Toshiba G8000 Series manual

Uninterruptible Pow er Sy stem (UPS) G8000 Series Operation Manual • Read this operation manual carefully before operating the UPS. • Retain this manual wi th t h e UPS f o r easy ref erence when required. • This manual was w ritt en for the UPS operator and maintenance personnel. © TOSHIBA Corporation 2005 All Rights Reserved. REQUIREMENT S[...]

1 Notice Please inform T oshiba Corporation or authoriz ed representative in case inconsistencies, omissions, or questions. The instructions contained in this manual are not intended to cover all of the details or variations in equipm ent, or to provide for every possible contingency concerning installation, operation, or m aintenance. Shoul d fur [...]

2 UNINTERRUPTIBLE POWER SUPPLY Complete the inform ation below f or the UPS sy stem received. Unless otherwise specified on the warranty card, the warranty period f or the UPS or U PS part is 36 months f rom the shipment date (see T IC bill of lading). Unless otherwise specified on the warranty card, the warranty period for a UPS battery is 24 m on[...]

3 Manual’s Purpose and Scope This manual provides inform ation on how to safely i nstall, operate, and maintain y our TIC power electronics product. This manual includes a sec tion of general saf ety instructions that desc ribes the warning labels and s y m bols that are used thr oughout the m anual. Read the m anual com pletely before installing[...]

4 2. Table of Contents Introduction 1 General S afety Instructions 5 Maintenance Pre cautions 7 Installation Pre cautions 11 Operating Prec autions 13 Important Safety Instructions 14 Safety Pre cautions 15 Labeling Requireme nts 19 Handling Precautions 22 Outline and Layout 24 Operating Interface 30 Graphics Intefac e 35 Operation 42 Troubleshooti[...]

5 3. General Safety Instructions DO NO T attempt to install, operate, m aintain or dispose of this equipm ent until y ou have read and understood all of the product safety inform ation and directions that are contained i n this m anual. Safety A lert Symbol The Safety Alert Sy mbol indicates that a potential personal injury hazard exists. The sy m [...]

6 Special Symbols To identify s pecial hazards, other symbols m ay appear in conjunction with the DANGER , WARNING and CA UTIO N signal words. T hese s y m bols indicate areas that require special and/or strict adherence to the procedures to prevent serious injury to personnel or death. Electrical Hazard Symbo l A sy m bol whi ch indicates a haza r[...]

7 4. Maintenance Precautions 1. Turn off , lock out, and tagout al l power sources before connecting the power wiring to the equipment or when performing m aintenance. 2. Hardwire ty pe UPS units are not equip ped with an over-current protection devi ce, nor do they h ave an output disconnect for the ac output. Therefore, a user- installed circuit [...]

8 — Strict adherence to the follow ing precautions is a requirement w hen w orking wit h batteries — To be perform ed by Qualified Personnel only . 1) Verify that the UPS is off and that the power cord is disconnected from the power source. 2) Remove watches, rings or other m etal objects. 3) Use tools with i nsulated handles to prevent inad ve[...]

9 Inspection/Storage/Disposal Inspection Upon receipt of the UPS , an inspection for shipping dam age should be perfor med. Use caution when removing the unit from the pallet. Refer to labels or documentation attached to packing m aterial. Uncrating Check the unit for loose, broken, bent or otherwise damaged parts. If dam age has occurred during sh[...]

10 Storage Maintenance • If stored at an am bient temperature less than 20° C (68° F), r echarge the batteries every 9 months. • If stored at an am bient temperature of 20° – 30° C (68° – 86° F), recharge the batteries every 6 m ont hs. • If stored at an am bient temperature of 30° – 40° C (86° – 104° F), recharge the batter[...]

11 5. Installati on Precautions 1) Install the unit in a well-ventilated location; allow at least 10 cm (4 inches) on all sides for air ventilation and for m aintenance. 2) Install the unit in a stable, level an d upright position that is free of excessive vibration. 3) Install the unit where the ambient tem perature is withi n the specified range.[...]

12 Please have the certified/qualified electr ician install the UPS per local, state and National Electrical Code. UPS faults or improper operat ion may occur if not installed properly per Codes and the installation manual . The UPS is to be installed i n a controlled environment. High temperature/humidity may shorten the life of components within [...]

13 6. Operating Precautions 1) The UPS should not be po wered up until the en tire operation manual has been read. 2) The voltage of the i nput powe r source m ust be withi n the range of +10% to - 30% of the rated inpu t voltage. The inp ut frequency must be wit hin the rated input fr equency range. Voltages and frequencies outside of the permiss [...]

14 7. Important Safety Instructions SA VE THESE INSTRUCTIONS T his instruction contains important instructions for G8000U Series 100, 150, 225 and 300kVA that shoul d be followed during the i nstallation, operation, a nd m aintenance of the UPS sy stem s. Please refer to the battery manufacturer’s instructions f or details on operating a nd maint[...]

15 8. Safety Precautions A pplication This UPS shall NOT be applied to support equipment (*) that could af fect 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 i thou[...]

16 WARNING If the UPS produces smoke or smells str ange, turn off AC i nput breaker and battery breaker immediately. Continued running may result in fire. Contact Toshiba or authorized representatives. Contact the Toshiba or authorized representatives in case of malfunction or fault. This UPS should be repaired by authoriz ed Toshiba service person[...]

17 WARNING Do NOT remov e the rear/side panels. The parts inside carry energy-high curr ent. That may result in electric shock, burns, personal injuries or UPS faults by removing these panels. CAUTION Operators should be certifi ed* personnel. Operation of the UPS by uncertified or untrained personnel may result in electric shock, personal injury o[...]

18 9. Labeling Requirements The exclam ation mark within a triangl e is intended to tell the user or the ser vice personnel that cautionary mar kings are located with “CAUTION,” “W ARNING,” or “DANGER.” Figure 1 - UPS exterior showing w arning label locations Locations of th e Warning L abels B DA NGER RISK OF ELECTRIC SHOCK This UPS re[...]

19 Locations of th e Warning L abels (150, 225 kVA). Locations of th e Warning L abels (300 kVA). Figure 2 - UPS exterior/interior showing w arning labels.[...]

20 The meaning of symbols used in the cautionary markings are as follows: 1) The exclam ation mark within a triangl e is intended to tell th e user or the service personnel that cautionary m arkings are located with “CAUTION,” “W A RNING,” or “DANGER.” 2) The lightning flash wi th arrowhead withi n a triangle is intended to t ell the us[...]

21 * The label G is attached at the ground wir e connection point. ** The lab el E is mounted in the vicinity of the main circuit transfor mers and re actors that can be seen from the back of the UPS. Figure 3 - Warning Labels. G Grounding Electro de Termina l H CA UTION The output ac circ uit is c onsidered as a separately derive d source. If loca[...]

22 10. Handling Precautions Perform daily inspections and planned periodic maint enance . In order to extend the service life and optimal performance, t he UPS must be installed in a suitable env ironment, and should have adequate daily/periodic inspections. The periodic inspection is significantly eff ective to prevent the UPS from f aults or acci[...]

23 Do NOT place pieces of metal, fl ammable objects or fingers into t he air vents or mechanical gaps of the UPS. It may cause f ire, explosions, or may give an electrical shock. Do NOT operate the UPS in wet locations. Operation in wet location may cause ele ctr ical shock, UPS fault or other accidents may occur. Keep the reset button pressed for [...]

24 11. Outline and Layout Do NOT open the front and/or rear panel. The parts inside carry energy-high curr ent. Touching them may result in electric shock, burns or UPS fault. Make sure the air vents on the front and top of the UPS are not covered. Covering the vents wi ll cause the temperat ure inside the UPS to rise and may result in f ire and/or[...]

25 Figure 5 shows the outline dimensions of the 300kVA UPS. Figure 5 - 300kVA UPS Exterior dimensions (front & right side). (76.8 ” ) W eight: 2,000kg (4,400lbs) Earth Ground Bus Earth Ground Bus (74.8”) (3.9”) (35.4”)[...]

26 11.1 UPS Connections Terminal Block s 100, 150, a nd 225kVA. The ter minals shown are located at the bottom inside of the 150/225k VA UPS. External cable size is recommended in the Table 1 and 2. Table 1 Recommended Cable Size and T ightenin g Torqu e for 150kVA UPS. The tightening torque must be greater than 90 percent of the recomm ended torqu[...]

27 Table 2 Recommended Cable Size and T ightenin g Torqu e for 225kVA UPS. The tightening torque must be greater than 90 percent of the recomm ended torque. Cable Siz e and Tig htening Torq ue f or 225kVA UPS (Only copper wires all owed) 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 k[...]

28 Terminal Bus 3 00kVA The terminal buses shown are located at the top inside of the 300kVA UPS. Dashed line in each terminal stands for side view of screw holes to tighten lugs. External cable siz e is recommended in the T able 3. This table shows only the torque to tig hten a terminal bus and a corresponding lug. Torq ue to tight en the cable en[...]

29 Table 4 - Recommend ed Lugs. 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 knockout plates ar e provided at the top of the 300kVA UPS. Holes are recommended in Figure 7. T he installing electrical contractor mu[...]

30 12. Operating Interface If the UPS produces smoke or smells str ange, immediately turn off circuit breakers of A C and DC input. Continued use may result in fire. Contact T oshiba or Authorized representatives. 12.1 Operating Sw itches Figure 8 and Table 5 show the location and functions of the operating switches to operate the UPS circuit shown[...]

31 Table 5 - Cont rol Functions. No. Device Name / Functi on Normal Position During Operation Remarks 1 “8A” Switch Control power source switch W hen AC input is normal, this switch energizes the control circuit. ON 2 “EPO” Switch Emergency powe r of f switch W henever this switch is pressed, UPS w ill stop operation, and al l the breakers [...]

32 12.2 Key -Switch and Buttons The k ey -switch and operating buttons on the graph ic panel are shown in Figure 10. S ee the sections titled "K ey-switch" a nd "Operating buttons" for each function. Figure 10 - Graphic Panel. 12.2.1 Key-switch Table 6 shows the function of the k ey-swi tch on t he graphic panel. Table 6 - Key-s[...]

33 12.2.2 Operating Butt ons Table 7 shows the functions of the operating buttons on the g raphic panel. NOTES Keep an operating button pressed for 0.5 seconds at least, wh en changing UPS modes. Keep the reset button pressed for 5 seconds to reset the UPS. The UPS may not respond if this duration i s too short. Table 7 Butto n functions. No. Name [...]

34 12.3 External Connections The term inal lay out of external connection TB1 is shown in Table 8. Table 8 External Connections. No. I/O Signal Name Operation 1 Output Low Bat tery Close at Low B attery 2 Output Backup Operation Close while Back up Operation 3 Output Fault Close by Faults 4 Output Inverter Supply Close during Norm al Operation 5 Ou[...]

35 13. Graphics Interface 13.1 LED Indication Figure 12 and Table 9 show the graphic panel detail. Figure 12 - Graphics Panel. 22 19 20 21 15 16 12 11 13 14 18 17 23 SCROLL U PS S U PP L Y WARNING FAULT OPERATION OPERATION INHIB ITED RUN STOP UPS EQUAL FLOAT CHA RGE A C SW ITCH FA ULT BY P AS S UPS RESET OUTPUT  A C SWITCH AC INPUT  CONVERTER[...]

36 Table 9 - LCD/LED Legend . No. Name Function 11 LCD LCD indicates operation procedure, measured data and warnings/faults. Detailed in the section titled "LCD Display ." 12 UPS SUPPL Y LED Tur ned on whi le the inverter is on. Flashes during start-up or stop procedure. 13 W ARNING LED Norm ally off. T urned on with w arnings, flashes wi[...]

37 13.2 LCD Indication LCD screens consist of the following terms. (1) Normal Display - Initial display , operation guidance, and measured data. (2) Fault Display - Display s detailed data when a fault occurs. (3) W arning Display - Display s detailed data when a warning occurs. The operator can scr oll through these menu items using the scroll but[...]

38 13.2.1 Normal Display The Normal Display screen indica tes t he UPS operational status and provides 15 screens: an operation guidance screen, an operation mode screen and 13 screens of measured data. Table 10 shows these screens page by page. Table 10 - Normal Display. No. LCD Screen Description 1 Operation Guidance (Exam ple 1) Shows the UPS st[...]

39 5 Measurement sc reen #3 Output current (peak) Show s the output current peak ( %) for each phase. Peak value of output current RMS value for rated current × 1.41 × 100 [%] 6 Measurement sc reen #4 AC input Shows the vol tage and frequency of the AC i nput. 7 Measurement sc reen #5 By pass input Shows the v oltage and frequency of the By pass [...]

40 13.2.2 Fault Display The Fault Display screen indi cates t he fault r ecords until they are reset. Table 11 - Fault Display Screen LCD Screen Description Indication of no fault This sc reen is display ed if there is no fault recorded, or after the reset button is pressed. Indication if faults recorded A fault record is shown with tim e stam p if[...]

41 13.2.4 LCD Scroll All the screens can be scrolled with the up/dow n buttons on the graphic panel. Name Description SCROLLUP Moves back to the previous screen (see Figure 10) SCROLL DOW N Moves forward to the next screen (see Figure 10) Initial screen <Normal sc reen> UPS SUPPLY A C-VO 480[V] A C - I O 50[ % ] OPERA TION M O DE NORMAL OPERA[...]

42 14. Operation This section describes the basic procedures to operate t he UPS. Operators should be qualified/t rained personnel. Operation of the UPS by unqualified or untrained personnel may result in electric shock, personal injury or f ault. Make sure you understand the meaning of the w arning labels on the equipment, and follow the precautio[...]

43 14.2 Pre-operational check Be sure to check the f ollow ing items before operating the UPS: (1) Make sure all covers/panels are in place and secured. (2) Make sure the t emperature control in the UPS/Battery room is within specif ied limits. (3) Bef ore starting the UPS, check t he power source for the UPS to m ake sure AC input power is on. (4)[...]

44 3 Press the "RUN" button for 0.5 sec. CONVERTER LED is on and INVERTER LED flashes. 4 Turn on the DC input breaker. BATTERIES LED is on. 5 Press the “UPS” button for 0.5 sec.* → This com pletes UPS startup procedure. BYPA SS LED is off and UPS LED is on. * Notes: - If the AC switch dose not function, contact Toshiba or authorized[...]

45 14.3.2 Swi tch Power Supply (UPS By pass) Table 14 show s t he procedure to transf er bet ween the UPS supply and the bypass. Table 14 - UPS Power Supply → → → → Bypass Power Supply. Step Procedure LCD/LED Status 1 Check AC INPUT LED and BY PASS LED are on to make sure power is being delivered to the UPS. 2 Press the "BYP ASS" [...]

46 * To change from Bypass to UPS supply, follow the procedure step #5 in Table 13. If the AC switch does not function, contact Toshiba or authorize d representatives. 14.3.3 Stop Table 15 shows the procedure to stop the UPS. Table 15 - Stopping procedure. Step Procedure LCD/LED S tatu s 1 Transf er to By pass supply as described in Table 14. UPS L[...]

47 3 Please wai t. → Procedure com pleted. 14.3.4 Complete Shutdow n This section shows the procedure to turn of f the control power and shut down the UPS completely. Table 16 - Complete Shut dow n. Step Procedure LCD/LED Status 1-3 Same as steps 1- 3 in "Stop" section. 4 Scroll the LCD screen to see the DC INPUT and mak e sure DC bus v[...]

48 14.3.5 Changing Between Flo at Charge and Equalize Charge This section shows the procedure to change the recharge mode between float charge and equali ze charge. (1) Table 17 shows the procedure to change from f loat charge to equaliz e charge. Table 17 - Change From Float Charge to Equalize Charge. Step Procedure LCD/LED Status 1 Make sure that[...]

49 (2) Table 18 shows the manual p rocedure to change fr om equalize charge to float charge. After recharging m ode is changed to equali ze, the mode will autom atically be changed back to float charge after a program m ed duration has elapsed. S o, m anual mode change is not usually required. Table 18 - Changing From Equalize Charge to Float Ch ar[...]

50 14.3.6 Changing to Float Charge from Protectio n Charge (If applicable) Table 19 shows the manual procedure to change from protection charge to float charge. This operation applies to batteries w hich needs protection charge when ove r tem perature. (1) The battery i s norm ally being charged at float charge m ode. (2) To prevent the battery the[...]

51 15. Troubleshooting W hen an error occurs in the UPS, error data is display ed on the LCD screen and the w aveform is saved. This section will describe the ty pes of errors, the error m ess ages display ed on the LCD screen, the process of saving wav efor ms and the procedures to correct the errors. 15.1 Ty pes of Errors The following ty pes of [...]

52 15.2 LCD Fault Display s W hen a fault occurs, a scr een is shown as in Figu re 15. W hen a warning o cc urs, a screen is shown as in Figure 16. Select th e desire d fault d ata with the s croll b uttons. Detailed f ault dat a will be dis played. Figure 15 Fault Display Select th e desire d warning data with the scr oll butto ns. Detailed warnin[...]

53 15.2.2 Warning Dat a Screen These sc reens appear when a w arning has occurred. Up to 10 screens c an be display ed. Figure 18 and Table 21 show a n exam ple of the screen and describe the data shown in the screen. Figure 18 - Warning Screen Example. Table 21 - Warning Dat a Screen Descriptions. No. Name Description  No The num ber of the m e[...]

54 15.2.3 Fault M essages Figure 19 show the l ocations for fault detection. Tables 22 through 26 li st the f ault messages desc ribed in section "Fault Data Screen." The content and di splay text for the fault and w arning m essages are in Tables 22 through 26. The UPS unit can be shipped with different protective configurations from the[...]

55 Table 23 - Warning – 1 (Co nverter stop/Inpu t pow er error). # Item LCD M essage Indication Description 1 27S AC I/P UV AC input vol tage is low. 2 59S AC I/P OV AC input vol tage is high. 3 95S I/P FREQ. ERR AC input frequency error. 4 47S AC PHASE ERR AC Input phase rotation e rror . Table 24 - Warning - 2 (Stop and restart). # Item LCD M e[...]

56 15.2.4 LCD Scroll w ith faults or w arnings. When the UPS has stopped due to a fault, be sure t o remove the memory card before resetting the LCD Fault Error screen on the panel. Resetting (restarting) the UPS wi thout rem oving the memor y card will delete the data needed to determ ine the cause of the fault. When removing the memory card, do N[...]

57 Table 27 - Scroll Buttons. No. Name Description  SCROLL UP Scrolls to the previous screen.  SCROLL DOW N Scrolls to the next screen.  RESET Deletes the stored w aveform and fault and warning data in the mem ory card. (Optional PC memor y card) Remarks * See section “Normal Display" for the screen contents. ** i ii , etc. represen[...]

58 15.3 Restoring UPS Operation Contact Toshiba in the event of malfunction or fault. This UPS should be repaired only by authoriz ed Toshiba service personnel. Servicing b y untraine d personnel m ay extend the fault or result in electric shock or pers onal injury . Do NOT attempt to modify or relocate the UPS. Electric shock, pers onal injury or [...]

59 16. UPS Specifications 16.1 General Specificati on Term s Specification Remark s Conform ing Standard UL1778-2001 UL, cUL, IEC Ambient Tem perature 0 ° ~40 ° C ( 32 ° ~1 04 ° F) Relative Humidity 30% ~ 90% Non-condensing Altitude < 1,000m ( < 3,280ft ) Insulation Resistance 3M W ith 500V-Megger Insulation w ithstanding AC 2kV – 1min.[...]

60 16.3 Electri cal Specification Rated Capacity 150kVA (120kW) 225kVA (180kW) 300kVA (240kW) AC Input Input Voltage 480V ( +10% ~ -15% ), 3-Phase 3-W ire Input Frequency 60Hz ± 5% Input Pow er Fac tor 0.95 ~ 1.00 Lagging ( at 100% Loa d ) Current Harm onic Distortion 6% Maxim um ( at 100% Load ) Input Capacity Required 154kVA 232kVA 309kVA Circui[...]

61 Appendix Word Definitions (1) W hol e UPS concern  UPS: Uninterruptible P ow er System (2) Circ uit breakers  MCCB: Molded C ase Circuit Breaker  ACB: Air Circuit Breaker (3) G raphical interface  Graphic display panel: It contains push buttons, an LCD and LED’s to show the operati ng procedure and/or the UPS status.  LCD: Liqui[...]

Filename: 57056-000 Operation Directory: J:inverterusersj lwil liam sTec hnical Publi cationsUPSG-8000Deliverables Tem plate: C:Program FilesMicrosoft O ffic eTem platesNorm al.dot Title: G8000U Operation Subject: Author: K.Okizaki Key words: Comm ents: Creation Date: 01/18/05 8:56 AM Change Number: 614 Last Saved On: 02/07/05 7:06 AM La[...]