Toshiba G8000 manual

© Copyright 2007 T oshiba International Corporation All rights reserved. Document: 59942-001 November 2007 UNINTERRUPTIBLE POWER SYSTEM (UPS) G8000 SERIES with Isolated Output INST ALLA TION and OPERA TION MANUAL[...]

[...]

G8000 Series with Isolated Output Installation and Operation Manual Document: 59942-001 November 2007 UNINTERRUPTIBLE POWER SYSTEM (UPS) G8000 SERIES with Isolated Output INST ALLA TION and OPERA TION MANUAL[...]

G8000 Series with Isolated Output Installation and Operation Manual The T oshiba products listed in this document are intended for usage in general electronics applications (computer , personal equipment, ofce equipment, measuring equipment, industrial robotics, domestic appliances, etc.). These T oshiba products are neither intended nor warrant[...]

G8000 Series with Isolated Output Installation and Operation Manual UNINTERRUPTIBLE POWER SYSTEM (UPS) Please complete the following information and retain for your records. Unless otherwise specied, the warranty period for the UPS or UPS part is 12 months from the shipment date (see T oshiba International Corporation bill of lading). Unless oth[...]

G8000 Series with Isolated Output Installation and Operation Manual Purpose This manual provides information on how to safely operate your T oshiba 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[...]

i G8000 Series with Isolated Output Installation and Operation Manual T able of Contents 1 Introduction .......................................................................................................................... 1 2 General Safety Instructions ...........................................................................................[...]

ii G8000 Series with Isolated Output Installation and Operation Manual 1 1.1 T erminal Blocks, T erminal Bus, and Power Cables .................................................... 3 0 1 1.3 Grounding Wire .......................................................................................................... 33 1 1.4 Control Wires................[...]

1 G8000 Series with Isolated Output 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[...]

2 G8000 Series with Isolated Output Installation and Operation Manual 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 manua[...]

3 G8000 Series with Isolated Output Installation and Operation Manual 2.2 Signal Words The signal words listed below are used throughout this manual. When the words DANGER, W ARNING, CAUTION and A TTENTION are used in this manual they will include important safety information that must be carefully followed. 2.3 Qualied Personnel Installation, o[...]

4 G8000 Series with Isolated Output Installation and Operation Manual Be trained and authorized to safely energize, de-energize, ground, lockout/tagout circuits and equipment, and clear faults in accordance with established safety practices. Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves, hard hats[...]

5 G8000 Series with Isolated Output Installation and Operation Manual 4 Safety Precautions The T oshiba products listed in this document are intended for usage in general electronics applications (computer , personal equipment, ofce equipment, measuring equipment, industrial robotics, domestic appliances, etc.). These T oshiba products are neith[...]

6 G8000 Series with Isolated Output Installation and Operation Manual 4.3 T ransporting/Unpacking W ARNING 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. See Installation Manual: Chapt[...]

7 G8000 Series with Isolated Output Installation and Operation Manual Fig. 4.1 Exterior Handling label CAUTION DO NOT transport, move, store, or place the UPS on its side. Forces due to heavy components inside may damage the UPS. A void vibration or shock exceeding 0.5G. Failing to observe this precaution may cause damage to the UPS. DO NOT allow t[...]

8 G8000 Series with Isolated Output Installation and Operation Manual 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[...]

9 G8000 Series with Isolated Output Installation and Operation Manual CAUTION Install the UPS in a controlled environment. Improper storage and installation environment may deteriorate insulation, shorten component life and cause malfunctions. See T able 5.1 - UPS Installation Environment Standards DO NOT tilt the UPS more than 10° from upright po[...]

10 G8000 Series with Isolated Output Installation and Operation Manual DO NOT block air vents. Blocking the vents will increase the internal temperatures and may result in UPS failure or re. DO NOT install the UPS where water may fall on it. W ater may cause electrical shock, personal injury or UPS failure. DO NOT use oor wax that contains si[...]

1 1 G8000 Series with Isolated Output Installation and Operation Manual T ABLE 5.1 - UPS INST ALLA TION ENVIRONMENT ST ANDARDS Item Environment standard Installation Location Indoors Ambient T emperature Minimum operating temperature: 32 °F (0 ° C) Maximum operating temperature: 104 °F ( 40 ° C) (UPS only) Maximum operating temperature: 95 °F [...]

12 G8000 Series with Isolated Output Installation and Operation Manual not inuence 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. 8) The user should provide ov[...]

13 G8000 Series with Isolated Output Installation and Operation Manual 5.1 Wiring/Connection W ARNING 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 ONL Y one (1) ground wire to the earth ground terminal. [...]

14 G8000 Series with Isolated Output Installation and Operation Manual 6 W arning Labels Below are representative warning labels and their location on the UPS. Exterior Handling labels shown in section 4.3, T ransporting/Unpacking, are in the manual packet, and attached to the UPS shipping covering and shipping pallet. A TTENTION Make sure all the [...]

15 G8000 Series with Isolated Output Installation and Operation Manual FIGURE 6.1 – G8000 WITH ISOLA TED OUTPUT UPS W ARNING LABELS 6.1 W arning Label Locations FIGURE 6.2 – 100 KV A UPS WARNING LABELS C A U T I O N Do no t t urn o ff while o pera tin g. 8A (control power source switch) Ri sk of elec trica l sho c k. PN 408 31 Heat s ink n ot g[...]

16 G8000 Series with Isolated Output Installation and Operation Manual FIGURE 6.3 – 150KV A UPS WARNING LABELS[...]

17 G8000 Series with Isolated Output Installation and Operation Manual 7 W eight and Dimensions T able 7.1 lists the unit and shipping weight(s) for G8000 UPS models illustrated in Figures 7.1 – 7.2. T ABLE 7.1 G8000 UPS UNIT AND SHIPPING WEIGHT(S) Model Unit Shipping 100 kV A 2206 lb (1000 kg) 2296 lb (1041.4 kg) 150 kV A 3200 lb (1451.5 kg) 329[...]

18 G8000 Series with Isolated Output Installation and Operation Manual FIGURE 7.2 - 150KV A UPS EXTERIOR DIMENSIONS (INCHES) TERMINAL BLOCKS “8A” SWITCH GROUND BUS[...]

19 G8000 Series with Isolated Output Installation and Operation Manual 8 T ransporting The UPS may be packed in a crate for extra protection during transportation. Avoid impact or vibration against the UPS during transportation. DO NOT expose the UPS directly to water . W ARNING When transporting the UPS by crane, follow the SPECIFIED WORK PROCEDUR[...]

20 G8000 Series with Isolated Output Installation and Operation Manual G8000 Series Installation Manual 21 8.1 Transporting By Crane Cables should have sufficient ratings and be of the same length. Make sure the suspension cables are hooked at eyebolts. See Fi gure 8.1. Keep the angle less than 60° b etween cables. Refer to Chapter 7 - Weight and [...]

21 G8000 Series with Isolated Output Installation and Operation Manual 8.2 T ransporting By Forklift Refer to Chapter 7 - Weight and Dimensions. V erify 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 undernea[...]

22 G8000 Series with Isolated Output Installation and Operation Manual 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 represnet[...]

23 G8000 Series with Isolated Output Installation and Operation Manual W ARNING Whi le oper ati ng in the inv ert er mode , placi ng the inpu t break er in the “OF F” pos iti on wil l swi tch the UPS to the batt ery backu p mod e. The output of the UPS will continue uninterrupted to the load. The unit must be in the bypass mode at the time that[...]

24 G8000 Series with Isolated Output Installation and Operation Manual 9.2 Maintenance Precautions All internal maintenance sould be performed by factory authorized personnel. 1) T urn of f, 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 eq[...]

25 G8000 Series with Isolated Output Installation and Operation Manual CAUTION DO NOT di spose of the bat terie s i n a re. The batteries may explode. DO NOT op en or mutil ate t he ba tte rie s. Released electrolyte is harmful to the eyes and skin and could also be toxic. DANGER A bat ter y can prese nt a risk of elec tri cal shoc k and high sh[...]

26 G8000 Series with Isolated Output Installation and Operation Manual 10 Installation W ARNING Keep the SPECIFIED CLEARANCE around the UPS. Inadequate space around the UPS makes it difcult to perform maintenance/inspections, lead to insufcient ventilation, and/or will cause malfunctions. See Figure 10.1 - UPS Clearance DO NOT tilt the UPS mo[...]

27 G8000 Series with Isolated Output Installation and Operation Manual 10.1 Unpacking Unpack the UPS indoors on a paved oor . The UPS should be as close as possible to its nal 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 forkl[...]

28 G8000 Series with Isolated Output Installation and Operation Manual 10.3 Anchor Bolts Install the anchor bolts to secure the UPS on the oor . 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 [...]

29 G8000 Series with Isolated Output Installation and Operation Manual 1 1 UPS Wiring Note: Always consult your local and NEC electrical codes for wiring, cabling, and circuit protection devices. requirements. Figure 1 1.1 illustrates the external wiring of the G8000 UPS. See corresponding section to each wiring term. Power cable connection at term[...]

30 G8000 Series with Isolated Output Installation and Operation Manual 1 1.1 T erminal Blocks, T erminal Bus, and Power Cables Note: Always consult your site specic, local, state, and NEC electrical codes for wiring, cabling, and circuit protection device requirements. The terminal blocks for the 100/150 kV A UPS are shown in Figure 1 1.2. The t[...]

31 G8000 Series with Isolated Output Installation and Operation Manual T ABLE 1 1.1 RECOMMENDED CRIMP TYPE COMPRESSION LUGS Wire Size Wire Strand Class Recommendation Crimp tool Required Burndy type Y35 or Y46 V endor Cat. No. Color Key Die Index 1/0 B I B Burndy Ilsco Burndy Y A25 CRA-1/OL Y A25-LB Pink Pink Black 12 / 348 12 / 348 13 2/0 B I B Bu[...]

32 G8000 Series with Isolated Output Installation and Operation Manual Cable knockout plates are provided at the bottom of the 100 kV A UPS, and at the bottom and top of the 150 kV A UPS. The recommended hole locations are illustrated in Figure 1 1.4 - 1 1.6 The ve (5) holes must be punched during installation. The dashed rectangle indicates the[...]

33 G8000 Series with Isolated Output Installation and Operation Manual 1 1.3 Grounding Wire W ARNING Be sure to ground the UPS as specied. Using the UPS without a proper ground will deteriorate the insulation, cause leakage of currents and electric shock.The resistance to ground should be less than or equal to 10 ohms. The 100/150 kV A earth gro[...]

34 G8000 Series with Isolated Output Installation and Operation Manual 1 1.4 Control Wires The control wires terminal layouts at TB1 (terminal bus 1) are shown below in T able 1 1.4. T ABLE 1 1.4 EXTERNAL CONNECTIONS No. I/O Signal Name Operation 1 Output Low Battery Closed at Low Battery 2 Output Backup Operation Closed during Backup Operation 3 O[...]

35 G8000 Series with Isolated Output Installation and Operation Manual The UPS battery cabinet and bypass breaker should be wired as shown below in Figure 1 1.8. FIGURE 1 1.8 - CONNECTION BETWEEN UPS, BA TTERY CABINET & BYP ASS BREAKER 10 1 1 12 13 14 15 16 17 18 19 20 21 22 TC TB1 Battery Cabinet Overheat B-Contact Bypass Breaker Ext. EPO (Cus[...]

36 G8000 Series with Isolated Output Installation and Operation Manual 1 1.5 Grounding Conguration T h i s se ct io n de sc ri be s th e gr ou nd in g co n gu ra ti on t o b e u se d wi th t hi s UP S. A 2 AWG (or 38 mm 2 ) factory-installeded jumper cable is provided between the neutral terminal and ground bus in the UPS cabinet. The jumper [...]

37 G8000 Series with Isolated Output Installation and Operation Manual 12 UPS Specications 12.1 General Specication T erms Specication Remarks Conforming Standard UL1778-2001 UL, cUL, IEC Ambient T emperature 32 – 104 ° F (0 – 40 ° C) Relative Humidity 30% – 90% Non-condensing Altitude < 3,280 ft (< 1,000 m) Contact T oshiba [...]

38 G8000 Series with Isolated Output Installation and Operation Manual 12.2 Mechanical Specication (cont.) Rated Capacity 150kV A Cabinet Protection Conformity IEC298 IP20* Exterior Paint Sherwin Williams, HHT2-7055, 079 Beige T exture Panel Thickness FRONT : 1/16 in. (1.6 mm) BACK/SIDE/TOP: 3/64 in. (1.2 mm) BOTTOM: 1/8 in. (3.2 mm) Input/Outpu[...]

39 G8000 Series with Isolated Output Installation and Operation Manual 12.3 Electrical Specication AC Input Rated Capacity 100 kV A (80 kW) 150 kV A (120 kW) Input V oltage 480 V ( +10% – -15% ), 3-Phase 3-Wire Input Frequency 60 Hz ±5% Input Power Factor 1.00 – 0.95 Lagging ( at 100% Load ) Current Harmonic Distortion 5% Maximum ( at 100% [...]

40 G8000 Series with Isolated Output Installation and Operation Manual 13 Operator Interface T able 13.1 shows the functions of the operating buttons on the graphic display panel. A TTENTION Press an operating button for at least 0.5 seconds to change UPS modes. Press the reset button for for at least 5 seconds to reset the UPS. The UPS may not res[...]

41 G8000 Series with Isolated Output Installation and Operation Manual 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. FIGURE 13.1 – GRAPHIC DISPLA Y P ANEL KEY -SWITCH/OPERA TING BUTTONS [...]

42 G8000 Series with Isolated Output Installation and Operation Manual 13.2 LCD/LED Indicators FIGURE 13.2 – GRAPHIC DISPLA Y P ANEL LCD/LED INDICA TORS 23 1 1 21 20 19 18 17 16 15 14 13 22 24 25 12[...]

43 G8000 Series with Isolated Output Installation and Operation Manual 13.3 LCD Indicators The operator can scroll through the following LCD display screens using the scroll buttons. T ABLE 13.1 - LCD DISPLA Y SCREENS Name Description Normal Display Displays operational status, operational guidance, and measured data. Fault Display Displays detaile[...]

44 G8000 Series with Isolated Output Installation and Operation Manual 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. T able 13.2 shows these screens page by page and illustrates the UPS Normal Display operational[...]

45 G8000 Series with Isolated Output Installation and Operation Manual T ABLE 13.2 - CONTINUED MEASUREMENT SCREENS O/P CURRENT (PEAK) Shows the peak output current peak (%) for each phase. U 50[%] V 50[%] W 50[%] Peak value of output current x 100 [%] RMS value for rated current x 1.41 AC INPUT Shows the AC Input V oltage (line-to-line) and frequen[...]

46 G8000 Series with Isolated Output Installation and Operation Manual 13.5 Fault Display The Fault Display screen displays the fault records until they are reset. The W arning Display screen displays the warning records until they are reset. The fault records will remain in memory until the reset button is pressed and held for at least 5 seconds, [...]

47 G8000 Series with Isolated Output Installation and Operation Manual 13.6 LCD Scroll Scroll through the LCD display screens (see Figure 10.4), 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 T ABL[...]

48 G8000 Series with Isolated Output Installation and Operation Manual 14 Operating the UPS This section describes the basic procedures to operate the UPS. Figure 1 1.1 shows the location and functions of the operating switches to operate the UPS. FIGURE 14.1 - EPO AND CONTROL POWER SUPPL Y OPERA TING SWITCHES W ARNING If the UPS produces smoke or [...]

49 G8000 Series with Isolated Output Installation and Operation Manual 14.1 Operation T ypes The operation types are summarized below . T ABLE 1 1.1 OPERA TION TYPES Operation Description Startup Starting up and operating the UPS. Switch Power Supply Switching power supply source between UPS and Bypass. Stop Stop the inverter and chopper/charger . [...]

50 G8000 Series with Isolated Output Installation and Operation Manual SYSTEM INITIALIZE BATTERIES AC SWITCH UPS BYPASS DISCHARGE  FLO AT CHAR GE  EQUAL CHARGE  㨪 AC INPUT ` CONVERTE R ` INVERTER 㨪 AC OUTPUT  BYPASS INPUT 㨪 14.3 Startup Procedures The procedure to start the UPS is shown in Steps 1-5. STEP 1 T urn on the control[...]

51 G8000 Series with Isolated Output Installation and Operation Manual Step 4-5 continues the procedure to start the UPS. STEP 4 T urn on the DC Input Breaker (72B) on the external battery cabinet. BA TTERIES LED is “ON”. STEP 5 *Press the “UPS” button for at least 0.5 seconds.This completes UPS startup procedure BYP ASS LED is “OFF”. U[...]

52 G8000 Series with Isolated Output Installation and Operation Manual 14.4 Switch Power Supply (UPS→Bypass) The procedure to transfer between the UPS supply and the bypass supply is shown in Steps 1-3 STEP 1 Check AC INPUT LED and BYP ASS LED are on to make sure power is being delivered to the UPS. STEP 2 Press the “BYP ASS” button for at le[...]

53 G8000 Series with Isolated Output Installation and Operation Manual 14.5 Stop The procedure to stop the UPS is shown in Steps 1-3. STEP 1 T ransfer to Bypass supply as described in Switch Power Supply . UPS LED is “OFF”. BYP ASS LED is “ON”. STEP 2 T urn off the DC Input Breaker (72B) on the external battery cabinet, and, press the G8000[...]

54 G8000 Series with Isolated Output Installation and Operation Manual 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 T ransfer to Bypass supply as described in Switch Power Supply . UPS LED is “OFF”. BYP ASS LED is “ON”. STEP 2 T urn off the DC Input Breaker[...]

55 G8000 Series with Isolated Output Installation and Operation Manual 14.7 Changing Between Float Charge and Equalize Charge The procedure to change the recharge mode between oat charge and equalize charge is shown in Steps 1-3. See the Note below for an explanation of Flaot and Equalize charge modes. STEP 1 Make sure that the FLOA T CHARGE LED[...]

56 G8000 Series with Isolated Output Installation and Operation Manual 14.8 Changing to Float Charge from Protection Charge (If applicable) The manual procedure to change from protection charge to oat 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 [...]

57 G8000 Series with Isolated Output Installation and Operation Manual 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. T o Reset the UPS a[...]

58 G8000 Series with Isolated Output Installation and Operation Manual 15.2 Faults and W arnings 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 T able 15.2 show a sample screen and describe the data shown in the screen. F AUL TS & WARNINGS 1 UPS OVERLOAD 09-09-06 0[...]

59 G8000 Series with Isolated Output Installation and Operation Manual 15.3 LCD Fault & W arning 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. BYP ASS F AUL T STOP F AUL TS & WAR[...]

60 G8000 Series with Isolated Output Installation and Operation Manual 15.4 Fault Messages Figure 15.4 show the corresponding circuit locations for fault detection codes. T ables 15.3 through 15.7 gives details for the fault and warning messages referred to in section 15.3. The “item” code assoiated with each fault or warning message may be use[...]

61 G8000 Series with Isolated Output Installation and Operation Manual T ABLE 15.5 - W ARNING - 2 (STOP AND REST ART) Item LCD Message Indication Description 27 I AC O/P UV AC output voltage is low . 30U UNIT F AUL T IGBT Stack Failure. 45 DC OV Over-voltage in DC circuit. 49 AC O/P OL Output overload 51 I INV . OC Inverter over-current. 59 I AC O/[...]

62 G8000 Series with Isolated Output Installation and Operation Manual 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 T able 15.8 for detail of the scroll butt[...]

63 G8000 Series with Isolated Output Installation and Operation Manual 15.6 Restoring UPS Operation The procedure to restore UPS operation is shown in Steps 1-2. The example shows the UPS restored after a trip fault occurred on inverter over current with the message “INV . OC.” STEP 1 Check the LCD screen. Also check other fault data screens wi[...]

64 G8000 Series with Isolated Output Installation and Operation Manual[...]

[...]

INDUSTRIAL DIVISION 13131 West Little Y ork Road, Houston, T exas 77041 T el (713) 466-0277 Fax. (713) 466-8773 US (877) 867-8773 Canada (800) 872-2192 Mexico 01/800/527-1204 www .T oshiba.com/ind Printed in the U.S.A.[...]