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Toshiba G8000 Power Supply User Manual

1. D D D 1 D alll D D 1 J 1 e7 e D 12 d R d J L L FIGURE 6 4 300 KVA UPS WARNING LABELS 16 G8000 Series Installation and Operation Manual TOSHIBA 7 Weight and Dimensions Table 7 1 lists the unit and shipping weight s for G8000 UPS models illustrated in Figure s 7 1 7 3 TABLE 7 1 G8000 UPS UNIT AND SHIPPING WEIGHT S Model 100 kVA 150 kVA 225 kVA 300 kVA TERMINAL BEN BLOCKS LILIL ILI CL Unit Shipping 1800 Ib 816kg 1850 Ib 840 kg 2600 Ib 1180kg 2689 Ib 1220 kg 3300 Ib 1 500kg 3389 Ib 1537 kg 4850 Ib 2205kg 5000 Ib 2273 kg 8A SWITCH MM Y E E BEIM 9 15 GROUND BUS FIGURE 7 1 100 KVA UPS EXTERIOR DIMENSIONS INCHES G8000 Series Installation and Operation Manual TOSHIBA 3 8 m 8 SWITCH TERMINAL BLOCKS GROUND BUS FIGURE 7 2 150 225 KVA UPS EXTERIOR DIMENSIONS INCHES GROUND BUS TERMINAL BLOCKS 2 8A SWITCH M
2. e E E 1 General Safety 1 5 1 TEGERE QUE EVE E URDU E 2 ZN uo S ccE 2 Be oncle o I T mw 3 2 9 QUANIMEG POLS 3 2 4 Factory Authorized Personnel ccccccccssececeeeeceeeeceeeeeeeeeeseeeeseeeeseeeeseeeeseeeeseeesneenaes 4 Important Safety 4 5 At 5 4 2 General 6 4 3 cama 6 4 4 8 Installation Precautions 9 1 COMMS CU ON ind assay ten 13 LL EU BEL I 14 6 1 Warning Label Locations
3. 38 11 5 Grounding salei 40 12 UPS 43 12 1 General SpecifcatlON cc 43 12 7 Mechanical SPSCIICAUOMN ona a Ea REA 43 12 3 Electrical 5pecifiCallOl 2 ramen rera tu bn bac t oen 45 13 1 cited iiem 46 13 1 Key Switch and nennen nennen sn nnne as 47 1932 LGODLED vor 48 13 3 LCD Indicators 49 134 Normal eE EE 50 Fau IS TAY erer e TE ENE EA E EA 52 o 6 0 E EREE 53 14 UPS ANEP EEEE 54 14 1 Operation 55 14 2 Pre operational 55 14 3 Startup 56 14 4 Switch Power Supply 5 58 ro oe oe gence aoe 59 14 6 Complete Shutdown sesssssssessssessseseseeee nennen nennen nnns n snas r esas nnns 60 14 7 Changing Between Float Charge a
4. ssseesseesessseseeeeeeeenne nnn nennen 15 VVGIGIE and DIMENSIONS RENTRER TE A 17 0 27 T Um 19 9 1 Transporting iu dei 20 o2 By iu du nt 21 Storage Operating 22 Operating PreCAUTONS 2 22 9 2 Maintenance Precautions 24 25 e A 26 iro 27 5 9 M m 27 ANCO TT 28 UPS WIFIBO ce E EDITA 29 11 1 Terminal Blocks and Power 30 PME USUI Breakers mcm 36 G8000 Series Installation and Operation Manual TOSHIBA To Cone og 36 P MEER
5. 50 G8000 Series Installation and Operation Manual TOSHIBA TABLE 13 2 CONTINUED MEASUREMENT SCREENS O P CURRENT PEAK U 5012001 V 50 W 50 AC INPUT AC I P V 480 V FREQ 60 0 Hz BYPASS INPUT BYP 480 V FREQ 60 0 Hz BATTERY BACK UP RATING 10 MIN DISCHARGING 15 MIN DC INPUT DC V 632 V BATT V 400 V 1 O A MODE COUNT UPS 35 H BATTERY 56 MIN 32 TIM TIME 03 24 06 13 58 G8000 Series Installation and Operation Manual Shows the peak output current peak 96 for each phase Peak value of output current x 100 9e RMS value for rated current x 1 41 Shows the AC Input Voltage line to line and frequency Shows the Bypass Input Voltage line to line voltage and frequency Shows the remaining battery backup time with rated load and cumulative discharged time Shows the internal DC bus voltage battery voltage and battery current The battery current value displayed is negative during recharge and positive during discharge Shows the cumulative UPS operation time the cumulative battery backup time and the number of battery backup operations The current time is displayed if there are no faults recorded or after the reset button is pressed Date is displayed in the mm ddyyy format The unit does not calculate daylight savings time Time is displayed in the 24 hour format e g 1 58 P M 1358 Hrs 51 TOSHIBA 13 5 Fault Dis
6. 551mm 4 x 12mm Dia 1 2 21 11 16 754mm 29 11 16 lt 100kVA T80S3K10KK6XSNH gt lt 150 225kVA gt 4 of 16mm diameter 4 screw holes WU icc Back 4 5 8 screw holes Side View 551mm 4 x 12mm Dia 1 2 1 21 11 16 Front Anchor Bolt 1 170mm 46 1 16 FIGURE 10 2 ANCHOR BOLT INSTALLATION DETAIL 250 300kVA gt 650mm 25 19 32 4 aac 572mm 572mm 572mm 22 1 2 22 1 2 22 1 2 FIGURE 10 3 HOLE LOCATIONS DIMENSIONS ON BOTTOM OF UPS 28 G8000 Series Installation and Operation Manual TOSHIBA 11 UPS Wiring Note Always consult your local and NEC electrical codes for wiring cabling and circuit protection devices requirements Figure 11 1 illustrates the external wiring of the G8000 UPS See corresponding section to each wiring Charger TB1 term Power cable connection at terminal blocks buses and external breaker provision for the AC input output Bypass Input and DC input e Earth ground wire at grounding terminal Control wire terminal TB1 battery cabinet and bypass breaker Bypass 2 Contactor Thyristor Q Bypass Breaker Bypass Contactor AC Input Input 363W 77 Contactor 7 Output B pe Input Breaker Rectifier Inverter Inverter Output Contactor Breaker i Chopper DC input Battery o Breaker Battery Cabinet g
7. Twezborge 2i5ibsO2kpm 5 Two2I0orlarger 275 3 2 6 Two 2 0 orlarger 275 indos 2 2 2i5ibsG2kpm Twozporlrger 2756104 3 2 275 iJbs 32 2127 Three 4 0 or larger 2 5 in bs 3 2 kg m Terminal is bus strip 13 Three 4 0 or larger 2 5 in bs 3 2 kg m Terminal is bus strip NOTE MAXIMUM CABLE SIZE IS 600MCM ONE BATTERY STRING SEE NOTE PG 35 IF USING MULTIPLE BATTERY STRINGS G8000 Series Installation and Operation Manual 31 TOSHIBA Cable knockout plates are provided at the bottom of the 100 kVA UPS and at the top and bottom of the 150 225 kVA UPS Older models of the G8000 150 225 kVA UPS do not come equipped with an upper knockout plate The recommended hole locations are illustrated in Figure 11 3 11 4 and 11 5 The five 5 holes must be punched during installation The dashed rectangle indicates the UPS opening behind the knockout plates PLATE 1 PLATE 2 2 Dia AC INPUT BYPASS AC OUTPUT BATTERY CONTROL WIRES FIGURE 11 3 BOTTOM CABLE KNOCKOUT PLATES 100 KVA T80S3K10KK6XS2H PLATE 1 PLATE 2 PLATE 3 2 Dia AC INPUT BYPASS AC OUTPUT BATTERY CONTROL WIRES FIGURE 11 4 BOTTOM CABLE KNOCKOUT PLATES 100 KVA T80S3K10KK6XSNH 150 225 KVA O 0 oil E ces ee es DES 0 7 AC INPUT BYPASS AC OUTPUT BATTERY CONTROL WIRES FIGURE 11 5
8. 877 867 8773 Canada 800 872 2192 Mexico 01 800 527 1204 www toshiba com ind Printed in the U S A
9. external battery cabinet BATTERIES LED is STEP 5 Press the UPS button for at least 0 5 seconds This completes UPS startup procedure BYPASS LED is UPS LED is ON NOTE If the AC switch does not function contact Toshiba or authorized representatives If the bypass power source is out of specification this operation will be inhibited In order to switch manually press the UPS button for 5 seconds or more 57 TOSHIBA 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 LED Key L3 LED Off EN LED On Juli LED Flash STEP 1 UPS SUPPLY Check AC INPUT LED and BYPASS LED are on to make sure power is being AC Vo 480 v 0 delivered to the UPS AC lo 50 8 m AC INPUT L L BATTERIES BYPASS INPUT INVERTER 2 m CONVERTER Bl FLOAT CHARGE EQUAL CHARGE 7 DISCHARGE AC OUTPUT Cj BYPASS STEP 2 BYPASS Press the BYPASS button for at least 0 5 seconds UPS LED is BYPASS LED is ON INVERTER 2 E CONVERTER AC INPUT L FLOAT CHARGE C EQUAL CHARGE BATTERIES DISCHARGE AC OUTPUT c m BYPASS INPUT STEP 3 Please wait until procedure is completed BYPASS AC Vo 480 V AC lo 50 PRESS UPS SWITCH A INVERTER 2 m CONV
10. 600 T3A2 600N TA 600 AU 600 G8000 Series Installation and Operation Manual 35 TOSHIBA 11 2 External Breakers The G8000 UPS units are not equipped with circuit breakers Qualified personnel should provide the external breakers for the AC input output bypass input and DC input See Figure 11 1 External Wiring Diagram for the circuit position of the breakers Table 11 7 shows the G8000 UPS minimum external breaker rating for each capacity The bypass input and the AC output require 3 pole breakers TABLE 11 7 EXTERNAL BREAKER RATING AC Input Bypass Input AC Output Input Minimum Breaker Rating Minimum Breaker Rating 100 kVA 480 V 150A 500 VDC 400A Capacity 150 kVA 480 V 225 A 500 VDC 600A 225 kVA 480 V 350A 500 VDC 900A 300 kVA 480 V 500A 500 VDC 1 200 A 11 3 Grounding Wire Be sure to ground the UPS as specified 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 225kVA earth grounding bus is located inside at the bottom front of the unit The 300 kVA earth grounding bus is located inside at the top left of the unit as well Use a 2 AWG or 38mm or larger cable for the grounding wire Run the grounding wire through the opening at the bottom or through a hole in the top knockout plate if available See Figure 11 9 Connect either
11. ANY MODIFICATIONS WITHOUT AUTHORIZATION BY TOSHIBA COULD RESULT IN PERSONAL INJURIES DEATH OR DESTRUCTION OF THE UPS TOSHIBA RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY FUNCTION OR DESIGN TOSHIBA DOES NOT ASSUME ANY LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR UPS DESCRIBED HEREIN NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS NOR THE RIGHTS OF OTHERS G8000 Series Installation and Operation Manual 5 TOSHIBA 4 2 General Maintenance DO NOT remove the rear side panels or any sheet metla not designed to be removed Removing rear side panels may result in electric shock burns personal injuries or UPS failure Keep the area arround the UPS clean Use a vacuum cleaner to clean the UPS Only factory authorized personnel sould perform internal general maintenance on the UPS Contact the authorized Toshiba Customer Support Center or an authorized Toshiba representative for informaton on proper disposal of UPS components It is illegal to dispose of certain components without conforming to environmental regulations for indusrial commercial waste 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 Chapter 8 Transporting DO NOT tilt the UPS
12. C Table 3 2 lists the nominal battery voltage TABLE 3 2 UPS NOMINAL BATTERY VOLTAGE CAPACITY NoMiNAL VOLTAGE FLOAT VOLTAGE 100 kVA 360 Vdc 405 V 150 kVA 360 Vdc 405 V 225 kVA 360 Vdc 405 V 300 360 Vdc 405 V 4 G8000 Series Installation and Operation Manual TOSHIBA 4 Safety Precautions The Toshiba products listed in this document are intended for usage in general electronics applications computer personal equipment office equipment measuring equipment industrial robotics domestic appliances etc These Toshiba products are neither intended nor warranted for use in equipment that if a malfunction or failure occurs may result in loss of human life or bodily injury collectively referred to as Unintended Usage Unintended Usage includes atomic energy control instruments airplane or spaceship instruments transportation instruments traffic signal instruments combustion control instruments medical operating room or life support equipment all types of safety devices etc Unintended Usage of Toshiba products listed in this document shall be made at the customer s own risk The application of the UPS without special consideration for equipment that supports human safety and or maintain public services may cause serious accidents 41 Disclaimer IN NO EVENT WILL TOSHIBA CORPORATION BE RESPONSIBLE OR LIABLE FOR EITHER INDIRECT OR CONSEQUENTIAL DAMAGE OR INJURY THAT MAY COME FROM THE USE OF THIS EQUIPMENT
13. General Safety Instructions Important Safety Instructions e Safety Precautions Installation Precautions Please read the G8000 Series Operation Manual for important instructions on operating the UPS This manual and the accompanying drawings should be considered a permanent part of the equipment and should be readily available for reference and review Dimensions shown in the manual are in metric and or the English customary equivalent Keep the Installation Manual and the Operation Manual near the UPS for necessary reference SAVE THESE INSTRUCTIONS G8000 Series Installation and Operation Manual 1 TOSHIBA 2 General Safety Instructions DO NOT attempt to transport install operate maintain or dispose of this equipment until you have read and understood all of the product safety information provided in this manual 2 1 Symbols The symbols listed below are used throughout this manual When symbols are used in this manual they will include important safety information that must be carefully followed Safety Alert Symbol indicates that a potential personal injury hazard exists Prohibited Symbol indicates DO NOT take action Mandatory Symbol indicates that the following instruction is required Ground Symbol indicates the location of the equipment grounding conductor Electrical Voltage amp Shock Hazard Symbol indicates parts inside may cause electric shock Explosion Hazard Symbol indicates parts may ex
14. LED On LED Flash STEP 1 Turn on the control power supply switch SYSTEM INITIALIZE Figure 14 1 and ensure the operation lock is set to OPERATION Figure 13 1 1 ram INVERTER is AC INPUT CONVERTER L E FLOAT CHARGE EE m BYPASS INPUT STEP 2 Wait for a few seconds BYPASS PRESS RUN SWITCH INPUT CONVERTER L E FLOAT CHARGE BYPASS INPUT STEP 3 BYPASS Press the RUN button for at least 0 5 seconds UPS STARTING CONVERTER LED is ON and INVERTER WAIT FOR A WHILE LED flashes O u J le AC INPUT CONVERTER INVERTER FLOAT CHARGE EQUAL CHARGE L L r3 BATTERIES m BYPASS BYPASS INPUT 56 G8000 Series Installation and Operation Manual 7 DISCHARGE TOSHIBA Step 4 5 continues the procedure to start the UPS LED Key C LED LED LED Flash BYPASS MOVE 72B TO ON POSITION CONVERTER INVERTER E AC INPUT HL BATTERIES O x BYPASS INPUT FLOAT CHARGE 7 EQUAL CHARGE DISCHARGE AC OUTPUT UPS SUPPLY Vo 480 V AC lo 50 CONVERTER S AC INPUT L L ES BATTERIES O x BYPASS INPUT FLOAT CHARGE 7 EQUAL CHARGE DISCHARGE BYPASS G8000 Series Installation and Operation Manual STEP 4 Turn on the DC Input Breaker 72B on the
15. battery OH contact open 17 ON when battery is connected aux contact on 18 ON during battery discharge 19 ON with nominal bypass input FLASHES when bypass is under voltage 85 20 Normally OFF ON when warning displayed on LCD FLASHES when AC input is abnormal 21 Normally OFF ON when faults occur 22 Lamp FLASHES during START or STOP sequence ON when inverter is operating 23 ON when the inverter output is connected to the UPS output 24 ON with AC output connected to the bypass inverter sources 25 ON when the bypass power supplies the load 46 G8000 Series Installation and Operation Manual TOSHIBA 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 OPERATION UPS CHARGE AC SWITCH FAULT EQUAL gt FIGURE 13 1 GRAPHIC DISPLAY PANEL KEY SWITCH OPERATING BUTTONS G8000 Series Installation and Operation Manual 47 TOSHIBA 13 2 LCD LED Indicators 09 OG OQ 99 Qoo 5 OPERATION CHARGE ACSWITCH FAULT EQUAL OPERATION BYPASS ME UPS INHIBITED FIGURE 13 2 GRAPHIC DISPLAY PANEL LCD LED INDICATORS 48 G8000 Series Installation and Operation Manual TOSHIBA 13 3 LCD Indicators The operator can scroll through the following LCD display screens using the scroll but
16. be left open The UPS is grounded by connecting the neutral terminal to the ground bus with the internal jumper cable See Figure 11 13 The jumper cable should stay in place See Figure 11 12 for the jumper cable location If a ground fault interrupter is installed the UPS is likely to trip the interrupter during transferring to from the bypass circuit It is recommended that the ground fault interrupter be set to a minimum delay of 0 5 seconds Input Source I I I I I I 3 13 iN PT 30 3d 3 o gt LT FA T N To the G iG c Cx s Load Jumper Cable 1 Remains in Place ew lt 7 FIGURE 11 13 GROUNDING CONFIGURATION WITHOUT INPUT NEUTRAL 11 5 3 Recommended Configuration for delta input If the input source is a delta connection 3 phase 3 wire without ground the neutral terminal in the UPS cabinet must be connected to the ground bus with the internal jumper cable as shown in Figure 11 14 The jumper cable should stay in place See Figure 11 12 for the jumper cable location Input Source A228 m 3 30 13 6 3 3 s To the G 1G i G mm G Load Jumper Cable Remains in Place Mee ew ew lt gt lt FIGURE 11 14 GROUNDING CONFIGURATION FOR NON GROUNDED DELTA INPUT G8000 Series Installation and Operation Manual 41 TOSHIBA 11 5 4 Ground
17. devices that are operating near by If such interference is experienced the UPS should be installed further away from the affected equipment G8000 Series Installation and Operation Manual 11 TOSHIBA and or powered from a different source than that of the installed equipment 8 The user should provide over current protection for hardwired UPS systems between the UPS output and the load input 9 After ensuring that all power sources are turned OFF and isolated in accordance with established lockout tagout procedures connect the power source wiring of the correct voltage to the input terminals of the UPS NOTE Ensure the input phasing is connected in clockwise rotation CW UPS internal circuitry is designed to disable further UPS operation if the input phasing is installed in counter clockwise rotation CCW 10 Connect the output terminals of the UPS to the load refer to NEC Article 300 Wiring Methods and Article 310 Conductors For General Wiring Size the branch circuit conductors in accordance with NEC Table 310 16 as published 9 2007 METAL CONDUIT IS NOT AN ACCEPTABLE GROUND Conductor Routing and Grounding 1 Use separate metal conduits for routing the input power output power and control circuits 2 Follow the wire size and tightening torque specifications 3 Always ground the unit to reduce the potential for electrical shock and to help reduce electrical noise 4 A separate ground cable shoul
18. followed during the installation operation and maintenance of the G8000 Series UPS Please refer to the battery manufacturer s instructions for details on operating maintaining and or replacing the batteries for each system Keep unauthorized personnel from batteries Only a certified service representative with battery experience should perform service on batteries VAN CAUTION Misuse of this equipment could result in personal injury and or equipment damage In no event will Toshiba Corporation be responsible or liable for either indirect or consequential damage or injury that may come from the use of this equipment The UPS system input and output is NOT equipped with an over current protection device or an output disconnection at the AC output The user should provide circuit breakers between the UPS AC input or Bypass input and the power sources and between the UPS output and the critical load input The minimum device ratings are listed in Table 3 1 TABLE 3 1 UPS MINIMUM DEVICE RATINGS CAPACITY OUTPUT INPUT BREAKER RATING OurPur BREAKER RATING 100kVA 480V 277Vac 480V 150A 480V 150A 150kVA 480V 277Vac 480V 225A 480V 225A 225kVA 480V 277Vac 480V 350A 480V 350A 480V 277Vac 480V 500A 480V 450A The maximum operating ambient temperature should be 104 F 40 C If the UPS is exposed to the same ambient temperature as the battery system the maximum operating ambient temperature should be 90 F 32
19. 1 are shown below in Table 11 8 TABLE 11 8 EXTERNAL CONNECTIONS Signal Name Operation Output Warning Closed if Warnings present 2 1 6 _10_ Output Bypass Supply Close during Bypass Operation 11 Output Output Signal Ground Ground for pin 1 5 amp 10 12 Input 14 Output 16 Output Output 18 Output Output 21 Output 22 Note All control wiring should be 18 AWG 0 823 or larger 38 G8000 Series Installation and Operation Manual TOSHIBA The UPS battery cabinet and bypass breaker should be wired as shown below in Figure 11 8 Power Source Jumper wire if battery OH is not applied To Bypass Input Power Source for trip coil Overheat B Contact Auxillary A contact UPS Cabinet Ext EPO Customer N O Contacts Battery Cabinet FIGURE 11 10 CONNECTION BETWEEN UPS BATTERY CABINET amp BYPASS BREAKER G8000 Series Installation and Operation Manual TOSHIBA 11 5 Grounding Configuration This section describes the grounding configuration to be used with various AC service entrance configurations Inadequate grounding will cause problems at start up Connections for the ground line and the neutral line must be made appropriately according to the system configuration 11 5 1 Recommended configuration for 4 wire input with Input Neutral grounded Figure 11 11 shows recommended grounding c
20. 733 kg m FRONT 43 7 16 in 1 100 mm Clearance BACK SIDE 0 in 0 mm TOP 15 3 4 in 400 mm ME 35 635 BTU h 46 268 BTU h 61 690 BTU h J 8 980 kcal h 11 659 kcal h 15 546 kcal h P20 Foreign objects that are 12mm 15 32 or larger are prevented from entering the enclosure of the UPS 44 G8000 Series Installation and Operation Manual TOSHIBA 12 3 Electrical Specification DO NOT open the front cover Electric shock burns or other personal injuries may occur if untrained personnel open the front cover AC Input Rated Capacity 100 kVA 80 kW 150 kVA 120 kW 225 kVA 180kW 300 kVA 240 kW Input Voltage 480 V 10 to 15 3 Phase 3 Wire Input Frequency 60 Hz 590 Input Power Factor 0 95 1 00 Lagging at 100 Load Current Harmonic Distortion 4 Maximum at 100 Load Input Capacity Required 107 kVA 154 kVA 232 kVA 309 kVA Circuit Breaker Rating At 480V 150 Trip 225 350 500 Input DC Input Rated Capacity 100 80 kW 150 120 kW 225 kVA 180 kW 300 kVA 240 kW Voltage Window 288 414 V Recharge Voltage Regulation AC Output Rated Capacity 100 80 kW 150 kVA 120 kW 225 kVA 180 kW 300 kVA 240 kW 60 Hz 0 01 at Free running Mode Synchronous Window To Utiity Line 100 Continuous 125 10 min 150 1 min G8000 Series Installation and Operation Manual 45 TOSHIBA 13 Operator Interface
21. BA TABLE 15 5 WARNING 2 STOP AND RESTART Item LCD Message Indication Description I AC O P UV AC output voltage is low OU UNIT FAULT IGBT Stack Failure DCOV overvotageinDC orot Over current in Battery section TABLE 15 6 WARNING OPERATION CONTROL Item LCD Message Indication Description 95C TABLE 15 7 WARNING GUIDANCE Item LCD Message Indication Description 26B BATT OVER HEAT Battery temperature is too high 80B1 BATT UV ALM Battery voltage is near cutoff voltage G8000 Series Installation and Operation Manual 67 TOSHIBA 15 5 LCD Scroll w faults or warnings This section describes how to scroll through the LCD screens when a fault has occurred when Fault Data screens exist Figure 15 5 shows the locations of the buttons to scroll the LCD screens See Table 15 8 for details of the scroll buttons and how they are used for screen scrolling A OPERATION UPS CHARGE SWITCH FAULT EQUAL gt FIGURE 15 5 POSITION OF SCROLL AND RESET BUTTONS TABLE 15 8 BUTTON FUNCTIONS Name Function SCROLL UP Scrolls to the previous screen SCROLL DOWN Scrolls to the following screen RESET Resets the UPS faults and warnings shown on the LCD and deletes fault history data stored in memory 68 G8000 Series Installation and Operation Manual TOSHIBA 15 6 Restoring UPS Operation Contact Toshiba in the event of malfunction or fau
22. ERTER NOTE AC INPUT L FLOAT CHARGE To change from Bypass to UPS supply cHarce follow the Startup Procedures STEP 5 a ee AC OUTPUT If the AC switch does not function contact Toshiba or authorized representatives BYPASS INPUT EA BYPASS 58 G8000 Series Installation and Operation Manual TOSHIBA 14 5 Stop The procedure to stop the UPS is shown in Steps 1 3 LED Key LED Off EN LED On Jul LED Flash BYPASS STEP 1 AC Vo 480 V Transfer to Bypass supply as described in AC lo 50 Switch Power Supply PRESS UPS SWITCH UPS LED is OFF BYPASS LED is ON O AC INPUT L L E BATTERIES O x BYPASS INPUT Bl FLOAT CHARGE EQUAL CHARGE 7 DISCHARGE BYPASS STEP 2 Turn off the DC Input Breaker 72B on the external battery cabinet and press the G8000 STOP button for at least 0 5 seconds BATTERIES LED is OFF INVERTER LED flashes then OFF FLOAT CHARGE LED and CONVERTER LED are OFF O a AC INPUT L L BATTERIES FLOAT CHARGE EQUAL CHARGE 7 DISCHARGE AC OUTPUT ras Li BYPASS BYPASS INPUT BYPASS STEP 3 Wait until procedure is completed O m AC INPUT PRESS RUN SWITCH CONVERTER INVERTER T l BATTERIES O C FLOAT CHARGE BYPASS BYPASS INPUT EQUAL CHARGE E DISCHARGE AC OUTPUT G8000 Ser
23. LECTRIC SHOCK Capacitors stay charged after power has been shut off Accidental contact with live parts can cause personal injury and death Turn off and lock out all power sources Wait at least five 5 minutes for power to dissipate then check voltage before servicing 39561 58705 TOGHIBA INTERNATIONAL CORPORATION IN J MFD IN U S A FROM FOREIGNAND DOMESTIC COMP CNENTS L oes el UL HOUSTON TEXAS tj 1 40831 J 57053 Heat sink not grounded control power source switch Do not turn off while operating Disconnect UPS and electrically test heat sink before touching PN 40831 6 1 Warning Label Locations I T le 1000001 5 5 5 8000 Series Installation and Operation Manual 15 TOSHIBA unu mm m Mi L d e cu 41 2 Y TET el a D n jeLioLlo n p T O rl a lof lo toj lo Ter eT o s perc ooo oo FIGURE 6 3 150 225 KVA UPS WARNING LABELS
24. LED i LED Flash UPS SUPPLY STEP 1 Make sure that the FLOAT CHARGE LED 480 is ON AC lo 50 EE AC INPUT CONVERTER INVERTER L FLOAT CHARGE BEES m BYPASS INPUT UPS SUPPLY STEP 2 Vo 480 V Press FLOAT EQUAL button for at least AC lo 50 0 5 sec Change completed EQUAL CHARGE LED is ON FLOAT CHARGE LED is OFF m AC INPUT L L BATTERIES 77 INVERTER FLOAT CHARGE BN EQUAL CHARGE CONVERTER DISCHARGE STEP 3 Please wait until procedure is completed BYPASS INPUT NOTE In equalize charge mode the battery is charged for a programmed period at a specified voltage depending on the battery spec rather than the float charge in order to prevent voltage deviations among battery cells This should be done once every six months if possible The G8000 UPS will automatically perform the equalize recharge after battery backup operation G8000 Series Installation and Operation Manual 61 TOSHIBA 14 8 Changing to Float Charge from Protection Charge If applicable The manual procedure to change from protection charge to float charge is shown in Step 1 3 This operation applies to batteries after they have experienced over temperature condition See the Note below for an explanation of float charge and protection charge LED Key C LED LED Jai LED Flash STEP 1 UPS SUPPLY Make sure t
25. NTERNATIONAL CORPORATION OR AUTHORIZED REPRESENTATIVE IN CASE OF INCONSISTENCIES OMISSIONS OR QUESTIONS The instructions contained in this manual are not intended to cover all of the details or variations in equipment nor to provide for every possible contingency concerning installation operation or maintenance Should further information be required or if problems arise which are not covered sufficiently contact your Toshiba sales office The contents of this instruction manual shall not become a part of or modify any prior or existing agreement commitment or relationship The sales contract contains the entire obligation of Toshiba International Corporation s UPS Division The warranty contained in the contract between the parties is the sole warranty of Toshiba International Corporation s UPS Division and any statements contained herein DO NOT create new warranties or modify the existing warranty Any electrical or mechanical modifications to this equipment without prior written consent of Toshiba International Corporation will void all warranties and may void the UL CUL listing Unauthorized modifications can also result in personal injury death or destruction of the equipment QUALIFIED PERSONNEL ONLY Qualified Personnel is one that has the skills and knowledge relating to the construction installation operation and maintenance of the electrical equipment and has received safety training on the hazards involved Refer to t
26. TOP ACCESS KNOCKOUT PLATE IF AVAILABLE 150 AND 225 KVA ONLY 32 G8000 Series Installation and Operation Manual TOSHIBA If your system is equiped with bus strip terminals for the A C INPUT BYPASS INPUT A C OUTPUT and BATTERY connections Toshiba recommends using the compression lugs listed in Table 11 4 or their equivalent for cable terminations for mounting on the bus strip 5 3 in 135 mm 1 97 in 1 77 in 50 mm 45 mm amp 4 4 1 75 in 45 mm 5 3 in 77 mm o6 FIGURE 11 6 TERMINAL BUS DETAIL TABLE 11 4 RECOMMENDED CRIMP TYPE COMPRESSION LUGS FOR BUS STRIP TERMINALS Wire Size Recommendation Crimp tool Required Burndy type Y35 Y46 Color Key Die Index YA25 12 348 CRA 1 OL 12 348 YA25 LB YA26 CRA 2 OL YA2T LB 27 14 101 CRB 3 OL 14 101 YA28 LB YA28 Purple CRB 4 0L Purple YA29 LB Yellow YA30 CRA 300L 17 298 YA32 LB 18 324 350 MCM Burndy YA31L Red 18 CRA 350 Red 18 600 MCM Burndy YA36L Green 22 600 22 G8000 Series Installation and Operation Manual 33 B TOSHIBA The terminal busses for the 300 kVA UPS are located inside at the top of the unit See Figure 11 6 The dashed line indicates the side view of the bolt holes Use 1 2 inch bolts to attach the lugs See Tables 11 5 for recommended cab
27. TOSHIBA UNINTERRUPTIBLE POWER SYSTEM UPS G8000 SERIES INSTALLATION and OPERATION MANUAL Document 57056 002 November 2007 Copyright 2007 Toshiba International Corporation All rights reserved TOSHIBA UNINTERRUPTIBLE POWER SYSTEM UPS G8000 SERIES INSTALLATION and OPERATION MANUAL Document 57056 002 November 2007 c UL Dus Copyright 2007 Toshiba International Corporation All rights reserved G8000 Series Installation and Operation Manual TOSHIBA The Toshiba products listed in this document are intended for usage in general electronics applications computer personal equipment office equipment measuring equipment industrial robotics domestic appliances etc These Toshiba products are neither intended nor warranted for usage in equipment that requires extraordinarily high quality and or reliability nor are they intended to be used in equipment that if a malfunction or failure occurs may result in loss of human life or bodily injury collectively referred to as Unintended Usage Unintended Usage includes atomic energy control instruments airplane or spaceship instruments transportation instruments traffic signal instruments combustion control instruments medical operating room or life support equipment all types of safety devices etc Unintended Usage of Toshiba products listed in this document shall be made at the customer s own risk NOTICE PLEASE INFORM TOSHIBA I
28. Table 13 1 shows the functions of the operating buttons on the graphic display panel ATTENTION 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 respond if the button press is too short TABLE 13 1 BUTTON AND INDICATOR FUNCTIONS See fig 13 1 and 13 2 Name Function 1 OPERATION LOCK Enables disables the buttons RUN STOP UPS BYPASS FLOAT EQUAL and RESET 2 STOP BUTTON Stops the UPS Transfers to bypass power if avialable 3 RUN BUTTON Starts the UPS Transfers the unit from bypass to UPS power 4 FLOAT EQUAL BUTTON Changes recharge mode between float charge and equalize charge 5 SCROLL UP BUTTON Scrolls the LCD screens up SCROLL DOWN BUTTON Scrolls the LCD screens down 7 RESET BUTTON Reset UPS faults and warnings shown on the LCD See Section 13 5 UPS BUTTON Transfers from bypass operation to normal operation BYPASS BUTTON Transfers from normal operation to bypass operation 10 ERO BUTTON during Bypass Supply 11 Displays the operational status and warning fault messsages 12 FLASHES during START or STOP sequence ON when operating in inverter mode 13 ON after DC bus capacitors are fully charged through the converter 14 ON with nominal AC input FLASHES with AC input under voltage 85 15 ON during float charge 16 during equalize charge or protection charge while
29. URE 11 2 TERMINAL BLOCKS OF 100 150 225 KVA UPS TABLE 11 1 RECOMMENDED CABLE SIZE amp TIGHTENING TORQUE FOR 100 KVA UPS Block Number Cable Size Tightening Torque AWGWborlager 275indos 3 2 AWG 10 ortarger 275 indos 3 2 AWG tO ortarger 275 indos 2 AWG 1WOorlarger 275 indos B2kgm 275 3 2 ko m NOTE MAXIMUM CABLE SIZE IS AWG 2 0 ONE BATTERY STRING SEE NOTE PG 35 IF USING MULTIPLE BATTERY STRINGS 30 G8000 Series Installation and Operation Manual TOSHIBA TABLE 11 2 RECOMMENDED CABLE SIZE amp TIGHTENING TORQUE FOR 150 KVA UPS Block Number Cable Size Tightening Torque 275 3 2 AWG 410 ortarger 275 indos 3 2 5 AWG AID orlarger 275indbs 3 2 6 AWG 40 ortarger 275 indos 2 AWG 4 0 ortarger 275 indos 3 2 9 AWG AO orlarger 2756104 3 2 _ 275 iJbs 32 vu Two or larger 2 5 in lbs 3 2 kg m Terminal is bus strip 13 Two or larger 2 5 in lbs 3 2 kg m Terminal is bus strip NOTE MAXIMUM CABLE SIZE IS 350MCM ONE BATTERY STRING SEE NOTE PG 35 IF USING MULTIPLE BATTERY STRINGS TABLE 11 3 RECOMMENDED CABLE SIZE amp TIGHTENING TORQUE FOR 225KVA UPS Block Number Cable Size Tightening Torque Two 2 0 orlarger 275 indos B2kgm 3 Two2 0orlarger 2756104 3 2
30. al for complete details FORKS 4Ft Minimum length WARNING Risk of tipping For safe handling lift UPS from back and sides only as shown above G8000 Series Installation and Operation Manual 7 TOSHIBA 4 4 Inspection Storage Inspection Upon receipt of the UPS an inspection for shipping damage should be performed Use caution when removing the unit from the pallet Refer to labels or documentation attached to packing material Unpacking Check the unit for loose broken bent or otherwise damaged parts If damage has occurred during shipping keep all original crating and packing materials for return to the shipping agent NOTE The factory warranty does not apply to damage incurred during shipping Ensure that the rated capacity and the model number specified on the nameplate conform to the order specifications Storage During periods of non use the following guidelines are recommended for storage Storage Preparation 1 Power up the UPS and allow it to operate with no load for 24 hours to fully charge the batteries 2 Stop the unit 3 Place the Main Circuit Breaker switch in the OFF position Storage Conditions For best results store the UPS in the original shipping container and place on a wood or metal pallet e Storage temperature range 4 to 104 F 20 to 40 C The optimum storage temperature is 70 F 21 C Ahigher ambient temperature will require recharging more frequently durin
31. an be displayed Figure 15 1 and Table 15 2 show a sample screen and describe the data shown in the screen FAULTS amp WARNINGS 1 1 UPS OVERLOAD 2 09 09 06 08 05 30 ITEM 4 FIGURE 15 1 SAMPLE FAULT DATA SCREEN TABLE 15 2 FAULT AND WARNING DATA SCREEN DESCRIPTIONS Name Description 1 Number The number of the message in the order that it was detected 1 10 Up to 10 screens of fault data can be displayed Shows the type of the fault or warning message The date mm dd yy and time in 24 hour format the fault was 3 Time detected Indicates there is fault screen before this screen Scroll Indicator Indicates there is a fault screen after this screen Indicates there fault screens before and after this screen Indicates whether there is a fault screen before or after this screen 4 64 G8000 Series Installation and Operation Manual TOSHIBA 15 3 LCD Fault amp Warning Displays When a fault occurs a screen is shown as in Figure 15 2 When a warning occurs a screen is shown as in Figure 15 3 Select the desired fault or warning data to be displayed using the scroll buttons BYPASS FAULT STOP FAULTS amp WARNINGS 1 FUSE BLOWN 09 09 06 08 05 30 FIGURE 15 2 FAULT DISPLAY UPS SUPPLY AC VO 480 V AC 10 50 FAULTS amp WARNINGS 1 UPS OVERLOAD 09 09 06 08 05 30 FIGURE 15 3 WARNING DISPLAY G8000 Series Installation
32. and Operation Manual 65 TOSHIBA 15 4 Fault Messages Figure 15 4 show the locations for fault detection Tables 15 3 through 15 7 gives details for the fault and warning messages referred to in section Fault Data Screen The item code associated with each fault or warning message may be used to determine the physical location of the fault or warning by referring to Figure 15 4 The UPS unit may be shipped with different protective configurations from the standard shown in Figure 15 4 if specified by the customer See the protective configuration indicated on the single line diagram for each UPS 51 49 271 Inverter 83MC1 z T Battery T 83 Chopper J 30U SE 76C L 26 71F 48 83BF FIGURE 15 4 PROTECTIVE DETECTORS LOCATIONS TABLE 15 3 FAULT TRIP ITEM LCD MESSAGE INDICATION DESCRIPTION 26 OVERHEAT _ MGHTEMPINTHECABNET Las STARTUPERR STARTUP WAS NOT COMPLETED WITHIN THE NORMAL TIME FRAME _ EMGSTOP AN EMERGENCY STOP WAS ACTIVATED VIA THE EXTERNAL TABLE 15 4 WARNING 1 CONVERTER STOP INPUT POWER ERROR ITEM LCD MESSAGE INDICATION DESCRIPTION AC I P UV AC INPUT UNDERVOLTAGE AC INPUT VOLTAGE IS TOO LOW AC PHASE ERR AC INPUT PHASE ROTATION ERROR 595 AC INPUT OVERVOLTAGE AC INPUT VOLTAGE IS TOO HIGH 95S I P FREQ ERR AC INPUT FREQUENCY ERROR 66 G8000 Series Installation and Operation Manual TOSHI
33. ating factor for installations above 3240 ft 1000m conductive particles silicone or oils No No flammable and or explosive gas 44 and or No flammable and or explosive gas 44 gas Nitrous acid gas NO Less than or equal to 0 02 PPM Nitrous oxides NOx Less than or equal to 0 02 PPM Ozone Less than or equal to 0 002 PPM Hydrochloric acid mist Less than or equal to 0 1 mg m 9 1 Operating Precautions Initial startup comisioning of the UPS should be performed by factory authorized personnel 1 The UPS should not be powered up until the entire operation manual has been read 2 The voltage of the input power source must be within the rated input voltage range The input frequency range must be within the rated input frequency range 22 G8000 Series Installation and Operation Manual TOSHIBA 3 The UPS should not be used with a load that has a rated input that is greater than the rated output of the UPS 4 If using the UPS to provide power to motors that require high starting current or with motors that require a long starting time call Toshiba support for guidance in over sizing the UPS for lock rotor current 5 DO NOT insert metal objects or combustible materials in the ventilation slots of the UPS 6 DO NOT place hang or paste any objects on the exterior surfaces of the UPS 7 The capacitors in the UPS maintain a residual charge for a while after turning the UPS off T
34. available allow enough space for forklift operations to unpack the UPS crate Then remove the crate Points to observe Retain all small articles during unpacking and installation Make sure that exterior paint is not scratched and that the UPS cabinet is not damaged DO NOT damage the UPS when using tools to remove packaging materials If provided DO NOT remove the plastic sheet cover until installation Do not remove the fan covers until UPS start up The fan covers should be removed by factory authorized personnel Packing materials should be disposed by the appropriate means Immediately report any abnormalities to Toshiba Customer Support Center or an authorized representative 10 2 UPS Clearance Maintain the indicated clearance during installation See Figure 10 1 Ensure that the front and top air vents are NOT blocked m 16 in 400 mm 909009000009000900009090000900009090009009000090909009009000099 Front 44 in 1100 mm Side 0 in 0 mm Back 0 in 0 mm FIGURE 10 1 UPS CLEARANCE G8000 Series Installation and Operation Manual 27 TOSHIBA 10 3 Anchor Bolts Install the anchor bolts to secure the UPS on the floor See Figure 10 2 for anchor bolt installation detail Use 12mm 1 2 diameter anchor bolts There are 16mm 5 8 diameter holes provided in the UPS base See Figure 10 3 for the hole locations and dimensions for the specified UPS models lt 100kVA T80S3K10KK6XS2H gt
35. care of protective equipment such as safety shoes rubber gloves hard hats safety glasses face shields flash clothing etc in accordance with established safety practices 4 Be trained in rendering first aid 5 Be knowledgeable of batteries and the required handling and maintenance precautions For further information on workplace safety visit www osha gov Misuse of equipment could result in injury and equipment damage In no event will Toshiba Corporation be responsible or liable for either indirect or consequential damage or injury that may result from the misuse of this equipment 24 G8000 Series Installation and Operation Manual TOSHIBA VAN CAUTION DO NOT dispose of the batteries in a fire The batteries may explode DO NOT open or mutilate the batteries Released electrolyte is harmful to the eyes and skin and could also be toxic VAN DANGER A battery can present a risk of electrical shock and high short circuit current 9 3 Disposal Please contact your local or state environmental agency for details on disposal of electrical components and packaging in your particular area It is illegal to dump lead acid batteries in landfills or dispose of them improperly Please help protect the Earth by contacting the environmental protection agencies in your area the battery manufacturer or call Toshiba toll free at 877 867 8773 for more information about recycling batteries G8000 Series Installatio
36. d be run inside the conduit with the input power output power and control circuits 12 G8000 Series Installation and Operation Manual TOSHIBA 5 1 Wiring Connection Perform wiring and connections with correct polarity Be careful when connecting the UPS to the battery system A wrong connection may cause damage to the UPS battery or charger Connect ONLY one 1 ground wire to the earth ground terminal A missing ground wire may cause an electrical shock hazard Connecting to more than one ground may cause a ground loop See Chapter 8 UPS Wiring DO NOT force bend or pull wires DO NOT damage wire insulation DO NOT place heavy objects on top of UPS Observe the above precautions when making wire connections or handling the wires Failing to observe these precautions may damage the insulation of the wires or may cause a fire or an electric shock hazard ATTENTION Follow the torque criteria for tightening screws Loose connections may cause fire due to heating See Chapter 11 UPS Wiring G8000 Series Installation and Operation Manual 13 TOSHIBA 6 Warning Labels Below are representative warning labels and their location on the UPS Exterior Handling labels shown in section 4 3 Transporting Unpacking are in the manual packet and attached to the UPS shipping covering and shipping pallet ATTENTION Make sure all the warning labels are installed in the appropriate locations If a label is miss
37. e forks against the base then lift 100 225 kVA 300 kVA 1 dla Insert the forks here Secure the forks against the base then lift FIGURE 8 6 TRANSPORTING UPS BY FORKLIFT G8000 Series Installation and Operation Manual 21 9 Storage Operating Environment Observe the following when storing the UPS e Store UPS indoors e Maximum storage time for the UPS between powered operation cycles is three years If the UPS has been stored for a period exceeding 36 months contact your factory authorized represnetative of guidance in starting the unit e Temperature fluctuations should be minimized e The optimal storage temperature range is 68 77 F 20 25 C e maximum temperature range of 32 104 F 0 40 C should be observed e The optimal relative humidity at the storage location should be between 50 60 e Humidity must not exceed 90 e Avoid locations where UPS may be exposed to corrosive gas e Avoid locations with dirt and or dust TABLE 9 1 UPS STORAGE OPERATING ENVIRONMENT STANDARDS Item Environment standard Storage Location Minimum storage temperature 32 F 0 C Ambient Temperature Maximum storage temperature 104 F 40 C Relative Humidit The relative humidity must be between 30 and 90 and without condensation due to temperature changes This equipment is rated for installations up to 3240 ft 1000m above Altitude sea level Consult with the factory to determine the der
38. g storage Avoid the following storage locations Locations that are subject to extreme temperature changes or high humidity Locations that are subject to high levels of dust or metal particles Locations that are subject to excessive vibration e Inclined floor surfaces 8 G8000 Series Installation and Operation Manual TOSHIBA 5 Installation Precautions Install the UPS in a controlled environment Improper storage and installation environment may deteriorate insulation shorten component life and cause malfunctions See Table 5 1 UPS Installation Environment Standards DO NOT tilt the UPS more than 10 from upright position Tilting the UPS more than 10 may cause crushing trapping or other personal injuries and cause physical damage to internal components Keep the SPECIFIED CLEARANCE around the UPS Inadequate space around the UPS makes it difficult to perform maintenance inspections will lead to insufficient ventilation and or cause malfunctions Install anchor bolts to secure the UPS to the installation floor The UPS may fall during an earthquake if the anchor bolts are not installed and secured Only factory authorized personnel should relocate modify or replace parts in the UPS after initial installation Electrical shock injury or UPS failure may occur if non authorized technicians attempt to modify or relocate the UPS Please contact Toshiba Customer Support Center if you plan to mo
39. h this equipment and the information supplied with it should be permitted to install and operate this equipment Installation of electrical equipment must be done in accordance with National Electrical Code and any other state or local codes Proper grounding and conductor sizing must be installed for safe operation During operation keep all covers in place and cabinet doors shut When performing visual inspections and maintenance if possible be sure the UPS is turned off and the incoming AC feed is turned off and locked out The UPS and Battery Cabinet will have hazardous voltages present even after the AC feed is turned off If it is necessary to make measurements with the power on do not touch any electrical connection points Remove all jewelry from wrists and fingers Make sure test equipment is in good safe operating condition While servicing stand on some type of insulation and be sure not to be grounded Follow the safety instructions given in the equipment manual carefully and observe all danger warning and caution notices 40308 D 40830 WARNING CRITICAL FUSE SIZING Incorrect fuse replacement size may result in fire or inadequate equipment protection Replace only with same type and rating of fuse PN 40830 G8000 Series Installation and Operation Manual TOSHIBA E 39561 F 58705 SERIAL LABEL G 57055 UNINTERRUPTIBLE POWER SUPPLY RISK OF E
40. hat the EQUAL CHARGE LED is ON 480 AC lo 50 aye AC INPUT CONVERTER INVERTER FLOAT CHARGE BATTERIES DISCHARGE BYPASS INPUT STEP 2 Make sure that the BATT FAULT1 warning UPS SUPPLY goes away AC 480 lo 50 STEP 3 Press FLOAT EQUALL button for atleast OQ m 0 5 seconds ne FLOAT CHARGE 7 EQUAL CHARGE DISCHARGE CONVERTER Procedure completed EN BATTERIES AC OUTPUT NOTE The battery is normally being charged at float charge mode To prevent thermal runaway of the battery this mode will automatically be changed to protection charge when a BATT FAULT1 Battery over temperature warning occurs In protection charge mode the battery is automatically charged at a voltage about 5 lower than float charge If the BATT FAULT 1 warning message goes away and a programmed duration is elapsed about 24 hours this mode will automatically be changed back to float charge Thus it is not usually required to change the recharge mode manually back to the float charge 62 G8000 Series Installation and Operation Manual TOSHIBA 14 9 Emergency Power Off EPO Press the EPO switch for immediate shutdown of all power through the UPS The signal from the EPO 15 processed as a hard fault by the UPS and results in gate blocks on the transistors and opens all the
41. he latest edition of NFPA 70E for additional safety requirements G8000 Series Installation and Operation Manual TOSHIBA UNINTERRUPTIBLE POWER SYSTEM UPS Please complete the following information and retain for your records Unless otherwise specified the warranty period for the UPS or UPS part is 12 months from the shipment date see Toshiba International Corporation bill of lading Unless otherwise specified the warranty period for a UPS battery is 36 months from the shipment date see Toshiba International Corporation Bill of Lading for shipping date JOB NUMBER MODEL NUMBER SERIAL NUMBER APPLICATION SHIPMENT DATE INSTALLATION DATE INSPECTED BY G8000 Series Installation and Operation Manual TOSHIBA Purpose This manual provides information on how to safely install and operate your Toshiba International Corporation power electronics product This manual includes a section of general safety instructions that describes the warning labels and symbols that are used throughout the manual Read the manual completely before installing operating or performing maintenance on this equipment This manual and the accompanying drawings should be considered a permanent part of the equipment and should be readily available for reference and review Dimensions shown in the manual are in metric and or the English customary equivalent Toshiba International Corporation reserves the right without prior notice to update info
42. he required discharge time for each UPS typeform is provided via a cabinet label and a CHARGE LED Wait for at least the minimum time indicated on the label and ensure that the CHARGE LED has gone out before opening the door of the UPS once the UPS power has been turned off 8 DO NOT attempt to disassemble modify or repair the UPS Call your Toshiba sales representative for repair information 9 Turn the power on only after installing ALL of the covers 10 DO NOT remove any covers of the UPS when power is on 11 If the UPS should emit smoke or an unusual odor or sound turn the power off immediately 12 Warning signs should be placed on or near the load as a notification that the load is being powered by the UPS 13 Additional warnings and notifications shall be posted at the equipment installation location as deemed required by Qualified Personnel 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 position for the UPS to shutdown power to the load VAN CAUTION After an Emergency Power Off EPO DO NOT reset the breaker until the UPS internal circuits have been fully discharged The UPS could be damaged if the unit is not fully discharged before the breaker is reset G8000 Series Installat
43. i 3 ja _ FIGURE 7 3 300 KVA UPS EXTERIOR DIMENSIONS INCHES 18 G8000 Series Installation and Operation Manual TOSHIBA 8 Transporting WARNING Whentransporting the UPS by crane followthe SPECIFIEDWORK PROCEDURE The suspension wire angle should be less than 60 The UPS falling or overturning may cause crushing trapping or other personal injuries DO NOT tilt the UPS more than 10 from upright position Tilting the UPS more than 10 may cause crushing trapping or other personal injuries CAUTION DO NOT transport move store or place the UPS on its side Excessive force applied from heavy components inside may damage the UPS Avoid vibration or shock exceeding 0 5G Failing to observe this precaution may cause damage to the UPS DO NOT allow the UPS to suffer shock or impact when unpacking Tools used to remove packaging materials may cause damage to the UPS DO NOT install the UPS where water may fall on it Water may cause electrical shock personal injury or UPS failure DO NOT push or pull on the sides of the packaging or the UPS to move it Always use a crane forklift or pallet jack for transporting and positioning the UPS Pushing pulling on the sides of the unit to move it may result in damage to the UPS See Figure 4 1 Exterior Handling label The UPS may be packed in a crate for extra protection during transportatio
44. ic display panel e SCROLL UP Moves back to the previous screen e SCROLL DOWN Moves forward to the next screen TABLE 13 4 DISPLAY SCREEN SCROLL SEQUENCE UPS SUPPLY AC VO 480 V AC 10 50 OPERATION MODE NORMAL OPERATION MODE SYNC The LCD displays a diagram of the electrical power flow O P VOLTAGE VOLT 480 V FREQ 60 0 HZ O P CURRENT R M S U 50 50 W 50 O P CURRENT PEAK U 50 V 50 W 50 Abbreveations AC Current Input Output Voltage Output E Current Output d AC INPUT AC I P V 480 V FREQ 60 0 HZ G8000 Series Installation and Operation Manual Alternating Direct Current FAULTS amp WARNINGS NO FAULT NO WARNING TIME 03 24 06 13 58 MODE COUNT UPS 35 H BATTERY 56 MIN 32 TIM DC INPUT DC V 632 V BATT V 400 V 1 O A BATTERY BACK UP RATING 10 MIN DISCHARGING 15 MIN BYPASS INPUT BYP I P V 480 V FREQ 60 0 HZ 53 TOSHIBA 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 If the UPS produces smoke or smells strange immediately turn off all AC and DC input circuit breakers Continued operation may result in fire Contact Toshiba or Authorized representatives DO NOT turn off the control power supply switch 8A during UPS operation This may resu
45. ies Installation and Operation Manual 59 TOSHIBA 14 6 Complete Shutdown The procedure to turn off the control power and shut down the UPS completely is shown in Steps 1 6 STEP 1 Transfer to Bypass supply as described in asses Switch Power Supply DC V 0 UPS LED is BATT V 0 V 0 BYPASS LED ON STEP 2 Turn off the DC input breaker and press the STOP button for at least 0 5 sec BATTERIES LED is OFF INVERTER LED flashes then OFF FLOAT CHARGE LED and CONVERTER LED are OFF STEP 3 Please wait until procedure is completed STEP 4 Scroll the LCD screen to see the DC INPUT and make sure DC bus voltage is OV STEP 5 Q ATTENTION off the control power supply switch STEP 5 This operation is different from Nothing is displayed on the LCD the instructions displayed on the screen All LED s are Be sure to perform the procedure as specified in this manual STEP 6 Turn off all breakers at AC output Bypass Input and AC Output Shutdown is completed and UPS is isolated 60 G8000 Series Installation and Operation Manual TOSHIBA 14 7 Changing Between Float Charge and Equalize Charge The procedure to change the recharge mode between float charge and equalize charge is shown in Steps 1 3 See the Note below for an explanation of Flaot and Equalize charge modes LED Key L LED
46. ing Configuration 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 11 12 for the jumper cable location During normal operation the UPS output is floating relative to the ground An isolation transformer is recommended at output distribution as shown in Figure 11 15 UPS Cabinet Input Source P Output Distribution To the Load Remove Jumper Cable 4 Mee ew ee eB me ee I FIGURE 11 15 GROUNDING CONFIGURATION WITH CORNER GROUNDED DELTA INPUT 42 G8000 Series Installation and Operation Manual TOSHIBA 12 UPS Specifications 12 1 General Specification Terms Specification Remarks Conforming Standard UL1778 2001 UL cUL Ambient Temperature 32 104 F 0 40 C Relative Humidity 3 9 Altitude 3 280 ft 1 000 m Contact Toshiba Technical Support for instalation above 3280 ft 1000 m 68 dB 150 225 kVA 72 dB 300 kVA 1m 39 away from front Insulation Breakdown 12 2 Mechanical Specification 100 kVA 100 kVA Rated Capacity T80S3K10KK6XS2H T80S3K10KK6XSNH Cabinet Protection IEC298 IP20 Conformity Exterior Paint Sherwin Williams HHT2 7055 079 Beige Texture FRONT 1 6 mm 1 16 in Panel Thickness BACK SIDE TOP 1 2mm 3 64 in BOTTOM 3 2mm 1 8 i
47. ing or illegible contact Toshiba Customer Support Center or authorized representative A 48082 A DANGER EN AC VOLTAGE This UPS receives power from more than one source Disconnect all AC sources before performing any service or testing inside this unit 48082 C 56875 FOR 100 150 225KVA A DANGER B 40308 HAZARDOUS VOLTAGES Hazardous voltages are used in the operation of this equipment and could cause severe personal injury or loss of life The following precautions should be observed to reduce the risk of injury or death USE COPPER CONDUCTORS ONLY REFER TO INSTRUCTION MANUAL FOR WIRE SIZE AND TIGHTENING TORQUE 1 2 3 4 5 6 7 8 9 10 11 12 13 U V U V U V 480V 480V 480V 400V AC INPUT BYPASS INPUT AC OUTPUT BATTERY C 58708 FOR 300KVA 58708 USE COPPER CONDUCTORS ONLY REFER TO INSTRUCTION MANUAL FOR WIRE SIZE AND TIGHTENING TORQUE 1 2 3 4 5 6 8 9 10 11 12 U V U V Ww N U V 480 400 480 480V AC INPUT BATTERY BYPASS INPUT AC OUTPUT 14 Only qualified technicians familiar wit
48. internal contactors To Reset the UPS after triggering the EPO do the following 1 Shut Down the UPS as described in section 14 6 2 Restart the UPS as described in section 14 3 15 Troubleshooting When an error occurs in the UPS error data is displayed on the LCD screen This section will describe the types of errors the error messages displayed on the LCD screen and the procedures to correct the errors 15 4 Types of Errors The following types of errors may occur in the UPS TABLE 15 1 OPERATION TYPES Description Fault Fault Trip The UPS has been tripped and has stopped operating The UPS is in Bypass mode Warning 1 Input Power Failure Power is supplied from the battery When the warning is corrected power will automatically be supplied from the AC input Warning 2 Stop and Restart The UPS transfers to Bypass supply and the UPS stops operating When the warning is corrected the UPS will Warning automatically be restarted and revert to UPS supply Warning Operation Control An error or a phenomena related to an error occurred Since this problem does not directly affect operation the system switches to synchronized mode Guidance An error or indication of an error has occurred but operation was not affected G8000 Series Installation and Operation Manual 63 TOSHIBA 15 2 Faults and Warnings Data Screen This screen appears when a trip error is detected Up to 10 screens of fault data c
49. ion and Operation Manual TOSHIBA 9 2 Maintenance Precautions All internal maintenance sould be performed by factory authorized personnel 1 Turn off lockout and tagout ALL power sources before connecting the power wiring to the equipment or when performing maintenance 2 Hardwire type UPS units are not equipped with an over current protection device nor do they have an output disconnect for the AC output A user installed circuit breaker should be provided between the UPS output and the load input 3 The maximum ambient operating temperature is 104 F 40 4 Only factory authorized personnel should service the UPS Contact Toshiba for the the nearest authorized service center 5 Battery servicing should be performed by factory authorized personnel only Contact your nearest factory authorized service center for battery replacement Qualified Personnel ONLY Qualified Personnel have the skills and knowledge relating to the construction installation operation and maintenance of the electrical equipment and has received safety training on the hazards involved Refer to the latest edition of NFPA 70E for additional safety requirements Qualified Personnel shall 1 Have read the entire operation manual 2 Be trained and authorized to safely energize de energize ground lockout and tag circuits and equipment and clear faults in accordance with established safety practices 3 Be trained in the proper use and
50. le size for the 300 kVA UPS See Table 11 4 and Table 11 6 for vendor recommended lugs 1 2 3 4 5 6 7 8 9 10 11 12 U V W _ U V W N U V W Ld Lee gt _ L BYPASS INPUT AC OUTPUT 3 phase 3 wire 3 phase 4 wire 3 phase 4 wire FIGURE 11 7 TERMINAL BUSSES OF THE 300 KVA UPS Figure 11 7 shows the four 4 cable knockout plates provided at the top of the 300 kVA UPS Seven 7 holes must be punched during installation The dashed rectangle indicates the UPS opening behind the knockout plates PLATE 1 PLATE 4 PLATE 2 PLATE 3 0 6 GROUND WIRE 0 6 CONTROL WIRES AC INPUT z BYPASS OUTPUT FIGURE 11 8 CABLE KNOCKOUT PLATES 300 KVA 34 G8000 Series Installation and Operation Manual TOSHIBA TABLE 11 5 RECOMMENDED CABLE SIZE AND TIGHTENING TORQUE FOR 300 KVA UPS Bus Number Cable Size Tightening Torque Two 4 0 AWG or larger 275 in lbs 3 2 kg m Two 4 0 AWG or larger 275 in lbs 3 2 kg m Two AWG orlarger 276 ibs 32kgm 5 8 wo4bAWGorlrger 276 inos Two 410 AWG orlarger 276 indos 32kgm 275 3 2 NOTE MAXIMUM CABLE SIZE IS 600MCM TWO BATTERY STRINGS OR MORE CONSULT FACTORY IF USING ONE BATTERY STRING TABLE 11 6 RECOMMENDED LUGS FOR USE WITH 300 KVA UPS Terminal Bus Recommendation Catalog TA 600 ILSCO AU 600 TA 600 T3A2 600N 7 10 11 12 600 AU 600 ILSCO TA
51. lt This UPS should be repaired only by factory authorized personnel Servicing by untrained personnel may extend the fault or result in electric shock or personal injury Do NOT attempt to modify or relocate the UPS Electric shock personal injury or fault may result if unauthorized personnel attempt to modify or relocate the UPS Be sure to contact toshiba customer service if you need to modifify or relocate the UPS Do not open the front and or rear panels The parts inside carry energy high current Touching them may result in electric shock burns or fault 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 5 Off Check the LCD screen LED On Also check other fault data screens with scroll buttons graphic panel BYPASS 1 INV OC 07 15 07 08 05 30 STEP 2 ANOTHER ITEM Contact Toshiba Customer Support and follow the directions given by the service AC INPUT INVERTER E FLOAT CHARGE EQUAL CHARGE CJ DISCHARGE CONVERTER aL L CI BATTERIES a Cj BYPASS BYPASS INPUT G8000 Series Installation and Operation Manual 69 TOSHIBA 70 G8000 Series Installation and Operation Manual TOSHIBA TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little Your road Houston Texas 77041 Tel 713 466 0277 Fax 713 466 8773 U S
52. lt in UPS faults TOSHIBA EPO Switch Emergency Power Off Switch See Section 14 9 Control Power Supply Switch FIGURE 14 1 EPO AND CONTROL POWER SUPPLY OPERATING SWITCHES 5A G8000 Series Installation and Operation Manual TOSHIBA 14 1 Operation Types The operation types are summarized below Operation TABLE 14 1 OPERATION TYPES Description Complete Shutdown Float Equalize Charge Protection Charge Startup Stop Switch Power Supply Turn off the control power supply Shut down the UPS completely Changing the battery recharge mode between float charge and equalize charge Automatic recharge mode transition from protection charge to float charge Starting up and operating the UPS Stop the inverter and chopper charger Switching power supply source between UPS and Bypass 14 2 Pre operational Check VAN CAUTION Perform the pre operational check before operating the UPS Before operating the UPS 1 Make sure all covers panels are in place and secured 2 Make sure the temperature in the UPS Battery room is within specified limits 3 Before starting the UPS check the power source to make sure AC input power is on 4 Make sure battery breaker s auxiliary A contact is connected to the terminal block TB1 G8000 Series Installation and Operation Manual 55 TOSHIBA 14 3 Startup Procedures The procedure to start the UPS is shown in Steps 1 5 LED Key C LED EN
53. more than 10 from upright position Tilting the UPS more than 10 may cause crushing trapping or other personal injuries 6 G8000 Series Installation and Operation Manual TOSHIBA CAUTION DO NOT transport move store or place the UPS on its side Forces due to heavy components inside may damage the UPS Avoid vibration or shock exceeding 0 5G Failing to observe this precaution may cause damage to the UPS DO NOT allow the UPS to suffer shock or impact when unpacking Tools used to remove packaging materials may cause damage to the UPS DO NOT push or pull on the sides of the packaging or the UPS to move it Always use a crane forklift or pallet jack for transporting and positioning the UPS Pushing pulling on the sides of the unit to move it may result in damage to the UPS See Figure 4 1 Exterior Handling label Fig 4 1 Exterior Handling label DO NOT TRANSPORT OR MOVE UPS PACKAGE FROM IT S SIDES MOVE THE UPS OR UPS PACKAGE BY FORKLIFT FROM BACK SIDE ONLY CABLES BY CRANE Cables should have sufficient rating and equal length Keep UPS leveled when lifting lowering and avoid impacts BY FORKLIFT Verify forklift maximum load capacity Do not push or Do not push Ensure that the forks are long enough lt Pullfromsides to support the UPS and are inserted properly Do not swing or tilt the UPS when lifting and or transporting See manu
54. n Input Output Cabling Entrance BOTTOM Ground Control Wiring Entrance BOTTOM W 36 8 in 935 mm W 55 1 in 1 400 mm Outline Dimension D 31 8 in 808 mm D 31 8 in ee mm H 79 2 in 2 012 mm H 79 2 in 2 012 mm Per Footprint 11 014 kg m 3 133 Ibs ft FRONT 43 7 16 in 1 100 mm Clearance BACK SIDE 0 in 0 mm TOP 15 3 4 in 400 mm 27 620 BTU h Heat Rejection 6 960 kcal h IP20 Foreign objects that are 12 mm 15 32 or larger are prevented from entering the enclosure of the UPS G8000 Series Installation and Operation Manual 43 TOSHIBA 12 2 Mechanical Specification cont Rated Capacity 150 kVA Cabinet Protection Conformity 225 kVA 300 kVA 298 IP20 Exterior Paint Sherwin Williams HHT2 7055 079 Beige Texture Panel Thickness Input Output Cabling Entrance Ground Control Wiring Entrance Clearance Outline Dimension TOP and BOTTOM TOP and BOTTOM W 55 1 in 1 400 mm D 31 8 in 808 mm H 79 2 in 2 012 mm FRONT 1 16 in 1 6 mm BACK SIDE TOP 3 64 in 1 2 mm BOTTOM 1 8 in 3 2 mm W 76 8 in 1 951 mm D 31 8 in 808 mm H 79 4 in 2 017 mm Unit Weight 2 600 Ibs 1 180 kg 3 300 Ibs 1 500 kg 4 850 Ibs 2 205 kg Shipping Weight 2 689 Ibs 1 220 kg 3 389 Ibs 1 538 kg 5 000 Ibs 2 273 kg 3 280 Ibs ft 16 014 kg m Floor Loading Per Footprint 4 134 Ibs ft 20 184 kg m 2 608 Ibs ft 12
55. n Avoid impact or vibration against the UPS during transportation DO NOT expose the UPS directly to water G8000 Series Installation and Operation Manual 19 TOSHIBA 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 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 lifting DO NOT swing or tilt the UPS Minimize the impact when lowering the UPS to the floor Figure 8 2 and 8 3 indicate unacceptable lifting Figure 8 4 and 8 5 show examples of acceptable and unacceptable operations Less than 60 FIGURE 8 1 CABLES AND EYEBOLTS TO LIFT THE UPS A More than 60 Uneven Cables FIGURE 8 2 ANGLE MORE THAN 60 FIGURE 8 3 UNEVEN CABLES E 4 MMM MM FIGURE 8 4 ACCEPTABLE OPERATION FIGURE 8 5 UNACCEPTABLE OPERATION 20 G8000 Series Installation and Operation Manual TOSHIBA 8 2 Transporting By Forklift Refer to Chapter 7 Weight and Dimensions Verify forklift maximum load capacity and ensure that the forks are long enough to properly support the UPS Insert the forks into the space shown in Figure 8 6 Spaces for the forks are provided underneath the UPS DO NOT swing or tilt UPS when lifting and or transporting Minimize the impact when lowering the UPS to the floor I ME Insert the forks here Secure th
56. n and Operation Manual 25 TOSHIBA 10 Installation 26 WARNING Keep the SPECIFIED CLEARANCE around the UPS Inadequate space around the UPS makes it difficult to perform maintenance inspections lead to insufficient ventilation and or will cause malfunctions See Figure 10 1 UPS Clearance DO NOT tilt the UPS more than 10 from upright position Tilting the UPS more than 10 may cause crushing trapping or other personal injuries Install anchor bolts to secure the UPS to the installation floor The UPS may fall during an earthquake if the anchor bolts are not installed and secured DO NOT transport move store or place the UPS on its side Forces due to heavy components inside may damage the UPS DO NOT allow the UPS to suffer shock or impact when unpacking Tools used to remove packaging materials may cause damage to the UPS DO NOT push or pull on the sides of the packaging or the UPS to move it Always use a crane forklift or pallet jack for transporting and positioning the UPS Pushing pulling on the sides of the unit to move it may result in damage to the UPS See Figure 4 1 Exterior Handling label G8000 Series Installation and Operation Manual TOSHIBA 10 1 Unpacking Unpack the UPS indoors on a paved floor The UPS should be as close as possible to its final storage location Overhead traveling cranes should be used to unpack any G8000 Series UPS If an overhead traveling crane is not
57. nd Equalize 61 14 8 Changing to Float Charge from Protection Charge If applicable 62 14 9 Emergency Power 63 1 MOORING E M 63 15 TPS aeternas dgio ne ne ee ere eae eee 63 15 2 Faults and Warnings Data Screen ccccccccecseeeeeeeeeeeeeeeeeeseeeeseeseesaaeeesaeeeesaeeeeesaes 64 15 3 LCD Fault amp Warning 5 65 Tob Fault MESSIDE Supsa IQ 66 15 5 LCD Scroll w faults or 68 15 0 RES ONNG UPS a dean ador 69 li G8000 Series Installation and Operation Manual TOSHIBA 1 Introduction This manual provides information on how to safely operate your G8000 Series Uninterruptible Power System UPS This manual includes a section of general safety instructions that describes the warning labels and symbols that are used throughout the manual Read the manual completely before installing operating or performing maintenance on this equipment Qualified personnel should read this manual carefully before transporting installing and wiring the UPS In addition have a thorough understanding of the information provided in the chapters titled
58. onfiguration when the input neutral is grounded The neutral line at the input source is usually grounded The neutral terminal in the UPS cabinet should be disconnected from the ground bus The neutral connection for the UPS bypass input should be grounded Input Source I I I I I I 36 136 DO O iN I I N T Q i ITA ET N N To the f Jumper Cable mew ww FIGURE 11 11 GROUNDING CONFIGURATION WITH INPUT NEUTRAL GROUNDED A 2 AWG or 38mm jumper cable is provided between the neutral terminal and ground bus in the UPS cabinet The qualified personnel should remove the jumper cable in this configuration The jumper cable location is illustrated below 100 225 kVA 300 kVA ee ler oi l l l l l l pod po fi pod I L J I L J Terminal I l Ground Ground Terminal Bus I i jr i i Remove l MLB Cable I i m mum mum Sq L NE NENNEN 5 mum mmm mum L NES _ FIGURE 11 12 JUMPER CABLE BETWEEN THE NEUTRAL TERMINAL amp GROUND BUS 40 G8000 Series Installation and Operation Manual TOSHIBA 11 5 2 Grounding Configuration without input neutral When the input source is wye connected the neutral line out to the bypass input should
59. play The Fault Display screen displays the fault records until they are reset The Warning Display screen displays the warning records until they are reset The fault records will remain in the memory until the reset button is pressed for at least 5 seconds even after the actual cause of the fault has been resolved Note that the fault records are not deleted when the UPS is turned off If the UPS is RESET while the system is in normal or bypass mode the fault history is cleared and operation continuse If the UPS is RESET while the system is on backup mode the system will power down reinitialize and restart 52 TABLE 13 3 FAULT amp WARNING DISPLAY SCREEN EXAMPLES FAULTS amp WARNINGS 1 FUSE BLOWN 09 09 06 08 05 30 ANOTHER ITEM FAULTS amp WARNINGS 1 UPS OVERLOAD 09 09 06 08 05 30 ANOTHER ITEM FAULTS amp WARNINGS NO ALARM NO WARNING A fault record is shown with time stamp An arrow indicates that another record can be displayed by pressing the up down buttons A warning record is shown with time stamp An arrow indicates that another record can be displayed by pressing the up down buttons This screen is displayed if there are no warnings recorded or after the reset button is pressed G8000 Series Installation and Operation Manual TOSHIBA 13 6 LCD Scroll Scroll through the LCD display screens see Figure 13 4 in sequence using the SCROLL UP and SCROLL DOWN buttons on the graph
60. plode G8000 Series Installation and Operation Manual TOSHIBA 2 2 Signal Words The signal words listed below are used throughout this manual When the words DANGER WARNING CAUTION and ATTENTION are used in this manual they will include important safety information that must be carefully followed The word DANGER in capital letters preceded by N DANGER the safety alert symbol indicates that an imminently hazardous situation exists if not avoided will result in death or serious injury to personnel The word WARNING in capital letters preceded by N WARNING the safety alert symbol indicates that a potentially hazardous situation exists if not avoided could result in death or serious injury to personnel The word CAUTION in capital letters preceded by N CAUTION the safety alert symbol indicates that a potentially hazardous situation exists if not avoided may result in minor or moderate injury The word CAUTION in capital letters without CAUTION the safety alert symbol indicates a potentially hazardous situation exists if not avoided may result in equipment and property damage The word ATTENTION in capital letters without ATTENTION the safety alert symbol indicates a potentially hazardous situation exists if not avoided may result in equipment and property damage 2 3 Qualified Personnel Installation operation and maintenance shall be performed by Qualified Personnel Only A Qualified Person is one tha
61. rmation make product changes or discontinue any product or service identified in this publication Toshiba is a registered trademark of the Toshiba Corporation All other product or trade references appearing in this manual are registered trademarks of their respective owners Toshiba International Corporation shall not be liable for direct indirect special or consequential damages resulting from the use of the information contained within this manual This manual is copyrighted No part of this manual may be photocopied or reproduced in any form without the prior written consent of Toshiba International Corporation Copyright 2007 Toshiba International Corporation All rights reserved Printed in the U S A Toshiba s Customer Support Center Contact the Toshiba Customer Support Center for assistance with application information or for any problems that you may experience with your Uninterruptible Power System UPS Toshiba Customer Support Center 8 a m to 5 p m CST Monday through Friday USA Toll Free 877 867 8773 Tel 713 466 0277 Fax 713 896 5212 You may also contact Toshiba by writing to Toshiba International Corporation 13131 West Little York Road Houston Texas 77041 9990 Attn UPS Product Manager For further information on Toshiba s products and services please visit our website at www toshiba com ind G8000 Series Installation and Operation Manual TOSHIBA 10 11 Table of Contents
62. t TII FIGURE 11 1 EXTERNAL WIRING DIAGRAM An external maintenance bypass may be installed in parallel with the UPS to allow servicing of the G8000 while maintaining power to the UPS load Contact the Toshiba Customer Service for further information G8000 Series Installation and Operation Manual 29 TOSHIBA 11 1 Terminal Blocks and Power Cables Note Always consult your site specific local state and NEC electrical codes for wiring cabling and circuit protection device requirements The terminal blocks for the 100 150 225 kVA UPS are shown in Figure 11 2 The terminal blocks are located inside at the bottom of the UPS If the UPS has terminal buses see Table 11 4 for lug recommendations Recommended external cable size and tightening torque for a single battery string are listed in Table 11 1 11 3 For two or more battery strings consult with Toshiba Technical Support Ensure that your installation adheres to local and NEC electrical codes Use only copper wires for external cables 1 2 3 4 5 6 7 8 9 10 11 12 13 _ IL IL dL IL IL IL IL 1L 1L IL O OIIO OIIO OIIO O O O O O OIIO OIIO O O O10 OIIO O O O O OHO OIIO O O O O OIIO O Ll U V W U V W N U V W N _ Ld Ld Lo AC INPUT BYPASS INPUT AC OUTPUT BATTERY FIG
63. t has the skills and knowledge relating to the construction installation operation and maintenance of the electrical equipment and has received safety training on the hazards involved Refer to the latest edition of NFPA 70E for additional safety requirements Qualified Personnel shall e Have read the entire operation manual e Be familiar with the construction and function of the ASD the equipment being driven and the hazards involved e Able to recognize and properly address hazards associated with the application of motor driven equipment e Be trained and authorized to safely energize de energize ground lockout tagout circuits and equipment and clear faults in accordance with established safety practices e Be trained in the proper care and use of protective equipment such as safety shoes rubber gloves hard hats safety glasses face shields flash clothing etc in accordance with established safety practices G8000 Series Installation and Operation Manual TOSHIBA e Be trained in rendering first aid For further information on workplace safety visit www osha gov 2 4 Factory Authorized Personnel Factory authorized personnel have been factory trained and certified to install service and repair the UPS Contact the Toshiba Customer Support Center for assistance in locating the factory authorized personnel nearest you 3 Important Safety Instructions The following contains important instructions that should be
64. the top or bottom earth ground bus but not both to the grounding wire The ground wire must have a crimp terminal with a 1 2 12mm diameter bolt hole The ground bus has 33 64 13mm bolt hole The connect the crimp terminal and ground bus together using a 7 16 10mm diameter bolt 36 G8000 Series Installation and Operation Manual TOSHIBA G8000 100 kVA Ground bus 10 mm 7 16 Bolt 12 mm or 1 2 Terminal 2 AWG 38 mm AU ground wire e Feed through opening g To facility earth ground Alternate ground wire routing G8000 150 225 kVA Facility earth ground through top knockout plate e Note Use either the top or the Ground bus 10 mm or bottom access for the ground 7 16 Bolt wire to connect to ground 2D buss but use only one ground 49 mm or ness Terminal 2AWG 38mm x ground wire e Feed through opening To facility earth ground G8000 300 kVA Facility earth ground A Ground wire routing through top knockout plate e Through knockout plate ja d on top recommended 10 7116 Y Ground bus Note Use either the top or the bottom grounding point but not both Doing so may degrade the performance of the unit Alternate ground wire location e FIGURE 11 9 EARTH GROUND WIRE G8000 Series Installation and Operation Manual 37 TOSHIBA 11 4 Control Wires The control wires terminal layouts at TB1 terminal bus
65. to vibrations 50 Hz 100 Hz must not exceed 0 1 mm Mechanical Shock The acceleration due to vibrations 20 Hz 50 Hz must not exceed 0 5 G No flammable and or explosive gas Hydrogen sulfide H S Less than or equal to 0 0001 PPM Sulfurous acid gas SO Less than or equal to 0 05 PPM Chlorine gas Cl Less than or equal to 0 002 PPM Flammable Gas Ammonia gas Less than or equal to 0 1 PPM Nitrous acid gas NO Less than or equal to 0 02 PPM Nitrous oxides NOx Less than or equal to 0 02 PPM Hydrochloric acid mist Less than or equal to 0 1 mg m Installation Precautions 1 Install the unit in a stable level and upright position that is free of excessive vibration 2 Install the unit where the ambient temperature is within the specified range 3 DO NOT install the UPS in areas that are subject to high humidity 4 DO NOT install the UPS in areas that allow exposure to direct sunlight 5 DO NOT install the UPS in areas that allow exposure to high levels of airborne dust metal particles or flammable gases 6 DO NOT install the UPS in areas near sources of electrical noise Ensuring a proper earth ground will reduce the effects of electrical noise and will reduce the potential for electrical shock 7 The UPS generates and can radiate radio frequency energy during operation Although RFI noise filters are installed inside of the unit there is no guarantee that the UPS will not influence some sensitive
66. tons TABLE 13 1 LCD DISPLAY SCREENS Description Normal Display Displays operational status operational guidance and measured data Fault Display Displays detailed data when a fault occurs Warning Display Displays detailed data when a warning occurs NORMAL DISPLAY v1 FAULT DISPLAY v1 WARNIG DISPLAY lt SCROLL UP O SCROLL DOWN FIGURE 13 3 CHANGING SCREENS WITH SCROLL BUTTONS G8000 Series Installation and Operation Manual 49 TOSHIBA 13 4 Normal Display The Normal Display screen indicates the UPS operational status and provides various screens an operation guidance screens mode screens and measured data screens Table 13 2 shows these screens page by page and illustrates the UPS Normal Display operational status screens TABLE 13 2 NORMAL DISPLAY SCREEN EXAMPLES OPERATIONAL STATUS SCREENS BYPASS Shows the UPS status at the top and guidance message or measured data underneath PRESS RUN SWITCH Shows a guidance message at start up UPS SUPPLY Shows the output voltage and current after start up AC VO 480 V AC 10 50 OPERATION MODE Shows the UPS Operation mode NORMAL OPERATION MODE SYNC MEASUREMENT SCREENS 07 3010 lt Output Voltage Shows the output line to line output voltage VOLT 480 V FREQ 60 0 Hz O P CURRENT R M S Output Current Shows the RMS output current U 50 for each phase 50 W 501
67. ve or make modifications to the UPS G8000 Series Installation and Operation Manual TOSHIBA DO NOT block air vents Blocking the vents will increase the internal temperatures and may result in UPS failure or fire DO NOT install the UPS where water may fall on it Water may cause electrical shock personal injury or UPS failure DO NOT use floor wax that contains silicon in the UPS storage area and or nearby rooms Floor wax that contains silicon may cause static electricity The UPS should be installed per local and or national electric codes by qualified personnel Faults or improper operation may occur if the UPS is not installed properly When an external maintenance bypass is installed for the UPS before switching to external bypass ensure that the UPS unit is switched to AC Bypass mode and the UPS control panel display verifies the unit is Bypass mode Switching to the external bypass while the unit is in UPS mode may damage the UPS 10 G8000 Series Installation and Operation Manual TOSHIBA TABLE 5 1 UPS INSTALLATION ENVIRONMENT STANDARDS Item Environment standard Installation Location Indoors The relative humidity must be between 30 90 noncondensing due to y temperature changes Installation environment must not have vibration frequencies 10 Hz 20 Hz Vibration and The acceleration due to vibrations less than 10 Hz must not exceed 0 5 G The total amplitude due

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