WÄRTSILÄ JOVYSTAR COMPACT S BAX 5452 User manual

BAX 5452
Operating manual
Wärtsilä
JOVYSTAR COMPACT S
30/40/50 kVA

Index
Date
Name
Alternation note
0
2015-11-11
D. Busboom
First edition
1
2016-01-28
D. Busboom
16/047
2
2016-11-02
D. Busboom
16/494
3
2016-11-30
D. Busboom
16/539
4
2017-01-10
D. Busboom
17/008
5
2017-01-24
D. Busboom
17/037
6
2017-06-26
D. Busboom
17/196

Contents
1Introduction 5
1.1 General instructions 5
1.2 Overview of warning information 6
2Description 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
3Installation 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
4Operation 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
5Commissioning and decommissioning procedures 44
5.1 Commissioning 44

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
6Servicing 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
7Dismantling and cleaning up 48
8Appendix 49
8.1 Technical data 49
8.2 Other technical documents 50

Wärtsilä JOVYSTAR COMPACT S BAX 5452 - 5 -
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.
Copyright
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.
 Copyright Wärtsilä JOVYATLAS EUROATLAS GmbH. All rights reserved.

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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.
i

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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.
i

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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)
30
40
50
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)
30
40
50
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)
30
40
50
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)
30
40
50
L – mm
505
H – mm
1505
X (min.) - mm
0
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)
30
40
50
Air volume (m3/h)
900
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 (%)
5
Maximum relative humidity (%)
95
Condensation
NO
Rainfall with wind (rain, snow, hail, etc.)
NO
Water with an origin other than rain
NO
Ice formation
NO
The UPS is designed to be installed in an environment that meets the following classifications.
K
Climatic conditions
In accordance with the technical specification
B
Biological conditions
3B1 (EN 60721-3-3)
C
Chemically active substances
3C2 (EN 60721-3-3)
S
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)
30
40
50
Input fuses [A]
Rectifier
63
80
100
Bypass
63
80
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
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