WÄRTSILÄ JOVYSTAR HP 200 kVA User manual

Operating manual
Wärtsilä JOVYSTAR HP
200-800kVA
BAX 4640 E

Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 2 -
Index
Date
Name
Status
0
07.02.2012
D. Busboom
First edition
1
17.02.2012
D. Busboom
12/084
2
23.02.2012
D. Busboom
12/097
3
15.05.2012
D. Busboom
12/243
4
20.11.2012
D. Busboom
12/551
5
20.04.2015
Chr. Fechteler
15/215
6
26.06.2017
D. Busboom
17/196
7
8
9
10

Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 3 -
General notes
Thank you for choosing the Uninterruptible Power Supply (UPS) of the JOVYATLAS JOVYSTAR E-series.
It represents a reliable protection for the attached loads.
Read this instruction carefully
This operating manual includes safety requirements, instructions for installation, as well as working instructions, to assist
you to get the maximum performance out of the UPS.
Keep this instruction on a safe place
It contains important rules for safe operation of this UPS and information for contacting the manufacturer service, in case
of any questions and problems regarding the UPS.
Keeping or recycling of the packing material
The packing material the UPS was projected with great attention in order to protect the UPS from damages during the
transportation. This material is also useful in case of returning the UPS to the manufacturer.
Damages during the transportation are not covered by the manufacturer guarantee.
Obligation to briefing
This operating instruction must be read carefully by all persons working on the UPS prior to installation and initial start-
up. It must also be read by all persons operating the UPS. This operating instruction is a composite part of the UPS. The
operator of this device is obliged to communicate these instructions to all personnel transporting, installing, operating or
maintaining the UPS.
Validity of this document
This operating instruction comprises the current technical specification of the UPS at the time of publication. The con-
tents is informational only and do not constitute a subject of contract.
Wärtsilä JOVYATLAS EUROATLAS GmbH reserves the right to make modifications with respect to contents and tech-
nical data in these operating instructions without prior notification. Wärtsilä JOVYATLAS EUROATLAS is not committed
to continuously update this document and therefore cannot be held liable for any inaccuracies or inapplicable information
in this operation instruction.
Limited guarantee
Our goods and services are subject to the general delivery terms for products of the electrical industry and our general
sales conditions. We reserve the right to change the contents of information with respect to technical data, operation,
weights and dimensions. Claims regarding the delivery of the products should be issued within one week after reception
along with the packing slip. Later claims will not be accepted.
Wärtsilä JOVYATLAS EUROATLAS GmbH will rescind all obligations such as warranty agreements, service contracts
etc. entered into by Wärtsilä JOVYATLAS EUROATLAS GmbH or its representatives without notice in the event of
maintenance and repairs being carried out with anything other than original spare parts.
Use of this document
This operating manual for the UPS is structured, that all necessary work for starting up, maintaining, repairing and oper-
ating the UPS can be performed by qualified personnel.
Copyright
No part of this operating manual may be reproduced or transmitted by any mechanical or electronic means without the
express prior written permission of WÄRTSILÄ JOVYATLAS EUROATLAS GmbH.
Copyright Wärtsilä JOVYATLAS EUROATLAS GmbH 2015. All rights reserved.

Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 4 -
Table of contents
1Technical Data 6
1.1 Autonomy Times, Dimensions And Weights 8
2General Notes 9
2.1 Introduction 9
2.2 Why Using A UPS? 9
3System description 11
3.1 Rectifier 12
3.2 Inverter 12
3.3 Battery and Battery Charger 12
3.4 Static Bypass 12
3.5 Manual Bypass 12
3.6 Front Panel 12
3.7 Operating status 13
3.7.1 Normal operation 13
3.7.2 Load supplied by bypass due to inverter fault 13
3.7.3 Rectifier failure or mains failure 13
3.7.4 Internal Manual bypass 14
4Installation 15
4.1 Reception of the UPS 15
4.2 Transport 15
4.3 Setting up 16
4.3.1 Dimensions Wärtsilä JOVYSTAR HP 200-300 kVA 17
4.3.2 Dimensions Wärtsilä JOVYSTAR HP 400 kVA 19
4.3.3 Dimensions Wärtsilä JOVYSTAR HP 500-600 kVA 21
4.3.4 Dimensions Wärtsilä JOVYSTAR HP 800 kVA 23
4.4 Electrical Connections 26
4.4.1 Terminal Board 27
4.4.2 Internal Connections between both switch cabinets: 30
4.4.3 Battery connection 31
5Operation 32
5.1 Setting Up 32
5.1.1 Start-up troubleshooting 32
5.2 Shut down procedure 33
5.3 Starting the Parallel Redundant System 33
5.4 Switch Off the Parallel Redundant System 33
5.5 Manual bypass procedure 33
5.5.1 Start-up from manual bypass (Single UPS) 34
5.5.2 Initiation of the Manual Bypass in Parallel Redundant Operation 35
5.5.3 Switch Off the Manual Bypass in Parallel Redundant Operation 35
5.6 Front Panel 35
5.6.1 Mimic description 35
5.7 Menu structure 37
5.7.1 Measures 37
5.7.2 Alarms 39
5.7.3 Special 40
5.7.4 Info 43
6Options 46
6.1 Parallel redundant system 46
6.1.1 Additional hardware 46
6.1.2 System layouts 46
6.2 Battery symmetry monitoring 46
6.3 Relay PCB 47
6.4 SNMP-Adaptor 47
6.5 Shut-down software 48

Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 5 -
6.6 Temperature compensation 48
6.7 MODBUS-Adapter 48
6.8 Manual Bypass for JST HP 400-800 kVA 48
7Maintenance 49
7.1 Visual checks 49
7.2 Functional test 49
7.3 Inspection of battery 50
7.3.1 Information about battery operation 50
7.3.2 Battery operating instructions 51
8Status messages and alarms 51
8.1 Measures in case of problems 57
9Customer service 58
10 Appendix 58

Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 6 -
1 Technical Data
Wärtsilä JOVYSTAR HP
Online UPS-Type
200 kVA
250 kVA
300 kVA
Output
Output apparent power (cos φ= 0,9)
200 kVA
250 kVA
300 kVA
Output active power (cos φ= 1)
180 kW
225 kW
270 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)
290 A
362 A
435 A
Rated output current (cos φ= 1,0)
261 A
325 A
391 A
THDU (according to IEC EN 62040-3)
- Linear load
- Non linear load
< 1 %
< 5 %
Input
Input voltage
3 x 400/230 V +15 % -20 %
Input frequency
50/60 Hz ±5 Hz
Input current (at 100 % load, without battery charging)
273 A
341 A
410 A
Input current (at 100 % load, max. battery current)
303 A
383 A
450 A
Input power factor (at 100 % load)
> 0,99
Input current THD (at 100 % load)
< 3 %
Battery
Number of battery cells
300
Compensation charging voltage
680 V (2,27 V/Z)
Cut-off voltage
496 V (1,65 V/Z)
Max. battery charging current (at 100 % load)
30 A
40 A
Max. battery charging current with activated DCM
(Dynamic charging mode, only at partial load)
100 A
Battery charging characteristic
IU (DIN 41773)
Overload capability/Output short circuit characteristic
Overload capability inverter
>100 % to 125 % to 10 min
> 125 % to 150 % to 1 min
> 150 % to 199 % to 10 s
= 200 % for 100 ms
Overload capability static bypass
150 % continuously
1000 % to 1 cycle
Short circuit characteristic (Bypass is available)
Immediate transfer to the bypass
Short circuit characteristic (Bypass is not available)
1. Current limitation to 200 % for 100 ms
2. Current limitation to 125 % for another 5 s
462 A
289 A
580 A
363 A
694 A
434 A
Design/Conformity
Dimensions (W x H x D)
1220 x 1905 x 895 mm
Weight (without battery)
970 kg
1090 kg
1170 kg
Paint
RAL 5026 / RAL 9006
Noise level
< 62 dB
EMV-class according to IEC EN 62040-2
C3
Class of protection according to IEC EN 62040-3
VFI SS 111
International protection
IP 20
Other data
Efficiency normal mode (at 100 % load)
> 95 %
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)
11,0 kW
13,7 kW
16,5 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
1 % every 100 m above 1000 m up to 5000 m
Required air cooling volume
3500 m³/h
4100 m³/h
4500 m³/h
UPS operating ambient temperature
0 to +40 °C
UPS storage temperature
-10 to +70 °C
Battery ambient temperature
(recommended battery ambient temperature, see also
battery operating instruction)
0 to +25 °C
+20 °C
Battery storage temperature
0 to +25 °C
Relative humidity (non condensing)
< 95 %
Wärtsilä JOVYSTAR HP E

Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 7 -
Online UPS-Type
400 kVA
500 kVA
600 kVA
800 kVA
Output
Output apparent power (cos φ= 0,9)
400 kVA
500 kVA
600 kVA
800 kVA
Output active power (cos φ= 1)
360 kW
450 kW
540 kW
720 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)
580 A
724 A
870 A
1060 A
Rated output current (cos φ= 1,0)
522 A
651 A
783 A
954 A
THDU (according to IEC EN 62040-3)
- Linear load
- Non linear load
< 1 %
< 5 %
Input
Input voltage
3 x 400/230 V +15 % -20 %
Input frequency
50/60 Hz ±5 Hz
Input current (at 100 % load, without battery charging)
550 A
687 A
824 A
1099 A
Input current (at 100 % load, max. battery current)
610 A
767 A
904 A
1220A
Input power factor (at 100 % load)
> 0,99
Input current THD (at 100 % load)
< 3 %
Battery
Number of battery cells
300
Compensation charging voltage
680 V (2,27 V/Z)
Cut-off voltage
496 V (1,65 V/Z)
Max. battery charging current (at 100 % load)
60 A
80 A
120 A
Max. battery charging current with activated DCM
(Dynamic charging mode, only at partial load)
100 A
200 A
Battery charging characteristic
IU (DIN 41773)
Overload capability/Output short circuit characteristic
Overload capability inverter
>100 % to 125 % for 10 min
> 125 % to 150 % for 1 min
= 150 % for 10 s
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 150 % for 150 ms
2. Current limitation to 125 % for another 5 s
695 A
579 A
870 A
725 A
1044 A
870 A
1390 A
1158 A
Design/Conformity
Dimensions (W x H x D)
1990 x 1920 x 990 mm
2440 x 2020 x 990 mm
3640 x 1920 x 990 mm
Weight (without battery)
1820 kg
2220 kg
2400 kg
3600 kg
Paint
RAL 5026 / RAL 9006
Noise level
< 60 dB
EMV-class according to IEC EN 62040-2
C3
Class of protection according to IEC EN 62040-3
VFI SS 111
International protection
IP 20
Other data
Efficiency normal mode (at 100 % load)
> 94,5 %
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)
22,0 kW
27,5 kW
33,0 kW
43,3 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
1 % every 100 m above 1000 m up to 5000 m
Required air cooling volume
3500 m³/h
4000 m³/h
4500 m³/h
7000 m³/h
UPS operating ambient temperature
0 to +40 °C
UPS storage temperature
-10 to +70 °C
Battery ambient temperature
(recommended battery ambient temperature, see also
battery operating instruction)
0 to +25 °C
+20 °C
Battery storage temperature
0 to +25 °C
Relative humidity (non condensing)
< 95 %

Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 8 -
1.1 Autonomy Times, Dimensions And Weights
NOTE:
Up to five charging/discharging cycles are necessary for obtaining the specified autonomy times. After-
wards the battery is well formatted and its maximum capacity is available.
200kVA
Autonomy times [min]
6
13
20
27
40
60
Battery type
50 x
JL205580
100 x
JL205560
100 x
JL205580
100 x
JL205600
150 x
JL205600
200 x
JL205600
Type of battery cabinet
1 x B14
2 x B14
2 x B14
2 x B14
3 x B14
4 x B14
Total weight of battery cabinet [kg]
Ca. 1770
Ca. 2740
Ca. 3530
Ca. 4030
Ca. 6040
Ca. 8050
250kVA
Autonomy times [min]
6
14
25
50
70
Battery type
50 x JL205600
100 x
JL205580
150 x
JL205580
200 x
JL205600
250 x
JL205600
Type of battery cabinet
1 x B14
2 x B14
3 x B14
4 x B14
5 x B14
Total weight of battery cabinet [kg]
Ca. 2020
Ca. 3530
Ca. 5290
Ca. 8050
Ca. 10060
300kVA
Autonomy times [min]
6
11
15
27
40
55
Battery type
100 x
JL205570
100 x
JL205580
100 x
JL205600
150 x
JL205600
200 x
JL205600
250 x
JL205600
Type of battery cabinet
2 x B14
2 x B14
2 x B14
3 x B14
4 x B14
5 x B14
Total weight of battery cabinet [kg]
Ca. 2900
Ca. 3530
Ca. 4030
Ca. 6040
Ca. 8050
Ca. 10060
400kVA
Autonomy times [min]
5
12
20
Battery type
150 x JL205560
150 x JL205570
200 x JL205580
Type of battery cabinet
3 x B14
3 x B14
4 x B14
Total weight of battery cabinet [kg]
Ca. 4200
Ca. 4440
Ca. 7140
500kVA
Autonomy times [min]
6
10
15
Battery type
150 x JL205580
150 x JL205590
200 x JL205580
Type of battery cabinet
3 x B14
3 x B14
4 x B14
Total weight of battery cabinet [kg]
Ca. 5380
Ca. 5710
Ca. 7140
600kVA
Autonomy times [min]
5
10
Battery type
150 x JL205580
200 x JL205580
Type of battery cabinet
3 x B14
4 x B14
Total weight of battery cabinet [kg]
Ca. 5380
Ca. 7140
800kVA
Autonomy times [min]
5
10
Battery type
200 x JL205580
250 x JL205580
Type of battery cabinet
4 x B14
5 x B14
Total weight of battery cabinet [kg]
Ca. 7140
Ca. 8925
All data refer to standard-battery (lifetime 10-12 years)
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Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 9 -
2 General Notes
It is mandatory to fulfil al works and safety requirements according to rules and instructions described herein for protect-
ing the personnel working at the UPS as well as maintaining optimal duty-cycles of the UPS. All personnel installing/de-
installing, starting up, and maintaining the unit must be familiar with and observe these safety regulations. Only qualified
personnel may carry out the described work with suitable and intact tools, equipment, test equipment and materials.
Important instructions are highlighted by "CAUTION:", "ATTENTION:", "NOTE:" and indented text.
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 to the UPS or some of its components.
NOTE:
This symbol identifies technical requirements and additional information requiring the operator's atten-
tion.
2.1 Introduction
Congratulations for chosen a UPS out of the JOVYSTAR E series! This type of static UPS incorporates the latest state of
technology in power electronics and digital signal processing. The UPS offers the optimal solution for problems in power
supply of computer-systems. UPS of this series are capable to communicate with different computer operating systems
through a standardized RS232-interface. The necessary software as well as additional hardware like SNMP-adapter or
MODBUS-adapter for remote control of the UPS is available as an option.
JOVYSTAR E UPS are real online systems (UPS-classification VFI SS 111 acc. IEC 62040-3), which prevents the at-
tached loads from mains disturbances like spikes, blackouts and voltage variations. The products are screened by an
effective quality management system.
Therefore the JOVYSTAR E offers a perfect solution for various power supply problems; the reliability of the product is
our major goal since over 60 years of experience in secured power supply and techniques.
The scope of this manual is to describe the UPS and to guide the installer and the user through the correct installation.
The installer and the user will have to read this manual with care and attention and correctly carry-out the instructions
provided, especially those relevant to security according to the local standards and regulations.
NOTE:
The manufacturer declines all responsibility for damages to people or equipment deriving from non-
fulfilment of the instructions mentioned in this manual.
2.2 Why Using A UPS?
The reliable power supply is one of the major issues when installing computer-based process controlling systems. The
main reasons of all disturbances are:
- Spikes, produced by switching devices in the mains distribution
- High frequency superposition caused by welding machines, fluorescence radiation, copy machines and other,
- Voltage variations, due to load variations of big inductive consumers, such as lifts, transformers, machines
and others,
- Voltage breakdown, due to disturbances in the mains,
- Frequency variations, caused by using separate power supply units.
The range of disturbances for the attached loads begins with data errors or storing-loss and extends to hardware failure
or even production blackouts. Therefore the quality of power supply is an important factor for the reliability of electronic
data processing equipment or any other sensitive loads.
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Wärtsilä JOVYSTAR HP 200-800kVA BAX 4640 E - 10 -
The best solution for a secure and safe power supply of critical loads is the use of an Uninterruptible Power Supply
(UPS). The UPS:
- Generates a constant voltage supply and frequency,
- Filters, respective suppresses mains disturbances down to a negligible value,
- Guarantees an uninterruptible power supply of the attached loads during a mains
failure for a specified period.
The UPS of the series JOVYSTAR E is a system, is being connected between the mains and the load. It always guaran-
tees a secure power supply to the load over a specified period of time. In comparison to conventional power sources
(mains, motor aggregates, generators*)) the main advantages of the JOVYSTAR E series are as follows:
-Optimal quality of the output voltage,
-Prevention from spikes, superposition, transient over-voltages etc.,
-Prevention from voltage variations and mains failures,
-Prevention from frequency variations,
-Low noise,
-Small, compact design,
-Remote control facility by SNMP-Adapter or MODBUS-Adapter (option)
*) NOTE:
The operation of a UPS system or other electronic consumers at a generator assumes that the planner
was informed of whether an interworking of the generator with the power electronics is without problems
possible before the installation of the entire system.
Some generators are so laid out that an operation with power electronic consumers is not possible be-
cause of the additional load with harmonics, power factor and commutation notches. In some cases can it
to troubles as tension imbalance, tendency towards oscillations and to the shut-off of the generator come.
Here it can help, to consult the generator manufacturer and to change the regulator of the generator where
appropriate or to make from the first so-called damping windings into the generator.
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