UNINTERRUPTIBLE POWER SYSTEM (UPS) G8000 SERIES INSTALLATION and OPERATION MANUAL 480/480 V 80/100/125/150/225/300/500 kW Document: 61001-002 April 2013 © Copyright 2013 Toshiba International Corporation All rights reserved.
UNINTERRUPTIBLE POWER SYSTEM (UPS) G8000 SERIES INSTALLATION and OPERATION MANUAL 480/480 V 80/100/125/150/225/300/500 kW Document: 61001-002 April 2013 © Copyright 2013 Toshiba International Corporation All rights reserved.
The Toshiba products listed in this document are intended for usage in general electronics applications (computer, personal equipment, office equipment, measuring equipment, industrial robotics, domestic appliances, etc.).
UNINTERRUPTIBLE POWER SYSTEM (UPS) Please complete the following information and retain for your records. Unless otherwise specified, the warranty period for the UPS or UPS part is 12 months from the shipment date (see Toshiba International Corporation bill of lading). Unless otherwise specified, the warranty period for a UPS battery is 36 months from the shipment date (see Toshiba International Corporation Bill of Lading for shipping date).
Purpose This manual provides information on how to safely install and operate your Toshiba International Corporation power electronics product. This manual includes a section of 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 1 Introduction...........................................................................................................................1 2 General Safety Instructions.................................................................................................2 2.1 Symbols........................................................................................................................2 2.2 Signal Words........................................................................
12 13 14 15 ii 11.2 150, 225, 300, and 500 kVA Buss Strip Terminals and Power Cables........................34 11.3 UPS Power Cable Conduit Landing Plates.................................................................39 11.4 External Breakers........................................................................................................42 11.5 Grounding Wire...........................................................................................................42 11.
16 Periodic Maintenance/Parts Replacement.......................................................................77 16.1 Scheduled Maintenance.............................................................................................77 16.2 Parts Replacement.....................................................................................................77 Appendix A - Installation Planning Guides..............................................................................79 80kVA IPG.............
iv G8000 Series Installation and Operation Manual
1 Introduction This manual provides information on how to safely operate your G8000 Series Uninterruptible Power System (UPS). This manual includes a section of 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. Qualified personnel should read this manual carefully before transporting, installing and wiring the UPS.
2 General Safety Instructions DO NOT attempt to transport, install, operate, maintain or dispose of this equipment until you have read and understood all of the product safety information provided in this manual. 2.1 Symbols The symbols listed below are used throughout this manual. When symbols are used in this manual they will include important safety information that must be carefully followed. Safety Alert Symbol indicates that a potential personal injury hazard exists.
2.2 Signal Words The signal words listed below are used throughout this manual. When the words DANGER, WARNING, CAUTION and ATTENTION are used in this manual they will include important safety information that must be carefully followed. 2.3 DANGER The word DANGER in capital letters preceded by the safety alert symbol indicates that an imminently hazardous situation exists, and if not avoided will result in loss of life or serious injury to personnel.
• Be trained in rendering first aid. For further information on workplace safety visit www.osha.gov. 2.4 Factory Authorized Personnel Factory authorized personnel have been factory trained and certified to install, service, and repair the UPS. Contact the Toshiba Customer Support Center for assistance in locating the factory authorized personnel nearest you.
TABLE 3.2 UPS NOMINAL BATTERY VOLTAGE 4 Capacity Nominal Voltage Float Voltage 80 kVA 360 Vdc 405 V 100 kVA 360 Vdc 405 V 125 kVA 360 Vdc 405 V 150 kVA 360 Vdc 405 V 225 kVA 360 Vdc 405 V 300 kVA 360 Vdc 405 V 500 kVA 480 Vdc 540 V Safety Precautions The Toshiba products listed in this document are intended for usage in general electronics applications (computer, personal equipment, office equipment, measuring equipment, industrial robotics, domestic appliances, etc.).
4.2 General Maintenance WARNING DO NOT remove the rear/side panels, or any sheet metla not designed to be removed. Removing rear/side panels may result in electric shock, burns, personal injuries or UPS failure. Keep the area arround the UPS clean. Use a vacuum cleaner to clean the UPS. Only factory authorized personnel sould perform internal general maintenance on the UPS.
CAUTION DO NOT transport, move, store, or place the UPS on its side. Forces due to heavy components inside may damage the UPS. Avoid vibration or shock exceeding 0.5G. Failing to observe this precaution may cause damage to the UPS. DO NOT allow the UPS to suffer shock or impact when unpacking. Tools used to remove packaging materials may cause damage to the UPS. DO NOT push or pull on the sides of the packaging.or the UPS to move it.
4.4 Inspection/Storage Inspection Upon receipt of the UPS, an inspection for shipping damage should be performed. Use caution when removing the unit from the pallet. Refer to labels or documentation attached to packing material. Unpacking Check the unit for loose, broken, bent or otherwise damaged parts. If damage has occurred during shipping, keep all original crating and packing materials for return to the shipping agent.
5 Installation Precautions CAUTION Install the UPS in a controlled environment. Improper storage and installation environment may deteriorate insulation, shorten component life and cause malfunctions. See Table 5.1 - UPS Installation Environment Standards DO NOT tilt the UPS more than 10° from upright position. Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries and cause physical damage to internal components. WARNING Keep the SPECIFIED CLEARANCE around the UPS.
DO NOT block air vents. Blocking the vents will increase the internal temperatures and may result in UPS failure or fire. DO NOT install the UPS where water may fall on it. Water may cause electrical shock, personal injury or UPS failure. DO NOT use floor wax that contains silicon in the UPS storage area and/or nearby rooms. Floor wax that contains silicon may cause static electricity. WARNING The UPS should be installed per local and/or national electric codes by qualified personnel.
TABLE 5.1 - UPS INSTALLATION ENVIRONMENT STANDARDS Item Environment standard Installation Location Indoors Minimum operating temperature: 32 °F (0 °C). Maximum operating temperature: 86 °F (30 °C) at 1.0 PF (UPS with/without battery system). Ambient Temperature Maximum operating temperature: 90 °F (32 °C) at 0.8 PF (UPS with battery system). Maximum operating temperature: 104 °F (40 °C) at 0.8 PF (UPS only). Average 24-hour operating temperature: 86 °F (30 °C) at 1.0 PF and 41 – 95 °F (5 – 35 °C) at 0.
7) The UPS generates and can radiate radio-frequency energy during operation. Although RFI noise filters are installed inside of the unit, there is no guarantee that the UPS will not influence some sensitive devices that are operating near by. If such interference is experienced, the UPS should be installed further away from the affected equipment and/or powered from a different source than that of the installed equipment.
5.1 Wiring/Connection WARNING Perform wiring and connections with correct polarity. Be careful when connecting the UPS to the battery system. A wrong connection may cause damage to the UPS, battery, or charger. Connect ONLY one (1) ground wire to the earth ground terminal. A missing ground wire may cause an electrical shock hazard. Connecting to more than one ground may cause a ground loop. See Chapter 8 - UPS Wiring DO NOT force, bend, or pull wires. DO NOT damage wire insulation.
6 Warning Labels Below are representative warning labels and their location on the UPS. Exterior Handling labels shown in section 4.3, Transporting/Unpacking, are in the manual packet, and attached to the UPS shipping covering and shipping pallet. NOTICE Make sure all the warning labels are installed in the appropriate locations. If a label is missing or illegible, contact Toshiba Customer Support Center or an authorized representative.
(D) 40830 (C) 58708 FOR 300KVA USE COPPER CONDUCTORS ONLY ! REFER TO INSTRUCTION MANUAL FOR WIRE SIZE AND TIGHTENING TORQUE 1 58708 U 2 3 4 V W - 5 6 7 + U V 8 9 10 W N U 11 12 V W 480 V 400 V 480 V 480 V A C INPUT BATTERY BYPASS INPUT AC OUTPUT WA R N I N G CRITICAL FUSE SIZING Incorrect fuse replacement size may result in fire or inadequate equipment protection. Replace only with same type and rating of fuse.
FIGURE 6.3 – 150/225 KVA UPS WARNING LABELS FIGURE 6.
FINAL LAYOUT NOT AVAILABLE AT THIS TIME: CONTACT THE FACTORY FOR ADDITIONAL INFORMATION FIGURE 6.
7 Weight and Dimensions Table 7.1 lists the unit and shipping weights for G8000 UPS models. See Appendix B for detailed outline and dimensioins of all models. TABLE 7.1 G8000 UPS UNIT AND SHIPPING WEIGHTS Model Unit Shipping 80 kVA 1390 lb. (630 kg) 1440 lb. (652 kg) 100 kVA 1740 lb. (789 kg) 1790 lb. (812 kg) 125 kVA 1740 lb. (789 kg) 1790 lb. (812 kg) 150 kVA 2467 lb. (1119 kg) 2556 lb. (1159 kg) 225 kVA 2980 lb. (1352 kg) 3069 lb. (1392 kg) 300 kVA 4575 lb. (2075 kg) 4725 lb.
8 Transporting WARNING When transporting the UPS by crane, follow the SPECIFIED WORK PROCEDURE. The suspension wire angle should be less than 60°. The UPS falling or overturning may cause crushing, trapping or other personal injuries. DO NOT tilt the UPS more than 10° from upright position. Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries. CAUTION DO NOT transport, move, store, or place the UPS on its side.
8.1 8.1Transporting ByBy Crane Transporting Crane Cables should have sufficient ratings and be of the same length. Make sure the suspension cables are Cables should have sufficient ratings andthe beangle of the same length. Make sure the suspension cables are hooked at eyebolts. See Figure 8.1. Keep less than 60° between cables. hooked at eyebolts. See Figure 8.1. Keep the angle less than 60° between cables. Refer to Chapter 7 - Weight and Dimension for UPS cabinet weight.
8.2 Transporting By Forklift Refer to Chapter 7 - Weight and Dimensions. Verify forklift maximum load capacity and ensure that the forks are long enough to properly support the UPS. Insert the forks into the space shown in Figure 8.6. Spaces for the forks are provided underneath the UPS. DO NOT swing or tilt UPS when lifting and/or transporting. Minimize the impact when lowering the UPS to the floor.
500 kVA (Ships in two parts, Input and Output Cabinets) Input Cabinet Output Cabinet Insert the forks here. Insert the forks here. Secure forks against the base and then lift. Secure forks against the base and then lift. FIGURE 8.
9 Storage/Operating Environment Observe the following when storing the UPS. • • Store UPS indoors. Maximum storage time for the UPS between powered operation cycles is three years. If the UPS has been stored for a period exceeding 36 months, contact your factory authorized represnetative of guidance in starting the unit. Temperature fluctuations should be minimized. The optimal storage temperature range is 68 – 77 °F (20 – 25° C).
input frequency range must be within the rated input frequency range. 3) The UPS should not be used with a load that has a rated input that is greater than the rated output of the UPS. 4) If using the UPS to provide power to motors that require high starting current or with motors that require a long starting time, call Toshiba support for guidance in over sizing the UPS for lock rotor current. 5) DO NOT insert metal objects or combustible materials in the ventilation slots of the UPS.
9.2 Maintenance Precautions All internal maintenance sould be performed by factory authorized personnel. 1) Turn off, lockout, and tagout ALL power sources before connecting the power wiring to the equipment or when performing maintenance. 2) Hardwire type UPS units are not equipped with an over-current protection device, nor do they have an output disconnect for the AC output. A user-installed circuit breaker should be provided between the UPS output and the load input.
CAUTION DO NOT dispose of the batteries in a fire. The batteries may explode. DO NOT open or mutilate the batteries. Released electrolyte is harmful to the eyes and skin and could also be toxic. DANGER A battery can present a risk of electrical shock and high short circuit current. 9.3 Disposal Please contact your local or state environmental agency for details on disposal of electrical components and packaging in your particular area.
10 Installation WARNING Keep the SPECIFIED CLEARANCE around the UPS. Inadequate space around the UPS makes it difficult to perform maintenance/inspections, lead to insufficient ventilation, and/or will cause malfunctions. See Figure 10.1 - UPS Clearance DO NOT tilt the UPS more than 10° from upright position. Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries. Install anchor bolts to secure the UPS to the installation floor.
10.1 Unpacking Unpack the UPS indoors on a paved floor. The UPS should be as close as possible to its final storage location. Overhead traveling cranes should be used to unpack any G8000 Series UPS. If an overhead traveling crane is not available, allow enough space for forklift operations to unpack the UPS crate. Then remove the crate. Points to observe 10.2 • • • • • Retain all small articles during unpacking and installation.
10.3 Anchor Bolts Install the anchor bolts to secure the UPS on the floor. See Figure 10.2 for anchor bolt installation detail. Use 12mm (1/2”) diameter anchor bolts. There are 16mm (5/8”) diameter holes provided in the UPS base. See Figure 10.3 for the hole locations and dimensions for the specified UPS models. 150/225 kVA (See Appendix B) Back 4 x 0.5 in. - Dia. (12 mm) 4 x 5/16 in. (16 mm) diameter screw holes 21.7 in. (551 mm) Front 4 screw holes (Side View) 46.1 in.
11 UPS Wiring 11 Figure UPS Wiring 11.1 illustrates the external wiring of the G8000 UPS. See corresponding section to each wiring term. Note: Always consult your local and NEC electrical codes for wiring, cabling, and circuit protection device requirements. Power cable connection at terminal blocks/buses and external breaker provision for the AC input/output, Bypass Input and DC input. Figure 11.1 illustrates the external wiring of the single-input G8000 UPS.
11 UPS Wiring Figure 11.1 illustrates the external wiring of the G8000 UPS. See corresponding section to each wiring term. • Power cablethe connection terminal blocks/buses external breaker provision for thesection AC Figure 11.2 illustrates external at wiring of the dual-inputand G8000 UPS. See corresponding to each wiring term.input/output, Bypass Input and DC input. •• Power Earth cable groundconnection wire at grounding terminal.
11.1 80/100/125 kVA Terminal Blocks and Power Cables Note: Always consult your site specific, local, state, and NEC electrical codes for wiring, cabling, and circuit protection device requirements. The terminal blocks for the 80/100/125 kVA UPS are shown in Figure 11.3. Recommended external cable sizes for both 75 °C and 90 °C copper wire for a single battery string are listed in Table 11.1–11.2. For two or more battery strings consult with Toshiba Technical Support.
TABLE 11.2 RECOMMENDED CABLE SIZE & TIGHTENING TORQUE FOR 100 KVA UPS Block Number Cable Size (Min-Max) 2 75 °C Copper Wire 90 °C Copper Wire Tightening Torque 1 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m) 2 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m) 3 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m) 4 (2) #1 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m) 5 (2) #1 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.
11.2 150, 225, 300, and 500 kVA Buss Strip Terminals and Power Cables Note: Always consult your site specific, local, state, and NEC electrical codes for wiring, cabling, and circuit protection device requirements. The 150, 225, 300 and 500 kVA UPS units have buss strip power terminals. 1.75 in. (45 mm) Figure 11.4 is a typical buss strip for a 150/225 kVA UPS. Figure 11.5 shows the arrangement of the terminal buss strips for the 150 and 225 kVA UPS units.
Figure 11.7 shows the terminal mounting hole arrangement for the terminal buss strips for the 500 kVA UPS units. Figure 11.8 shows the arrangement of the terminal buss strips for the 500 kVA UPS. The buss strips are located inside at the top of the unit. The dashed line on terminals 1–13 indicates the side view of the bolt holes. Use 1/2 inch bolts to attach the lugs. 3-Phase AC Power Lugs 3-Phase Neutral and Battery (DC) Power Lugs 6 x 0.5625 in. Dia. (14.3 mm) 6 x 0.5625 in. Dia. (14.3 mm) 0.875 in.
See Table 11.5 – Table 11.6 for recommended cable sizes for the 150, 225, 300 and 500 kVA UPS. TABLE 11.3 RECOMMENDED CRIMP TYPE COMPRESSION LUGS FOR BUS STRIP TERMINALS Wire Size Wire Strand Class Recommendation Crimp tool Required Burndy type Y35 or Y46 Vendor Cat. No.
TABLE 11.4 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 150 KVA UNIT (USE 75 °C Copper Wire) Block Number Cable Size (Min-Max) 75 °C Copper Wire 90 °C Copper Wire Tightening Torque2 1 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m) 2 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m) 3 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m) 4 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb.
4 Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear. TABLE 11.6 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 300 KVA UPS Bus Number Cable Size (Min-Max) 75 °C Copper Wire 90 °C Copper Wire Tightening Torque2 1 (2) 250 kcmil – (3) 2/0 (2) 4/0 – (3) 1/0 540 in.-lb. (61 N•m) 2 (2) 250 kcmil – (3) 2/0 (2) 4/0 – (3) 1/0 540 in.-lb. (61 N•m) 3 (2) 250 kcmil – (3) 2/0 (2) 4/0 – (3) 1/0 540 in.-lb.
11.3 UPS Power Cable Conduit Landing Plates Cable conduit landing plates are provided at the bottom of the 80 kVA and100 kVA UPS, at the top and bottom of the 150/225 kVA UPS (Older models of the G8000 150/225 kVA UPS do not come equipped with an upper conduit landing plate.), and at the top only of the 300/500kVA. The recommended conduit landing arrangements are illustrated in Figure 11.9 thru 11.13. The five (5) holes must be punched during installation.
3.35 in. 17.72 in. AC OUTPUT BYPASS Recommended Conduit Placement Order in Top Conduit Landing Plate BATTERY 4.74 in. AC INPUT 0.7 in. 0.7 in. 7.48 in. 21.85 in. CONTROL WIRES 42.126 in. BASE PLATES - DIMENSIONS 23.11 in. UPS BASE BOTTOM ENTRY DIMENSIONS 5.9 in. FRONT OF UPS 21.5 in. 4.36 in. FIGURE 11.10 - BOTTOM CONDUIT LANDING PLATES 100 KVA (T80S3K10KK6XSNH); 150/225 KVA 4.74 in. CONTROL WIRES Recommended Conduit Placement Order in Top Conduit Landing Plate 4.27 in.
Figure 11.12 shows the four (4) cable landing plates provided at the top of the 300 kVA UPS. Seven (7) holes must be punched during installation. The dashed rectangle indicates the UPS opening behind the conduit landing plates. AC INPUT 37.4 in. BATTERY BATTERY AC OUTPUT BYPASS 7.09 in. 0.76 in. GROUND WIRE 8.66 in. 21.26 in. 7.09 in. 8.66 in. 3.15 in. 7.09 in. 8.66 in. 3.93 in. CONTROL WIRES 0.76 in. Recommended Conduit Placement Order in Top Conduit Landing Plates 56.70 in.
11.4 External Breakers The G8000 UPS units are not equipped with circuit breakers. Qualified personnel should provide the external breakers for the AC input/output, bypass input and DC input. See Figure 11.1 – External Wiring Diagram, for the circuit position of the breakers. Table 11.7 shows the G8000 UPS minimum external breaker rating for each capacity. The Bypass, AC Input, and AC Output require 3-pole breakers. TABLE 11.7 UPS MINIMUM DEVICE RATINGS Capacity 11.
G8000 - 80/100 kVA G8000 - 300 kVA Facility earth ground. Ground wire routing through top conduit landing plate. Ground bus 10 mm or 7/16 in. Bolt 10 mm or 7/16 in. Bolt 12 mm or 1/2 in. Terminal AWG 2 (38 mm2) ground wire Through conduit landing plate on top (recommended) Note: Use either the top or the bottom grounding point, but not both. Doing so may degrade the performance of the unit.
11.6 Control Wires The control wires terminal layouts at TB1 (terminal bus 1) are shown below in Table 11.8. TABLE 11.8 EXTERNAL CONNECTIONS No.
The UPS battery cabinet and bypass breaker should be wired as shown below in Figure 11.15. Power Source Jumper wire if battery OH is not applied TC To Bypass Input Bypass Breaker 10 11 12 13 Power Source for trip coil 14 15 16 17 Overheat B-Contact 18 19 To DC Input 20 21 22 Auxillary Acontact TB1 UPS Cabinet Ext. EPO (Customer) N.O. Contacts Battery Cabinet FIGURE 11.15 - CONNECTION BETWEEN UPS, BATTERY CABINET & BYPASS BREAKER 11.
Input Source < UPS Cabinet > 3φ 3φ N N 3φ 3φ G 3φ 3φ G N N G G To the Load Remove Jumper Cable FIGURE 11.16 - GROUNDING CONFIGURATION WITH INPUT NEUTRAL GROUNDED Input Source < UPS Cabinet > φ A 2 AWG (or 38 mm ) jumper3cable is provided between the neutral terminal and ground bus in the UPS cabinet. The qualified personnel should remove the jumper cable in this configuration. The jumper cable N location is illustrated below.
Input Source 11.7.2 Cabinet > Grounding< UPS Configuration (without input neutral) 3φ 3φ When the input source is wye-connected, the neutral line out to the bypass input should be left open. The N N UPS is grounded by connecting the neutral terminal to the ground bus with the internal jumper cable. See 3φ 3φ φ 3φ Figure311.18. To the Load N The jumper cable should stay in place. See Figure N11.17 for the jumper cable location.
Remains in Place Input Source < UPS Cabinet > 3φ 11.7.4 3φ N Grounding Configuration (with corner-grounded delta-input) 3φ 3φ 3φ 3φ N N To the If one phase of delta-input source is grounded (B-phase for example), the ground bus in the UPSLoad cabinet G G G G should NOT be connected to the neutral terminal of UPS output. Jumper Cable The jumper cable should be removed see Figure 11.17 for the jumper cable Remains in Place location.
12 UPS Specifications 12.
G8000 Specifications Model Number Output T80S3K08 KK6XSxx T80S3K10 KK6XSxx T80S3K12 KK6XSxx Voltage T80S3K22 KK6XSxx ±1% for 0-100%Balanced and Unbalanced Loads Voltage Adjustment Range ±3% for 100% Linear Loads Crest Factor ±5% for 100% Non-Linear Loads 2 Transient Voltage Response ±2% Max with a 100% Step Loads (without utilizing batteries) ±1.
G8000 Specifications Model Number Environment (cont.) T80S3K08 KK6XSxx T80S3K10 KK6XSxx T80S3K12 KK6XSxx T80S3K15 KK6Xxx T80S3K22 KK6XSxx T80S3K30 KK6XSxx T80S3K50 KK6XSxx Dimension - Width 36.8 in. (935 mm) 55.1 in. (1400 mm) 76.8 in. 1951 mm) 101.8 in. (2586 mm) Depth 32.5 in. (826 mm) 31.8 in. (808 mm) 35.7 in. (907 mm) 37.4 in. (945 mm) 79.4 in. (2017 mm) 79.7 in. (2024 mm) Height 79.2 in.
12.2 Typical Efficiency vs. Load UPS Efficiency at Percent Full Load* 25% 50% 75% 100% 80 kVA 83.9% 85.3% 90.0% 90.6% 100 kVA 86.4% 90.1% 91.2% 91.0% 125 kVA 88.5% 90.9% 90.9% 90.2% 150 kVA 86.9% 91.7% 92.3% 93.3% 225 kVA 87.9% 91.9% 92.3% 91.9% 300 kVA 88.8% 91.6% 92.2% 92.8% 500 kVA 91.6% 91.1% 90.2% 93.3% * Actual efficiency may differ due to manufacturing variations and input power quality.
13 Operator Interface Table 13.1 shows the functions of the operating buttons on the graphic display panel. NOTICE Press an operating button for at least 0.5 seconds to change UPS modes. Press the reset button for at least 5 seconds to reset the UPS. The UPS may not respond if the button press is too short. TABLE 13.1 BUTTON AND INDICATOR FUNCTIONS (See fig. 13.1 and 13.2) # Name Function 1 OPERATION LOCK Enables/disables the buttons RUN, STOP, UPS, BYPASS, FLOAT/EQUAL, and RESET.
13.1 Key-Switch and Buttons The key-switch and operating buttons on the graphic display panel are shown in Figure 13.1. See the sections titled “Key-switch” and “Operating buttons” for each function. 5 6 1 2 3 4 9 7 8 EPO 10 FIGURE 13.
13.2 LCD/LED Indicators 11 20 12 21 13 14 22 23 15 16 24 17 25 19 18 FIGURE 13.
13.3 LCD Indicators The operator can scroll through the following LCD display screens using the scroll buttons. TABLE 13.2 - LCD DISPLAY SCREENS Name Description Normal Display Displays operational status, operational guidance, and measured data. Fault Display Displays detailed data when a fault occurs. Warning Display Displays detailed data when a warning occurs. NORMAL DISPLAY SCROLL UP FAULT DISPLAY SCROLL DOWN WARNIG DISPLAY FIGURE 13.
13.4 Normal Display The Normal Display screen indicates the UPS operational status and provides various screens: an operation guidance screens, mode screens and measured data screens. Table 13.3 shows these screens page by page and illustrates the UPS Normal Display operational status screens. TABLE 13.3 - NORMAL DISPLAY SCREEN EXAMPLES OPERATIONAL STATUS SCREENS BYPASS Shows the UPS status at the top and guidance message or measured data underneath.
TABLE 13.3 - CONTINUED MEASUREMENT SCREENS O/P CURRENT (PEAK) U V W 50[%] 50[%] 50[%] AC INPUT Shows the peak output current peak (%) for each phase. Peak value of output current RMS value for rated current x 1.41 x 100 [%] Shows the AC Input Voltage (line-to-line) and frequency. AC I/P-V 480[V] FREQ. 60.0[Hz] Shows the Bypass Input Voltage (line-to-line voltage) and frequency. BYPASS INPUT BYP I/P-V 480[V] FREQ. 60.
13.5 Fault Display The Fault Display screen displays the fault records until they are reset. The Warning Display screen displays the warning records until they are reset. The fault records will remain in the memory until the reset button is pressed for at least 5 seconds, even after the actual cause of the fault has been resolved. Note that the fault records are not deleted when the UPS is turned off.
13.6 LCD Scroll Scroll through the LCD display screens (see Figure 13.5), in sequence, using the “SCROLL UP” and “SCROLL DOWN” buttons on the graphic display panel. • SCROLL UP - Moves back to the previous screen • SCROLL DOWN - Moves forward to the next screen TABLE 13.5 DISPLAY SCREEN SCROLL SEQUENCE UPS SUPPLY FAULTS & WARNINGS AC-VO 480[V] AC- I O 50[%] NO FAULT NO WARNING OPERATION MODE NORMAL OPERATION MODE SYNC. (The LCD displays a diagram of the electrical power flow.
14 Operating the UPS This section describes the basic procedures to operate the UPS. Figure 14.1 shows the location and functions of the operating switches to operate the UPS. WARNING If the UPS produces smoke or smells strange, immediately turn off all AC and DC input circuit breakers. Continued operation may result in fire. Contact Toshiba or Authorized representatives. DO NOT turn off the control power supply switch (8A) during UPS operation. This may result in UPS faults.
14.1 Operation Types The operation types are summarized below. TABLE 14.1 OPERATION TYPES 14.2 Operation Description Complete Shutdown Turn off the control power supply. Shut down the UPS completely. Float / Equalize Charge Changing the battery recharge mode between float charge and equalize charge. Protection Charge Automatic recharge mode transition from protection charge to float charge. Startup Starting up and operating the UPS. Stop Stop the inverter and chopper/charger.
14.3 Startup Procedures The procedure to start the UPS is shown in Steps 1-5. STEP 1 LED Key - LED Off - LED On - LED Flash SYSTEM INITIALIZE Turn on the control power supply switch. (Figure 14.1) and ensure the operation lock is set to OPERATION. (Figure 13.1 - 1) UPS AC INPUT CONVERTER INVERTER FLOAT CHARGE AC SWITCH EQUAL CHARGE BATTERIES DISCHARGE AC OUTPUT BYPASS BYPASS INPUT STEP 2 BYPASS Wait for a few seconds.
Step 4-5 continues the procedure to start the UPS. LED Key - LED Off - LED On - LED Flash STEP 4 BYPASS Turn on the DC Input Breaker (72B) on the external battery cabinet. MOVE 72B TO ‘ON’ POSITION BATTERIES LED is “ON”. UPS AC INPUT INVERTER CONVERTER FLOAT CHARGE AC SWITCH EQUAL CHARGE BATTERIES DISCHARGE AC OUTPUT BYPASS BYPASS INPUT UPS SUPPLY STEP 5 AC - Vo 480 V AC - Io 50% *Press the “UPS” button for at least 0.5 seconds. This completes UPS startup procedure BYPASS LED is “OFF”.
14.4 Switch Power Supply (UPS to Bypass) The procedure to transfer between the UPS supply and the bypass supply is shown in Steps 1-3 LED Key - LED Off - LED On - LED Flash STEP 1 UPS SUPPLY Check AC INPUT LED and BYPASS LED are on to make sure power is being delivered to the UPS. AC - Vo 480 v AC - Io 50% UPS AC INPUT CONVERTER INVERTER FLOAT CHARGE AC SWITCH EQUAL CHARGE BATTERIES DISCHARGE BYPASS BYPASS INPUT STEP 2 AC OUTPUT BYPASS Press the “BYPASS” button for at least 0.5 seconds.
14.5 Stop The procedure to stop the UPS is shown in Steps 1-3. LED Key - LED Off - LED On - LED Flash BYPASS STEP 1 AC - Vo 480 V AC - Io 50% PRESS ‘UPS’ SWITCH Transfer to Bypass supply as described in Switch Power Supply. UPS LED is “OFF”. BYPASS LED is “ON”.
14.6 Complete Shutdown The procedure to turn off the control power and shut down the UPS completely is shown in Steps 1-6. STEP 1 Transfer to Bypass supply as described in Switch Power Supply. UPS LED is “OFF”. BYPASS LED is “ON”. BYPASS DC-V 0 [V] BATT-V 0 [V] BATT-I 0 [A] STEP 2 Turn off the DC input breaker, and, press the “STOP” button for at least 0.5 sec. BATTERIES LED is “OFF”. INVERTER LED flashes then “OFF”. FLOAT CHARGE LED and CONVERTER LED are “OFF”.
14.7 Changing Between Float Charge and Equalize Charge The procedure to change the recharge mode between float charge and equalize charge is shown in Steps 1-3. See the Note below for an explanation of Float and Equalize charge modes. LED Key - LED Off - LED On - LED Flash STEP 1 UPS SUPPLY Make sure that the FLOAT CHARGE LED is “ON”.
14.8 Changing to Float Charge from Protection Charge (If applicable) The manual procedure to change from protection charge to float charge is shown in Step 1-3.This operation applies to batteries after they have experienced over temperature condition. See the Note below for an explanation of float charge and protection charge. STEP 1 LED Key - LED Off - LED On - LED Flash UPS SUPPLY Make sure that the EQUAL CHARGE LED is “ON”.
14.9 Emergency Power Off (EPO) Press the EPO switch for immediate shutdown of all power through the UPS. The signal from the EPO is processed as a “hard fault” by the UPS and results in gate-blocks on the transistors and opens all the internal contactors. To Reset the UPS after triggering the EPO, do the following: 1. Shut Down the UPS as described in section 14.6. 2. Restart the UPS as described in section 14.3.
15.2 Faults and Warnings Data Screen This screen appears when a trip error is detected. Up to 10 screens of fault data can be displayed. Figure 15.1 and Table 15.2 show a sample screen and describe the data shown in the screen. FAULTS & WARNINGS 1 UPS OVERLOAD 09-09-06 08:05:30 ↓ANOTHER ITEM 1 2 3 4 FIGURE 15.1 - SAMPLE FAULT DATA SCREEN TABLE 15.2 - FAULT AND WARNING DATA SCREEN DESCRIPTIONS # Name Description 1 Number The number of the message in the order that it was detected (1 - 10).
15.3 LCD Fault & Warning Displays When a fault occurs, a screen is shown as in Figure 15.2. When a warning occurs, a screen is shown as in Figure 15.3. Select the desired fault or warning data to be displayed using the scroll buttons. BYPASS FAULT STOP FAULTS & WARNINGS 1 FUSE BLOWN 09-09-06 08:05:30 FIGURE 15.2 - FAULT DISPLAY UPS SUPPLY AC-VO 480[V] AC- I O 50[%] FAULTS & WARNINGS 1 UPS OVERLOAD 09-09-06 08:05:30 FIGURE 15.
15.4 Fault Messages Figure 15.4 show the locations for fault detection. Tables 15.3 through 15.7 gives details for the fault and warning messages referred to in section “Fault Data Screen.” The “item” code associated with each fault or warning message may be used to determine the physical location of the fault or warning by referring to Figure 15.4. The UPS unit may be shipped with different protective configurations from the standard shown in Figure 15.4, if specified by the customer.
TABLE 15.5 - WARNING - 2 (STOP AND RESTART) Item LCD Message Indication Description 27I AC O/P UV AC output voltage is low. 30U UNIT FAULT IGBT Stack Failure. 45 DC OV Over-voltage in DC circuit. 49 AC O/P OL Output overload 51I INV. OC Inverter over-current. 59I AC O/P OV AC output voltage is high. 76C BATT. OC Over-current in Battery section. TABLE 15.6 - WARNING (OPERATION CONTROL) Item LCD Message Indication Description 27C BYPASS UV Bypass input voltage is low.
15.5 LCD Scroll (w/ faults or warnings) This section describes how to scroll through the LCD screens when a fault has occurred (when Fault Data screens exist). Figure 15.5 shows the locations of the buttons to scroll the LCD screens. See Table 15.8 for details of the scroll buttons and how they are used for screen scrolling. 5 6 7 FIGURE 15.5 - POSITION OF SCROLL AND RESET BUTTONS TABLE 15.8 - BUTTON FUNCTIONS # Name Function 5 SCROLL UP Scrolls to the previous screen.
15.6 Restoring UPS Operation WARNING Contact Toshiba in the event of malfunction or fault. This UPS should be repaired only by factory authorized personnel. Servicing by untrained personnel may extend the fault or result in electric shock or personal injury. Do NOT attempt to modify or relocate the UPS. Electric shock, personal injury or fault may result if unauthorized personnel attempt to modify or relocate the UPS. Be sure to contact toshiba customer service if you need to modify or relocate the UPS.
16 Periodic Maintenance/Parts Replacement The G8000 is designed to provide long-term trouble-free power conditioning and backup. Optimum performance can be best maintained by regular, periodic, preventive maintenance. 16.1 Scheduled Maintenance The G8000 UPS should have scheduled maintenance performed on it annually by a factory-authorized service provider.
78 G8000 Series Installation and Operation Manual
Appendix A - Installation Planning Guides TOSHIBA G8000 Series UPS 80kVA IPG Installation Planning Guide for 80kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx) General Mechanical Information Dimensions (W x D x H) Inches Floor Loading Lbs./ft. 2 Weight Lbs. 36.8” x 32.5” x 79.2” 1,740 Approximate Full-Load Heat Rejection Btu/Hr 210 Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back 28,321 15.75” 43.
TOSHIBA G8000 Series UPS Installation Planning Guide for 80kVA UPS Top Front Right Side Bottom Access Only Power Terminals: Two 2/0 AWG max. per terminal Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx) G8000 80KVA OUTLINE DRAWING G8000 80kVA UPS Cabling Connection Dimensions Rev. 2.
TOSHIBA G8000 Series UPS Installation Planning Guide for 80kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations. Anchorage Pattern for G8000 80kVA UPS Rev. 2.
100kVA IPG TOSHIBA G8000 Series UPS Installation Planning Guide for 100kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx) General Mechanical Information Dimensions (W x D x H) Inches Floor Loading Lbs./ft. 2 Weight Lbs. 36.8” x 32.5” x 79.2” 1,740 Approximate Full-Load Heat Rejection Btu/Hr 210 Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back 33,746 15.75” 43.
TOSHIBA G8000 Series UPS Installation Planning Guide for 100kVA UPS Top Front Right Side Bottom Access Only Power Terminals: Two 2/0 AWG max. per terminal Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx) G8000 100kVA UPS Cabling Connection Dimensions G8000 100KVA OUTLINE DRAWING Rev. 2.
TOSHIBA G8000 Series UPS Installation Planning Guide for 100kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations. Anchorage Pattern for G8000 100kVA UPS Rev. 2.
125kVA IPG TOSHIBA G8000 Series UPS Installation Planning Guide for 125kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx) General Mechanical Information Dimensions (W x D x H) Inches Floor Loading Lbs./ft. 2 Weight Lbs. 36.8” x 32.5” x 79.2” 1,740 Approximate Full-Load Heat Rejection Btu/Hr 210 Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back 33,746 15.75” 43.
TOSHIBA G8000 Series UPS Installation Planning Guide for 125kVA UPS Top Front Right Side Bottom Access Only Power Terminals: Two 2/0 AWG max. per terminal Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx) G8000 UPS 125KVA OUTLINE DRAWING G8000 100kVA Cabling Connection Dimensions Rev. 0 86 Page 2 of 3 G8000-IPG-125kVA 0.
TOSHIBA G8000 Series UPS Installation Planning Guide for 125kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations. Anchorage Pattern for G8000 100kVA UPS Rev. 0 G8000 Series Installation and Operation Manual Page 3 of 3 G8000-IPG-125kVA 0.
150kVA IPG TOSHIBA G8000 Series UPS Installation Planning Guide for 150kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx) General Mechanical Information Dimensions (W x D x H) Inches Floor Loading Lbs./ft. 2 Weight Lbs. 55.1” x 31.8” x 79.2” 2,467 Approximate Full-Load Heat Rejection Btu/Hr 203 38,754 Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back 15.75” 43.
TOSHIBA G8000 Series UPS Installation Planning Guide for 150kVA UPS G8000 150KVA OUTLINE DRAWING Top Front Top/Bottom Access Right Side Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx) G8000 150kVA UPS Cabling Connection Dimensions Rev. 2.
TOSHIBA G8000 Series UPS Installation Planning Guide for 150kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations. Anchorage Pattern for G8000 150kVA UPS Rev. 2.
225kVA IPG TOSHIBA G8000 Series UPS Installation Planning Guide for 225kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K22KK6XSxx) General Mechanical Information Dimensions (W x D x H) Inches Weight Lbs. 55.1” x 31.8” x. 79.2” 2,980 Floor Loading Lbs./ft. 2 Approximate Full-Load Heat Rejection Btu/Hr 245 Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back 67,667 15.75” 43.
TOSHIBA G8000 Series UPS Installation Planning Guide for 225kVA UPS Top Front G8000 225 KVA OUTLINE DRAWING Top/Bottom Access Right Side Standard System: 480V Input, 480Y/277V Output (P/N T80S3K22KK6XSxx) G8000 225kVA UPS Cabling Connection Dimensions 92 Rev. 2.
TOSHIBA G8000 Series UPS Installation Planning Guide for 225kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K22KK6XSxx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations. Anchorage Pattern for G8000 225kVA UPS Rev. 2.
300kVA IPG TOSHIBA G8000 Series UPS Installation Planning Guide for 300kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K30KK6XSxx) General Mechanical Information Dimensions (W x D x H) Inches Floor Loading Lbs./ft. 2 Weight 76.8” x 35.7” x 79.2” Lbs. 4,575 240 Approximate Full-Load Heat Rejection Btu/Hr 89,011 Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back 15.75” 43.
TOSHIBA G8000 Series UPS Installation Planning Guide for 300kVA UPS G8000 Series Installation and Operation Manual G8000 300kVA UPS Cabling Connection Dimensions Front Top Cable Entry: Top Only Right Side Standard System: 480V Input, 480Y/277V Output (P/N T80S3K30KK6XSxx) 95
TOSHIBA G8000 Series UPS Installation Planning Guide for 300kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K30KK6XSxx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. TheUPS base has eight pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.
500kVA IPG TOSHIBA G8000 Series UPS Installation Planning Guide for 500kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K50KK6XSxx) General Mechanical Information Dimensions (W x D x H) Inches Floor Loading Lbs./ft. 2 Weight 101.8” x 37.4” x 79.7” Lbs. 6520 247 Approximate Full-Load Heat Rejection Btu/Hr 101,490 Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back 15.
TOSHIBA G8000 Series UPS Installation Planning Guide for 500kVA UPS Top Front Cable Entry: Top Only Standard System: 480V Input, 480Y/277V Output (P/N T80S3K50KK6XSxx) G8000 300kVA UPS Cabling Connection Dimensions 98 G8000 Series Installation and Operation Manual
TOSHIBA G8000 Series UPS Installation Planning Guide for 500kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K50KK6XSxx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has eight pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations. Anchorage Pattern for G8000 500kVA UPS Rev. 0.
100 G8000 Series Installation and Operation Manual
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Appendix C - 500kVA Input- and Output- Cabinet Joining Instructions Joining the G8000 500kVA Sections 1. Remove Shipping Material (Retain Connection Kit Box and Manual). 2. On a leveled floor bring the two cabinets together. Input cabinet on the left side. See FIG. 1. Leave a gap of 0.25”-0.30” between the cabinets. See FIG. 2. ”-0.30” AP OF 0.25 LEAVE A G ABINETS C BETWEEN ET INPUT CABIN NET OUTPUT CABI FIG. 1 FIG. 2 3. 4. On Input cabinet: Open the door, remove back panel (retain hardware).
BACK REMOVE PANEL , BOLT NCH AT I F L R, FL RT HA INSE K WASHE C ER LO WASH OPEN R DOO FIG. 3 INS ER LOC T HAL K W F-IN CH A WA SHER, BOLT SHE , FLA R T FIG. 4 5. On Output cabinet: Open the door. Insert Neutral bus between the cabinets as shown in FIG. 5 & FIG. 6 and connect on corresponding output and input cabinet neutral bus using 3/8-16X1.25” bolt, flat, belleville washer and nut (supplied). Insert Belleville washer between flat washer and nut. 6. Insert AC Bus (qty.
Insert Belleville washer between flat washer and nut. NEU TRA L BU S DC BUS FIG. 5 AC B US R CONTROL CONNECTO ) ET BIN CA UT (FROM INP 8. Connect the Control plug/connector (male) located in input cabinet to the mating connector (female) in the output cabinet thru conduit plate in the side panels. See FIG. 5 & FIG. 6. 9. Connect the Ground cable located in input cabinet to the Ground Bus located in the output cabinet thru the grommet hole in the side panels.
FIG.
INDUSTRIAL DIVISION 13131 West Little Your road, Houston, Texas 77041 Tel (713) 466-0277 Fax (713) 466-8773 U.S. (877) 867-8773 Canada (800) 872-2192 Mexico 01/800/527-1204 www.toshiba.com/ind Printed in the U.S.A.