, such as arranties, service agreements
etc., if replacement parts other than original Wärtsilä JOVYATLAS EUROATLAS GmbH parts or parts
purchased from Wärtsilä JOVYATLAS EUROATLAS GmbH are used in servicing and repair.
Copyright
Any disclosure, reproduction and/or copying of this operating manual, by electronic or mechanical
means, in hole or in part, requires the express prior ritten consent of Wärtsilä JOVYATLAS
EUROATLAS GmbH.
 Copyright Wärtsilä JOVYATLAS EUROATLAS GmbH 2015. All rights reserved.

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1.2 Overview of warning information
Correct operation and servicing and adherence to the safety regulations are essential in order to protect
personnel and ensure that the system is constantly operational. All personnel involved in
installing/dismantling, start-up, operation and service of this equipment must be familiar ith and
observe these safety regulations. Only trained and qualified personnel may carry out the described ork
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 orking and operational procedures requiring absolute
compliance to avoid any danger to personnel.
ATTENTION:
This symbol identifies all orking and operational procedures requiring absolute
compliance to prevent any damage or disruption to the uninterruptible po er 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 po er supply is one of many major issues hen using electronic data processing
and process control systems. The main causes of many interruptions to po er supply are:
 Spikes produced by s itching devices on the mains distribution
 High frequency superposition caused by elding 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 po er supply units
The range of disturbances extends from data corruption to memory leaks and from hard are failure to
production stoppages. Therefore, the quality of the po er supply is key to the reliability of electronic
data processing equipment. The perfect solution for a secure, uninterrupted po er supply for critical
consumers is thus the UPS (Uninterruptible Po er Supply). The UPS:
 Generates a constant supply voltage and frequency
 Reduces mains disturbances and feedback
 Guarantees an uninterruptible po er supply to connected consumers for a specified period
during a mains failure
In comparison ith conventional po er sources such as the mains po er supply or generators*, the
cutting edge technology featured in UPS systems in the JOVYCUBE series brings the follo ing
outstanding advantages:
 Minimum mains feedback caused by active IGBT rectifiers
 Extended communication interfaces
• Serial port (USB) to read out the alarm history and for soft are updates
• SNMP adapter for remote monitoring, data exchange via a LAN connection
• MODBUS adapter for remote monitoring, data transfer using MODBUS protocol via
RS485 interface
• Enhanced capacity and redundancy based on installation of additional modules
• Relay card ith alarm messages for industrial remote monitoring via floating contacts
NOTE:
Operation of a UPS or other electronic consumers using a generator assumes that before
installing the complete system the planner has established hether the generator can be
used in conjunction ith po er electronics.
Some generators are designed such that operation ith po er electronics consumers is
not possible due to the additional loading ith harmonics, po er factor and commutation
notches. In some cases faults may occur such as voltage unbalance, a tendency to
oscillate and the shutting do n 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 indings in the generator from the outset.
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2.1 Functional description
The block diagram sho s the functional design of a JOVYCUBE UPS. It normally comprises several
parallel s itched single modules. The "ICB", "MBCB", "BCB" and "OCB" s itches are used to start and
shut do n the UPS as ell as to s itch over to the bypass. Additionally, for maintenance purposes the
battery can be disconnected from the UPS. The dra ing includes the optional static bypass (smart
bypass).
2‑1 Block diagram of a JOVYCUBE UPS
Key to the block diagram
 Mains/bypass
→ UPS supply
 ICB → Input 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 UPS module
One UPS module on its o n in fact provides all the functionality of a conventional UPS system, including
a rectifier, inverter and battery charger.
The main benefit of these UPS modules lies in their hot-pluggable and hot-s ap capability.
This means that in live operation you can plug additional modules into the UPS cabinet, provided there
are free slots available, and remove modules from it, provided the po er supply of the remained
modules is sufficient.
2‑2 The block diagram gives an description of the topology and operation of a 20kVA module

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2.1.2 Static bypass module
Depending on the operating mode, the static bypass module (SBP module for short) improves the
consumers' supply reliability and/or saves energy. Thanks to the 200 kVA/kW output and a short-circuit
current of max. 2,900 A/20 ms per module and phase, fuse triggering due tom short circuits or load
surges presents no problem.
There are t o operating modes available. These are set either using the s itch on the module or in the
soft are.
In VFI mode (voltage and frequency independent), load is supplied through the UPS. The static s itch
only becomes active in the event of a malfunction, of overload or if there is a short circuit. Load is applied
to the SBP module ithin 5 ms.
In ECO mode, load is supplied permanently via the SBP module. As mentioned above, this offers the
benefit of reduced energy consumption. In the event of failures and/or mains grid irregularities, battery
mode is engaged immediately, thus ensuring critical load.
2 - 1 Topology with shared input 2 - 2 Topology with separate input
As the diagrams sho , the module is connected in parallel to the 20 kVA UPS modules.
The module's dimensions correspond to those of a UPS module. The SBP can therefore be retrofitted
into an existing system ithout difficulties provided there is sufficient space and shared input is ensured.
2.1.3 UPS system
A UPS system normally comprises several UPS modules interconnected inside a UPS cabinet by ay
of a rail system hich together supply the po er needed by the connected consumers.
If you install an additional UPS module in such a UPS system you ill be sure of maintaining the best
possible safe supply to connected consumers, as the redundant UPS module maintains the po er
supply in the event of a technical fault in one of the primary modules.
In such a case you can easily and conveniently replace the faulty UPS module ith a ne one hile the
other modules continue supplying the connected consumers.
2.1.4 Battery
The battery orks in standby parallel operation, hich 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.
2.1.5 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
NOTE:
The block diagrams include the optional SBP static bypass. It is integrated into the system depending
on the UPS design.
2.2.1 Normal operation
In normal operation, all the installed UPS modules supply the connected consumers, ith the po er
demand being spread equally across all the UPS modules.
Online operation
 The mains feeds the rectifiers.
 The rectifiers provide the DC voltage for the inverter and charge the battery.
 The inverters supply the load at the output ith the necessary energy.
2‑3 Online operation: load supplied via the inverter
2.2.2 Module error
 The mains feeds the rectifiers.
 The rectifiers provide the DC voltage for the inverter and charge the batteries.
 In the event of a module error, the module concerned is shut do n and the load is distributed
across the remaining modules, provided enough reserve is available. If not enough reserve as
available, the UPS ould s itch to overload mode and so supply to the consumers ould no
longer be assured. For that reason, e recommend running a redundant 20kVA module in
parallel.
2‑4 Module error: Load supplied via the remaining UPS modules