TOSHIBA UNINTERRUPTIBLE POWER SYSTEM THREE-PHASE 15/25/30/50 kVA UPS 4200FA CT/XT User’s Manual Document Number: 53878-006 Date: September 2007
TOSHIBA 4200FA CT/XT THREE-PHASE 15/25/30/50 kVA UNINTERRUPTIBLE POWER SYSTEM CT-Internal Batteries XT- External Batteries or External Transformer USER’S MANUAL FOR MODELS C42F3F150X#MBN C42F3F150F#MBN C42#3#150##MXN C42F3F250X#MBN C42F3F250F#MBN C42#3#250##MXN T42F3F300X#MBN T42F3F300F#MBN T42#3#300##MXN T42F3F500XAMBN T42F3F500F#MBN T42#3#500##MXN TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Road Houston, TX 77041-9990
TOSHIBA IMPORTANT NOTICE The Instructions contained in this manual are not intended to cover all of the details or variations in equipment or to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be required or should particular problems arise which are not covered sufficiently the matter should be referred to the local TOSHIBA sales office.
TOSHIBA TABLE OF CONTENTS IMPORTANT NOTICE....................................................................................................... 2 TABLE OF CONTENTS.................................................................................................... 3 Purpose and Scope of Manual ....................................................................................... 5 Contacting TOSHIBA Customer Support Center ..........................................................
TOSHIBA 6.0 Operating the UPS ............................................................................................... 37 6.1 AC Input Mode (Normal Operation).................................................................................................. 37 6.2 Bypass Mode.................................................................................................................................... 38 6.4 Battery Backup Mode ....................................................................
TOSHIBA Purpose and Scope of Manual This manual provides information on how to safely install, operate, and maintain your TOSHIBA power electronics product. This manual includes a section on General Safety Instructions that describes the warning labels and symbols that are used throughout the manual. Read the manual completely before installing, operating, or performing maintenance on this equipment.
TOSHIBA GENERAL SAFETY INSTRUCTIONS DO NOT attempt to install, operate, maintain or dispose of this equipment until you have read and understood all of the product safety information and directions that are contained in this manual. Safety Alert Symbol The Safety Alert Symbol indicates that a potential personal injury hazard exists. The symbol is comprised of an equilateral triangle enclosing an exclamation mark.
TOSHIBA EQUIPMENT WARNING LABELS DO NOT attempt to install, operate, maintain or dispose of this equipment until you have read and understood all of the product warnings and user directions that are contained in this instruction manual. Shown below are examples of warning labels that may be found attached to the equipment. DO NOT remove or cover any of the labels. If the labels are damaged or if additional labels are required, contact your TOSHIBA representative for additional labels.
TOSHIBA DANGER RISK OF ELECTRIC SHOCK Capacitors stay charged after power has been shut off. Accidental contact with live parts can cause personal injury and death. Turn off and lock out all power sources. Wait at least five (5) minutes for power to dissipate then check voltage before servicing. 39561 DANGER HAZARDOUS VOLTAGES Hazardous voltages are used in the operation of this equipment and could cause severe personal injury or loss of life.
TOSHIBA NOTE: This Label for Battery Units Only 4200FA CT/XT User’s Manual 9
TOSHIBA IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during the installation, maintenance, and operation of the UPS and its batteries to assure safe and proper operation 1. Turn off, lockout, and tagout all power sources before connecting the power wiring to the equipment or when performing maintenance. 2.
TOSHIBA The maximum ambient temperature in which the Uninterruptible Power System (UPS) should be operated is 104 °F (40 °C) without batteries, and 89 °F (32 °C) if the battery cabinet is subject to the same ambient temperature as the UPS. The nominal battery voltage for all internal battery models is 288 VDC. The nominal battery voltage for all external battery models is 288 VDC.
TOSHIBA The following precautions should be observed when working with batteries. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) Verify that the “UPS” is off and that the Input Circuit Breaker is in the off position. Remove watches, rings, jewelry, or other metal objects. Use tools with insulated handles to prevent accidental shorts. Wear rubber gloves and boots. Do not lay tools or metal parts on top of batteries. Determine if the battery is grounded. If grounded, remove source of the ground.
TOSHIBA INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITÉ ATTENTION Cette notice contient des instructions importantes concernant la sécurté Un battery puet présenter un risque de choc électrique, de brûlure par transfert d’ énergie. ATTENTION L’élimination des batteries est règlementèe.
TOSHIBA 1.0 Product Description 1.1 Theory of Operation An Uninterruptible Power Supply (UPS) is a system that is installed between the commercial power and the critical load. The UPS provides steady AC output power during commercial power fluctuations and interruptions. During “Normal Operation” the UPS utilizes commercial AC power and removes high voltage spikes and transients caused by switching and faults on the utility. The result of this process is maximum power conditioning and regulation.
TOSHIBA 2.0 Unpacking/Inspection/Storage/Disposal 2.1 Unpacking the new UPS equipment 15/25/30 kVA: Upon receipt of the UPS, a careful inspection for shipping damage should be made. Units shipped within North America are shrink-wrapped; those outside North America are crated. 1. Remove packing material. 1a. For international units, remove the screws that attach the shipping crate to the pallet. Remove the crate and foam packing material. 2. Unbolt the rails from both the unit and the shipping pallet.
TOSHIBA 2.2 Unpacking the new UPS equipment 50 kVA: Upon receipt of the UPS, a careful inspection for shipping damage should be made. Units shipped within North America are shrink-wrapped; those outside North America are crated. 1. Remove packing material. 1a. For international units, remove the screws that attach the shipping crate to the pallet. Remove the crate and foam packing material. 2. Unbolt the rails from both the unit and the shipping pallet. Place the rails on the front of the pallet.
TOSHIBA 2.3 Inspection of the new UPS equipment After Unpacking: 1) Check the unit for loose, broken, bent or other damaged parts. If damage has occurred during shipment, keep all packing materials for return to the shipping agent. The equipment warranty will not apply to units that are damaged during shipment. 2) Check to see that the rated capacity and the model number specified on the nameplate conform to the order specifications. 2.
TOSHIBA 3.0 Installation Precautions Based on the 4200FA UPS external dimensions and the way the outer panels are removed; minimum amounts of unobstructed space around the unit are necessary for ventilation and maintenance access. The following section and Fig. 3.1 shows the minimum clearances required for proper UPS site installation. 3.1 Equipment Placement 1) Do not install the UPS on an inclined surface, or areas that are subject to frequent vibrations or jolting. This could damage UPS circuits.
TOSHIBA 3.2 System Preparation (Pre-Power) Before connecting the UPS to a power source; move the Circuit Breakers (ON/OFF), on the front panel, to the OFF position and move the operation STOP/RUN key switch, on the front panel, to the STOP position. 3.3 Operating Precautions 1) The UPS should not be powered up until the entire User’s Manual has been reviewed, and understood. 2) The input power source voltage must be within +10% to -15% of the rated input voltage to initially start the UPS.
TOSHIBA 13) Additional warnings and notifications shall be posted at the equipment installation location as deemed required by Qualified Personnel. When the UPS is in the Inverter mode, turning the breaker to the OFF position will cause the unit to go into the battery backup mode. The UPS will continue to provide power to the load. The unit must be in Bypass mode and then the breaker turned to the OFF position for the UPS to shut down power to the load.
TOSHIBA 4.1.
TOSHIBA 4.1.3 Recommended Wire Size and Torque Requirements UPS Input and Output Terminals Minimum Wire Size and Torque Requirements UPS Input and Output Terminals 15/25/30 kVA (USE MINIMUM 75 °C INSULATED COPPER WIRING) Phase: (A) (B) (C) 15 kVA 25 kVA 30 kVA Input: (H1) (H2) (H3) AWG Torque AWG Torque AWG Torque 208 V 8 51 in-lbs. 4 51 in-lbs. 2 87 in-lbs. 220 V 8 51 in-lbs. 4 51 in-lbs. 2 87 in-lbs. 240 V 8 51 in-lbs. 4 51 in-lbs. 2 87 in-lbs. 380 V 10 35 in-lbs. 8 51 in-lbs. 6 51 in-lbs.
TOSHIBA 4.1.4 Power Connection Cable Routing and Conduit Placement 15/25/30 kVA The following illustrates the proper cable routing that should be followed during the power connection process of the 15/25/30 kVA. CONDUIT MOUNTING PANEL INPUT CONDUIT OUTPUT CONDUIT BATTERY CONDUIT Note: 1) Input and Output conductors shall be installed in separate conduits, and installed in accordance with the latest edition of NEC and the Local Authority having jurisdiction.
TOSHIBA 4.2 Control Circuit and External Battery Interface Connections 15/25/30 kvA The following illustrates the wiring connections of the Control Circuits, and Battery Interface Circuits. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) 4.2.1 Low Battery Battery Discharge Fault Not Used Inverter Supply Inverter Supply P24A3 Remote Run P24A3 Remote Stop Bypass COMMON EPO EPO Battery Connection (+) Positive (-) Negative (3) Battery Shunt Trip (4) Battery Shunt Trip (5) Battery Aux.
TOSHIBA 4.
TOSHIBA 4.3.
TOSHIBA 4.3.2 Power Connection Cable Routing and Conduit Placement 50 kVA The following illustrates the proper cable routing that should be followed during the power connection process for the 50kVA.
TOSHIBA 4.4 Control Circuit and External Interface Connections 50 kVA The following illustrates the wiring connections of the Control Circuits, and Battery Interface Circuits for the 50kVA. (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) 4.4.1 (3) Battery Shunt Trip (4) Battery Shunt Trip (5) Battery Aux. (6) Battery Aux.
TOSHIBA 4.5 4.5.1 Communication Interface Remote Contact This interface is a standard feature and is available as dry switch contacts through a DB9 male connector located on the front of the UPS. The following schematic shows the contact state and pin assignment for each signal and the associated DB9 connector pinout.
TOSHIBA 4.5.2 RS-232C The RS-232C serial communication interface is available through a DB9 female connector located on the inside of the UPS. This interface allows control of the UPS from a computer network running TOSHIBA RemotEyeII™ software. The computer and the UPS are connected through a serial RS-232C communication port.
TOSHIBA 5.0 Specifications 5.
TOSHIBA 5.2 4200FA 15/25 kVA w/Internal Transformer Model Number Inverter Overload Capacity Bypass Overload Capacity Crest Factor Neutral Line Conductor Harmonic Voltage Distortion C42#3*150#AMXN C42#3*250#AMXN # =(B: 208; H: 220; C: 240; N: 380–415; D: 480; M: 600) VAC *=(F: 208; H: 220 wye; J: 240; P: 380–415 wye; K: 480 wye: M:600) 15 kVA 25 kVA 20.0” x 36.3” x 59.7” (50.8 cm x 92.2 cm x 151.
TOSHIBA 5.
TOSHIBA 5.
TOSHIBA 5.
TOSHIBA 5.
TOSHIBA 6.0 Operating the UPS 6.1 AC Input Mode (Normal Operation) The following illustration shows circuit power flow when the UPS is operating normally in the AC Input Mode. The converter of the UPS, including a boost chopper circuit, converts the AC input power into DC power. The boost chopper circuit maintains a constant voltage and provides current limiting for charging the batteries. It also supplies a DC voltage of the proper level to the inverter section.
TOSHIBA 6.2 Bypass Mode If the UPS unit is severely overloaded or develops an internal fault, power flow is automatically switched from the main circuit to the Bypass circuit. Power flow through the bypass is shown in the following illustration. This changeover occurs automatically in less than 4 milliseconds in phase (Make-Before-Break).
TOSHIBA 6.4 Battery Backup Mode The following illustration shows power flow during the battery backup mode. When commercial AC power failures occur, the batteries instantly begin supplying DC voltage to the main inverter circuit. This circuit inverts (hence; Inverter) the DC power into AC power. The AC power is available at the output. This back-up process will continue until the battery voltage drops below a specific minimum level. When this occurs, the batteries will stop supplying power to the load.
TOSHIBA 6.5 Battery Backup Time and Discharge Process The UPS system, when used in conjunction with a TOSHIBA designed Battery System, is designed to provide several minutes of back-up time (Refer to the Battery System Manual for back-up times). These times are valid when the unit is operating under full load. When these models are operating at half load, the batteries can provide approximately 2 times the specified value.
TOSHIBA 6.7 Battery Recharging The illustration below shows a graphical representation of the UPS battery recharge process after a full discharge. The recharge process usually consists of three steps. During the first step, the charging current is maintained at approximately 4.0 amperes for the 15/25/30 kVA with internal batteries, 10.0 amperes for the 15/25/30 kVA with internal transformer and approximately 11.5 amperes for all 50 kVA models.
TOSHIBA 6.8 Front Panel Layout (All Units) Refer to the following illustration for the entire UPS front panel operating procedures. 4-line 4-lineliquid liquid crystal crystaldisplay display screen screen(see (see Section Section 6.12) 6.9) Emergency Emergency Power powerOff offswitch switch (see (seeSection Section6.9) 6.
TOSHIBA 6.10 Audible Alarm Functions Audible alarms will sound when the UPS is in the Battery Backup Mode, has a fault, is at the low battery voltage, or is in an overload condition. The following chart shows the audible alarm pattern duration for each condition. Time intervals are shown in seconds. The audible alarm can be silenced, by pressing “BUZZ STOP” on the keypad.
TOSHIBA 6.11.1 LED (Light Emitting Diode) System Status The following chart shows the UPS system status that can be determined by decoding the "on" and "off" condition of the LED lamps. It should be used in conjunction with the LCD display and the audible alarms for total system monitoring.
TOSHIBA 6.12.2 Line-2 System Fault Messages Line-2 fault messages are automatically displayed when a system fault is detected. LINE-2 MESSAGES Display Message Translation DCOC DC Over-current DCUB DC Unbalanced DCOV DC Over-voltage OH Overheat (internal) OL Output Overload VOUV Inverter Under-voltage VOOV Inverter Over-voltage 6.12.3 Line-3 System Messages Line–3 messages show load current information, and user selected instructions. 6.12.
TOSHIBA Note: 1) Line-4 will be blank when the BATT key is pressed during Battery Backup Mode with normal battery voltage. 2) The # symbol signifies numerical values or other information supplied by the UPS. 6.13 Initial Battery Charge The UPS Battery System must be charged before it is used for the first time or when the unit has not been used (AC power source removed) for more than 10 days.
TOSHIBA 6.14 Start-up Procedure The UPS batteries must be charged before the UPS is used for the first time or if the unit has not been used (AC power source removed) for more than 10 days. If the batteries are charged then use the following start-up procedure: 1) Verify that all power switches are off, and that the "STOP/RUN” Switch on the UPS is in the “STOP” position. 2) Switch on the power at the Customer Provided UPS input distribution panel. 3) Move the UPS Circuit Breakers to "on.
TOSHIBA 6.15 Shutdown Procedure When turning off the UPS, the following shutdown procedure should be used: Move the “STOP/RUN” key switch, located on the front panel, to “STOP." Operation of the inverter halts. Output power is now provided to the load through the unit's Bypass circuit. While in this state of operation; if a power failure occurs in the commercial power source, the UPS will lose power. Power to the critical load device will be interrupted.
TOSHIBA 6.16.1 From UPS to Maintenance Bypass 1) Move the “STOP/RUN” key switch, located on the front panel, to “STOP." Operation of the UPS inverter stops. Output power is now provided to the load through the Bypass circuit. While in this mode, if a power failure occurs on the commercial power source, the UPS will lose power. Power to the critical load device will be interrupted. The battery charging circuit and chopper circuit remains active.
TOSHIBA 6.17 Keypad Overview The following illustrates the 12-key data entry pad with each key functionally labeled. MONI BATT F1 IN OUT BATT TEST BUZZ STOP MENU ENTER RESET MONI Press to display system-monitoring screens. BATT Press to display UPS battery conditions. F1 Press to change settings of various menus. IN Press to display UPS input conditions. OUT Press to display UPS output conditions. BATT TEST Press to execute On-Line Battery test.
TOSHIBA 6.18 Key Functions 6.18.1 MONI After the UPS has been successfully started, the system will be in the normal 'AC Input Mode' of operation. The LCD screen will automatically display the main MONI (monitor) function. If the MONI key is pressed at this time the screen output will not change. The MONI function automatically monitors the entire UPS system. The LCD screen will automatically switch "off" after a period of keypad inactivity and switch "on" if any key is pressed.
TOSHIBA 6.18.4 BATT Key When the BATT key is pressed during normal 'AC Input Mode' of operation, the LCD screen displays details about the battery capacity. The following system message is displayed: - UPS ON-LINE BATTERY VOLTAGE=324V CHARGE CURR.=0% If an AC input power failure occurs, and no abnormal operating conditions are present, the UPS will switch to standard 'Battery Backup Mode'.
TOSHIBA When the battery test is completed, the previous operation will be resumed and the main system MONI screen will be displayed.
TOSHIBA 6.19 Menu Data Screens 6.19.
TOSHIBA DISPLAY DURATION SET <3 MIN> 30 MIN >Δ/∇: CHANGE DATA >ENTER:ACCEPT CHANGE Press the 'up' or 'down' arrow key to move the marker between the two available idle mode times. Press the ENTER key to save the change or press the MENU key to exit to the main menu and discard the change. Note: If any of the following conditions occur, the LCD-Idle Mode will be inhibited and the LCD will remain on continuously: 1) The UPS has received an EPO command. 2) The UPS is in Battery-Discharge Mode.
TOSHIBA 6.19.6 Output Voltage Adjustment When the MENU key is pressed and held 3-4 seconds during normal 'AC Input Mode' of operation, the LCD screen displays the output voltage on the present output voltage adjust screen: OUTPUT VOLT. ADJUST OUTPUT VOLTAGE.=###% >F1:DATA SET MODE > Δ/∇ :PREV/NEXT SCREEN Press the F1 key to display the following active adjustment screen: OUTPUT VOLT.
TOSHIBA 6.19.
TOSHIBA After the load is reduced, if the STOP/RUN key switch is in the RUN position, the UPS will automatically return to 'Inverter Operation’ after a period of time.
TOSHIBA Press the F1 key again to display the record relating to each subsequent discharge event. BACKUP HISTORY ( #) #MIN##SEC VB=324V BT *PF OL >Δ/∇: EXIT F1: NEXT Press the ‘up’ or ‘down’ arrow keys to return to the Battery Discharge Count screen. BATT DISCHARGE COUNT # TIMES > F1: FOR DETAILS >Δ/∇: TO SCROLL Press the ‘up’ or ‘down’ arrow keys to display the Fault Count screen.
TOSHIBA 7.0 UPS Protection System 7.1 System Protection Features The preceding one-line schematic illustrates the electrical locations of the protection devices on all UPS models. Input Abnormal MBS Overcurrent Overload Bypass MCCB Input Power Isolating XFMR Converter Overcurrent Output Power Inverter Overvoltage/ Undervoltage Charger/ Chopper Low Batteryt External Batteries 7.2 System Protection Functions The following chart shows the built-in UPS fault protection functions on all models.
TOSHIBA Protection Item Memory error (EERR) Internal overheat (OH) DC circuit overvoltage (DCOV) DC circuit overcurrent (DCOC) LCD Message Cause Operation Mode after Fault Audible Alarm Visible Alarm Relay Contact Alarm Auto-Retransfer MAIN EEPROM ERROR Control board chip error OVERHEAT; INTERNAL Fan failure; high ambient DC OVERVOLTAGE Chopper malfunction DC OVERCURRENT Inverter / chopper fault Start is inhibited Bypass operation; chopper and inverter are stopped Yes; continuous buzzer RED fault
TOSHIBA 8.3 9) Parts Replacement The following list shows intervals for periodic maintenance and replacement of certain UPS parts. 1) Batteries: VRLA (Valve Regulated Lead Acid) batteries do not require the adding of water or electrolyte. The charging voltage, temperature, performance and connection resistance must be monitored periodically. Necessary corrective maintenance must be made in order to assure the UPS supplies safe reliable power.
TOSHIBA 9.0 External Dimensions / Shipping Dimensions / Weights 9.1 External Dimensions 15/25/30 kVA 20.0 in. (508 mm) 59.7 in. (1516 mm) 56.0 in. (1422 mm) 36.3 in.
TOSHIBA 9.2 External Dimensions 50kVA 35.5 in. (901 mm) 59.3 in. (1506 mm) 38.3 in.
TOSHIBA 9.3 Shipping Dimensions and Weights Shipping Dimensions, Standard Inches (cm) 42.8 (109) 49.0 (125) 64.6 (164) 67.6 (172) Shipping Dimensions, with crate Inches (cm) 43.5 (111) 49.8 (127) 69.6 (177) 69.6 (177) Shipping Dimensions, Standard Inches (cm) 54.0 (137) 48.0 (122) 64.3 (163) 67.3 (171) Shipping Dimensions, with crate Inches (cm) 54.8 (139) 50.3 (128) 69.9 (178) 69.
INDUSTRIAL DIVISION 13131 West Little York Rd., Houston, TX 77041 Tel: 713/466-0277 Fax 713/466-8773 US 877/867-8773 Canada 800/872-2192 Mexico 01/800/527-1204 www.toshiba.com/ind Printed in the U.S.A.
