UNINTERRUPTIBLE POWER SYSTEM (UPS) G9000 SERIES INSTALLATION AND OPERATION MANUAL 480/480 V 80/100/160/225/300/500/750 kVA Document: 4GBA0012 Rev.
G9000 Installation and Operation Manual
G9000 SERIES INSTALLATION AND OPERATION MANUAL 480/480 V 80/100/160/225/300/500/750 kVA Document No. 4GBA0012 Rev.
G9000 Installation and Operation Manual
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.
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.
Table of Contents List of Tables ........................................................................................................................................... ii List of Figures ..........................................................................................................................................iii How to use this Manual ........................................................................................................................... 1 1 INTRODUCTION .............
List of Tables Table 1.1 UPS installation environment ................................................................................... 4 Table 1.2 Rating of bypass input circuit breaker .................................................................... 5 Table 1.3 Power specifications ................................................................................................. 20 Table 1.4 UPS module information ...............................................................................
List of Figures Figure 1.1 Single line diagram – normal operation .................................................................... 8 Figure 1.2 Single line diagram – bypass operation ................................................................... 9 Figure 1.3 Single line diagram – battery operation .................................................................... 10 Figure 1.4.1 UPS parts location (80,100kVA)...............................................................................
Figure 2.18 The connector (CN1) of PSAU-60 (PS1).................................................................. 44 Figure 2.19 The terminal block (TN) of PSAU-60 (PS1) ............................................................. 44 Figure 2.20 The connector (CN44) of PSAU-60 (PS1) ............................................................... 44 Figure 2.21 The connector (CN27) of DPAU-60 (SW1) .............................................................. 44 Figure 3.
How to use this Manual This manual is designed for ease of use, giving the user easy and quick reference to information. This manual uses notice icons to draw attention to the user important information regarding the safe operation and installation of the UPS. The notice icons used in this manual are explained below, and should be taken into account and adhered to whenever they appear in the text of this manual.
1 INTRODUCTION The Toshiba Uninterruptible Power Supply System (UPS) is designed to provide many years of reliable protection from power failure, brown-outs, line noise, and voltage transients. To ensure optimum performance of the equipment, follow the manufacturer's instructions. This manual contains descriptions required to operate the UPS. Please read this manual carefully and retain it for future reference. IMPORTANT SAFETY INSTRUCTIONS 1.1.1.1.1.1.1.
WARNING 2 CAUTION In no event will TOSHIBA be responsible or liable for either indirect or consequential damage or injury that may come from the misuse of this equipment. Don’t modify the UPS entirely or partially. Any modifications without authorization by TOSHIBA could result in personal injuries, death or destruction of the UPS. PROHIBIT 1.1 SAFETY PRECAUTIONS APPLICATION This UPS shall NOT be applied to support equipment (*) that could affect human lives.
! WARNING 3 NOTE The UPS is to be installed in a controlled environment. Improper storage and installation environment may deteriorate insulation, shorten component life and cause malfunctions. Keep the installation environment per standard described as follows: UPS Installation Environment TABLE 1.1 No.
! WARNING 4 NOTE This UPS does not include a Bypass input circuit breaker (MCCB) to protect the bypass circuit. The Bypass input circuit breaker (MCCB) is to be field supplied and installed. Recommended Breaker (MCCB)'s Specifications are as follows: TABLE 1.
1.2 GENERAL The Toshiba G9000 UPS is designed to provide continuous and clean electrical power to a critical load. Additionally the UPS monitors power conditions affecting the load. In the event of an input power failure, the UPS will supply power to the critical load for the specified battery time. If the input power is not restored promptly, back up power from the UPS battery permits the orderly shutdown of equipment supported by the UPS. The UPS is simple to start-up, operate and maintain.
1.3 DEFINITIONS UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS Module Cabinet and associated batteries that function as a system to provide continuous, conditioned AC power to a load. This is sometimes referred to as the "System". UPS MODULE CABINET - The metal enclosure which contains the Converter / Charger, Inverter, Static Transfer Switch, Internal Bypass line, operator controls, and internal control systems required to provide specified AC power to a load.
1.4 OPERATION OVERVIEW The UPS provides two power paths between the utility source and the critical load. Figure 1.1 shows the path for normal operation, with the load powered by the inverter. Figure 1.2 shows the path for bypass operation, with the load supplied through the static bypass line. A) Normal operation: Load power supplied by each system UPS inverter. FIGURE 1.
In the event of a UPS module failure during Parallel Operation, the critical load power will be continually supplied and shared by all other UPS. ! The Bypass Input breaker and cables are to be supplied and installed by the user or the constructor. (See WARNING 4 on page 5) NOTE B) Bypass Operation: Load Power supplied through UPS internal static bypass line. FIGURE 1.2 Single Line Diagram - Bypass Operation: Load fed through static bypass line.
In the event of a load overcurrent, the UPS transfers to bypass without interruption to the critical load. In the case of the Parallel Operation, all UPS will transfer to bypass without interruption to the critical load. The internal control system determines the operation of the two paths, with the load powered from the inverter being the normal operation. C) Battery operation: Load Power supplied by UPS battery. FIGURE 1.
When power is restored after a low battery shutdown, the UPS converter(s) automatically restarts operation, the charger(s) recharges the batteries and the Inverter(s) is automatically restarted without operator intervention. Load is automatically assumed by the inverter without operator intervention.
FIGURE 1.4.1 UPS Parts Location (80,100kVA) UPS module 8. Parallel I/F PCB IFAU-08 Front View CPMS EMB CPMC 88F Inverter, Converter, Charger Unit 5. Relay PCB RYAU-09 1. LCD touch panel monitor display 2. Display PCB DPAU-81 4. Main PCB UPGR-M 6. External Communication Connector 7. Parallel control PCB TLCR-C 3. External I/F PCB IOAU-09 Ground Fault Sensor FDAU-04 CB3 10. Grounding Bar (E) 52C 52S CB1 * Item 9 (AC input, AC output, DC input terminal) is not shown in Figure 1.4.1.
FIGURE 1.4.3 UPS Parts Location (300kVA) a) UPS cabinet – Front View b) Door Backside (Main Cabinet) 1. LCD Touch Panel Monitor Display Door Door 1. LCD Touch Panel Monitor Display 5. Power Supply PCB PSAU-73 2. Display PCB DPAU-81 Power Supply PCB PSAU-60 Ground Fault Sensor FDAU-04 6. External Communication Connector 4. Main PCB UPGR-M Landing Cabinet Main Cabinet c) UPS cabinet – Front Inside View 52S CPMC CB3 CPMS 3. External I/F PCB (IOAU-09) EMB CB1 52C 9. AC Input A, B, C 9.
FIGURE 1.4.4 UPS Parts Location (500kVA) a) UPS cabinet – Front View 1. LCD Touch Panel Monitor Display Left Door b) Backside of Left Door 1. LCD Touch Panel Monitor Display Right Door Door 2. Display PCB DPAU-81 Power Supply PCB PSAU-60 4. Main PCB UPGR-M 6. External Communication Connector Landing Cabinet Main Cabinet c) UPS cabinet – Front Inside View 52S CB3 CPMC 3. External I/F PCB (IOAU-09) CPMS CB1 EMB 52C 9. AC Input A, B, C 9.
FIGURE 1.4.5 UPS Parts Location (750kVA) a) UPS cabinet – Front View Door Left Door 1. LCD Touch Panel Monitor Display b) Backside of Left Door 6. External Communication Connector Right Door 1. LCD Touch Panel Monitor Display 2. Display PCB DPAU-81 4. Main PCB UPGR-M Landing Cabinet Main Cabinet c) UPS cabinet – Front Inside View 52S 5. Power Supply PCB (PSAU-73) 3. External I/F PCB (IOAU-09) CPMC CPMS CB3 EMB CB1 52C 9. AC Input A, B, C 9.
FIGURE 1.5 Display PCB DPAU-81 CNV.SW switch 11. SW1 RESET switch START button STOP button FIGURE 1.6 13. SW6 MAINTENANCE button 12. SW5 TEST switch External I/F PCB IOAU-09 17.
FIGURE 1.7.1 Parallel I/F PCB IFAU-08 (80-225kVA) IFAU-08 CBIN CBOUTCAIN CAOUT CN94 TLIN TLOUT CN96 CN95 CN97 CN96 TLOUT TLBOUT TLAOUT G9000 Installation and Operation Manual DAS-8S ON 1... TLAIN OFF DAS-8S CN98 TLIN TLBIN ON 1... CN99 CN954 CN953 CB2IN CB1IN CIN CN952 CN951 CA2IN CA1IN OFF 8 Parallel I/F PCB IFAU-09 (300-750kVA) 8 FIGURE 1.7.
FIGURE 1.8 MAIN PCB UPGR-M 15. SW3 52L S/W switch 14. SW2 BOOT switch 11. SW1 RESET switch Description of Figures 1.4.1-5 to 1.8: 1. LCD Touch Panel Monitor Display The Liquid Crystal Display (LCD) Touch Panel Monitor Display indicates power flow, measured values and fault and error messages via user selectable display screens. Refer to FIGURE 2.1 for details. 2. Display PCB DPAU-81 (Figure 1.
4. Main PCB UPGR-M (Figure 1.8): Switches on UPGR-M board : FOR SERVICE PERSONNEL ONLY - (11) SW1 (RESET switch) - (14) SW2 (BOOT switch) - (15) SW3 (52L S/W switch) 5. 6. a) Relay PCB RYAU-09 (80-225kVA) b) Power Supply PCB PSAU-73 (300-750kVA) External Communication Connector RS232C connector on DPAU-81 board : FOR SERVICE PERSONNEL ONLY Refer to FIGURE 2.18 for details. 7.
1.5 SPECIFICATIONS The UPS nameplate displays the rated kVA as well as nominal voltages and currents. The nameplate is located on the inside of the UPS front door. TABLE 1.3 Power Specifications Rated output Input voltage Bypass input voltage Output voltage Power 3 phase / 3 wire 3 phase / 3 wire 3 phase / 3 wire 80kVA / 72kW 480V 480V 480V 100kVA / 90 kW 480V 480V 480V 160kVA / 144kW 480V 480V 480V 225kVA / 202.
TABLE 1.4 UPS Module Information a) Overall Dimension Width UPS [in.] [kVA] (mm) 27.6 80 (700) 27.6 100 (700) 35.4 160 (900) 35.4 225 (900) 51.2 300 (1300) 70.9 500 (1800) 90.6 750 (2300) Depth [in.] (mm) 32.8 (832) 32.8 (832) 32.8 (832) 32.8 (832) 32.7 (830.6) 32.7 (830.6) 32.7 (830.6) Height [in.] (mm) 80.6 (2,047) 80.6 (2,047) 80.6 (2,047) 80.6 (2,047) 80.7 (2,050) 80.7 (2,050) 80.7 (2,050) Net Weight [lbs.
TABLE 1.5.a Detail of Specifications Rated Output kVA Rated Output kW AC INPUT Configuration Voltage Frequency Power Factor Input kVA (Max Input kVA) Walk-in Function Start-up Delay Input Current (Max Input Current) Input Current Limiter Reflected Current THDi 80 72 100 90 76 kVA 95 kVA (86 kVA chg) (107 kVA chg) 91 A (103 A) 160 144 225 202.5 300 300 500 500 3 phase, 3 wire 480 V (+15% to -20%) 60 Hz (+/-10%) >.
Rated Output kVA Batt. Capacity Required at Full Load Output Number of Cells 80 75 kWB 100 94 kWB 160 149 kWB 225 210 kWB 300 311 kWB 500 518 kWB 750 776 kWB 240 AC OUTPUT Configuration Voltage Voltage Regulation Voltage Adj. Range Voltage Unbalance THD (VOUT) Crest Factor Transient Response Transient Recovery Time Frequency Frequency Synch.
Rated Output kVA 80 Enclosure Audible Noise Listings/Standards 100 160 225 300 500 750 NEMA 1 70 dB @ 1 m 72 dB @ 1 m 73 dB @ 1 m UL; cUL; FCC Class A-Article 47 – Part 15 B; UL; cUL; IEC 62040-2; ISO 9001; ISO14001; ANSI C62.41 (IEEE 587 Cat. B) ISO 9001; ISO14001; ANSI C62.41 (IEEE 587 Cat. B) 3 Years Parts and Labor Included Warranty Emergency Power Off MONITORING Dry Contacts Included RS232 Port Intelligent Monitoring (Optional) Display TABLE 1.5.
TABLE 1.6 Rating of Contactors, Breakers and Fuses OUTPUT CAPACITY OF EQUIPMENT NUMBER Contactor CB1 Breaker AC input contactor 80kVA 100kVA 160kVA 225kVA 300kVA 500kVA 750kVA 72kW 90kW 144kW 202.
2 OPERATOR CONTROLS AND INDICATORS The G9000 Series operator controls and indicators are located as follows (Door exterior) : FIGURE 2.
2.1 LED DISPLAY 1) Load on inverter [ LOAD ON INVERTER ](green) Illuminates when power is supplied from inverter to the critical load. (Indicates the state of inverter transfer switch "52C".) 2) Battery operation [ BATTERY OP. ](orange) Illuminates when power is supplied from batteries following a power failure. 3) Load on bypass [ LOAD ON BYPASS ](orange) Illuminates when power is supplied to load devices by static bypass. (Indicates the state of bypass transfer switch "52S".
2.3 LIQUID CRYSTAL DISPLAY (8) The Liquid Crystal Display (LCD) touch panel indicates power flow, measured values, operational guidance, data records and error messages. The LCD panel has a back-light which facilitates viewing in different ambient lighting conditions. The LCD will automatically clear and turn off, if the screen is not activated within 3 minute period. The LCD is turned back on when it is touched again.
FIGURE 2.3.1 FIGURE 2.3.2 Startup/Shutdown Guidance Startup guidance FIGURE 2.3.3 Shutdown guidance Follow Startup/Shutdown guidance accordingly. B) MEASUREMENT MENU (FIGURES 2.4.1 to 2.4.3) This screen shows details of measured values. Input and Output values are displayed. During Battery operation, Remaining battery power and Run time are also displayed. FIGURE 2.4.
FIGURE 2.4.2 C) Output values FIGURE 2.4.3 Values in Battery operation OPERATION MENU (FIGURES 2.5.1 to 2.5.2) This screen prompts the user to select: (a) whether the start & stop operation will be performed by local or remote operation; (b) date & time adjustment; (c) battery equalizing charge. The battery equalizing charge operation key will appear when battery equalizing charge is set up (Setup is based on battery type). FIGURE 2.5.1 Remote/Local operation select FIGURE 2.5.
D) LOG MENU (FIGURES 2.6.1 to 2.6.3) This LOG MENU displays two Touch icons in EVENT LOG and BATTERY LOG. Pressing the EVENT LOG icon, up to 50 condition/operation records will be displayed. Press ▲ or ▼ button for page turning. Pressing the BATTERY LOG icon, Number of battery operations and Summed battery operation time are displayed. FIGURE 2.6.1 FIGURE 2.6.2 Event log G9000 Installation and Operation Manual Log menu FIGURE 2.6.
2.3.2 Input Power Failure During an Input Power Failure, the UPS inverter will be powered by the UPS batteries. The following will be displayed on the main and measurement screen (Indication of battery operation and remaining battery time). FIGURE 2.7.1 Main screen (Battery operation) FIGURE 2.7.2 Measurement screen (Battery operation) The LCD will display a battery low voltage message when the battery capacity is near depletion.
1) MESSAGE The display shows a fault code, the description of the fault and a guidance of what action is to be taken by the user. A maximum of 10 faults are displayed at one time. If an input power failure occurs during a fault condition, the fault indication and input power failure announcement are alternatively displayed at 5 second intervals. FIGURE 2.9 2) Message screen SILENCE ALARM This icon will appear when a failure occurs.
2.4 EXTERNAL SIGNAL TERMINAL BLOCK The UPS is equipped with a series of input/output terminals for external annunciation of alarms and for remote access of certain UPS functions. The layout of terminals is shown in Figure 2.10.1 and 2.10.2 with a functional description of the input/output port presented. OUT1 to OUT8 are user programmable, but factory default settings are shown in Figure 2.10.1. Adding same external I/F PCB “IOAU-09”, doubling signal outputs is applicable for OUT1 to OUT8. FIGURE 2.10.
FIGURE 2.10.2 External Signal Terminal Block (NEC Class2) TN1 2 4 6 8 10 12 14 16 18 20 1 3 5 7 9 11 13 15 CB2 UVR Battery Breaker Panel CB2 AX 52L AX Load Circuit Breaker IN1: REMOTE INVERTER START IN2: REMOTE INVERTER STOP (User supplied dry contact) IN3: BATTERY TEMP.
A) Output Contacts (for external alarm annunciation) Output contacts consist of form “A”(NO) dry type contacts. Rated capacity of all output contacts is NEC Class2 (30Vdc/1Adc). All dry contacts should be operated at their rated values or lower. Figure 2.11 illustrates a typical installation. The external relay can also be a lamp, LED, computer, etc. FIGURE 2.
! The UPS is equipped with a selectable output contact feature. The above alarms are the default settings. Contact Toshiba International Corporation for setup information. NOTE B) Input Contacts (for remote access of UPS) External contacts are provided by the user of the UPS system. Terminal voltage at the UPS is 24VDC. Provide external dry contact accordingly. Do not apply voltages to remote access input terminals. Damage to UPS may result. PROHIBIT Refer to Figure 2.
Details of input contacts for remote access : TN1 Terminals 7 to 8 Remote "Inverter Start" input terminal (IN1) Used to start inverter from a remote location. UPS must be programmed for remote operation. Refer to Operations Menu for procedure. Terminals 9 to 10 Remote "Inverter Stop" input terminal (IN2) Used to stop inverter from a remote location. UPS must be programmed for remote operation. Refer to Operations Menu for procedure. Terminals 11 to 12 "Battery Temp.
2.5 RemotEyeII INTRODUCTION The “RemotEyeII”* is available as a UPS system monitoring tool. The RemotEyeII supplies a network function to monitor UPS units via Simple Network Management Protocol (SNMP) and Hypertext Transfer Protocol (HTTP) methods. The RemotEyeII module is installed at the rear of the front door in G9000 UPS units. The configuration of the RemotEyeII is shown in FIGURE 2.13.1 (80-225kVA), FIGURE 2.13.2 (300kVA) and FIGURE 2.13.3 (500-750kVA). FIGURE 2.13.
FIGURE 2.13.2 Configuration of the RemotEyeII (300kVA) Back of the front door (Main cabinet) RemotEyeII DPAU-81 (SW1) Cable2 Cable3 (provided) PSAU-60 (PS1) Cable1 (provided) * Consult Toshiba International Corporation for details on“RemotEyeII” monitoring software and its capabilities.
FIGURE 2.13.3 Configuration of the RemotEyeII (Overview: 500-750kVA) Back of the front left door (Main cabinet) Cable2, Cable3 (provided) RemotEyeII PSAU-60 (PS1) Cable1 (provided) DPAU-81 (SW1) * Consult Toshiba International Corporation for details on“RemotEyeII” monitoring software and its capabilities.
The Power Supply PCB (PSAU-60, designated as PS1) and the Cable1 (designated as 3BBA0083P001) are equipped with G9000 UPS units. The Cable2 (D-sub 9pin) and the Cable3 (12V power cable) are included in the RemotEyeII package. The Power Supply PCB (PS1) provides connectivity between the Display Control PCB (DPAU-81, designated as SW1) and the RemotEyeII module in G9000 UPS units. The RemotEye II communicates with the UPS via a Cable2. The connection is described in FIGURE 2.14 below.
The parts (included RemotEyeII) for UPS monitoring are listed below. TABLE 2-1 Parts No. Parts list for UPS monitoring Part name Qt’y 1 PSAU-60* :Power supply PCB (PS1) 1 2 3BBA0083P001 :Cable1 1 3 RemotEyeII module 1 4 D-sub 9-pin to RJ45 Cable:Cable2 1 5 12V Power Cable:Cable3 * – PCB revision suffix may be applied. 1 FIGURE 2.15 PSAU-60 PCB (PS1) D-sub connector CN1 to be connected with RemotEyeII. Connector CN44 to be connected with CN27 of DPAU-81(SW1).
2.6 CONNECTOR DEFINITION FIGURE 2.18 5 4 3 2 1 9 8 7 6 The connector (CN1) of PSAU-60 (PS1) DB9 Description Pin 1 Not used Pin 2 RXD Receive data Pin 3 TXD Transmit data Pin 4 Not used Pin 5 GND Signal ground Pin 6 Not used Pin 7 Not used Pin 8 Not used Pin 9 Not used D-SUB 9Pin (male) FIGURE 2.19 1 P The terminal block (TN) of PSAU-60 (PS1) TB2 Pin 1 Pin 2 +12VS GND(S) Description +12VDC +12VDC ground N 2 Terminal Block 2Pin FIGURE 2.
3 3.1 INSTALLATION AND OPERATION TRANSPORTATION AND INSTALLATION TABLE 3.1 How to transport and install the system Transportation Installation Transport unit with forklift. Using the pre-drilled four holes in the UPS If carry by overhead crane, use four M12 channel base, anchor the unit using eyebolts. (Not provided) appropriate hardware. (Not provided) Do not transport UPS cabinet laid horizontally. PROHIBIT ! Cabinets must be maintained upright within ± 15° of the vertical during handling.
D) External Battery Supply Please refer to the following when installing and maintaining batteries: 1. The customer shall refer to the battery manufacturer's installation manual for ! battery installation and maintenance instructions. 2. The maximum permitted fault current from the remote battery supply, and the DC voltage rating of the battery supply over-current protective device are NOTE shown in Table 3.3. TABLE 3.3 Maximum Permitted Fault Current 3.
! NOTE 3. After the completion of the input power cables connection: With a phase rotation meter, check that the phase rotation of the AC Input power terminals A, B and C as well as the Bypass Input power terminals A40, B40 and C40 are correct. The proper phase rotation is clockwise A(R) → B(S) → C(T). Connect the grounding conductor from the input service entrance to the UPS Ground Bar (E). 4.
(3) Connect the external signal terminal block as desired. Refer to Section 2.4 and Figure 2 2.10 for functional description. 14 AWG (2mm ), or less, shielded conductor is recommended. 1. Confirm that all UPS internal contactors (breakers) "CB1", "CB2", and "CB3" ! are open before energizing UPS. 2. UPS power terminals are supplied with stud type fittings. It is recommended that compression lugs be used to fasten all input/output power NOTE 6. cables.
TABLE 3.4 Recommended Cable Sizes kVA Input Output Capacity Voltage Voltage 80kVA 480V 480V 100kVA 480V 480V 160kVA 480V 480V 225kVA 480V 480V 300kVA 480V 480V 500kVA 480V 480V 750kVA 480V 480V Input Side Cable Size 1 AWG – 1/0 AWG 2/0 AWG – 3/0 AWG 250 MCM – 300 MCM 500 MCM – (2) x 250 MCM (2) x 250 MCM – (2) x 300 MCM (3) x 300 MCM – (3) x 350 MCM (4) x 350 MCM – (5) x 250 MCM Torque ft. lbs 17-22 ft. lbs 17-22 ft. lbs 17-22 ft. lbs 17-22 ft. lbs 29-39 ft. lbs 29-39 ft.
TABLE 3.5 Crimp Type Compression Lug WIRE WIRE RECOMMENDATION SIZE STRAND (CODE) CLASS VENDOR CAT. NO.
FIGURE 3.2.1. Diagram of input/output bus bars and terminal blocks (80-225kVA) Location of bus bars and terminal blocks (Bottom Entry) Detailed Power Terminals H=80.6” (2047mm) D=32.8” (832mm) 160kVA to 225kVA : 35.4” (900mm) 80kVA to 100kVA : 27.6” (700mm) For power terminals, use 1/2” (12mm) Diameter bolts.
FIGURE 3.2.2. Diagram of input/output bus bars and terminal blocks (300kVA) Location of bus bars and terminal blocks (Bottom/Top/Left Side Entry) H=80.7” (2050mm) D=32.7” (830.6mm) External Block IOAU-09 Detailed Power Terminals For power terminals, use 1/2” (12mm) diameter bolts. 51.2" (1300) A AC Input AC Input A, B, C Grounding Bar C A40 78.7" (2000) Bypass Input A40, B40, C40 DC Input BP, BN AC Output A50, B50, C50 Bypass Input B40 C40 BP DC Input BN A50 Grounding Bar (not shown) 15.
FIGURE 3.2.3. Diagram of input/output bus bars and terminal blocks (500kVA) Location of bus bars and terminal blocks (Bottom/Top/Left Side Entry) H=80.7” (2050mm) D=32.7” (830.6mm) Detailed Power Terminals For power terminals, use 1/2” (12mm) diameter bolts. A 70.9" (1800) External Block IOAU-09 AC Input AC Input A, B, C B E Grounding Bar C A40 78.
FIGURE 3.2.4. Diagram of input/output bus bars and terminal blocks (750kVA) Location of bus bars and terminal blocks (Bottom/Top/Left Side Entry) Detailed Power Terminals H=80.7” (2050mm) D=32.7” (830.6mm) For power terminals, use 1/2” (12mm) diameter bolts. 90.6" (2300) External Block IOAU-09 A AC Input AC Input A, B, C B E Grounding Bar C A40 78.
FIGURE 3.3.
FIGURE 3.3.
FIGURE 3.3.
FIGURE 3.4.
FIGURE 3.4.
FIGURE 3.4.
FIGURE 3.
FIGURE 3.
FIGURE 3.7.1 Diagram of Power Wire & Control Wire Connections for 4 units in MMS Configuration (80-225kVA) UPS-1 IFAU-08 CN96 TLIN *1 IOAU-09 TN1 5 6 CN95 TLOUT CN94 CBIN CBOUT Use Ethernet STP (Shielded Twisted Pair) Cable for all communication cabling. Use of UTP (Unshielded Twisted Pair) Cable may cause malfunction.
FIGURE 3.7.2a Diagram of Power Wire & Control Wire Connections for 2 units in MMS Configuration (300-750kVA) UPS-1 *1 Use Ethernet STP (Shielded Twisted Pair) Cable ( Cat 5 or Cat 6) with RJ45 modular connectors for all communication cabling. Use of UTP (Unshielded Twisted Pair) Cable may cause malfunction. Total cable length from UPS-1 to UPS-2 should be within 100m.
FIGURE 3.7.2b Detail of IFAU-09 Control Wire Connections for 2 units in MMS Configuration (300-750kVA) No.1 UPS IFAU-09 No.
FIGURE 3.7.3a Diagram of Power Wire & Control Wire Connections for 3 or 4 units in MMS Configuration (300-750kVA) UPS-1 *1 *1 IFAU-09 CN99 TLBIN CN98 TLAIN CN97 TLBOUT CN96 TLAOUT *2 Use Ethernet STP (Shielded Twisted Pair) Cable( Cat 5 or Cat 6) with RJ45 modular connectors for all communication cabling. Use of UTP (Unshielded Twisted Pair) Cable may cause malfunction. Total cable length from UPS-1 to UPS-n should be within 100m.
FIGURE 3.7.3b Detail of IFAU-09 Control Wire Connections for 3 or 4 units in MMS Configuration (300-750kVA) No.1 UPS IFAU-09 No.2 UPS IFAU-09 No.
FIGURE 3.7.4a Diagram of Power Wire & Control Wire Connections for 5 to 8 units in MMS Configuration (300-750kVA) UPS-1 *1 *1 IFAU-09 CN99 TLBIN CN98 TLAIN CN97 TLBOUT CN96 TLAOUT *2 IOAU-09 TN1 5 6 ON CN954 CB2IN CN953 CB1IN CN952 CA2IN CN951 CA1IN CN944 CB2OUT CN943 CB1OUT CN942 CA2OUT CN941 CA1OUT Use Ethernet STP (Shielded Twisted Pair) Cable ( Cat 5 or Cat 6) with RJ45 modular connectors for all communication cabling. Use of UTP (Unshielded Twisted Pair) Cable may cause malfunction.
FIGURE 3.7.4b Detail of IFAU-09 Control Wire Connections for 5 to 8 units in MMS Configuration (300-750kVA) No.1 UPS IFAU-09 No.2 UPS IFAU-09 No.
3.4 OPERATING PROCEDURES For Parallel Operation system, refer to section “D) MMS Start-up Procedure”. (Parallel Operation system is herein after MMS [Multi Module System]) A) Start-up Procedure Before the UPS startup, the internal Bypass line starts to supply the unconditioned bypass input power to the load if the External input (or Bypass) Circuit Breaker is closed. Be ! extremely careful with closing the External input (or Bypass) Circuit Breaker.
B) Shut-down Procedure If a total UPS shutdown is required, verify that the critical load is OFF. a.) Press the "START/STOP" icon from the Main Menu or the Operation Menu on the LCD. b.) On the LCD panel, press “START/STOP” icon, and then select “SHUTDOWN GUIDANCE” icon. (Refer to Figure 2.3) c.) Follow the “SHUTDOWN GUIDANCE” until Inverter stops. The UPS will simultaneously transfer to Bypass operation. d.
C) Bypass Operation Procedure ** Transfer from Inverter to Bypass 1. Check for “SYNC” on the LCD. 2. Press the "START/STOP” icon on the LCD. 3. Follow the “SHUTDOWN GUIDANCE” and Press the "STOP" icon on the LCD. ** Transfer from bypass to inverter. UPS 1. Press the "START/STOP" icon on the LCD. 2. Follow the “STARTUP GUIDANCE” and Press the "START" icon on the LCD.. ! NOTE 72 When "REMOTE OPERATION MODE" is displayed on the LCD panel, the inverter start operation can only be performed remotely.
D) MMS Start-up Procedure External Circuit Check (Ensure System is in Maintenance Bypass) 1. Verify that Tie cabinet Maintenance bypass breaker 52MB is closed. 2. Verify that Tie cabinet Output breaker 52CS is open. 3. Verify that Tie cabinet UPS breakers 52L1, 52L2…and 52Ln are closed. Start-up from UPS-1 to UPS-n 1. Start-up each UPS in accordance with “A) Start-up Procedure”. Each UPS will start Inverter Operation synchronized with the bypass input.
4 RESPONSE TO UPS FAILURE UPS FAULT Annunciator Silence Recording of Fault Depress “SILENCE ALARM” icon on Main Menu. Refer to the list of fault codes in section 6.0 for error description. Take necessary action according to display guidance. Primary Action When faults happen, contact the Authorized Toshiba Service Information to Service Representatives or call Toshiba International Corporation at 1-877-867-8773.
5 PARTS REPLACEMENT Contact Toshiba International Corporation or its authorized service representatives on all issues regarding the replacement of parts. A) Battery Battery lifetime may vary according to the frequency of use and the average ambient operating temperature. The end of battery life is defined as the state of charge resulting in an ampere-hour capacity less than, or equal to, 80% of nominal capacity. Replace battery if its capacity is within this percentage.
6 FAULT CODES This section covers fault codes, their description and required action. At time of error : Verify and record the occurrence of the alarm. Note details of alarm message displayed on the LCD display panel. Contact Toshiba International Corporation at 1-877-867-8773.
Failure Code List Table 6.1 Fault Code Note 3 Note 1 Note 2 Buzzer External relay contact Failure lamp Code indication Status message UA801 AC INPUT VOLTAGE OUT OF RANGE Input line voltage is out of the specified range. CHECK INPUT POWER SOURCE Intermittent sound Alarm AC input abnormal － UA802 AC INPUT FREQUENCY OUT OF RANGE Input line frequency is out of the specified range.
Note 3 Code indication UA824 Meaning Guidance Intermittent sound Intermittent sound Intermittent sound Intermittent sound Alarm － Alarm － Alarm － Alarm － The battery circuit breaker (CB2) is open. 52C OPEN PROHIBITED EMERGENCY BYPASS SWITCH ON The interlock for the inverter output contactor (52C) is active. Emergency bypass switch has been turned on. UA833 52L OPEN The load circuit breaker(52L) is turned off.
Note 3 Code indication UF109 Status message Meaning UF163 Lit on Major Lit on Minor Flicker Minor Flicker Minor Flicker CHECK BATTERY Intermittent sound Minor Battery abnormal Flicker BATTERY OVERTEMPERATU RE Detection of overtemperature at the batteries. CHECK BATTERY Intermittent sound Minor Battery abnormal Flicker BATTERY LIQUID LOW Low level of battery electrolyte solution. CHECK BATTERY Intermittent sound Minor Battery abnormal Flicker Detection of DC ground fault.
Note 3 Code indication UF201 UF202 UF203 UF204 UF206 UF207 UF208 INVERTER OVERVOLTAGE INVERTER UNDERVOLTAGE INVERTER OVERCURRENT OUTPUT CIRCUIT ABNORMAL UPS CONTROL CIRCUIT ERROR ZERO PHASE OVERCURRENT UPS CONTROL CIRCUIT ERROR Meaning Detection of output overvoltage. Output voltage dropped.below specs. Detection of inverter overcurrent. Detection of a large variation of the reference error signal (current reference and actual current).
Note 3 Code indication UF301 UF302 UF303 UF305 UF306 UF309 UF310 UF320 UF323 UF331 UF332 UF333 UF334 UF352 UF363 UF371 UF372 UF374 UF375 UF376 UF377 UF378 UF379 Status message UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR INVERTER VOLTAGE ABNORMAL CONTROL POWER SUPPLY ABNORMAL UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT ERROR UPS CONTROL CIRCUIT
Note 3 Code indication Status message Meaning UF401 52S ABNORMAL Error to close the contactor 52S. UF402 52S ABNORMAL Error to open the contactor 52S. UF420 52L OPERATION ERROR UF451 52S ABNORMAL Load circuit breaker 52L opened during inverter operation. Contactor 52S failed during load transfer from inverter to bypass. UF452 CB3 ABNORMAL (Note 1) 1) Contactor CB3 is not working properly.
7 DAILY INSPECTION Please perform the daily inspection while the UPS is running. The daily inspection items are shown in Table 7.1. ! The customers can only inspect exterior or environment of cabinet. When the customers want to perform the detailed inspection, contact the Authorized Toshiba Service Representatives or call Toshiba International Corporation at 1-877-867-8773. NOTE TABLE 7.1 How to perform daily inspection No. Subject Procedure Term 1. 2. 3. 4.
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APPENDIX A Installation Planning Guides (IPG) Installation Planning Guide for 80kVA UPS Standard System: 480V Input, 480V Output General Mechanical Information Dimensions (W x D x H) Weight Floor Loading Approximate Full-Load Heat Rejection Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Inches Lbs. Lbs./ft. 2 kBtu/Hr Top Front Bottom Sides** Back 27.6” x 32.8” x 80.6”* 855 136 10.
Installation Planning Guide for 100kVA UPS Standard System: 480V Input, 480V Output General Mechanical Information Dimensions (W x D x H) Weight Floor Loading Approximate Full-Load Heat Rejection Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Inches Lbs. Lbs./ft. 2 kBtu/Hr Top Front Bottom Sides** Back 27.6” x 32.8” x 80.6”* 855 136 13.5 20” 40” 0” 0” 0” * Height includes removable fan housing – Frame height is 78.7.
Installation Planning Guide for 160kVA UPS Standard System: 480V Input, 480V Output General Mechanical Information Dimensions (W x D x H) Weight Floor Loading Approximate Full-Load Heat Rejection Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Inches Lbs. Lbs./ft. 2 kBtu/Hr Top Front Bottom Sides** Back 35.4” x 32.8” x 80.6”* 1160 144 17.8 20” 40” 0” 0” 0” * Height includes removable fan housing – Frame height is 78.7.
Installation Planning Guide for 225kVA UPS Standard System: 480V Input, 480V Output General Mechanical Information Dimensions (W x D x H) Weight Floor Loading Approximate Full-Load Heat Rejection Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Inches Lbs. Lbs./ft. 2 kBtu/Hr Top Front Bottom Sides** Back 35.4” x 32.8” x 80.6”* 1230 152 25.1 20” 40” 0” 0” 0” * Height includes removable fan housing – Frame height is 78.7.
Installation Planning Guide for 300kVA UPS Standard System: 480V Input, 480V Output General Mechanical Information Dimensions (W x D x H) Weight Floor Loading Approximate Full-Load Heat Rejection Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Inches Lbs. Lbs./ft. 2 kBtu/Hr Top Front Bottom Sides** Back 51.2” x 32.7” x 80.7”* 2260 195 31.7 23.6” 42.3” 0” 0” 0” * Height includes removable fan housing – Frame height is 78.7.
Installation Planning Guide for 500kVA UPS Standard System: 480V Input, 480V Output General Mechanical Information Dimensions (W x D x H) Weight Floor Loading Approximate Full-Load Heat Rejection Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Inches Lbs. Lbs./ft. 2 kBtu/Hr Top Front Bottom Sides** Back 70.9” x 32.7” x 80.7”* 3360 205 52.8 23.6” 42.3” 0” 0” 0” * Height includes removable fan housing – Frame height is 78.7.
Installation Planning Guide for 750kVA UPS Standard System: 480V Input, 480V Output General Mechanical Information Dimensions (W x D x H) Weight Floor Loading Approximate Full-Load Heat Rejection Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Inches Lbs. Lbs./ft. 2 kBtu/Hr Top Front Bottom Sides** Back 90.6” x 32.7” x 80.7”* 4250 207 79.2 23.6” 42.3” 0” 0” 0” * Height includes removable fan housing – Frame height is 78.7.
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