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© Copyright 2013 T oshiba International Corporation All rights reserved. Document: 61001-002 April 2013 G8000 SERIES INST ALLA TION and OPERA TION MANUAL 480/480 V 80/100/125/150/225/300/500 kW UNINTERRUPTIBLE POWER SYSTEM (UPS)[...]

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G8000 Series Installation and Operation Manual UNINTERRUPTIBLE POWER SYSTEM (UPS) © Copyright 2013 T oshiba International Corporation All rights reserved. G8000 SERIES INST ALLA TION and OPERA TION MANUAL 480/480 V 80/100/125/150/225/300/500 kW Document: 61001-002 April 2013[...]

G8000 Series 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 warranted for usage in equip[...]

G8000 Series 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 otherwise specied, th[...]

G8000 Series Installation and Operation Manual Purpose This manual provides information on how to safely install and 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 the manu[...]

i G8000 Series Installation and Operation Manual T able of Contents 1 Introduction ..........................................................................................................................1 2 General Safety Instructions ................................................................................................2 2.1 Symbols ...[...]

ii G8000 Series Installation and Operation Manual 1 1.2 150, 225, 300, and 500 kV A Buss Strip T erminals and Power Cables .......................34 1 1.3 UPS Power Cable Conduit Landing Plates ................................................................39 1 1.4 External Breakers .................................................................[...]

iii G8000 Series Installation and Operation Manual 16 Periodic Maintenance/Parts Replacement ......................................................................77 16.1 Scheduled Maintenance ............................................................................................77 16.2 Parts Replacement .......................................[...]

iv G8000 Series Installation and Operation Manual[...]

1 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 be[...]

2 G8000 Series 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 manual. When symbols are u[...]

3 G8000 Series 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, operation, and mainten[...]

4 G8000 Series Installation and Operation Manual • Be trained in rendering rst aid. For further information on workplace safety visit www .osha.gov . 2.4 Factory Authorized Personnel Factory authorized personnel have been factory trained and certied to install, service, and repair the UPS. Contact the T oshiba Customer Support Center for[...]

5 G8000 Series Installation and Operation Manual T ABLE 3.2 UPS NOMINAL BA TTERY VOL T AGE C ap aCity n Ominal V Ol t age F lOa t V Ol t age 80 kV A 360 Vdc 405 V 100 kV A 360 Vdc 405 V 125 kV A 360 Vdc 405 V 150 kV A 360 Vdc 405 V 225 kV A 360 Vdc 405 V 300 kV A 360 Vdc 405 V 500 kV A 480 Vdc 540 V 4 Safety Precautions The T oshiba products listed[...]

6 G8000 Series Installation and Operation Manual 4.2 General Maintenance W ARNING 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[...]

7 G8000 Series Installation and Operation Manual 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 the UPS to suffer shock or impact when unpacking. T ool[...]

8 G8000 Series 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 otherwise damaged pa[...]

9 G8000 Series 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 position. T ilting the [...]

10 G8000 Series 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 silicon in the UPS stor[...]

11 G8000 Series 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: 86 °F (30 ° C) at 1.0 PF (UPS with/without battery system). Maximum operating temperat[...]

12 G8000 Series Installation and Operation Manual 7) The UPS generates and can radiate radio-frequency energy during operation. Although RFI noise lters are installed inside of the unit, there is no guarantee that the UPS will not inuence some sensitive devices that are operating near by . If such interference is experienced, the UPS should b[...]

13 G8000 Series 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. A missing ground wire[...]

14 G8000 Series 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 cover- ing and shipping pallet. NOTICE Make sure all the warning labels are inst[...]

15 G8000 Series Installation and Operation Manual 6.1 W arning Label Locations FIGURE 6.2 – 80/100/125 KV A UPS WARNING LABELS DA NGE R Hazardous vo lt ag es are used in the operat i on of this e quipment and could c ause severe personal inj ury or los s of l i fe. The follow ing prec a ut io ns should be observ ed to reduce the ris k of injury o[...]

16 G8000 Series Installation and Operation Manual FIGURE 6.3 – 150/225 KV A UPS WARNING LABELS FIGURE 6.4 - 300 KV A UPS WARNING LABELS[...]

17 G8000 Series Installation and Operation Manual FIGURE 6.3 – 500 KV A UPS WARNING LABELS FINAL LA YOUT NOT A V AILABLE A T THIS TIME: CONT ACT THE F ACTOR Y FOR ADDITIONAL INFORMA TION[...]

18 G8000 Series Installation and Operation Manual 7 W eight and Dimensions T able 7.1 lists the unit and shipping weights for G8000 UPS models. See Appendix B for detailed outline and dimensioins of all models. T ABLE 7.1 G8000 UPS UNIT AND SHIPPING WEIGHTS Model Unit Shipping 80 kV A 1390 lb. (630 kg) 1440 lb. (652 kg) 100 kV A 1740 lb. (789 kg) 1[...]

19 G8000 Series 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 PROCEDURE. The suspension wir[...]

20 G8000 Series Installation and Operation Manual 8.1 T ransporting By Crane Cables should have sufcient ratings and be of the same length. Make sure the suspension cables are 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. Keep UPS leveled when l[...]

21 G8000 Series 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 underneath the UPS. DO NOT sw[...]

22 G8000 Series Installation and Operation Manual FIGURE 8.7 -TRANSPORTING 500 KV A UPS BY FORKLIFT ( See Appendix C for cabinet mating insturctions) Input Cabinet Insert the forks here. Secure forks against the base and then lift. 500 kV A (Ships in two parts, Input and Output Cabinets) Output Cabinet Insert the forks here. Secure forks against th[...]

23 G8000 Series 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 represnetative o[...]

24 G8000 Series Installation and Operation Manual W ARNING While operating in the inverter mode, placing the input breaker in the “OFF” position will switch the UPS to the battery backup mode. The output of the UPS will continue uninterrupted to the load. The unit must be in the bypass mode at the time that the breaker is placed in the “OFF?[...]

25 G8000 Series Installation and Operation Manual 9.2 Maintenance Precautions All internal maintenance sould be performed by factory authorized personnel. 1) T urn 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-cu[...]

26 G8000 Series Installation and Operation Manual 9.3 Disposal Please contact your local or state environmental agency for details on disposal of electrical components and packaging in your particular area. It is illegal to dump lead-acid batteries in landlls or dispose of them improperly . Please help protect the Earth by contacting the environ[...]

27 G8000 Series 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 more than 10 ° from up[...]

28 G8000 Series 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 forklift operations to unp[...]

29 G8000 Series 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 dimensions for the sp[...]

30 G8000 Series Installation and Operation Manual 1 1 UPS Wiring Note: Always consult your local and NEC electrical codes for wiring, cabling, and circuit protection device requirements. Figure 1 1.1 illustrates the external wiring of the single-input G8000 UPS. See corresponding section to each wiring term. • Power cable connection at terminal b[...]

31 G8000 Series Installation and Operation Manual Figure 1 1.2 illustrates the external wiring of the dual-input G8000 UPS. See corresponding section to each wiring term. • Power cable connection at terminal blocks/buses and external breaker provision for the AC input/output, Bypass Input and DC input. • Earth ground wire at grounding terminal.[...]

32 G8000 Series Installation and Operation Manual 1 1.1 80/100/125 kV A T erminal Blocks 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 80/100/125 kV A UPS are shown in Figure 1 1.3. Recommended external ca[...]

33 G8000 Series Installation and Operation Manual T ABLE 1 1.2 RECOMMENDED CABLE SIZE & TIGHTENING TORQUE FOR 100 KV A UPS Block Number Cable Size (Min-Max) 2 Tightening T orque 75 °C Copper Wire 90 °C Copper Wire 1 (2) #3 – (2) 2/0 A WG 2/0 – (2) 2/0 A WG 50 in.-lb. (5.6 N•m) 2 (2) #3 – (2) 2/0 A WG 2/0 – (2) 2/0 A WG 50 in.-lb. (5[...]

34 G8000 Series Installation and Operation Manual 1 1.2 150, 225, 300, and 500 kV A Buss Strip T erminals 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 150, 225, 300 and 500 kV A UPS units have buss strip power terminals. Figure [...]

35 G8000 Series Installation and Operation Manual Figure 1 1.7 shows the terminal mounting hole arrangement for the terminal buss strips for the 500 kV A UPS units. Figure 1 1.8 shows the arrangement of the terminal buss strips for the 500 kV A UPS. The buss strips are located inside at the top of the unit. The dashed line on terminals 1–13 indic[...]

36 G8000 Series Installation and Operation Manual See T able 1 1.5 – T able 1 1.6 for recommended cable sizes for the 150, 225, 300 and 500 kV A UPS. T ABLE 1 1.3 RECOMMENDED CRIMP TYPE COMPRESSION LUGS FOR BUS STRIP TERMINALS Wire Size Wire Strand Class Recommendation Crimp tool Required Burndy type Y35 or Y46 V endor Cat. No. Color Key Die Inde[...]

37 G8000 Series Installation and Operation Manual T ABLE 1 1.4 RECOMMENDED CABLE SIZE AND F ASTENER TORQUE FOR 150 KV A UNIT (USE 75 °C Copper Wire) Block Number Cable Size (Min-Max) Tightening T orque 2 75 °C Copper Wire 90 °C Copper Wire 1 300 kcmil – (2) #1 A WG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m) 2 300 kcmil – (2) #1 A WG 250[...]

38 G8000 Series Installation and Operation Manual 4 Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear . T ABLE 1 1.6 RECOMMENDED CABLE SIZE AND F ASTENER TORQUE FOR 300 KV A UPS Bus Number Cable Size (Min-Max) Tightening T orque 2 75 °C Copper Wire 90 °C Copper Wire 1 ([...]

39 G8000 Series Installation and Operation Manual 1 1.3 UPS Power Cable Conduit Landing Plates Cable conduit landing plates are provided at the bottom of the 80 kV A and100 kV A UPS, at the top and bottom of the 150/225 kV A UPS (Older models of the G8000 150/225 kV A UPS do not come equipped with an upper conduit landing plate.), and at the top on[...]

40 G8000 Series Installation and Operation Manual FRONT OF UPS 0.7 in. 0.7 in. 21.5 in. 4.74 in. AC INPUT BYP ASS AC OUT - PUT BA TTERY CONTROL WIRES Recommended Conduit Placement Order in T op Conduit Landing Plate FIGURE 1 1.1 1 - TOP ACCESS CONDUIT LANDING PLA TE (150 AND 225 KV A ONL Y) 4.36 in. 21.5 in. 31.5 in. 4.27 in. TOP ENTRY DIMENSIONS F[...]

41 G8000 Series Installation and Operation Manual Figure 1 1.12 shows the four (4) cable landing plates provided at the top of the 300 kV A UPS. Seven (7) holes must be punched during installation. The dashed rectangle indicates the UPS opening behind the conduit landing plates. Figure 1 1.13 shows the three (3) conduit landing plates provided at t[...]

42 G8000 Series Installation and Operation Manual 1 1.4 External Breakers The G8000 UPS units are not equipped with circuit breakers. Qualied personnel should provide the external breakers for the AC input/output, bypass input and DC input. See Figure 1 1.1 – External Wiring Diagram, for the circuit position of the breakers. T able 1 1.7 shows[...]

43 G8000 Series Installation and Operation Manual FIGURE 1 1.14 - EARTH GROUND WIRE CONNECTIONS G8000 - 80/100 kV A 12 mm or 1/2 in. T erminal 10 mm or 7/16 in. Bolt Feed-through opening A WG 2 (38 mm 2 ) ground wire T o facility earth ground Groundbus G8000 - 300 kV A Through conduit landing plate on top (recom- mended) Alternate ground wire lo[...]

44 G8000 Series Installation and Operation Manual 1 1.6 Control Wires The control wires terminal layouts at TB1 (terminal bus 1) are shown below in T able 1 1.8. T ABLE 1 1.8 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 Output Fault Closed if[...]

45 G8000 Series Installation and Operation Manual The UPS battery cabinet and bypass breaker should be wired as shown below in Figure 1 1.15. FIGURE 1 1.15 - CONNECTION BETWEEN UPS, BA TTERY CABINET & BYP ASS BREAKER 1 1.7 Grounding Conguration This section describes the grounding conguration to be used with various AC service entrance co[...]

46 G8000 Series Installation and Operation Manual FIGURE 1 1.16 - GROUNDING CONFIGURA TION WITH INPUT NEUTRAL GROUNDED A 2 A WG (or 38 mm 2 ) jumper cable is provided between the neutral terminal and ground bus in the UPS cabinet. The qualied personnel should remove the jumper cable in this conguration. The jumper cable location is illustrate[...]

47 G8000 Series Installation and Operation Manual 1 1.7.2 Grounding Conguration (without input neutral) When the input source is wye-connected, the neutral line out to the bypass input should be left open. The UPS is grounded by connecting the neutral terminal to the ground bus with the internal jumper cable. See Figure 1 1.18. The jumper cable [...]

48 G8000 Series Installation and Operation Manual 1 1.7.4 Grounding Conguration (with corner-grounded delta-input) If one phase of delta-input source is grounded (B-phase for example), the ground bus in the UPS cabinet should NOT be connected to the neutral terminal of UPS output. The jumper cable should be removed see Figure 1 1.17 for the jump[...]

49 G8000 Series Installation and Operation Manual 12 UPS Specications 12.1 Specication T able G8000 Specications Model Number T80S3K08 KK6XSxx T80S3K10 KK6XSxx T80S3K12 KK6XSxx T80S3K15 KK6Xxx T80S3K22 KK6XSxx T80S3K30 KK6XSxx T80S3K50 KK6XSxx Input Rated Output Capacity 80 kV A / 80 kW 100 kV A / 100 kW 125 kV A / 100 kW 150 kV A / 150 kW[...]

50 G8000 Series Installation and Operation Manual G8000 Specications Model Number T80S3K08 KK6XSxx T80S3K10 KK6XSxx T80S3K12 KK6XSxx T80S3K15 KK6Xxx T80S3K22 KK6XSxx T80S3K30 KK6XSxx T80S3K50 KK6XSxx Output V oltage 480Y/277V Conguration 3-Phase; 4-Wire + Gnd V oltage Regulation ±1% for 0-100%Balanced and Unbalanced Loads ±2% for 0-100% Bal[...]

51 G8000 Series Installation and Operation Manual G8000 Specications Model Number T80S3K08 KK6XSxx T80S3K10 KK6XSxx T80S3K12 KK6XSxx T80S3K15 KK6Xxx T80S3K22 KK6XSxx T80S3K30 KK6XSxx T80S3K50 KK6XSxx Environ- ment (cont.) 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.[...]

52 G8000 Series Installation and Operation Manual 12.2 T ypical Efciency vs. Load UPS Efciency at Percent Full Load* 25% 50% 75% 100% 80 kV A 83.9% 85.3% 90.0% 90.6% 100 kV A 86.4% 90.1% 91.2% 91.0% 125 kV A 88.5% 90.9% 90.9% 90.2% 150 kV A 86.9% 91.7% 92.3% 93.3% 225 kV A 87.9% 91.9% 92.3% 91.9% 300 kV A 88.8% 91.6% 92.2% 92.8% 500 kV A 91.6[...]

53 G8000 Series Installation and Operation Manual 13 Operator Interface T able 13.1 shows the functions of the operating buttons on the graphic display panel. 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 shor[...]

54 G8000 Series 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 EPO 5 6 10 7 8 4 3 2 [...]

55 G8000 Series Installation and Operation Manual 13.2 LCD/LED Indicators FIGURE 13.2 – GRAPHIC DISPLA Y P ANEL LCD/LED INDICA TORS 23 11 21 20 19 18 17 16 15 14 13 22 24 25 12[...]

56 G8000 Series Installation and Operation Manual 13.3 LCD Indicators The operator can scroll through the following LCD display screens using the scroll buttons. T ABLE 13.2 - LCD DISPLA Y SCREENS Name Description Normal Display Displays operational status, operational guidance, and measured data. Fault Display Displays detailed data when a fault o[...]

57 G8000 Series 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 13.3 shows these screens page by page and illustrates the UPS Normal Display operational status screens. T AB[...]

58 G8000 Series Installation and Operation Manual T ABLE 13.3 - 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 frequency . AC I/P-V 480[V] [...]

59 G8000 Series 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 the memory until the reset button is pressed for at least 5 seconds, even after the actual caus[...]

60 G8000 Series Installation and Operation Manual 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 T ABLE 13.5 DISPLA Y SCREE[...]

61 G8000 Series Installation and Operation Manual 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. FIGURE 14.1 - EPO AND CONTROL POWER SUPPL Y OPERA TING SWITCHES W ARNING If the UPS produces smoke or smells strange, immedi[...]

62 G8000 Series Installation and Operation Manual 14.1 Operation T ypes The operation types are summarized below . T ABLE 14.1 OPERA TION TYPES Operation Description Complete Shutdown T urn off the control power supply . Shut down the UPS completely . Float / Equalize Charge Changing the battery recharge mode between oat charge and equalize char[...]

63 G8000 Series Installation and Operation Manual 14.3 Startup Procedures The procedure to start the UPS is shown in Steps 1-5. STEP 1 T urn on the control power supply switch. (Figure 14.1) and ensure the operation lock is set to OPERA TION. (Figure 13.1 - 1) STEP 2 W ait for a few seconds. STEP 3 Press the “RUN” button for at least 0.5 second[...]

64 G8000 Series 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”. UPS LED is “ON”. [...]

65 G8000 Series Installation and Operation Manual CONVERTER INVERTER UPS AC OUTPUT BA TTERIES BYP ASS INPUT DISCHARGE EQUAL CHARGE FLOA T CHARGE BYP ASS AC INPUT AC SWITCH UPS SUPPL Y AC - V o 480 v AC - Io 50% 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 STEP [...]

66 G8000 Series 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 “STOP” button fo[...]

67 G8000 Series 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 , and, press the “[...]

68 G8000 Series 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 Float and Equalize charge modes. STEP 1 Make sure that the FLOA T CHARGE LED is “ON”. STEP 2 [...]

69 G8000 Series 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 explanation of oat[...]

70 G8000 Series 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 after triggering the E[...]

71 G8000 Series 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 08:05:30 ↓ANOTHER IT[...]

72 G8000 Series 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 & WARNINGS 1 FUSE BLOWN 09[...]

73 G8000 Series Installation and Operation Manual 15.4 Fault Messages Figure 15.4 show the locations for fault detection. T ables 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 l[...]

74 G8000 Series 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/P OV AC output voltag[...]

75 G8000 Series 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 details of the scroll buttons and how they are[...]

76 G8000 Series 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 with scroll buttons gra[...]

77 G8000 Series Installation and Operation Manual 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 perfor[...]

78 G8000 Series Installation and Operation Manual[...]

79 G8000 Series Installation and Operation Manual Appendix A - Installation Planning Guides TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 8 0kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K08KK6 XS xx) Rev. 2. 2 Page 1 of 3 G8000 - IPG - 80 k VA General M echani c a l Information Dimensions (W x D x H) Weight Fl[...]

80 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 8 0kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K08KK6 XS xx) Rev. 2. 2 Page 2 of 3 G8000 - IPG - 80 k VA G8000 80k VA UPS C abling Connection Dim ensions Top Front Right Side Bottom Access Only Power Ter minals: Tw[...]

81 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 8 0kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K08KK6 XS xx) Rev. 2. 2 Page 3 of 3 G8000 - IPG - 80 k VA Anchorag e pattern: Install a nchor bolts to s ecure the UPS to the floor. Use 1/2” ( 12mm) di ameter ancho[...]

82 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 100kVA UPS Standard Sy stem: 4 80V Input, 48 0Y/277V Outpu t ( P/N T80S 3K 10 KK6XS xx) Rev. 2.2 Page 1 of 3 G8000 - I PG - 100kVA General M echani c a l Information Dimensions (W x D x H) W eight Floor Loading Approximate Full - Load Heat [...]

83 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 100kVA UPS Standard Sy stem: 4 80V Input, 48 0Y/277V Outpu t ( P/N T80S 3K 10 KK6XS xx) Rev. 2.2 Page 2 of 3 G8000 - I PG - 100kVA G8000 100k VA UPS C abling Connec tion Di mensions Top Front Right Side Bottom Access Only Power Ter minals: [...]

84 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 100kVA UPS Standard Sy stem: 4 80V Input, 48 0Y/277V Outpu t ( P/N T80S 3K 10 KK6XS xx) Rev. 2.2 Page 3 of 3 G8000 - I PG - 100kVA Anchorag e pattern: Install a nchor bolts to s ecure the UPS to the floor. Use 1/2” ( 12mm) di ameter ancho[...]

85 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 125 kVA UPS Standard Sy stem: 4 80V Input, 48 0Y/277V Outpu t ( P/N T80S 3K 12 KK6XS2 xx) Rev. 0 Pag e 1 of 3 G8000 - IPG -1 25 kVA 0.8 PF General M echani c a l Information Dimensions (W x D x H) Weight Floor Loading Approximate Full - Loa[...]

86 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 125 kVA UPS Standard Sy stem: 4 80V Input, 480Y/277 V Output ( P/N T80S 3K 12 KK6XS2 xx) Rev. 0 Pag e 2 of 3 G8000 - IPG -1 25 kVA 0.8 PF G8000 100k VA UPS C abling Connec tion D imensi ons Top Front Right Side Bottom Access Only Power Ter [...]

87 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 125 kVA UPS Standard Sy stem: 4 80V Input, 48 0Y/277V Outpu t ( P/N T80S 3K 12 KK6XS2 xx) Rev. 0 Pag e 3 of 3 G8000 - IPG -1 25 kVA 0.8 PF Anchorag e pattern: Install a nchor bolts to s ecure the UPS t o the f loor . Use 1/2” ( 12mm) di a[...]

88 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 1 5 0kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 15 KK6XS xx) Rev. 2. 2 Page 1 of 3 G8000 - IPG -15 0k VA General M echani c a l Information Dimensions (W x D x H) W eight Floor Loading Approximate Full - Load He[...]

89 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 1 5 0kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 15 KK6XS xx) Rev. 2. 2 Page 2 of 3 G8000 - IPG -15 0k VA G8000 150k VA UPS C abling Connec tion Di mensions Top Front Right S ide Top/Bottom Access G8000 150KV A O[...]

90 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 1 5 0kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 15 KK6XS xx) Rev. 2. 2 Page 3 of 3 G8000 - IPG -15 0k VA Anchorag e pattern: Install a nchor bolts to secur e the UP S to the floor . Use 1/2” ( 12mm) di ameter [...]

91 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 225 kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 22 KK6XS xx) Rev. 2. 3 Page 1 of 3 G8000 - IPG - 225 k VA General M echani c a l Information Dimensions (W x D x H) Weight Floor Loading Approximate Full - Load Hea[...]

92 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 225 kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 22 KK6XS xx) Rev. 2. 3 Page 2 of 3 G8000 - IPG - 225 k VA G8000 225k VA UPS C abling Connec tion Di mensions Top Front Right S ide Top /Bottom Access G8000 225 KV A[...]

93 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 225 kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 22 KK6XS xx) Rev. 2. 3 Page 3 of 3 G8000 - IPG - 225 k VA Anchorag e pattern: Install a nchor bolts to s ecure the UPS to the floor. Use 1/2” ( 12mm) di ameter an[...]

94 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 300 kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 30 KK6XS xx) Rev. 2. 3 Page 1 of 3 G8000 - IPG -3 00k VA General M echani c a l Information Dimensions (W x D x H) W eight Floor Loading Approximate Full - Load Hea[...]

95 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Instal lation Pl anning G uide fo r 300 kVA UPS Standard System: 480 V Input, 480Y/277V O utput ( P/N T80 S3K 30 KK6 XS xx) Rev. 2. 3 Page 2 of 3 G8000 - IPG -3 00kVA G8000 3 00kVA U PS Cabl ing C onnection Di mensions Top Front Right S ide Cable Entr y: Top Only[...]

96 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Instal lation Pl anning G uide fo r 300 kVA UPS Standard System: 480 V Input, 480Y/277V O utput ( P/N T80 S3K 30 KK6 XS xx) Rev. 2. 3 Page 3 of 3 G8000 - IPG -3 00kVA Anchor age pat tern: I nstall a nchor bolts to secure the U PS to the floor. Use 1/2” ( 12mm ) diameter an[...]

97 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 5 00 kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 50 KK6XS xx) Rev. 0.0 Page 1 of 3 G8000 - IPG -5 00k VA General M echani c a l Information Dimensions (W x D x H) W eight Floor Loading Approximate Full - Load Hea[...]

98 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Instal lation Pl anning G uide fo r 5 00 kVA UPS Standard System: 480 V Input, 480Y/277V O utput ( P/N T80 S3K 50 KK6 XS xx) Rev. 0.0 Page 2 of 3 G 8000 - IPG -5 00k VA G8000 3 00kVA U PS Cabl ing C onnection Di mensions Top Front Cabl e Entry: Top Only[...]

99 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installat ion Pla nning Gui de for 5 00 kVA UPS Standard System: 480V Inp ut, 48 0Y/277 V Outpu t ( P/N T80S 3K 50 KK6XS xx) Rev. 0.0 Page 3 of 3 G8000 - IPG -5 00k VA Anchorag e pattern: Install a nchor bolts to s ecure the UPS to the floor. Use 1/2” ( 12mm ) di ameter an[...]

100 G8000 Series Installation and Operation Manual[...]

101 G8000 Series Installation and Operation Manual Appendix B - Outline Drawings FIGURE B.1 - G8000 80/100/125 KV A OUTLINE DRA WING[...]

102 G8000 Series Installation and Operation Manual FIGURE B.2 - G8000 150/225 KV A OUTLINE DRA WING[...]

103 G8000 Series Installation and Operation Manual FIGURE B.3 - G8000 300 KV A OUTLINE DRA WING[...]

104 G8000 Series Installation and Operation Manual FIGURE B.4 - G8000 500 KV A OUTLINE DRA WING[...]

105 G8000 Series Installation and Operation Manual Appendix C - 500kV A Input- and Output- Cabinet Joining Instructions Joining the G8000 500kV A Sections 1. Remove Shipping Material (Retain Connection Kit Box and Manual). 2. On a leveled oor bring the two cabinets together . Input cabinet on the left side. See FIG. 1. Leave a gap of 0.25”-0.3[...]

106 G8000 Series Installation and Operation Manual 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, at, belleville washer and nut (supplied). Insert Belleville washer between at washer and n[...]

107 G8000 Series Installation and Operation Manual Insert Belleville washer between at washer and nut. 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[...]

108 G8000 Series Installation and Operation Manual NEUTRAL BUS AC BUS DC BUS FIG . 6[...]

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