Toshiba G8000 Series manual

Uninterruptible Pow er Sy stem (UPS) G8000 Series Installation Manual • Read this operation manual carefully before installing the UPS. • Retain this manual wi th the UPS for easy reference when required. • This manual was w ritten f or the consulting engineer, architect, and electr ical contractor. © TOSHIBA Corporation 2005 All Rights Rese[...]

1 The instructions contained in this manual are not intended to cover all of the details or va riations in equipment, or to provide for every poss ible contingen cy concerning i nstallation, op eration, or maintenance. Should further inform ation be required or if problems arise which are not covered suff iciently contact your Toshiba sales office.[...]

2 UNINTERRUPTIBLE POWER SUPPLY Complete the inform ation below for the UPS sy stem received. Unless otherwise specified, the warranty period for the UPS or UPS part is 36 m onths from the shipment date (see T IC bill of ladin g). Unless otherwise specified, the warranty period for a UPS battery is 24 m onths fr om the shipm ent date (see TIC bill o[...]

3 Manual’s Purpose and Scope This m anual provides inform ation on how to s afely install, operate, and m aintain y our T IC power electronics product. T his manual includes a s ection of general safety instructions that describes the warning labels and symbols that are used throughout the manual. Read the m anual c ompletely before installing, o[...]

4 2. General Safety Instructions DO NOT attem pt to install, operate, m aintain or dispose of this equipment until you have read and understood all of the product safety inform ation and di rections that are contained in thi s m anual. Safety A lert Symbol The Safety Aler t Symbol indicates that a potential pers onal injury hazard ex ists. T he sym[...]

5 3. IMPORTANT SAFETY INSTRU CTIONS SA VE THESE INSTRUCTIONS This instruction contains im portant instructions for the G8000 Series that should be follow ed during the installation, ope ration, and maintenance of the UPS sy s tems. Please refer to the battery m anufacturer ’s instructions for details on operating and maintaining the batteries for[...]

6 4. Safety Precautions A pplicati on The UPS shall NOT be applied to support equipment (* ) that could affect the human lives. Special considerations are required w hen applying this UPS to the equipment (**) that affect human safety and/or maintain public services. Be sure to contact/inform Toshiba if i t is such a case. The application w it hout[...]

7 General Terms WARNING Do NOT remov e the rear/side panels. The parts inside carry energy -high current. T hat may result in electric shock, burns, pers onal injuries or UPS faults by removing these panels. Do NOT modify the UPS, relocate after i nitial i nstallation or replace parts by untrained personnel. Electrical shock, injury or UPS faults m[...]

8 5. Installation Precautions Personnel WARNING Please have a certified/qualified electr ician install t he UPS per local and/or national electric codes. UPS faults or improper operation m ay oc cur if not installed properly per c odes and the install ation manual. Transportation/Unpacking CAUTION Do not transport, move, store, or place the UPS on [...]

9 Installation Environment CAUTION The UPS is to be i nstalled in a controll ed environment. Improper s torage and installa tion environment may deterio rate insulation, shorten component life and cause malfunctions. Keep the install ation envi ronment per standard descr ibed in Table 5.1. Table 5.1 - UPS Installation Environm ent Standard No. Item[...]

10 WARNING Keep the specified clearance around the UPS. Leaving no space m akes it diff icult to carry out maintenance, inspections, causes insuff icient venti lation, and cool ing leading to malf unctions. Keep the UPS room clean. Use a vacuum cleaner to clean the UPS. Also, Do NOT use silicon-contained waxes on the floor in the UPS room and in th[...]

11 Wiring/Connection WARNING Be careful w hen connecting the UPS to the battery panel. A wrong connection may c ause damage to the UPS, battery , or charger. Perform wiring and connectio ns with correct polarity . The tightening torque of screw s must conform to the tightening criteri a. Loose connections may cause fire due to heating. When making [...]

12 W arning label che ck (1) Warning label locations on t he UPS are shown in t he Figures below . Please make sure these w arning labels are placed in specified spots. (2) Please read all w arning labels and understand w hat t hey mean. (3) Make sure w arning labels are alw ays legible. Do NOT allow the l abels to be removed or cov ered. Locations[...]

13 Figure 5.3 - 250/300kVA UPS exterior/interior show ing w arning l abels. Locations of th e Warning Labels (150/180/225 kVA ). Figure 5.2 - 150/180/225kVA UPS exterior/interior show ing w arning l abels.[...]

14 The m eanings of the following l abel sy m bols are as follows: 1) The lightning flash wi th arrowhead w ithin a triangl e is intended to t ell the user or the service personnel that parts inside the p roduct are a risk of electric shock to personnel. 2) The ground symbol in a blu e circle is intended to tel l the user or the service personnel t[...]

15 F DA NGER RISK OF ELECTRIC SHOCK OR ELECTRIC ENERGY-HIGH C URRENT LEVELS Dangerou s electric charge may be stored in capacitor and associated ci rcuitry. Test before touching. E DA NGER RISK OF ELECTRIC SHOCK Capacitors stay charged after power ha s been shut off. Acci dental contact with live parts can cause personal injury and death. Turn off [...]

16 6. Contents 1. Introduction 1 2. GENERA L SAFETY INSTRUCTIONS 4 3. IMPORTA NT SA FETY INSTRUCTIONS 5 4. Safety P recautions 6 5. Installation Preca utions 8 6. Contents 16 7. Dimensions and Wei ght 17 8. Transportation 20 8.1 Transportation by a crane 20 8.2 Transportation by a forklift 22 9.0 Storage 23 10.0 Installa tion 24 10.1 Unpacking 25 1[...]

17 7. Dimensions and Weight Figure 7.1~7.3 show the outline dimensions and we ights of G8000 UPS. Figure 7.1 - 100/125kVA UPS Exterior dimensions (front & right side). (74.8”) (3.9”) Earth Ground Bus (41.3”) (50.4”) (31.5”) W eight 100kVA: 1,000kg (2,200lbs) 125kVA: 1,200kg (2,640lbs )[...]

18 Figure 7.2 - 150/180/225kVA UPS Exterior dimensions (front & right side). (55.1”) (31.5”) (46 ” ) (74.8”) (3.9”) Earth Ground Bus W eight 150kVA: 1,200kg (2,640lbs) 180/225kVA: 1,500kg (3,300lbs)[...]

19 (76.8”) W eight: 2,000kg (4,400lbs) Earth Ground Bus Earth Ground Bus (74.8”) (3.9”) (35.4”) Figure 7.3 - 250/300kVA UPS Exterior dimensions (front & right side).[...]

20 8. Transportation A void vibration or shock exceeding 0.5 G to the UPS. Failing to ob serve this precaution may cause damage to the unit. Do NOT expose the UPS to water. Exposing the UPS to w ater m ay damage or deteriorate the UPS . The UPS is packed in a crate to bear external force well during transportation. How ever, the following points sh[...]

21 Figure 8.2 and 8.3 show unacceptable examples for lifting. Make sure that the UPS doesn’t swing o r tilt. Then lift the UPS. Keep UPS level while lifting. Minimize the i mpac t of a sudden stop when lo wering the UP S to a resting surface. Figure 8.4 and 8.5 show examples of good and unacceptable operations. Figure 8.4 - Good operation. Figure[...]

22 8.2 Transportation by a forklift Space for the fork s is provided underneath the UP S. Insert the fork s into the space shown in Figure 8.6. Make sure f orklift’s m axim um load is enough to carry UPS . Refer to chapter 7 “Dim ension and W eight” for UPS weight. Ensure that the UPS doe s not swing or tilt. Then li ft and transport the UPS [...]

23 9. Storage Observe following poi nts when storing the UP S. (1) Be sure to store UPS indoors. (2) The best tem perature at storing location is 20~25° C (68~77° F). In case this temperature is diff icult to be maintained, a temperature window of 0~40° C (32~104° F) should be observed. Tem perature fluctuat ions should be minim al. (3) Relativ[...]

24 10. Ins tallation When transporting the UPS, do not ti lt the UPS more than 10 ° ° ° ° from upright. Titling the UPS more than 10 ° may cause personal i njury i n the event that it falls or is overturned. Do not transport, mov e, store, or place the UPS on its side. Excessive force applied from heavy objec ts placed inside of the cabinet ma[...]

25 10.1 Unpacking Make sure that UPS unpacking is conducted on the paved floor indoor, w hich should be as close as possible to the install ing location. A building with ov erhead traveling cranes is expected to unpack large- sized UPS . If a crane is not availabl e, obtain a w ide enough space for fork lift operations. Also keep space around the U[...]

26 10.3 A nchor bolts Tighten the anchor bolts to secure the UPS on the floor. Tightening detail is shown in Figure 10.2. Anchor bolts of 12mm (1/2”) diam eter are to be used, clearance holes of 16mm (5/8”) diam eter are provided in the UPS ba se. Figure 10.3 - Hole locati ons and dimensions for anchor bolts. 4 of 16mm-diam eter (5/8 ” ) scre[...]

27 11. Wiring 11.1 Overview Figure 11.1 shows the external w iring diagram of G8000 UPS. W iring work is sum m arized belo w. 1) Power cable connection for AC inpu t, By pass Input, AC output, a nd DC input at terminal blocks or buses. 2) External breaker provision at AC input, B y pass Input, AC output, and DC i nput. 3) Earth ground wi re at grou[...]

28 11.2 Terminal Blocks and Power Cables The term inal blocks are shown in Figure 11.2 and a re located inside at the b ottom of each 100/125/150/180/2 25kVA UPS. External cable siz e and tighteni ng torque are recomm ended in the Table 11.1~11.5. Only copper wires are allowe d for external cables. Figure 11.2 - Terminal Blocks of 100/125/150/180/2[...]

29 Table 11.2 Recommended Cable Size and T ightening T orque for 125kVA UPS. Block Number Cable Siz e Tightening T orque 1 AW G 4/0 or larger 3.2 kg -m (275 in-lbs) 2 AW G 4/0 or larger 3.2 kg -m (275 in-lbs) 3 AW G 4/0 or larger 3.2 kg -m (275 in-lbs) 4 AW G 4/0 or larger 3.2 kg -m (275 in-lbs) 5 AW G 4/0 or larger 3.2 kg -m (275 in-lbs) 6 AW G 4/[...]

30 Table 11.4 Recommended Cable Size and T ightening T orque for 180kVA UPS. Block Number Cable Siz e Tightening T orque 1 Two 2/0 or larger 5.8 kg -m (500 in-lbs) 2 Two 2/0 or larger 5.8 kg -m (500 in-lbs) 3 Two 2/0 or larger 5.8 kg -m (500 in-lbs) 4 Two 2/0 or larger 5.8 kg -m (500 in-lbs) 5 Two 2/0 or larger 5.8 kg -m (500 in-lbs) 6 Two 2/0 or l[...]

31 Three cable k nockout plates are provided at bottom of each 100/125/150/180/225kVA UPS. Hol es are recom mended in Figure 11.3. The installing electrical contractor must punch the 5 holes. Three solid rectangles show the cable knockout plates’ outline. The dashed rectangle shows the UPS op ening under the pl ates. Figure 11.3 - Cable knockout [...]

32 Table 11.6 Recommended Cable Size and T ightening T orque for 250kVA UPS. Bus Number Cable Siz e Torque t o tighten the terminal bus 1 Two 250MCM or larger 2.5~4.5 k g-m (215~386 in-lbs) 2 Two 250MCM or larger 2.5~4.5 k g-m (215~386 in-lbs) 3 Two 250MCM or larger 2.5~4.5 k g-m (215~386 in-lbs) *4 Two 350M CM or larger 2. 5~4.5 kg -m (215~386 in-[...]

33 Table 11.8 Recommended Lu gs. Recommendation At Terminal Bus # Vendor Catalog # 1 2 3 ILSCO TA-600 AU-600 4 5 ILSCO TA-600 T3A2-600N 6 7 8 TA-600 AU-600 9 TA-600, T3A2-600N 10 11 12 ILSCO TA-600 AU-600 Four cable knock out plates are provided at th e top of the 250/300kVA UPS. See Fi gure 11.5 for hole information. The six holes m ust be punched[...]

34 11.3 External Breakers The G8000 UPS units are not equippe d with circuit breakers. The electrical contractor s hould provid e the external breakers f or AC input, By pass input, DC input, and AC o utput. See Figure 11.1 for the position of the breakers. Table 11.9 shows the minimum rating for each capacity of G8000 UPS breakers. The Bypass inpu[...]

35 11.4 Grounding Wire Be sure to ground the UPS as specified. Using the UPS w ithout a proper ground w ill deteriorate the insulation and may cause electric shock due to leakage cur rents. The resistance to ground should be 10 Ω or less. A grounding bus is provi ded on the inside of the each unit. The bus is located on the front at the bottom of[...]

36 11.5 Control Wires The term inal lay out of control wires at TB1 is shown in Table 11.10. Table 11.10 External Connections No. I/O Signal Name Operation 1 Output Low Batte ry Close at Low B attery 2 Output Backup Operation Close while Backup Operation 3 Output Fault Close by Faults 4 Output Inverter Supply Close during Norm al Operation 5 Output[...]

37 11.6 Grounding configuration This section descr ibes the grounding configuration with AC i nput service entrance. As inadequate groundi ng configuration causes problems on start- up, connections for the ground line and the neutral l ine must be done properly according to the sy s tem conf iguration. 11.6.1 Recommended configuration w ith input n[...]

38 11.6.2 Grounding configuration w it hout input neutral W hen th e neutral line cannot be fed to the by pass input from the input source which is wy e-connected, the neutral terminal in the UPS cabinet must be connected to the ground bus in order to stabiliz e the UPS potential as show n in Figure 11.10. Thus, the jumper cable should stay on. See[...]

39 11.6.4 Grounding configuration w it h corner-grounded delta-input If a phase of delta-input source is grounded (B-phase for exam ple), the ground bus in the UP S cabinet should NOT be connected to the neutral terminal of UPS output. So, the jumper cable should be disconnected. See Figure 11.9 for the jumper cable location. The UPS output is floa[...]

Filename: 57490 -000 Install Directory: J:inverte ruser sjlwilliamsTechnical PublicationsUPSG- 8000De liverable s Temp late: C:Program FilesMicrosoft OfficeTe mplatesNormal.dot Title: G8000 I nstallati on Subject: Author: K.Okizaki Keyword s: Comments: Creation Date: 01/19/ 05 1:00 PM Change Numbe r: 376 Last Saved On: 02/07/ 05 7:12 AM [...]