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UNINTERRUPTIBLE POWER SYSTEM (UPS)
INSTALLATION AND
OPERATION MANUAL
480/480 V 500kVA
Document:
Ref:
94861-000
4GBH0099 Rev. B
December 2015
G2020 Series UPS Installation and Operation Manual – 94861-000
INSTALLATION AND OPERATION MANUAL
480/480 V
500kVA
Document No. 94861-000
Ref: 4GBH0099 Rev. B
December 2015
G2020 Series UPS Installation and Operation Manual – 94861-000
IMPORTANT NOTICE
The Instructions contained in this manual are not intended to cover all of the details or variations
in equipment or to provide for every possible contingency to be met in connection with
installation, operation, or maintenance. Should further information be required or should
particular problems arise which are not covered sufficiently the matter should be referred to the
local TOSHIBA sales office.
The contents of this instruction manual shall not become a part of or modify any prior or existing
equipment, commitment, or relationship. The sales contract contains the entire obligation of
TOSHIBA INTERNATIONAL CORPORATION. The warranty contained in the contract between
the parties is the sole warranty of TOSHIBA, 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 will void all warranties and may void UL/CUL listing.
Unauthorized modifications may also result in equipment damage, personal
injury, or loss of life.
UNINTERRUPTIBLE POWER SYSTEM
If additional information or technical assistance is required call TOSHIBA Customer Support Center toll
free at 1- 877-867-8773, or write to: Toshiba International Corporation, 13131 West Little York Road,
Houston, TX 77041-9990: Attn: UPS Product Manager.
Please complete the following information for your records. Unless otherwise specified on the warranty
card, the warranty period for the UPS or UPS part is 36 months from the shipment date (see bill of lading).
Unless otherwise specified on the warranty card, the warranty period for a UPS battery is 36 months full
replacement, and an additional 7 years pro-rated from the shipment date (see bill of lading).
Keep this manual with the UPS equipment.
Job Number:
Model Number:
Serial Number:
Application:
Shipping Date:
Date of Installation:
Inspected By:
G2020 Series UPS Installation and Operation Manual – 94861-000
Purpose and Scope of Manual
This manual provides information on how to safely install, operate, and maintain your TOSHIBA power
electronics product. This manual includes a section on 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 equivalent.
TOSHIBA reserves the right, without prior notice, to update information, make product changes, or to
discontinue any product or service identified in this publication.
TOSHIBA is a registered trademark of TOSHIBA INTERNATIONAL CORPORATION. All other product or
trade references appearing in this manual are registered trademarks of their respective owners.
TOSHIBA shall not be liable for technical or editorial omissions or mistakes in this manual. Nor
shall it be liable for incidental or consequential damages resulting from the use of information
contained in 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 2015 TOSHIBA INTERNATIONAL CORPORATION
All rights reserved.
Printed in Japan
Contacting TOSHIBA Customer Support Center
The TOSHIBA Customer Support Center can be contacted to obtain help in resolving any Uninterruptible
Power System problem that you may experience or to provide application information.
The center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Support Center’s toll free
number in USA is (877) 867-8773.
You may contact TOSHIBA by writing to:
TOSHIBA INTERNATIONAL CORPORATION.
SOCIAL INFRASTRUCTURE SYSTEMS GROUP
POWER ELECTRONICS DIVISION
13131 West Little York Rd.
Houston, TX 77041-9990
Attn: UPS Product Manager
www.toshiba.com/tic/industrial-systems/uninterruptible-power-systems
G2020 Series UPS Installation and Operation Manual – 94861-000
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G2020 Series UPS Installation and Operation Manual – 94861-000
Table of Contents
List of Tables ..................................................................................................................................................ii
List of Figures ................................................................................................................................................ iii
1
How to use this Manual ......................................................................................................................... 1
2
INTRODUCTION ................................................................................................................................... 2
3
GENERAL .............................................................................................................................................. 6
3.1
DEFINITIONS................................................................................................................................ 7
3.2
OPERATION OVERVIEW ............................................................................................................. 7
3.2.1
Normal Operation: Load power supplied by each system UPS inverter ................................... 8
3.2.2
Bypass Operation: Load power supplied through UPS internal static bypass line. .................. 9
3.2.3
Battery operation: Load Power supplied by UPS battery. ....................................................... 10
3.2.4
UPS Parts Location ................................................................................................................. 12
3.3
4
OPERATOR CONTROLS AND INDICATORS .................................................................................... 19
4.1
LED DISPLAY ............................................................................................................................. 20
4.2
EPO BUTTON (Emergency Power Off button) ........................................................................... 20
4.3
LIQUID CRYSTAL DISPLAY ...................................................................................................... 21
4.3.1
MENU ...................................................................................................................................... 21
4.3.2
Input Power Failure ................................................................................................................. 26
4.3.3
Fault Indication ........................................................................................................................ 26
4.4
5
SPECIFICATIONS ...................................................................................................................... 16
EXTERNAL AUX CONTACT INPUT AND OUTPUT TERMINAL BLOCKS ............................... 27
4.4.1
Aux Contacts – Input ............................................................................................................... 28
4.4.2
Aux Contacts – Output ............................................................................................................ 31
®
4.5
RemotEye INTRODUCTION ..................................................................................................... 33
4.6
CONNECTOR DEFINITION........................................................................................................ 36
INSTALLATION AND OPERATION .................................................................................................... 38
5.1
TRANSPORTATION AND INSTALLATION................................................................................ 38
5.2
INSTALLATION PROCEDURE................................................................................................... 38
5.3
PROCEDURE FOR CABLE CONNECTIONS ............................................................................ 39
5.4
OPERATING PROCEDURES..................................................................................................... 53
6
RESPONSE TO UPS FAILURE .......................................................................................................... 59
7
PARTS REPLACEMENT ..................................................................................................................... 60
8
FAULT CODES .................................................................................................................................... 61
9
DAILY INSPECTION............................................................................................................................ 68
APPENDIX A
Installation Planning Guides (IPG) ................................................................................... 69
G2020 Series UPS Installation and Operation Manual – 94861-000
i
List of Tables
Table 2–1
UPS Installation Environment ........................................................................................................... 4
Table 2–2
Rating of Bypass Input Circuit Breaker............................................................................................. 5
Table 3–1
Power Specifications ...................................................................................................................... 16
Table 3–2
UPS Module Information................................................................................................................. 16
Table 3–3
UPS Module Information (Packing Dimension) .............................................................................. 16
Table 3–4
Specifications .................................................................................................................................. 17
Table 3–5
Rating of Contactors, Breakers, and Fuses ................................................................................... 18
Table 4–1
External Input Functions ................................................................................................................. 30
Table 4–2
External Output Functions .............................................................................................................. 32
Table 4–3
Parts List for UPS Monitoring ......................................................................................................... 35
Table 5–1
Transport by Overhead Crane ........................................................................................................ 38
Table 5–2
List of UPS Weights ........................................................................................................................ 38
Table 5–3
Maximum Permitted Fault Current .................................................................................................. 39
Table 5–4
Recommended Cable Sizes ........................................................................................................... 42
Table 5–5
Recommended Hardware ............................................................................................................... 42
Table 5–6
Crimp Type Compression Lug ........................................................................................................ 43
Table 7–1
Standard Replacement Parts List ................................................................................................... 60
Table 7–2
Replacement Air Filters .................................................................................................................. 61
Table 8–1
Fault Code ...................................................................................................................................... 62
Table 9–1
How to Perform Daily Inspection .................................................................................................... 68
ii
G2020 Series UPS Installation and Operation Manual – 94861-000
List of Figures
Figure 3-1
Single Line Diagram – Normal Operation: Load fed by UPS inverter .............................................. 8
Figure 3-2
Single Line Diagram – Bypass Operation: Load fed through static bypass line .............................. 9
Figure 3-3
Single Line Diagram – Battery Operation:
Figure 3-4
UPS Parts Location (500kVA) ........................................................................................................ 12
Figure 3-5
Display PCB DPAU-81 ................................................................................................................... 13
Figure 3-6
MAIN PCB UPHR-W ...................................................................................................................... 13
Figure 3-7
External I/F PCB IOAU-09.............................................................................................................. 13
Figure 4-1
Operation/Display Panel (Front panel) ........................................................................................... 19
Figure 4-2
Main Screen ................................................................................................................................... 21
Figure 4-3
Startup/Shutdown Screen .............................................................................................................. 22
Figure 4-4
Startup Guidance ........................................................................................................................... 22
Figure 4-5
Shutdown Guidance ....................................................................................................................... 22
Figure 4-6
Input Values ................................................................................................................................... 23
Figure 4-7
Output Values ................................................................................................................................. 23
Figure 4-8
Values in Battery operation ............................................................................................................ 23
Figure 4-9
Remote/Local Operation Select ..................................................................................................... 24
Figure 4-10
Date & Time Adjustment .............................................................................................................. 24
Figure 4-11
Log Menu ..................................................................................................................................... 25
Figure 4-12
Event Log ..................................................................................................................................... 25
Figure 4-13
Battery Log ................................................................................................................................... 25
Figure 4-14
Main Screen (Battery Operation) ................................................................................................. 26
Figure 4-15
Measurement Screen (Battery Operation) ................................................................................... 26
Figure 4-16
Main Screen (Fault Indication) ..................................................................................................... 26
Figure 4-17
Message Screen .......................................................................................................................... 27
Figure 4-18
Location of External Signal Terminal Block on IOAU-09 PCB ..................................................... 27
Figure 4-19
Control Wiring for Aux Input Contacts .......................................................................................... 28
Figure 4-20
External Signal Input Terminal Block (with default settings) ........................................................ 29
Figure 4-21
Control Wiring for Aux Output Contacts ....................................................................................... 31
Figure 4-22
External Signal Output Terminal Block (with default settings) ..................................................... 31
Figure 4-23
RemotEye® Installation (Overview 500kVA) ............................................................................... 33
Figure 4-24
Connection between Display Control PCB (SW1) and RemotEye
Figure 4-25
PSAU-60 (PS1) ............................................................................................................................ 35
Figure 4-26
DPAU-81 (SW1) ........................................................................................................................... 35
Figure 4-27
Cable1 (3BBA0083P001) ............................................................................................................. 35
Figure 4-28
Connector (CN1) of PSAU-60 (PS1) ............................................................................................ 36
Figure 4-29
Terminal Block (TN) and VH connector (CN2) of PSAU-60 (PS1) .............................................. 36
Load fed by Battery................................................... 10
®
G2020 Series UPS Installation and Operation Manual – 94861-000
Module............................... 34
iii
Figure 4-30
Connector (CN44) of PSAU-60 (PS1) .......................................................................................... 36
Figure 4-31
Connector (CN27) of DPAU-81 (SW1)......................................................................................... 37
Figure 4-32
Connector (CN26) of DPAU-81 (SW1)......................................................................................... 37
Figure 5-1
UPS Terminal Designation ............................................................................................................. 43
Figure 5-2
Diagram of input/output bus bars and terminal blocks ................................................................... 44
Figure 5-3
Diagram of Power Wire & Control Wire Inter-Connect between UPS and Battery ........................ 45
Figure 5-4
Diagram of Power Wire Connections (Parallel System Configuration) .......................................... 46
Figure 5-5
Diagram of Power & Control Wire Connections for 2 units in MMS Configuration ........................ 47
Figure 5-6
Detail of IFAU-09 Control Wire Connections for 2 units in MMS Configuration ............................. 48
Figure 5-7
Diagram of Power & Control Wire Connections for 3-4 units in MMS Configuration ..................... 49
Figure 5-8
Detail of IFAU-09 Control Wire Connections for 3 or 4 units in MMS Configuration ..................... 50
Figure 5-9
Diagram of Power Wire & Control Wire Connections for 5 to 8 units in MMS Configuration ......... 51
Figure 5-10
Detail of IFAU-09 Control Wire Connections for 5 to 8 units in MMS Configuration .................... 52
Figure 5-11
Circuit Protectors Location ........................................................................................................... 53
Figure 5-12
Automatic Startup of Inverter and Converter ............................................................................... 54
Figure 5-13
Close Battery Breaker .................................................................................................................. 54
Figure 5-14
Press and Hold START Button .................................................................................................... 54
Figure 5-15
Transfer from Online to Bypass ................................................................................................... 55
Figure 5-16
Transfer from Bypass to Online ................................................................................................... 55
Figure 5-17
Initiate Shutdown .......................................................................................................................... 56
Figure 5-18
UPS Transfers to Bypass ............................................................................................................. 56
Figure 5-19
Open Battery Breaker................................................................................................................... 57
Figure 5-20
LCD Screen (MMS Operation) ..................................................................................................... 58
iv
G2020 Series UPS Installation and Operation Manual – 94861-000
1
How to use this Manual
This manual is designed for ease of use, giving the user easy and quick reference to information.
This manual uses notice icons to draw attention to the user important information regarding the safe
operation and installation of the UPS. The notice icons used in this manual are explained below, and
should be taken into account and adhered to whenever they appear in the text of this manual.
Warning: A warning symbol shows potentially hazardous situation or condition which
could result in personal injury or death, if not avoided.
WARNING
Caution: A caution symbol shows potentially hazardous situation or condition which
could result in personal injury or equipment damage, if not avoided.
CAUTION
!
Note: A Note symbol shows the information the user or the service personnel should
observe during the UPS operation or service work.
NOTE
Prohibit: A prohibit symbol shows the act the user or the service personnel should
NEVER perform during the UPS installation, operation or service work.
PROHIBIT
Safety Recommendations: If any problems are encountered while following this manual, Toshiba field
service group assistance and correspondence is recommended.
G2020 Series UPS Installation and Operation Manual – 94861-000
1
2
INTRODUCTION
The TOSHIBA Uninterruptible Power Supply System (UPS) is designed to provide many years of
reliable protection from power failure, brown-outs, line noise, and voltage transients. To ensure
optimum performance of the equipment, follow the manufacturer's instructions. This manual contains
descriptions required to operate the UPS. Please read this manual carefully and retain it for future
reference.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
CAUTION
This manual contains important instructions for the G2020 SERIES Uninterruptible Power Supply
System that should be followed during installation and maintenance of the UPS and batteries.
WARNING 1
WARNING
Lethal voltages exist within the equipment during operation. Observe all warning
and cautions in this manual. Failure to comply may result in serious injury or death.
Obtain qualified service for this equipment as instructed.
2
G2020 Series UPS Installation and Operation Manual – 94861-000
WARNING 2
WARNING
In no event will TOSHIBA be responsible or liable for either indirect or consequential damage
or injury that may come from the misuse of this equipment.
Don’t modify the UPS entirely or partially.
Any modifications without authorization by TOSHIBA could result in
personal injuries, death or destruction of the UPS.
PROHIBIT
1.1
SAFETY PRECAUTIONS
APPLICATION
This UPS shall NOT be applied to support equipment (*) that could affect human
lives.
* • Medical operation room equipment
• Life support equipment (artificial dialysis, incubators, etc.)
• Toxic gas or smoke eliminators
• Equipment that must be provided under fire laws, construction
standards or other ordinances
PROHIBIT
• Equipment equivalent to the above
Special considerations are required when applying this UPS to the equipment
(**) that affect human safety and/or maintain public services.
**
!
NOTE
• Equipment to supervise or control airways, railways, roads,
sea-lanes or other transportation.
• Equipment in nuclear power plants.
• Equipment to control communications.
• Equipment equivalent/similar to the above mentioned.
G2020 Series UPS Installation and Operation Manual – 94861-000
3
WARNING 3
WARNING
The UPS is to be installed in a controlled environment.
Improper storage and installation environment may deteriorate insulation, shorten component
life and cause malfunctions.
Keep the installation environment per standard described as follows:
Table 2–1 UPS Installation Environment
No
Item
Environment standard
1
Installation
Location
Indoors
2
Ambient
temperature
Minimum temperature: 32°F (0°C)
Maximum temperature: 104°F (40°C)
The average temperature over any 24-hour period must be in the range
41°F (5°C) to 95°F (35°C).
3
4
Relative
humidity
The relative humidity must be held between 5 and 95%.
There must be no condensation due to temperature changes.
Altitude
This equipment must not be applied at altitude that exceeds
6500 ft. (1981 m) above sea level.
5
Dust
Dust in the room where the UPS is installed must not exceed normal
atmospheric dust levels. In particular, that dust should not include iron
particles, oils or fats, or organic materials such as silicone.
6
Inflammable
gas
There should be no inflammable/explosive gas.
Hydrogen sulfide (H2S)
No more than 0.003 PPM
following
Sulfurous acid gas (SO2)
No more than 0.01 PPM
IEC654-4
Chlorine gas (Cl2)
No more than 0.002 PPM
Ammonia gas (NH3)
No more than 1 PPM
Nitrous oxides (NOx)
No more than 0.05 PPM
Ozone (O3)
No more than 0.002 PPM
Part 4
4
G2020 Series UPS Installation and Operation Manual – 94861-000
WARNING 4
WARNING
This UPS does not include a Bypass input circuit breaker (MCCB) to protect
bypass circuit. The Bypass input circuit breaker (MCCB) is to be field supplied and
installed. Recommended Breaker (MCCB)'s Specifications are as follows:
Table 2–2 Rating of Bypass Input Circuit Breaker
Capacity
(kVA)
Bypass Voltage
(Vac)
Bypass Current
(Aac)
Breaker
(A)
500
480
601
800
AC input and AC output overcurrent protection and disconnect devices shall be field supplied
and installed. The DC circuit breaker (MCCB) shall be field supplied and installed. The
overcurrent protection device should be installed in the Battery cabinet and rated as indicated
in Table 3–5.
!
The DC input overcurrent protection (Battery disconnect breaker)
hereinafter will be referred as “CB2”.
NOTE
G2020 Series UPS Installation and Operation Manual – 94861-000
5
3
GENERAL
The TOSHIBA G2020 SERIES UPS is designed to provide continuous and clean electrical power to
a critical load. Additionally the UPS monitors power conditions affecting the load.
In the event of an input power failure, the UPS will supply power to the critical load for the specified
battery time.
If the input power is not restored promptly, backup power from the UPS battery permits the orderly
shutdown of equipment supported by the UPS. The UPS is simple to start-up, operate and maintain.
The G2020 SERIES UPS is available in 500 kVA. Specifications are shown in Section 3.3.
This manual provides an overview of the G2020 SERIES components and their functions. The
appearance and purpose of operator controls and indicators is described with procedures for operation,
start-up, shutdown and basic maintenance included.
6
G2020 Series UPS Installation and Operation Manual – 94861-000
3.1
DEFINITIONS
UNINTERRUPTIBLE POWER SYSTEM (UPS) – All components within the UPS Module Cabinet and
associated batteries that function as a system to provide continuous, conditioned AC power to a load.
This is sometimes referred to as the "System".
UPS MODULE CABINET – The metal enclosure which contains the Converter / Charger, Inverter,
Static Transfer Switch, Internal Bypass line, operator controls, and internal control systems required
to provide specified AC power to a load.
UPS MODULE – The Converter / Charger and Inverter assemblies which, under the direction of the
internal control system and operator controls, provide specified AC power to a load.
INVERTER – The UPS components which contain the equipment and controls necessary to convert
DC power from the Converter / Charger, or the battery, to AC power required by the critical load.
CONVERTER / CHARGER – The UPS components which contain the equipment and controls
necessary to convert input AC power to regulated DC power required for battery charging and for
supplying power to the Inverter.
STATIC TRANSFER SWITCH – The device which connects the critical load to the bypass line when
the Inverter cannot supply continuous power.
BYPASS LINE – The line which conducts electricity directly from the input power source to the critical load
during Maintenance or whenever the UPS is not completely operational.
AC INPUT POWER – Power provided by the electrical utility company, or auxiliary generator, which is
connected to the UPS for supplying the critical load.
BATTERY – The rechargeable battery strings which supply DC power to the inverter to maintain
continuous AC power to the load during AC input power failure conditions.
3.2
OPERATION OVERVIEW
The UPS provides two power paths between the utility source and the critical load.
Figure 3-1 shows the path for normal operation, with the load powered by the inverter.
Figure 3-2 shows the path for bypass operation, with the load supplied through the static bypass line.
Figure 3-3 shows the path for battery operation, with the load powered by the inverter.
G2020 Series UPS Installation and Operation Manual – 94861-000
7
3.2.1
Normal Operation: Load power supplied by each system UPS inverter
CB
UPS Module
52S
Bypass
input
CB3
User
supplied
CB
Static Transfer
Switch
CONVERTER
/ CHARGER
CB1
INVERTER
52C
AC input
Output
User
supplied
Power Flow
Not in Use
Battery Cabinet
CB2
External
BATTERY
Figure 3-1 Single Line Diagram – Normal Operation: Load fed by UPS inverter
During normal operation, the path through the UPS inverter is used to power the load.
In Figure 3-1 input AC power is converted to DC by the Converter. DC power is utilized to charge the UPS
battery and to provide power to the Inverter. The Inverter converts the DC power to clean AC power to
supply the critical load.
The conversion-inversion process eliminates any voltage transients or fluctuations existing in the input
power before it reaches the critical load.
The power drawn by the critical load is equally shared between all UPS systems when multiple UPSs are
in Parallel Operation. (Refer to Figure 5-4 that shows a sample of Parallel Operation System
Configuration.)
8
G2020 Series UPS Installation and Operation Manual – 94861-000
In the event of a UPS module failure during Parallel Operation, the critical load power will be
continually supplied and shared by all other UPS.
!
The Bypass Input breaker and cables are to be supplied and installed by the user or the
contractor. (See WARNING 4 on page 5)
NOTE
3.2.2
Bypass Operation: Load power supplied through UPS internal static bypass line.
CB
UPS Module
52S
Bypass
input
CB3
User
supplied
CB
Static Transfer
Switch
CB1
CONVERTER
/ CHARGER
INVERTER
52C
AC input
Output
User
supplied
Power Flow
Not in Use
Battery Cabinet
CB2
External
BATTERY
Figure 3-2 Single Line Diagram – Bypass Operation: Load fed through static bypass line
Figure 3-2 shows the Internal Bypass line is a Hard-wired line through 52S which supplies the critical load
with unconditioned bypass input power. Upon switching to the Internal Bypass line, the Static Transfer
Switch line through CB3 (herein after STS contactor CB3) supplies the power immediately, and then the
Internal Bypass line through 52S supplies the power. In the event of a switching to the Bypass line, the
power to the critical load will be uninterrupted. The purpose of this Internal Bypass line is to route power to
the critical load while the UPS module is de-energized (converter and inverter), and during Start-up before
the system is fully operational.
Each UPS internal static bypass line will equally share the power supplied to the critical load whenever the
system is in the Parallel Operation.
G2020 Series UPS Installation and Operation Manual – 94861-000
9
In the event of a load overcurrent, the UPS transfers to bypass without interruption to the critical load. In
the case of the Parallel Operation, all UPS will transfer to bypass without interruption to the critical load.
The internal control system determines the operation of the two paths, with the load powered from the
inverter being the normal operation.
3.2.3
Battery operation: Load Power supplied by UPS battery.
CB
UPS Module
52S
Bypass
input
User
supplied
CB
CB3
CONVERTER
/ CHARGER
CB1
Static Transfer
Switch
INVERTER
52C
AC input
Output
User
supplied
Power Flow
Not in Use
Battery Cabinet
CB2
External
BATTERY
Figure 3-3 Single Line Diagram – Battery Operation: Load fed by Battery
Figure 3-3 shows that in the event of AC input source failure or interruption, the UPS Converter(s)* will
de-energize and the UPS battery(s)* will immediately discharge and supply DC power to the Inverter to
maintain continuous AC power to the load. This operation will continue until:
a) The battery capacity expires and the inverter turns off, or
b)
Input power is restored.
(When input power is restored the converter will simultaneously power
the inverter and critical load, and recharge the batteries.)
A fully charged battery will provide power for the specified time at the rated load, or longer, at a reduced
load.
* (s) : In the case of the Parallel Operation
10
G2020 Series UPS Installation and Operation Manual – 94861-000
When power is restored after a low battery shutdown, the UPS converter(s) automatically restarts
operation, the charger(s) recharges the batteries and the Inverter(s) is automatically restarted without
operator intervention. Load is automatically assumed by the inverter without operator intervention.
*
(s) : In the case of the Parallel Operation
The power drawn by the load is equally shared between all UPS regardless of the presence or absence of
the UPS that is (are) in battery operation or not whenever the system is in the Parallel Operation.
G2020 Series UPS Installation and Operation Manual – 94861-000
11
3.2.4
UPS Parts Location
See Figure 3-4 for parts location in the UPS.
1. LCD Touch Panel
Monitor Display
Left
Door
Right
Door
1. LCD Touch Panel
Monitor Display
3. External
Communication
Connector
Cable
Entry
Section
2. Display PCB
DPAU-81
4. Main PCB
UPHR-W
1) UPS cabinet – Front View
CB3
2) Back side of right door
52S
CPMC
CPMS
EMB
52C
5. External I/F PCB
(IOAU-09)
AC Capacitor
CB1
Converter
Unit
Inverter
Unit
Chopper
Unit
2) Backside of
Bypass Module door
Figure 3-4 UPS Parts Location (500kVA)
12
G2020 Series UPS Installation and Operation Manual – 94861-000
13. SW6
MAINTENANCE
switch
12. SW5
TEST switch
3. External
Communication
Connector
11. SW1
RESET switch
Figure 3-5 Display PCB DPAU-81
16.
52L S/W switch
15.
BOOT switch
14.
RESET switch
Figure 3-6 MAIN PCB UPHR-W
17. External contact
signal terminal block
Figure 3-7 External I/F PCB IOAU-09
G2020 Series UPS Installation and Operation Manual – 94861-000
13
Description of Figure 3-4 to Figure 3-7:
1.
LCD Touch Panel Monitor Display
The liquid crystal display (LCD) touch panel monitor display indicates power flow, measured values
and fault and error messages via user selectable display screens.
Refer to Figure 4-1 for details.
2.
Display PCB DPAU-81
Switches on DPAU-81 board: FOR SERVICE PERSONNEL ONLY
- (11) SW1 (RESET switch)
- (12) SW5 (TEST switch)
- (13) SW6 (MAINTENANCE button)
3.
External Communication Connector
RS232C connector on DPAU-81 board: FOR SERVICE PERSONNEL ONLY
Refer to Figure 4-32 for details.
4.
Main PCB UPHR-W
Switches on UPHR-W board: FOR SERVICE PERSONNEL ONLY
- (14) RESET switch
- (15) BOOT switch
- (16) 52L S/W switch
5.
External I/F PCB IOAU-09
Signal I/F on IOAU-09 board
- (17) External contact signal terminal block
Refer to Figure 4-20 and Figure 4-22 for details.
6.
Control Relay PCB PSAU-80 (not shown)
7.
Parallel control PCB TLCR-E (not shown)
For use in Parallel Operation system application: Option
8.
Parallel I/F PCB IFAU-09 (not shown)
For use in Parallel Operation system application: Option
Refer to Figure 5-5 thru Figure 5-10 for details.
9.
AC input, AC output, DC input terminal (not shown)
Refer to Figure 5-2 for details
10. Grounding Bar (E) (not shown)
Refer to Figure 5-2 for details
14
G2020 Series UPS Installation and Operation Manual – 94861-000
Switches on Display PCB DPAU-81
11. "RESET" switch (FOR SERVICE PERSONNEL ONLY)
This switch resets errors resulting from alarm conditions.
12. "TEST" switch (FOR SERVICE PERSONNEL ONLY)
This switch changes system operation to the test-mode.
13. "MAINTENANCE" button (FOR SERVICE PERSONNEL ONLY)
This switch sets the UPS menu parameters.
Switches on MAIN PCB UPHR-W
14. "RESET" switch (FOR SERVICE PERSONNEL ONLY)
This switch resets the processor on the main control circuit board
15. "BOOT" switch (FOR SERVICE PERSONNEL ONLY)
This switch boots the processor on the main control circuit board following alarm conditions.
16. "52L S/W" switch (FOR SERVICE PERSONNEL ONLY)
This switch prohibits turning on the AC output contactor “52C” during test/maintenance in Parallel
Operation system application.
TB on External I/F PCB IOAU-09
17. External contact signal terminal block
Terminal block to connect contact signal input/output lines to and from external dry contacts. Refer to
Figure 4-20 and Figure 4-22 for details.
G2020 Series UPS Installation and Operation Manual – 94861-000
15
3.3
SPECIFICATIONS
The UPS nameplate displays the rated kVA as well as nominal voltages and currents. The nameplate is
located on the backside of the UPS front left door..
Table 3–1 Power Specifications
Rated output
Input voltage
Bypass input voltage
Output voltage
Power
3 phase / 3 wire
3 phase / 3 wire
3 phase / 3 wire
500 kVA / 500 kW
480 V
480 V
480 V
Table 3–2 UPS Module Information
UPS
[kVA]
Width
[in. (mm)]
Depth
[in. (mm)]
Height
[in. (mm)]
Net Weight
[lbs. (kg)]
Typ. Heating
at 100% load
[kBTU/h]
Cable
Knockout
500
59.1
(1500)
33.5
(850)
80.6
(2,047)
2,756
(1250)
31.2
BOTTOM
TOP
LEFT SIDE
Table 3–3 UPS Module Information (Packing Dimension)
UPS
[kVA]
Width
[in. (mm)]
Depth
[in. (mm)]
500
78.4
(1990)
40.2
(1020)
16
Height
Gross Weight
[in. (mm)]
[lbs. (kg)]
87.4
(2220)
3086
(1400)
G2020 Series UPS Installation and Operation Manual – 94861-000
Table 3–4 Specifications
Rated Output kVA
Rated Output kW
AC INPUT
500
500
Configuration
Voltage
Frequency
Reflected Current THDi
3 phase, 3 wire
480 V +15% to -20%
60 Hz ±10%
3% typ. at 100% load (no input filter required)
Configuration
Voltage
Frequency
3 phase, 3 wire
480 V ±10%
60 Hz ±5%
Type
Ride Through
Nominal Voltage
Minimum Voltage
Number of Cells
Lead Acid
Application Specific
480 Vdc
400 Vdc
240
Configuration
Voltage
Voltage Regulation
Frequency
Frequency Regulation
Power Factor
Power Factor Range
Voltage THD
3 phase, 3 wire
480 V
±1%
60 Hz
±0.01% in free running mode
Unity (nominal)
0.7 Lagging to 0.8 Leading (within output kW rating)
2% maximum THD at 100% linear load
5% maximum THD at 100% non-linear load
±2% maximum at 100% load step
±1% maximum at loss/return of AC power
±5% maximum at load transfer to/from static bypass
Less than 20ms
1% maximum at 100% unbalanced load
1 deg. maximum at 100% Load
125% for 1 minutes
150% for 10 seconds
500% for 1 cycle
(with bypass available)
STATIC BYPASS INPUT
BATTERY
AC OUTPUT
Transient Response
Transient Recovery Time
Voltage Unbalance
Phase Displacement
Inverter Overload
Bypass Overload
ENVIRONMENTAL**
Cooling
Operating Temperature
Relative Humidity
Altitude
Location
Forced Air
32 °F to 104 °F (0 °C to 40 °C).
Recommended : 68゚F to 86゚F ( 20°C to 30°C)
5% – 95% Non-Condensing
0 to 6500 ft. (1981 m) No Derating at 104゚F (40゚C)
Indoor (free from corrosive gases and dust)
Paint Color
Clearance Required
Munsell N1.5 (Black)
Top : 24 in. (610 mm)
Front : 40 in. (1016 mm)
Rear : 0 in. (0 mm)
Sides: 0 in. (0 mm) if sidecars used, 1 in. (25 mm) if no sidecars used.
**Indication that the unit is intended for installation in a temperature-regulated,
indoor area that is relatively free of conductive contaminants.
G2020 Series UPS Installation and Operation Manual – 94861-000
17
Table 3–5 Rating of Contactors, Breakers, and Fuses
OUTPUT CAPACITY OF EQUIPMENT
NUMBER
APPLICATION
500kVA
Contactors
500kW
CB1
AC input contactor
680A
CB3
STS contactor
260A
52C
Inverter output
contactor
680A
52S
Bypass contactor
680A
88RC
Breakers
CB2
18
Control circuit
contactor
Battery disconnect
breaker
(Recommended)
20A
1400A
User supply
AC input breaker
(Recommended)
800A
User supply
Bypass input breaker
(Recommended)
800A
FCR, FCS, FCT
FIU, FIV, FIW
AC fuse
400A / 690V
FUA, FUB, FUC
Control power fuse
30A / 600V
FBS1, FBS2, FBS3
Control power fuse
30A / 600V
FOA, FOB, FOC
Control power fuse
30A / 600V
(OPTION)
FSU, FSV, FSW
Bypass input fuse
315A / 690V
G2020 Series UPS Installation and Operation Manual – 94861-000
4
OPERATOR CONTROLS AND INDICATORS
The G2020 Series operator controls and indicators are located as follows (Door exterior):
8
3
4
2
5
1
6
7
Figure 4-1 Operation/Display Panel (Front panel)
G2020 Series UPS Installation and Operation Manual – 94861-000
19
4.1
LED DISPLAY
1) Load on inverter [ LOAD ON INVERTER ](green)
Illuminates when power is supplied from inverter to the critical load.
(Indicates the state of inverter transfer switch "52C".)
2) Battery operation [ BATTERY OP. ](yellow)
Illuminates when power is supplied from batteries following a power failure.
3) Load on bypass [ LOAD ON BYPASS ](yellow)
Illuminates when power is supplied to load devices by static bypass.
(Indicates the state of bypass transfer switch "52S".)
4) Overload [ OVERLOAD ](yellow)
Illuminates in overload condition.
5) LCD fault [ LCD FAULT ](red)
Illuminates when an error occurs.
6) UPS fault [ UPS FAULT ](red)
[Annunciator: intermittent or constant tones]
Illuminates when an error occurs in the system. In this case, the details of the error are
indicated on the display panel.
4.2
EPO BUTTON (Emergency Power Off button)
When EPO button (7) activated, the Emergency Power Off (EPO) function shuts down the UPS
module. The critical load will lose power and also shutdown. The EPO function can be performed both
locally and remotely.
20
G2020 Series UPS Installation and Operation Manual – 94861-000
4.3
LIQUID CRYSTAL DISPLAY
The Liquid Crystal Display (LCD) touch panel (8) indicates power flow, measured values, operational
guidance, data records and error messages. The LCD panel has a back-light which facilitates viewing
in different ambient lighting conditions. The LCD will automatically clear and turn off, if the screen is
not activated within 3 minute period. The LCD is turned back on when it is touched again. The
ERROR indicator is cleared after 24 hours and can be reproduced by pressing any key on the panel.
4.3.1
MENU
A)
MAIN MENU
The LCD panel indicates power flow and measured values, while also operating the start/stop
function. The LCD panel also allows the user to verify the status and operation of the UPS Module.
Figure 4-2 Main Screen
The following will be displayed when the START/STOP key on the MAIN MENU is pressed
(Jump into OPERATION MENU):
1) Startup/Shutdown Guidance
The display indicates the Startup and Shutdown guidance for the UPS system. If this operation is
PIN protected, the user is required to enter the security PIN before the screen can be accessed.
When in remote mode, the message “REMOTE operating model” will appear on this Screen. The
user cannot operate the start and stop functions without changing the setup from remote mode to
local mode.
When bypass voltage is abnormal, the message “Bypass voltage abnormal” will appear.
- Start: When the bypass voltage is abnormal, the LCD asks the operator if an interrupted
transfer is acceptable (Load may be lost).
- Stop: When the bypass voltage is abnormal, the user cannot transfer from inverter
to bypass line.
G2020 Series UPS Installation and Operation Manual – 94861-000
21
Figure 4-3 Startup/Shutdown Screen
Figure 4-4 Startup Guidance
Figure 4-5 Shutdown Guidance
Follow Startup/Shutdown guidance accordingly
22
G2020 Series UPS Installation and Operation Manual – 94861-000
B)
MEASUREMENT MENU
This screen shows details of measured values. Input and Output values are displayed. During
Battery operation, Remaining battery power and Run time are also displayed.
Figure 4-6 Input Values
Figure 4-7 Output Values
Figure 4-8 Values in Battery operation
G2020 Series UPS Installation and Operation Manual – 94861-000
23
C) OPERATION MENU
This screen prompts the user to select: (a) whether the start & stop operation will be performed by
local or remote operation; (b) date & time adjustment; (c) battery equalizing charge. The battery
equalizing charge operation key will appear when battery equalizing charge is set up (Setup is
based on battery type).
Figure 4-9 Remote/Local Operation Select
Figure 4-10 Date & Time Adjustment
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G2020 Series UPS Installation and Operation Manual – 94861-000
D) STATUS MENU
This LOG MENU displays two Touch icons in EVENT LOG and BATTERY LOG.
Pressing the EVENT LOG icon, up to 50 condition/operation records will be displayed.
Press ▲ or ▼ button for page turning.
Pressing the BATTERY LOG icon, Number of battery operations and Summed battery operation
time are displayed.
Figure 4-11 Log Menu
Figure 4-12 Event Log
Figure 4-13 Battery Log
G2020 Series UPS Installation and Operation Manual – 94861-000
25
4.3.2
Input Power Failure
During an Input Power Failure, the UPS inverter will be powered by the UPS batteries. The following
will be displayed on the main and measurement screen (Indication of battery operation and remaining
battery time).
Figure 4-14 Main Screen (Battery Operation)
Figure 4-15 Measurement Screen (Battery
Operation)
The LCD will display a battery low voltage message when the battery capacity is near depletion. The
End of Battery Discharge announcement is displayed when the battery end voltage is reached. At this
time, the inverter will perform an electronic shutdown to prevent battery loss of life typical from
extreme deep discharge conditions. When the input power is restored, the inverter will automatically
restart to power the load, and the batteries will be simultaneously recharged. The End of Battery
announcement is shown at the bottom of the screen.
4.3.3
Fault Indication
“MESSAGE” and “SILENCE ALARM” icons will appear on the main menu when UPS failure
condition has occurred.
Figure 4-16 Main Screen (Fault Indication)
The following will be displayed when the MESSAGE icon on the main menu is pressed.
26
G2020 Series UPS Installation and Operation Manual – 94861-000
1)
MESSAGE
The display shows a fault code, the description of the fault and a guidance of what action is to be taken
by the user. A maximum of 10 faults are displayed at one time. If an input power failure occurs during a
fault condition, the fault indication and input power failure announcement are alternatively displayed at 5
second intervals.
Figure 4-17 Message Screen
2)
SILENCE ALARM
This icon will appear when a failure occurs. The audible alarm (announcing the failure) can be
silenced by pressing this icon.
4.4
EXTERNAL AUX CONTACT INPUT AND OUTPUT TERMINAL BLOCKS
The UPS is equipped with terminals strips TN1 (Input) and TN2 (Output) on the Auxiliary Connection
Board, IOAU-09.
Some of these terminals are user-assignable to a variety of functions.
These can
be programmed to:
•
Inputs
(TN1): Control the UPS remotely, or report environmental data to the UPS.
•
Outputs (TN2): Report status data from the UPS to external annunciation/monitoring devices.
TN1: INPUT (NEC Class2)
1
3
2
5
4
7
6
9 11 13 15 17 19
8 10 12 14 16 18 20
TN2: OUTPUT (NEC Class2)
1
3
2
5
4
7
6
9 11 13 15 17 19
8 10 12 14 16 18 20
Figure 4-18 Location of External Signal Terminal Block on IOAU-09 PCB
G2020 Series UPS Installation and Operation Manual – 94861-000
27
4.4.1
Aux Contacts – Input
The Input terminal provides four (IN1 thru IN4) programmable contacts that can be set to any of the
functions in Table 4–1.
Do not apply voltages to remote access input terminals.
Damage to UPS may result.
PROHIBIT
Inputs require a dry NO (Normally Open) contact to be wired on the corresponding terminals on
TN1 of IOAU-09.
Closing this contact activates the selected functionality set for that input.
Inputs provide a signal or "wetting" voltage of 24VDC / 8.3 mA.
See Figure 4-19.
The
The function
takes effect immediately upon contact closure, and is removed immediately upon opening.
External block IOAU-09
External to
UPS Cabinet
UPS Cabinet
Signal
Relay
Coil
Switch
Common
Wire Size: #14AWG
(2 mm2) or less
24VDC
Relay Coil current: 8.3mA
User supplied
0.5s – 4s
ON
OFF
Use Momentary
Switches only
Figure 4-19 Control Wiring for Aux Input Contacts
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G2020 Series UPS Installation and Operation Manual – 94861-000
See Figure 4-20, and Table 4–1.
TN1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
+
TN1
1(+)-2(-)
Setting
Remarks
CB2 UVT (Battery Breaker Panel)
3-4
CB2 AX
(Battery Breaker Panel)
5-6
52L AX (Load Circuit Switch)
7-8
IN1: REMOTE INVERTER START
9-10
IN2: REMOTE INVERTER STOP
11-12
IN3: BATTERY TEMP. HIGH
13-14
IN4: POWER DEMAND
15-16
REMOTE EPO
17-18
N/A
19-20
N/A
User supplied
dry contact
UPS
NOTE:
For multiple battery cabinets, the UVT signals must be connected in parallel with UPS TN1-1 &-2.
For multiple battery cabinets, the Auxiliary Switches must be wired in series with UPS TN1-3 & -4.
Figure 4-20 External Signal Input Terminal Block (with default settings)
The input logic can be reversed by setting the Active Level to "Neg" when selecting the input function.
This will be annunciated on the Setup screen for the inputs by an "R" next to the Input Port.
For Example:
"IN1
1" indicates the UPS will remote start when contact closes.
"IN1
R1" indicates the UPS will remote start when contact opens.
In all cases, a switch having a protective cover is recommended in order to reduce the
possibility of accidental operation.
CAUTION
G2020 Series UPS Installation and Operation Manual – 94861-000
29
Table 4–1 External Input Functions
Code
Function
0
NONE
1*
REMOTE INVERTER START
Description
Starts UPS inverter from remote location. Use momentary (0.5 to 4 sec.)
switches only.
This is the default setting on IN1
Stops UPS inverter from remote location. Use momentary (0.5 to 4 sec.)
REMOTE INVERTER STOP
switches only.
This is the default setting on IN2
Driven by any customer-provided NO (Normally Open) dry contact thermal
detection device installed in the UPS's Battery Cabinet(s). When the
contact closes, the UPS decreases its battery charging maximum limit to
BATTERY TEMP ABNORMAL 95% of the set charging voltage. If the contacts stay closed (the battery
temp is still abnormal) for two hours, the UPS will shut off its battery
charger. (Battery operation will still possible)
This is the default setting on IN3
Driven by any customer-provided NO (Normally Open) dry contact.
Closing the contact limits the input current to a value (10-150% of the UPS's
rated input) set in the TEST MENU – ”Power Demand Level 1" by an
POWER DEMAND 1
Authorized Toshiba Service Provider. Opening the contact returns the
UPS to its normal operation parameters.
This is the default setting on IN4.
2*
6*
3*
*Default Settings from Factory.
30
G2020 Series UPS Installation and Operation Manual – 94861-000
4.4.2
Aux Contacts – Output
The Output terminal strip TN2 provides eight (OUT1 thru OUT8) Form "A" NO (Normally Open) dry
type programmable contacts to drive annunciation signals sourced or "wetted" by external monitoring
devices.
All output contacts are rated for NEC Class 2 operation (30VDC / 1ADC.)
The output dry contacts should be operated at their rated values or lower.
Figure 4-21 illustrates a
typical installation. The external relay can be a lamp, LED, computer, etc.
External block IOAU-09
External to
UPS Cabinet
UPS Cabinet
Terminal
Relay
Contact
Relay
Coil
Terminal
Wire Size: #14AWG
(2 mm2) or less
User supplied
NEC Class 2
Power Source
Figure 4-21 Control Wiring for Aux Output Contacts
TN2
1
2
3
4
5
6
7
8
9
10
12
14
16
18
20
11
13
15
17
19
TN2
Setting
1-2
SUMMARY ALARM
3-4
OUT1: LOAD ON BYPASS
5-6
OUT2: LOAD ON INVERTER
7-8
OUT3: BATTERY OPERATION
9-10
OUT4: CONVERTER OPERATION
11-12
OUT5: BATTERY LOW VOLTAGE
13-14
OUT6: OVERLOAD
15-16
OUT7: TOTAL ALARM
17-18
OUT8: SPARE
19-20
52C CLOSE
* Relay contactor (52C close): Normally Closed
UPS
Figure 4-22 External Signal Output Terminal Block (with default settings)
G2020 Series UPS Installation and Operation Manual – 94861-000
31
These contacts can be programmed to provide any of the functions shown in Table 4–2.
The default
programmed values are indicated with an asterisk (*).
Table 4–2 External Output Functions
Code
Function
0
NONE
18 *
LOAD ON BYASS
17 *
LOAD ON INVERTER
20 *
BATTERY OPERATION
21 *
CONVERTER OPERATION
8*
BATTERY LOW VOL.2
10 *
OVERLOAD
1*
TOTAL ALARM
Description
Activated when the power is supplied from the bypass.
This is the default setting on OUT1.
Activated when the power is supplied from the inverter.
This is the default setting on OUT2.
Activated when the battery is operating following an AC power failure.
This is the default setting on OUT3.
Activated when the converter is operating.
This is the default setting on OUT4
Activated when the battery voltage drops below Discharge Warning Voltage
Level 2 during inverter operation. This level is set in the TEST MENU by an
Authorized Toshiba Service Provider.
This is the default setting for OUT5.
Activated when an overload of 105% or more had occurred to the system.
This is the default setting on OUT6.
Summary alarm; activated when any minor, major, fault or alarm has
occurred with the system.
This is the default setting on OUT7.
*Default output settings
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G2020 Series UPS Installation and Operation Manual – 94861-000
4.5
®
RemotEye INTRODUCTION
The RemotEye4 is available as a UPS system monitoring tool. The RemotEye4 supplies a network
function to monitor UPS units via Simple Network Management Protocol (SNMP) and Hypertext Transfer
Protocol (HTTP) methods.
The RemotEye4 module is installed at the rear of the front door in G2020 UPS units. The
configuration of the RemotEye4 is shown in Figure 4-23 and Figure 4-24 shows detailed connection.
Bushing, Support
RemotEye
(Installed here)
Cable2
(provided with
RemotEye4)
DPAU-81
(SW1)
PSAU-60
(PS1)
UPHR-W
(UP1)
Cable1
(provided)
Back of the front left door (Main cabinet)
Figure 4-23 RemotEye® Installation (Overview 500kVA)
®
* Consult Toshiba International Corporation for details on“RemotEye ” monitoring software
and its capabilities.
G2020 Series UPS Installation and Operation Manual – 94861-000
33
The Power Supply PCB (PSAU-60, designated as PS1) and the Cable1 (designated as 3BBA0083P001)
are equipped with G2020 UPS units.
The Cable2 between RemotEye4 and PSAU-60 PCB is included in the RemotEye 4 package.
The Power Supply PCB (PS1) provides connectivity between the Display Control PCB (DPAU-81,
designated as SW1) and the RemotEye 4 module in G2020 UPS units.
The RemotEye 4 communicates with the UPS via a Cable2. The connection is described in Figure 4-24
below.
The UPS has to be de-energized when the RemotEye 4 module is installed for safety
reason.
CAUTION
* Consult Toshiba International Corporation for details on “RemotEye 4” monitoring software
and its capabilities.
DPAU-81
SW1
Cable1
3BBA0083P001
PSAU-60
PS1
(male)
12V Power
Communication
Cable2
UPS Gold Finger Connector(GF1)
RemotEye4
NETWORK (RJ45)
EMD (RJ45)
Figure 4-24 Connection between Display Control PCB (SW1) and RemotEye® Module
34
G2020 Series UPS Installation and Operation Manual – 94861-000
The parts for UPS monitoring are listed below.
Table 4–3 Parts List for UPS Monitoring
Parts No.
1
2
3
4
Part name
Power supply PCB (PS1): PSAU-60*
Cable1: 3BBA0083P001
RemotEye 4 module
Cable2 (included in the RemotEye 4 package)
Qt’y
1
1
1
1
* – PCB revision suffix may be applied.
D-sub connector CN1
to be connected with
RemotEye.
Connector CN44
to be connected with
CN27 of DPAU-81(SW1).
Terminal block TN
to feed 12VDC power
to RemotEye.
(12V across P to N)
Connected with
3BBA0083P001(Cable1)
Shown in Figure 4-27.
Figure 4-25 PSAU-60 (PS1)
Optional interface CN2
to feed 12VDC power
(12V Pin#1 to #2)
(Note 12VDC exposed)
Connector CN27
to be connected with
CN44 of PSAU-60(PS1).
Figure 4-26 DPAU-81 (SW1)
D3200 5pin
(Housing)
Figure 4-27 Cable1 (3BBA0083P001)
G2020 Series UPS Installation and Operation Manual – 94861-000
35
4.6
CONNECTOR DEFINITION
DB9
5
4
3
2
1
9
8
7
6
D-SUB 9Pin (male)
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Description
RXD
TXD
GND
-
Not used
Receive Data
Transmit Data
Not used
Signal Ground
Not used
Not used
Not used
Not used
Figure 4-28 Connector (CN1) of PSAU-60 (PS1)
1
1
P
TB2
Pin 1
Pin 2
N
Description
+12VS
GND(S)
+12VDC
+12VDC ground
2
2
Terminal Block 2Pin
VH 2Pin
Figure 4-29 Terminal Block (TN) and VH connector (CN2) of PSAU-60 (PS1)
1
D5
2
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
3
4
5
Description
RXD
TXD
GND
+24VS
GND(S)
Receive data
Transmit data
Signal ground
+24VDC
+24VDC ground
D3200 5Pin (contact)
Figure 4-30 Connector (CN44) of PSAU-60 (PS1)
36
G2020 Series UPS Installation and Operation Manual – 94861-000
1
D5
2
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
3
4
5
Description
RXD
TXD
GND
+24VS
GND(S)
Receive data
Transmit data
Signal ground
+24VDC
+24VDC ground
D3200 5Pin (contact)
Figure 4-31 Connector (CN27) of DPAU-81 (SW1)
FOR SERVICE PERSONNEL ONLY
DB9
1
6
2
7
3
8
4
9
5
D-SUB 9Pin (male)
Pin 1
Pin 2
Pin 3
Pin 4
Pin 5
Pin 6
Pin 7
Pin 8
Pin 9
Description
RXD
TXD
GND
-
Not used
Receive Data
Transmit Data
Not used
Signal Ground
Not used
Not used
Not used
Not used
Figure 4-32 Connector (CN26) of DPAU-81 (SW1)
G2020 Series UPS Installation and Operation Manual – 94861-000
37
5
INSTALLATION AND OPERATION
5.1
TRANSPORTATION AND INSTALLATION
Transport with forklift.
If carry by overhead crane, use four eyebolts (Not provided)
Table 5–1 Transport by Overhead Crane
Model
500 kVA
UPS Cabinet
4 x M20 Lifting Eyes
Landing Cabinet *
4 x M16 Lifting Eyes
* Use lifting eyes on landing cabinet only to lift landing cabinet by itself, not as part of assembled unit.
Install the unit using the four pre-drilled holes in the UPS channel base.
Anchor the unit using appropriate
hardware. (Not provided).
Do not transport UPS cabinet laid horizontally.
PROHIBIT
!
Cabinets must be maintained upright within ± 15° of the vertical
during handling.
NOTE
5.2
INSTALLATION PROCEDURE
A)
Note the load tolerance of the floor
Refer to Table 5–2 for list of UPS weights.
Table 5–2 List of UPS Weights
UPS Capacity (kVA)
Weight (lb.)
B)
C)
500
2,756
Minimum clearance required for ventilation
Right side
1 in. (25 mm) (not required when sidecars are used)
Left side
1 in. (25 mm) (not required when sidecars are used)
Back side
0.0 in. (0 mm)
Top side
24 in. (610 mm) (for air flow)
Space requirement for routine maintenance
Allow for the following space at the time of installation.
38
Front
40 in. (1016 mm)
Sides
0.0 in. (0 mm)
Back side
0.0 in. (0 mm)
Top side
20 in. (500 mm)
G2020 Series UPS Installation and Operation Manual – 94861-000
D)
External Battery Supply
Please refer to the following when installing and maintaining batteries:
1. The customer shall refer to the battery manufacturer's installation manual for
!
battery installation and maintenance instructions.
2. The maximum permitted fault current from the remote battery supply and the DC
voltage rating of the battery supply over-current protective device are shown in
NOTE
Table 5–3.
Table 5–3 Maximum Permitted Fault Current
5.3
UPS Capacity
(kVA)
DC Voltage
Rating (V)
Maximum Permitted
Fault Current (A)
500
480
25,000
PROCEDURE FOR CABLE CONNECTIONS
1.
Confirm the capacity of the UPS being installed. Identify the input/output power
Terminal blocks accordingly as shown in the Figure 5-1 and Figure 5-2.
2.
Connect the internal control wire and power wire.
(1) Control wire Inter-connect
1.
CB2 UVR to terminal TN1-1, 2 of external I/F PCB IOAU-09.
2.
CB2 ON Auxiliary to terminal TN1-3, 4 of external I/F PCB IOAU-09.
(2) Power wire (AC input, Bypass input, AC output) Inter-connect
a.) From user’s distribution panel
1.
X1 (A-phase) to A bus bar in UPS
2.
X2 (B-phase) to B bus bar in UPS
3.
X3 (C-phase) to C bus bar in UPS
b.) DC Input to UPS
!
NOTE
3.
1.
Positive cable to BP bus bar in UPS
2.
Negative cable to BN bus bar in UPS
After the completion of the input power cables connection:
With a phase rotation meter, check that the phase rotation of the AC Input power
terminals A, B and C as well as the Bypass Input power terminals A40, B40 and C40 are
correct. The proper phase rotation is clockwise A(R) → B(S) → C(T).
Connect the grounding conductor from the input service
entrance to the UPS Ground Bar (E).
REQUIRED
G2020 Series UPS Installation and Operation Manual – 94861-000
39
4.
Two (2) sources feeding the UPS:
(1) Connect the AC input power cables from the input service entrance to the AC input power
terminals, identified as A, B, C in Figure 5-1 and Figure 5-2. Input cables must be sized for
an ampere rating larger than the maximum input drawn by the converter. (Refer to equipment
nameplate for current ratings.) Confirm that an external bypass input circuit breaker (MCCB)
is installed (refer to WARNING 4, page 10). Connect the bypass input power cables from the
input service entrance to the bypass input power terminals, identified as A40, B40 and C40 in
Figure 5-1 and Figure 5-2. Bypass input cables must be sized for an ampere rating larger
than the maximum output current capacity of the UPS. Refer to Table 5–4 for recommended
cable sizes.
(2) Connect the external signal terminal block as desired.
Refer to Section 4.4 and Figure 4-19
2
thru Figure 4-22 for functional description. 14 AWG (2mm ), or less, shielded conductor is
recommended.
5.
One (1) source feeding the UPS:
(1) Confirm that an external input circuit breaker sized to protect both the AC input and the
bypass line is installed. (Refer to equipment nameplate for current ratings.) Connect the
bypass input power cables from the input service entrance to the bypass input power
terminals, identified as A40, B40 and C40 in Figure 5-1 and Figure 5-2. Input cables must be
sized for an ampere rating larger than the maximum current capacity of the UPS. Refer to
Table 5–4 for recommended cable sizes.
(2) Using adequately sized conductors and referring to the appropriate figure identified in Figure
5-1 and Figure 5-2, connect jumper bypass terminals A40, B40, C40 to AC input power
terminals A, B, C as identified in Figure 5-1 and Figure 5-2.
(3) Connect the external signal terminal block as desired. Refer to Section 4.4 and Figure 4-19
2
thru Figure 4-22 for functional description. 14 AWG (2mm ), or less, shielded conductor is
recommended.
!
NOTE
40
1. Confirm that all UPS internal contactors (breakers) "CB1", "CB2", and "CB3" are
open before energizing UPS.
2. UPS power terminals are supplied with stud type fittings.
It is recommended that compression lugs be used to fasten all input/output power
cables.
G2020 Series UPS Installation and Operation Manual – 94861-000
6.
Procedure for Cable Connections for Parallel Operation System
(1) Confirm the number of units to be connected in parallel. Identify the input/output power
terminal blocks and control wire connections for parallel operation systems as shown in the
appropriate Figure 5-1 and Figure 5-2.
(2) Connect the external control wire and power wire.
!
Straight through, shielded CAT5 cables with metal shrouded RJ-45 plugs on both sides
are to be used for the parallel control signal cables. Use of any other cables could cause
erroneous communication failures.
NOTE
a.) Control wire connection
Parallel configuration wiring (Refer to Figure 5-4 to Figure 5-10)
-
52L control signal from Toshiba Tie Cabinet (TTC) to UPS-n IOAU-09
(TN1– 5, 6).
-
Parallel control signal for TLAx, TLBx, CAx, and CBx as shown in Figure 5-5 to
Figure 5-10.
b.) Power wire connection
From UPS AC Output Terminals to Toshiba Tie Cabinet (TTC) (Refer to Figure 5-1 and
Figure 5-2)
G2020 Series UPS Installation and Operation Manual – 94861-000
41
Table 5–4 Recommended Cable Sizes
Input Side
Output Side
Bypass Side
DC Input Side
kVA
Input
Output
Cable
Torque
Cable
Torque
Cable
Torque
Cable
Torque
Capacity
Voltage
Voltage
Size
in. lbs
Size
in. lbs
Size
in. lbs
Size
in. lbs
500kVA
480V
480V
3 x 250MCM
347 - 469
3 x 250MCM
347 - 469
3 x 250MCM
347 - 469
or larger
in. lbs
or larger
in. lbs
or larger
in. lbs
4 x 400MCM
347 - 469
in. lbs
*1 – Use 75 degree C copper wire.
*2 – The cables must be selected to be equal or larger to the sizes listed in the table.
*3 – Voltage drop across power cables not to exceed 2% of nominal source voltage.
*4 – Allowable ampere-capacities based on copper conductors with 75 degree C. insulation at ambient temperature of 40 degree C.
Table 5–5 Recommended Hardware
UPS Capacity
Bolt size
Flat washer
size
Split
lockwasher
size
Nut size
500kVA
M12 x 40mm
M12
M12
M12
42
G2020 Series UPS Installation and Operation Manual – 94861-000
Table 5–6 Crimp Type Compression Lug
WIRE
SIZE
(CODE)
1
WIRE
STRAND
CLASS
B
1/0
I
B
2/0
I
B
3/0
I
B
4/0
I
B
250 MCM
I
B
300 MCM
I
B
350 MCM
I
B
400 MCM
I
B
500 MCM
I
B
I
NOTE:
VENDOR
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
CAT. NO.
YA1C
CRA-1L
YA25-LB
YA25
CRA-1/OL
YA25-LB
YA26
CRA-2/OL
YA27-LB
YA27
CRB-3/OL
YA28-LB
YA28
CRB-4/OL
YA29-LB
YA29
CRA-250L
YA30-LB
YA30
CRA-300L
YA32-LB
YA31
CRA-350L
YA34-LB
YA32
CRA-400L
YA36-LB
YA34
CRA-500L
YA38-LB
CRIMP TOOL REQUIRED
BURNDY TYPE Y35 OR Y46
COLOR KEY
DIE INDEX
GREEN
11 / 375
GREEN
11 / 375
--1019
PINK
12 / 348
PINK
12 / 348
--1020
BLACK
13
BLACK
13
--1021
ORANGE
14 / 101
ORANGE
14 / 101
--1022
PURPLE
15
PURPLE
15
--1023
YELLOW
16
YELLOW
16
--1024
WHITE
17 / 298
WHITE
17 / 298
--1026
RED
18 / 324
RED
18 / 324
--1027
BLUE
19 / 470
BLUE
19 / 470
--1027
BROWN
20 / 299
BROWN
20 / 299
--1029
When using crimp type lugs, the lugs should be crimped to the specifications given in the
manufacturer's instructions for both crimp tool and lug.
Bypass
Input
AC
Input
RECOMMENDATION
Terminals
A40
B40
C40
Terminals
A
B
C
52S
CB3
Converter
/Charger
/ CHA
CB1
CB2
Inverter
Static Transfer
Switch
52C
Terminals
A50
B50
C50
AC
Output
Terminals
BP
BN
External
Battery
Figure 5-1 UPS Terminal Designation
G2020 Series UPS Installation and Operation Manual – 94861-000
43
Location of bus bars and terminal blocks (Bottom/Top/Left Side entry)
D=33.5” (850mm)
Detailed Power Terminals
For power terminals, use 1/2” (12mm)
diameter bolts.
59.2”(1500)
A
AC Input
A, B, C
AC Input
B
E
Grounding
Bar
C
Bypass Input
A40 , B 40, C40
A40
78.7’’(2000)
AC Output
A50 , B 50, C50
DC Input
BP, BN
Bypass
Input
B40
C40
A50
AC
Output
B50
C50
Grounding Bar
(not shown )
BP
DC Input
15.7” (400)
BN
UPS module (500kVA)
Figure 5-2 Diagram of input/output bus bars and terminal blocks
44
G2020 Series UPS Installation and Operation Manual – 94861-000
External signal
terminal
IOAU-09 – [TN1]
1
2
3
4
DC Power
Terminals
BN BP
User
Supplied
CB2 (DC Circuit Breaker
UVR
Auxiliary
User
Supplied
“–” Negative
UPS Module
External signal
terminal
IOAU-09 – [TN1]
1
2
3
4
DC Power
Terminals
BN BP
UPS Module
User
Supplied
“+” Positive
DC Breaker for
Battery Cabinet
CB2 (DC Circuit Breaker
User
Supplied
CB2 (DC Circuit Breaker
UVR
UVR
Auxiliary
Auxiliary
User
Supplied
“–” Negative
“+” Positive
DC Breaker for
Battery Cabinet 1
User
Supplied
“–” Negative
“+” Positive
DC Breaker for
Battery Cabinet n
Figure 5-3 Diagram of Power Wire & Control Wire Inter-Connect between UPS and Battery
G2020 Series UPS Installation and Operation Manual – 94861-000
45
Toshiba Tie Cabinet (TTC)
UPS-1
Bypass
Bypass input
AC input
CB1
52MB
Maintenance
Bypass Breaker
52S
Converter
/Charger
Inverter
AC output
52C
Bypass input
AC input
UPS-2
Bypass
CB1
52L1
UPS
Breaker
CB2 Battery
52S
Converter
/Charger
Inverter
Output
Breaker
52CS
AC output
52C
52L2
UPS
Breaker
CB2 Battery
UPS-n
Bypass input
AC input
Bypass
CB1
52S
Converter
/Charger
Inverter
AC output
UPS
Breaker
52Ln (*1)
52C
(*1) n: Maximum=8
CB2 Battery
Figure 5-4 Diagram of Power Wire Connections (Parallel System Configuration)
46
G2020 Series UPS Installation and Operation Manual – 94861-000
Communication
Cabling
*1
NOTE
! Use Ethernet STP (Shielded
Twisted Pair) Cable (Cat 5 or better)
with shielded RJ45 modular
connectors for all communication
cabling.
Use of UTP (Unshielded Twisted Pair)
Cable may cause malfunction.
NOTE
TLAx and TLBx are redundant signal
lines. CAx and CBx are redundant
signal lines.
Redundant lines provide reduced
vulnerability to cable damage when
TLAx/CAx circuits are installed in
separate conduit from TLBx/CBx
circuits.
NOTE
! Total cable length from UPS-1
to UPS-2 should be within 100m.
*1
UPS-1
IFAU-09
CN99
TLBIN
CN98
TLAIN
CN97
TLBOUT
CN96
TLAOUT
*2
*2
Return from the last
UPS module to the first UPS
module (continuous loop).
DIP switch position
UPS-1 and UPS-2: ON
Toshiba Tie Cabinet (TTC)
Signal
Cabling
ON
CN954
CB2IN
CN953
CB1IN
CN952
CA2IN
CN951
CA1IN
47
48
49
50
CN944
CB2OUT
CN943
CB1OUT
CN942
CA2OUT
CN941
CA1OUT
*2
52L2-AX
A50
B50
C50
ON
IFAU-09
CN99
TLBIN
CN98
TLAIN
CN97
TLBOUT
CN96
TLAOUT
IOAU-09
TN1
5
6
ON
CN954
CB2IN
CN953
CB1IN
CN952
CA2IN
CN951
CA1IN
Power
Cabling
AC OUTPUT
UPS-1
A
B
C
CN944
CB2OUT
CN943
CB1OUT
CN942
CA2OUT
CN941
CA1OUT
*2
52L1-AX
AC
OUTPUT
UPS-2
*2
*1
IOAU-09
TN1
5
6
AC
OUTPUT
A50
B50
C50
UPS-2
A
B
C
ON
Figure 5-5 Diagram of Power & Control Wire Connections for 2 units in MMS Configuration
G2020 Series UPS Installation and Operation Manual – 94861-000
47
No.1 UPS
IFAU-09
No.2 UPS
IFAU-09
CN99 TLBIN
CN99 TLBIN
CN98 TLAIN
CN98 TLAIN
CN97 TLBOUT
CN97 TLBOUT
CN96 TLAOUT
CN96 TLAOUT
CN954 CB2IN
CN954 CB2IN
CN953 CB1IN
CN953 CB1IN
CN952 CA2IN
CN952 CA2IN
CN951 CA1IN
CN951 CA1IN
CN944 CB2OUT
CN944 CB2OUT
CN943 CB1OUT
CN943 CB1OUT
CN942 CA2OUT
CN942 CA2OUT
CN941 CA1OUT
CN941 CA1OUT
IOAU-09
IOAU-09
~~~~~
~~~~~
Figure 5-6 Detail of IFAU-09 Control Wire Connections for 2 units in MMS Configuration
48
G2020 Series UPS Installation and Operation Manual – 94861-000
Communication
Cabling
*1
NOTE
! Use Ethernet STP (Shielded
Twisted Pair) Cable (Cat 5 or better)
with shielded RJ45 modular
connectors for all communication
cabling.
Use of UTP (Unshielded Twisted Pair)
Cable may cause malfunction.
NOTE
TLAx and TLBx are redundant signal
lines. CAx and CBx are redundant
signal lines.
Redundant lines provide reduced
vulnerability to cable damage when
TLAx/CAx circuits are installed in
separate conduit from TLBx/CBx
circuits.
NOTE
!
Total cable length from UPS-1
to UPS-2 should be within 100m.
*1
UPS-1
IFAU-09
CN99
TLBIN
CN98
TLAIN
CN97
TLBOUT
CN96
TLAOUT
*2
ON
CN954
CB2IN
CN953
CB1IN
CN952
CA2IN
CN951
CA1IN
CN944
CB2OUT
CN943
CB1OUT
CN942
CA2OUT
CN941
CA1OUT
*2
Toshiba Tie Cabinet (TTC)
AC
OUTPUT
A50
B50
C50
ON
UPS-2
IFAU-09
CN99
TLBIN
CN98
TLAIN
CN97
TLBOUT
CN96
TLAOUT
*2
*2
35
36
37
38
.
.
.
49
50
52L1-AX
52L2-AX
52Ln-AX
*3
OFF
AC
OUTPUT
A50
B50
C50
OFF
IFAU-09
CN99
TLBIN
CN98
TLAIN
CN97
TLBOUT
CN96
TLAOUT
*2
Power
Cabling
AC OUTPUT
UPS-1
A
B
C
UPS-2
A
B
C
UPS-n *3
Return from the last
UPS module to the first UPS
module (continuous loop).
*2 DIP switch position
UPS-1 and UPS-n: ON
Otherwise: OFF
*3 n = 3-4 (maximum) for this
cabling configuration
IOAU-09
TN1
5
6
Signal
Cabling
CN954
CB2IN
CN953
CB1IN
CN952
CA2IN
CN951
CA1IN
CN944
CB2OUT
CN943
CB1OUT
CN942
CA2OUT
CN941
CA1OUT
*1
IOAU-09
TN1
5
6
IOAU-09
TN1
5
6
.
.
.
UPS-n *3
A
B
C
ON
CN954
CB2IN
CN953
CB1IN
CN952
CA2IN
CN951
CA1IN
CN944
CB2OUT
CN943
CB1OUT
CN942
CA2OUT
CN941
CA1OUT
*2
AC
OUTPUT
A50
B50
C50
ON
Figure 5-7 Diagram of Power & Control Wire Connections for 3-4 units in MMS Configuration
G2020 Series UPS Installation and Operation Manual – 94861-000
49
No.1 UPS
IFAU-09
No.2 UPS
IFAU-09
No.N UPS
IFAU-09
CN99 TLBIN
CN99 TLBIN
CN99 TLBIN
CN98 TLAIN
CN98 TLAIN
CN98 TLAIN
CN97 TLBOUT
CN97 TLBOUT
CN97 TLBOUT
CN96 TLAOUT
CN96 TLAOUT
CN96 TLAOUT
CN954 CB2IN
CN954 CB2IN
CN954 CB2IN
CN953 CB1IN
CN953 CB1IN
CN953 CB1IN
CN952 CA2IN
CN952 CA2IN
CN952 CA2IN
CN951 CA1IN
CN951 CA1IN
CN951 CA1IN
CN944 CB2OUT
CN944 CB2OUT
CN944 CB2OUT
CN943 CB1OUT
CN943 CB1OUT
CN943 CB1OUT
CN942 CA2OUT
CN942 CA2OUT
CN942 CA2OUT
CN941 CA1OUT
CN941 CA1OUT
CN941 CA1OUT
IOAU-09
IOAU-09
IOAU-09
~~~~~
~~~~~
~~~~~
Figure 5-8 Detail of IFAU-09 Control Wire Connections for 3 or 4 units in MMS Configuration
50
G2020 Series UPS Installation and Operation Manual – 94861-000
Communication
Cabling
*1
NOTE
! Use Ethernet STP (Shielded
Twisted Pair) Cable (Cat 5 or better)
with shielded RJ45 modular
connectors for all communication
cabling.
Use of UTP (Unshielded Twisted Pair)
Cable may cause malfunction.
NOTE
TLAx and TLBx are redundant signal
lines. CAx and CBx are redundant
sgnal lines.
Redundant lines provide reduced
vulnerability to cable damage when
TLAx/CAx circuits are installed in
separate conduit from TLBx/CBx
circuits.
!
NOTE
Total cable length from UPS-1
to UPS-2 should be within 100m.
*1
UPS-1
IFAU-09
CN99
TLBIN
CN98
TLAIN
CN97
TLBOUT
CN96
TLAOUT
*2
ON
CN954
CB2IN
CN953
CB1IN
CN952
CA2IN
CN951
CA1IN
CN944
CB2OUT
CN943
CB1OUT
CN942
CA2OUT
CN941
CA1OUT
*2
Toshiba Tie Cabinet (TTC)
AC
OUTPUT
A50
B50
C50
ON
UPS-2
IFAU-09
CN99
TLBIN
CN98
TLAIN
CN97
TLBOUT
CN96
TLAOUT
*2
*2
AC
OUTPUT
A50
B50
C50
OFF
52L1-AX
52L2-AX
52Ln-AX
*3
*2
Power
Cabling
AC OUTPUT
UPS-1
A
B
C
UPS-2
A
B
C
IFAU-09
CN99
TLBIN
CN98
TLAIN
CN97
TLBOUT
CN96
TLAOUT
Figure 5-9
35
36
37
38
.
.
.
49
50
OFF
UPS-n *3
Return from the last
UPS module to the first UPS
module (continuous loop).
*2 DIP switch position
UPS-1 and UPS-n: ON
Otherwise: OFF
*3 n = 5-8 (maximum) for this
cabling configuration
IOAU-09
TN1
5
6
Signal
Cabling
CN954
CB2IN
CN953
CB1IN
CN952
CA2IN
CN951
CA1IN
CN944
CB2OUT
CN943
CB1OUT
CN942
CA2OUT
CN941
CA1OUT
*1
IOAU-09
TN1
5
6
IOAU-09
TN1
5
6
.
.
.
UPS-n
*3
A
B
C
ON
CN954
CB2IN
CN953
CB1IN
CN952
CA2IN
CN951
CA1IN
CN944
CB2OUT
CN943
CB1OUT
CN942
CA2OUT
CN941
CA1OUT
*2
AC
OUTPUT
A50
B50
C50
ON
Diagram of Power Wire & Control Wire Connections for 5 to 8 units in MMS Configuration
G2020 Series UPS Installation and Operation Manual – 94861-000
51
No.1 UPS
IFAU-09
IFAU-09
No.N UPS
IFAU-09
CN99 TLBIN
CN99 TLBIN
CN99 TLBIN
CN98 TLAIN
CN98 TLAIN
CN98 TLAIN
CN97 TLBOUT
CN97 TLBOUT
CN97 TLBOUT
CN96 TLAOUT
CN96 TLAOUT
CN96 TLAOUT
CN954 CB2IN
CN954 CB2IN
CN954 CB2IN
CN953 CB1IN
CN953 CB1IN
CN953 CB1IN
CN952 CA2IN
CN952 CA2IN
CN952 CA2IN
CN951 CA1IN
CN951 CA1IN
CN951 CA1IN
CN944 CB2OUT
CN944 CB2OUT
CN944 CB2OUT
CN943 CB1OUT
CN943 CB1OUT
CN943 CB1OUT
CN942 CA2OUT
CN942 CA2OUT
CN942 CA2OUT
CN941 CA1OUT
CN941 CA1OUT
CN941 CA1OUT
IOAU-09
IOAU-09
IOAU-09
~~~~~
Figure 5-10
52
No.2 UPS
~~~~~
~~~~~
Detail of IFAU-09 Control Wire Connections for 5 to 8 units in MMS Configuration
G2020 Series UPS Installation and Operation Manual – 94861-000
5.4
OPERATING PROCEDURES
NOTE: To avoid inadvertently placing the UPS online or offline the START and STOP switches must
be pressed and held for a period of several seconds to execute the command.
• START – Press and hold the START switch for approximately 2 seconds.
• STOP – Press and hold the STOP switch for approximately 5 seconds.
For Parallel Operation system, refer to section “E) MMS Start-up Procedure”.
(Parallel Operation system is herein after referred to as a MMS [Multi Module System])
On-screen guidance for Starting and Stopping the UPS can be obtained by
pressing the OPERATION tab icon.
A)
Start-up Procedure
Before the UPS startup, the internal Bypass line starts to supply the unconditioned bypass
!
NOTE
input power to the load if the External input (or Bypass) Circuit Breaker is closed. Be
extremely careful with closing the External input (or Bypass) Circuit Breaker.
Confirm the position of the circuit protectors (CPMC, CPMS and EMB) located at the
upper right part of the cabinet (Figure 5-11).
1) CPMC and CPMS: ON;
2) EMB: OFF.
CPMC
CPMS
EMB
Figure 5-11 Circuit Protectors Location
a.) Verify the Battery Disconnect Circuit Breaker (CB2) is open or in the tripped position. (user
supplied)
b.) Verify the External Input /Bypass Circuit Breaker for each unit is closed. (user supplied)
c.) If a dual source is feeding the UPS, close the External AC Input Circuit Breaker manually (user
supplied).
d.) The LCD panel boots up automatically and opens up in the “MAIN” Tab; the Converter and
Inverter will start automatically (Figure 5-12).
NOTE: On the initial startup of the G2020, both the Bypass (52S) and the Inverter (52C)
contactors will be open (Figure 5-12b). After the initial startup, the UPS will subsequently
startup in Bypass mode (Figure 5-16).
e.) FOR GUIDANCE IN STARTING THE UPS, select “OPERATION” tab on the LCD panel, then
press the “STARTUP GUIDANCE” icon (Figure 4-3) and follow the on-screen directions to
continue UPS start-up (Figure 4-4). (The directions are the same as given in the following
steps.)
OR remain on the “MAIN” tab and continue with step f).
G2020 Series UPS Installation and Operation Manual – 94861-000
53
a.
b.
Figure 5-12 Automatic Startup of Inverter and Converter
f) Close the Battery Breaker. (The START/STOP icon will not work until the battery breaker is closed.)
The display will show CB2 is closed and the battery backup is now online. (Figure 5-13)
Figure 5-13 Close Battery Breaker
g) Press the STOP/START icon on the display, then press and hold the START button (Figure 5-14a) for
two (2) seconds until the UPS transfers to load on INV. (Figure 5-14b)
a.
54
b.
Figure 5-14 Press and Hold START Button
G2020 Series UPS Installation and Operation Manual – 94861-000
!
When "REMOTE OPERATION MODE" is displayed on the LCD panel, the inverter start
operation can only be performed remotely. If local inverter start operation is required (at
the UPS), select "LOCAL ONLY" or “REMOTE & LOCAL” in the OPERATION MENU.
NOTE
B)
Transfer from Online to Bypass Procedure
Transfer to Bypass to remove power from the inverter but continue to provide utility power to the
critical load.
a.) Press the "START/STOP" icon from the “MAIN” Menu on the LCD.
b.) On the LCD panel, press and hold STOP for five (5) seconds. (Figure 5-14a)
c.) The UPS transfers to Bypass. (Figure 5-15) The Bypass contactor (52S) closes and the
Inverter contactor (52C) opens. (Figure 5-15b)
a.
.
b.
Figure 5-15 Transfer from Online to Bypass
C)
Transfer from Bypass to Online Procedure
Transfer from Bypass to Online to provide the load with conditioned, reliable power.
a.) Press the "START/STOP" icon from the “MAIN” Menu on the LCD.
b.) On the LCD panel, press and hold START for two (2) seconds.
c.) The UPS transfers to Online. The Bypass contactor (52S) opens and the Inverter contactor
(52C) closes. (Figure 5-16b)
a.
b.
Figure 5-16 Transfer from Bypass to Online
G2020 Series UPS Installation and Operation Manual – 94861-000
55
D)
Shut-down Procedure
If a total UPS shutdown is required, verify that the critical load is OFF.
Verify the load is OFF if the next step is to be performed.
Power to the load has been supplied through the bypass line. Power to load will be
CAUTION
lost after execution of the next step. The load will drop.
a.) Press the "START/STOP" icon from the Main Menu or the Operation Menu on the LCD.
b.) On the LCD panel, press “START/STOP” icon, and then press and hold STOP for 5 seconds.
(Figure 5-17b)
a.
b.
Figure 5-17 Initiate Shutdown
c.)
The UPS transfers to Bypass. The Bypass contactor (52S) closes and the Inverter contactor
(52C) opens. (Figure 5-18)
Figure 5-18 UPS Transfers to Bypass
d.) In Bypass, both of the Inverter and the Converter remain energized until complete disconnection
from all power sources.
In bypass mode, all UPS power terminals are still alive. Lethal voltages are present.
De-energize all external sources of AC and DC power. Before removing the covers,
wait 5 minutes after de-energizing. Check no-voltage before handling UPS. Be
careful of the devices even when the UPS has been de-energized, since internal
devices may be energized.
WARNING
56
G2020 Series UPS Installation and Operation Manual – 94861-000
e.) If stopping both the Inverter and Converter is required, open the Battery Disconnect circuit
breaker CB2. (Figure 5-19)
Figure 5-19 Open Battery Breaker
!
When "REMOTE OPERATION MODE" is displayed on the LCD panel, the inverter
start operation can only be performed remotely. If local inverter stop operation is
required (at the UPS), select "LOCAL ONLY" or “REMOTE & LOCAL” in the
OPERATION MENU.
NOTE
Verify the load is OFF if the next step is to be performed.
WARNING
!
Power to the critical load is supplied through the bypass line.
Power to the critical load will be lost after execution of the next step. The
load will drop.
NOTE
f.)
If a dual source is feeding the UPS, open the External AC Input Circuit Breaker (user supplied)
manually.
g.) If turning off all power to the critical load is required, open the External Bypass Input Circuit
Breaker (user supplied) manually.
G2020 Series UPS Installation and Operation Manual – 94861-000
57
E) MMS Start-up Procedure
External Circuit Check (Ensure System is in Maintenance Bypass)
1. Verify that Tie cabinet Maintenance bypass breaker 52MB is closed.
2. Verify that Tie cabinet Output breaker 52CS is open.
3. Verify that Tie cabinet UPS breakers 52L1, 52L2…and 52Ln are closed.
Start-up from UPS-1 to UPS-n
1. Start-up each UPS in accordance with “A) Start-up Procedure”. Each UPS will start Inverter
Operation synchronized with the bypass input.
The Maintenance Bypass Switch is
synchronized with the Static Transfer Switch.
Transfer from Maintenance Bypass to MMS Bypass Operation
1. Close Tie cabinet breaker 52CS.
2. Open Tie cabinet Breaker 52MB.
!
NOTE
When "REMOTE OPERATION MODE" is displayed on the LCD panel, the inverter
start operation can only be performed remotely. If local inverter start operation is
required (at the UPS), select "LOCAL ONLY" or “REMOTE & LOCAL” in the
OPERATION MENU.
Transfer from UPS MMS Bypass Operation To UPS MMS Inverter Operation
1. Transfer MMS Bypass Operation to MMS Inverter Operation from Operation Menu on any UPS
LCD as shown in Figure 5-20.
Transfer from UPS MMS Inverter Operation To UPS MMS Bypass Operation
1. Transfer MMS Inverter Operation to MMS Bypass Operation from Operation Menu on any UPS
LCD as shown in Figure 5-20.
Figure 5-20 LCD Screen (MMS Operation)
58
G2020 Series UPS Installation and Operation Manual – 94861-000
6
RESPONSE TO UPS FAILURE
UPS FAULT
Annunciator Silence
Recording of Fault
Depress “SILENCE ALARM” icon on Main Menu.
Refer to the list of fault codes in section 6.0 for error description.
Take necessary action according to display guidance.
Primary Action
Information to Service
When faults happen, contact the Authorized Toshiba Service
Representatives or call Toshiba International Corporation at
1-877-867-8773.
!
NOTE
Note
The error code indicated on the LCD display panel when an UPS
alarms is very important.
In order to reduce repair time, please include this information,
along with the operation and load status for all correspondence to
Toshiba field service group.
G2020 Series UPS Installation and Operation Manual – 94861-000
59
7
PARTS REPLACEMENT
A) Recommended Maintenance
Toshiba International Corporation recommends the UPS have regular preventative
maintenance (PM) visits to ensure optimum operation and longevity. Toshiba recommends two
Major PM’s per year, at six month intervals.
A Major PM includes maintenance of the batteries and an offline inspection of the UPS.
Contact Toshiba International Corporation Service Department at 1-877-867-8773 for further
details.
B) Battery
Battery lifetime may vary according to the frequency of use and the average ambient
operating temperature. The end of battery life is defined as the state of charge resulting in an
ampere-hour capacity less than, or equal to, 80% of nominal capacity.
Battery replacement is recommended if its capacity is within this percentage.
C) UPS Component Parts
UPS components have a defined life expectancy (Fans, Capacitors, Filters, etc.)
Contact Toshiba International Corporation or its authorized service representatives for a
complete parts replacement schedule. Recommended replacement time interval varies with
operating environment.
Contact Toshiba International Corporation or its authorized service representatives for
application specific recommendations.
Table 7–1 Standard Replacement Parts List
Parts name
Cooling fans
Life Expectancy
5 years
Electrolytic Capacitors
15 years
AC filter Capacitors
15 years
Control Relays
15 years
Contactors
15 years
PCB
15 years
Control power supply
15 years
LCD
10 years
Fuses
10 years
Thermal relays
10 years
Any parts replacements (including modification) without authorized by
Toshiba could result in personal injuries, death or destruction of the
UPS.
WARNING
60
G2020 Series UPS Installation and Operation Manual – 94861-000
D) Air Filters
Air filters can be obtained in bulk quantities from Toshiba International Corporation. Use
only air filters specified by Toshiba.
Table 7–2 Replacement Air Filters
UNIT
500kVA
8
Toshiba Part Number
T90-AF-20x30x1
T90-AF-15x30x1
Quantity
1 (Left Door)
1 (Right Door)
FAULT CODES
This section covers fault codes, their description and required action at time of error.
In the event of a fault occurring:
A)
Verify and record the occurrence of the alarm. Note details of alarm message displayed on
the LCD display panel.
Contact Toshiba International Corporation at 1-877-867-8773.
B)
If a circuit breaker (MCCB) has tripped, depress the toggle to reset the breaker before closing
it again.
G2020 Series UPS Installation and Operation Manual – 94861-000
61
Table 8–1 Fault Code
Code
indication
(Note 3)
Status
message
UA801
AC INPUT
VOLTAGE OUT
OF RANGE
UA802
UA803
UA804
UA805
INVERTER
OVERLOAD
UA806
INVERTER
OVERLOAD
UA807
INVERTER
OVERLOAD
UA808
INVERTER
OVERLOAD
UA810
INVERTER
OVERLOAD
UA812
UA813
UA814
62
AC INPUT
FREQUENCY
OUT OF
RANGE
AC INPUT
PHASE
ROTATION
ERROR
CONVERTER
OPE.
INHIBITED
BYPASS
VOLTAGE OUT
OF RANGE
BYPASS
PHASE
ROTATION
ERROR
BYPASS
FREQUENCY
OUT OF
RANGE
UA815
TRANSFER
INHIBITED
UA817
EMERGENCY
STOP
ACTIVATED
UA821
TRANSFER
INHIBITED
UA822
TRANSFER
INHIBITED
UA824
CB2 OPEN
UA827
52C OPE.
INHIBITED
Meaning
Input line voltage is out of the
specific range.
Input line frequency is out of
the specified range.
Input line power conductors
are not wired in a proper phase
sequence.
The converter interlock is
active.
The output load current has
exceeded 105% of the rated
current.
The output load current has
exceeded 110% of the rated
current.
The output load current has
exceeded 125% of the rated
current.
The output load current has
exceeded 150% of the rated
current.
Short time over-current has
exceeded 150% of the rated
current
Bypass line voltage is out of
the specific range.
Bypass line power conductors
are not wired in a proper phase
sequence.
Bypass line frequency is out of
the specific range.
Transfer to bypass is not
available due to bypass
abnormality.
The emergency stop was
activated by the EPO switch or
an external contact.
The UPS cannot transfer to the
bypass because the inverter
output is not synchronized to
the bypass.
The UPS cannot transfer to the
bypass because of backup
generator operation.
The battery circuit breaker
(CB2) is open.
The interlock for the inverter
output contactor (52C) is
active.
Buzzer
External
relay contact
(Note 1)
Failure
lamp
(Note 2)
Intermittent
sound
AC input
abnormal
-
Intermittent
sound
AC input
abnormal
-
Intermittent
sound
AC input
abnormal
-
Intermittent
sound
-
-
Intermittent
sound
Overload
-
Intermittent
sound
Overload
-
Intermittent
sound
Overload
-
Intermittent
sound
Overload
-
Intermittent
sound
Overload
-
Intermittent
sound
Bypass
Input
Abnormal
-
Intermittent
sound
Bypass
Input
Abnormal
-
Intermittent
sound
Bypass
Input
Abnormal
-
-
Intermittent
sound
-
-
-
-
-
-
-
-
-
-
-
-
-
-
TURN ON
CB2
Intermittent
sound
-
-
-
Intermittent
sound
-
-
Guidance
CHECK
INPUT
POWER
SOURCE
CHECK
INPUT
POWER
SOURCE
CHECK
INPUT
POWER
SOURCE
WARNING:
DECREASE
LOAD
WARNING:
DECREASE
LOAD
WARNING:
DECREASE
LOAD
WARNING:
DECREASE
LOAD
WARNING:
DECREASE
LOAD
CHECK
BYPASS
INPUT
CHECK
BYPASS
INPUT
CHECK
BYPASS
INPUT
G2020 Series UPS Installation and Operation Manual – 94861-000
Code
indication
(Note 3)
Status
message
UA831
EMERGENCY
BYPASS SWITCH
ON
UA833
52L OPEN
UA834
BATTERY
DEPLETED/AC
OUT STOPPED
UA835
TRANSFER
INHIBITED
UA841
CONVERTER
OPE. INHIBITED
UA860
REMOTE
BUTTON
ABNORMAL
UA861
LOCAL BUTTON
ABNORMAL
Guidance
Buzzer
External
relay contact
(Note 1)
Failure
lamp
(Note 2)
Emergency bypass switch
has been turned on.
-
Intermittent
sound
-
-
The load circuit breaker
(52L) is turned off.
-
Intermittent
sound
-
-
The battery voltage has
reached the depleted level.
-
-
End-ofDischarge
Lit on
-
-
-
-
-
Intermittent
sound
-
-
-
Intermittent
sound
-
-
-
Intermittent
sound
-
-
-
-
-
-
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Meaning
BALANCER
OVERLOAD
EXTERNAL
ALARM
The UPS could not transfer
to the bypass because the
bypass source has an
abnormality.
The interlock for the
converter input contactor
(CB1) is active on external
input.
Remote start signal is being
received continuously for a
considerable time.
Local start or stop signal is
being received continuously
for a considerable time.
The UPS detected a neutral
point voltage unbalance.
External Alarm relay turned
on.
UF001
INPUT CIRCUIT
ABNORMAL
Detection of a large variation
of the reference error signal.
UF002
CONVERTER
OVERCURRENT
Detection of converter
overcurrent.
UF003
CONVERTER
ABNORMAL
Pre-charging circuit is not
working properly.
UF004
CONVERTER
OVERCURRENT
Detection of converter
overcurrent.
UF011
CB1 ABNORMAL
UF052
CB1 ABNORMAL
UF056
CONVERTER
OVERCURRENT
Detection of converter
overcurrent.
UF057
CONVERTER
OVERCURRENT
Detection of converter
overcurrent.
UF059
INPUT CIRCUIT
ABNORMAL
Detection of a large variation
of the reference error signal.
UF102
DC
OVERVOLTAGE
DC voltage surpasses the
overvoltage level.
UF103
DC
UNDERVOLTAGE
DC voltage dropped below
the undervoltage level.
UA870
UA890
Major discrepancy between
reference signal and actual
state of contactor CB1.
Minor discrepancy between
reference signal and actual
state of contactor CB1.
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
Intermittent
sound
Intermittent
sound
G2020 Series UPS Installation and Operation Manual – 94861-000
63
Code
indication
(Note 3)
Meaning
UF108
CHOPPER
OVERCURRENT
Detection of DC overcurrent.
UF109
DC UNBALANCED
Major unbalance of the
neutral point voltage.
UF110
ZERO PHASE
OVERCURRENT
Detection of converter
zero-sequence overcurrent.
UF112
DC CIRCUIT
ABNORMAL
Sudden change of the DC
voltage level.
UF113
DC CIRCUIT
ABNORMAL
Unit current unbalance.
UF119
DC GROUND
FAULT
Detection of DC ground
fault.
UF128
CONTROL
POWER SUPPLY
ABNORMAL
UF151
DC VOLTAGE
ABNORMAL
UF152
DC VOLTAGE
ABNORMAL
Power supply voltage to SiC
driver PCB is below the
specified level.
24 hours after input power
restoration, batteries do not
reach float voltage level.
Unable to equalize the
voltage of various batteries
after 24 hours.
UF154
CB2 ABNORMAL
UF156
UF157
64
Status
message
CHG.STOPPED
(BATTERY
OVERTEMP.)
BATTERY
OVERTEMPERA
TURE
During UVT, status signal
from CB2 is ON.
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuouss
ound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
CHECK
BATTERY
Intermittent
sound
Detection of DC ground fault
(L).
UF161
CHG.STOPPED
(DC VOLT.
ABNORMAL)
UF151 failure is running for
over 24 hours.
UF162
BATTERY
ABNORMAL
Failure detection based on
battery self-check.
UF163
BATTERY
VOLTAGE
ABNORMAL
Battery voltage is
abnormality.
GROUND FAULT
Major
CHECK
BATTERY
GROUND FAULT
UF159
Continuous
sound
Detection of over
temperature at the batteries.
UF159
CHG.STOPPED
(DEVICE
STATUS)
Failure
lamp
(Note 2)
Intermittent
sound
Low level of battery
electrolyte solution.
UF172
External
relay contact
(Note 1)
CHECK
BATTERY
BATTERY LIQUID
LOW
VDB SENSOR
ABNORMAL
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
Buzzer
UF157 failure persisted for
over 2 hours.
UF158
UF170
Guidance
Detection of a large variation
of the difference between
control-only and
protection-only battery
voltage.
Energy storage device
abnormal
Detection of DC ground fault
(M).
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
Minor
Battery
abnormal
Minor
Battery
abnormal
Minor
Battery
abnormal
Flicker
Flicker
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
G2020 Series UPS Installation and Operation Manual – 94861-000
Code
indication
(Note 3)
Status
message
Meaning
UF201
INVERTER
OVERVOLTAGE
Detection of output
overvoltage.
UF202
INVERTER
UNDERVOLTAGE
Output voltage dropped.
UF203
INVERTER
OVERCURRENT
Detection of inverter
overcurrent.
UF204
OUTPUT
CIRCUIT
ABNORMAL
UF206
UPS CONTROL
CIRCUIT ERROR
UF207
ZERO PHASE
OVERCURRENT
Inverter zero-sequence
overcurrent.
UF208
UPS CONTROL
CIRCUIT ERROR
Cross current is abnormality.
UF209
52C ABNORMAL
Error to close the contactor
52C.
UF210
52C ABNORMAL
Error to open the contactor
52C.
UF211
52C ABNORMAL
No answer from contactor
52C during inverter
operation.
UF213
OVERTEMPERAT
URE
Heat sinks temperature
exceeds thermal settings.
UF214
COOLING FAN
ABNORMAL
Thermal relay activated
protection.
UF217
INVERTER
OVERVOLTAGE
Detection of inverter output
phase overvoltage.
UF230
ZERO PHASE
OVERCURRENT
Detection of zero-sequence
overcurrent.
UF253
UPS CONTROL
CIRCUIT ERROR
UF256
OUTPUT
VOLTAGE
ABNORMAL
Discrepancy between output
voltage and inverter voltage,
or between output voltage
and bypass voltage.
UF257
52C ABNORMAL
UF258
LOAD
ABNORMAL
UF259
ANOTHER UPS
ABNORMAL
Detection of a large variation
of the reference error signal
(current reference and actual
current).
Discrepancy between output
voltage and external voltage
(bypass, common ac bus)
Output voltage is out of the
specified range.
Contactor 52C failed to open
during load transfer from
inverter to bypass.
Load transfer due to
overload for over 4 times
within 5 minutes.
No detection of another UPS
voltage signal.
Buzzer
External
relay contact
(Note 1)
Failure
lamp
(Note 2)
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Guidance
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
G2020 Series UPS Installation and Operation Manual – 94861-000
65
Code
indication
(Note 3)
Status
message
UF301
UPS CONTROL
CIRCUIT ERROR
UF302
UPS CONTROL
CIRCUIT ERROR
UF303
UPS CONTROL
CIRCUIT ERROR
UF305
UPS CONTROL
CIRCUIT ERROR
UF306
UPS CONTROL
CIRCUIT ERROR
UF309
UF310
66
INVERTER
VOLTAGE
ABNORMAL
CONTROL
POWER SUPPLY
ABNORMAL
Meaning
AD reference has an
abnormal value.
Detection of an external
interruption during the
software execution.
Timer does not reset in the
specified period (WDT
settings)
Detection of an abnormal
clock speed in the DSP or
FPGA.
Control power supply voltage
is below the specified level.
Inverter voltage is out of the
specified range.
Backup control power
supplies exhibit abnormal
condition.
Cable disconnection in the
parallel interface board
during load supply.
UF320
UPS CONTROL
CIRCUIT ERROR
UF323
UPS CONTROL
CIRCUIT ERROR
Major communication error
during parallel operation.
UF331
UPS CONTROL
CIRCUIT ERROR
Major abnormal detected in
the converter unit
UF332
UPS CONTROL
CIRCUIT ERROR
Major abnormal detected in
the inverter unit
UF333
UPS CONTROL
CIRCUIT ERROR
Major abnormal detected in
the chopper unit
UF334
UPS CONTROL
CIRCUIT ERROR
Major abnormal detected in
the converter unit
UF352
CONTROL
POWER SUPPLY
ABNORMAL
UF363
UPS CONTROL
CIRCUIT ERROR
Backup control power
supplies exhibit abnormal
condition.
Synchronization status
signal is being received for a
considerable time.
UF371
UPS CONTROL
CIRCUIT ERROR
Minor communication error
during parallel operation.
UF372
UPS CONTROL
CIRCUIT ERROR
Unable to synchronize the
inverter output and the
bypass voltage.
UF374
UPS CONTROL
CIRCUIT ERROR
Cable disconnection in the
parallel interface board.
UF375
UPS CONTROL
CIRCUIT ERROR
UF376
UPS CONTROL
CIRCUIT ERROR
Unable to achieve
synchronization for parallel
operation.
No control response from
another UPS although its
detection is possible.
Guidance
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
Buzzer
External
relay contact
(Note 1)
Failure
lamp
(Note 2)
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittents
ound
Minor
Flicker
G2020 Series UPS Installation and Operation Manual – 94861-000
Code
indication
(Note 3)
Status
message
Meaning
Guidance
UF377
UPS CONTROL
CIRCUIT ERROR
Overload detection signal is
being received continuously
for a considerable time.
UF378
UPS CONTROL
CIRCUIT ERROR
No answer for sending
synchronizing signal.
UF379
UPS CONTROL
CIRCUIT ERROR
Abnormal clock speed of the
parallel control board
processor.
UF401
52S ABNORMAL
Error to close the contactor
52S.
UF402
52S ABNORMAL
Error to open the contactor
52S.
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
UF420
52L OPERATION
ERROR
UF451
52S ABNORMAL
UF452
CB3 ABNORMAL
Load circuit breaker 52L
opened during inverter
operation.
Contactor 52S failed during
load transfer from inverter to
bypass.
Contactor CB3 is not
working properly.
CHECK 52L
CALL
SERVICE
ENGINEER
CALL
SERVICE
ENGINEER
Buzzer
External
relay contact
(Note 1)
Failure
lamp
(Note 2)
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Continuous
sound
Major
Lit on
Intermittent
sound
Minor
Flicker
Intermittent
sound
Minor
Flicker
(Note 1)
1) "Major" is defined as a major failure. Load transferred from the inverter circuit to the static
bypass line;
2) "Minor" is defined as a minor failure. UPS continues to operate normally, but cause of alarm
must be identified;
(Note 2)
Indicates one of two possible LED illumination patterns – continuously on (lit on) or intermittent
(flicker).
(Note 3)
Code indication means:
UA+++ ----------------------UF+++ ----------------------U%0++ ----------------------U%1++ ----------------------U%2++ ----------------------U%3++ ----------------------U%4++ ----------------------U%8++ ----------------------U%+00 - U%+49 --------U%+50 - U%+99 --------*)
*)
Alarm
Failure
Rectifier circuit failure
DC circuit failure
Inverter circuit failure
Control circuit failure
Bypass system failure
Alarm
Major failure
Minor failure
“+” denotes any numeral from 0 to 9
“%” denotes either “A” or “F”
G2020 Series UPS Installation and Operation Manual – 94861-000
67
9
DAILY INSPECTION
Please perform the daily inspection while the UPS is running. The daily inspection items are shown in
Table 9–1.
!
The customers can only inspect exterior or environment of cabinet. When the
customers want to perform the detailed inspection, contact the Authorized Toshiba
Service Representatives or call Toshiba International Corporation at 1-877-867-8773.
NOTE
Table 9–1 How to Perform Daily Inspection
No. Subject
Procedure
Term
1.
2.
3.
4.
68
Environmental
ambient
Cabinet
Construction
Operation
LEDs
Period
Criteria and/or Action needed
Method/Tool
Dust or Gas
Daily
Visual check and
smelling
Ventilate room atmosphere if dusty or smelling gas.
Dewdrops
Condensation
Daily
Visual check
Fix the dripping source
Dehumidify upon necessity.
Temperature
Humidity
Daily
Thermometer
hygrometer
Temperature: 32 – 104 °F Humidity: 30 – 90%
No condensation.
To be controlled at about 77 °F by A/C.
Vibration or
Audible noise
Daily
Touch and hearing
Check if fans have irregular sound.
Contact service representative in case of
abnormalities.
Overheating
When needed Touching exterior
Contact service representative in case of
abnormalities.
Air filter clog
When needed Visual check
Clean/wipe if clogged or dusty.
LCD sharpness
Brightness
Left-bottom LED
Daily
Visual check
No characters faded, illegible, or any other
abnormalities.
Left-bottom LED should be green.
Contact service representative when the LED shows
red with the backlight lost.
Indication terms:
Output voltage
Output current
AC input voltage
Output frequency
Battery voltage
Battery current
DC voltage
Daily
Visual check
Check indication terms/values if within the adequate
window.
Also check indication meters on surface of optional
cabinet, if installed.
4 status LEDs
Daily
Visual check
Check if LEDs turn on, off or flash according to the
operation.
2 fault LEDs
Daily
Visual check
If UPS fault LED turns on, scroll the screen to see
fault codes and record the codes.
Contact service representative to tell about fault
codes and UPS symptom.
G2020 Series UPS Installation and Operation Manual – 94861-000
APPENDIX A
Installation Planning Guides (IPG)
Installation Planning Guide for 500kVA UPS
Standard System: 480V Input, 480V Output
General Mechanical Information
Dimensions
(W x D x H)
Inches
Weight
Lbs.
59.1” x 33.5” x 80.6”*
2,756
Floor
Loading
Lbs./ft. 2
201
Approximate Full-Load
Heat Rejection
BTU/Hr
31,200
* Height includes removable fan housing – Frame height is 78.7”.
** 0” clearance for peripheral equipment, 1” clearance for walls.
Mechanical Clearance (Inches)from UPS
for Ventilation and Maintenance Access
Top
Front
Bottom
Sides**
24”
40”
0”
0”
Back
0”
Primary AC Input (480V 3-Phase / 3-Wire)
Maximum Input Power Demand
Normal Mode (Recharge Mode)
Suggested External
Overcurrent Protection
External Feeder Wire Size: Min. – Max. Per Phase
kVA
PF
Amps
Amps
AWG or kcmil at 75º C Temp. Rating
509 (560)
>0.99
612 (673)
800 AT
(3) x 300 kcmil – (3) x 350 kcmil
Alternate (Bypass) AC Input (480V 3-Phase / 3-Wire)
Maximum Input Power Demand
Suggested External
Overcurrent Protection
External Feeder Wire Size:
Min. – Max. Per Phase
kVA
PF
Amps (Max.)
Amps
AWG or kcmil at 75º C Temp. Rating
500
1.0
601
800 AT
(3) x 300 kcmil – (3) x 350 kcmil
Battery Input (480VDC Nominal)
Battery Capacity Required
for Full Load Output
Suggested External Overcurrent Protection
Three (3) Cabinets in parallel:
DC Cable Size per Cabinet***
kWB
Amps
AWG or kcmil at 75º C Temp. Rating
N/A – Toshiba-Supplied Battery Cabinets
518 @ 1.0 PF
1 x 500 kcmil (ea. Cabinet)
equipped with built-in overcurrent Protection
*** Contact Toshiba Factory Representative for different multiple Battery Cabinet Configurations.
AC Output (480V 3-Phase / 3-Wire)
Rated Output Power
Suggested External
Overcurrent Protection
kVA
PF
Amps
Amps
500
1.0
601
800 AT
Important Notes:
1. Maximum input current is limited to 106% of the full-load
input current.
2. Output load conductors are to be installed in separate
conduit from input conductors.
3. Control wires and power wires are to be installed in separate
conduits.
4. Recommended AC input and output overcurrent protection
based on continuous full load current per NEC.
5. Wiring shall comply with all applicable national and local
electrical codes.
6. Grounding conductors to be sized per NEC Article 250-122.
Neutral conductors to be sized per NEC Article 310.15.
•
Primary AC Input: 3φ, 3-wire + ground.
•
Alternate AC Input: 3φ, 3-wire + ground.
•
AC Output: 3φ, 3-wire + ground.
•
DC Input: 2-wire (Positive/Negative) + ground.
7. Nominal battery voltage based on the use of VRLA type
batteries (2.0 volts/cell nominal).
8. Maximum battery discharge current based on lowest
permissible discharge voltage of 1.67 VPC.
9. DC wires should be sized to allow not more than a 2-volt
drop at maximum discharge current.
External Feeder Wire Size:
Min. – Max. Per Phase
AWG or kcmil at 75º C Temp. Rating
(3) x 300 kcmil – (3) x 350 kcmil
10. Weights do not include batteries or other auxiliary equipment
external to the UPS.
11. Cable sizing calculations based on the following assumptions:
• Minimum size is smallest size based on ampacity at 30 °C.
• Maximum size cable is based on cable bend radius
limitations at the UPS terminals.
• Not more than 3 current-carrying conductors installed in
conduit in ambient temperature of 30 °C.
• Temperature rating of copper conductors/terminals: 75 °C in
conduit.
• Reference: 2005 NEC Handbook, Table 310.16.
NOTE: Consult latest edition of applicable national and
local codes for possible variations.
12. Ratings of wires and overcurrent devices are suggested
minimums. Consult with a registered Professional Engineer
within your local area for proper size selections.
TOSHIBA INTERNATIONAL CORPORATION
Social Infrastructure Systems Group
Power Electronics Division
13131 West Little York Road
Houston, TX 77041
Telephone: (877) 867-8773
Fax: (713) 896-5212
Web Site:
www.toshiba.com/tic/industrial/uninterruptible-power-systems
G2020 Series UPS Installation and Operation Manual – 94861-000
69
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G2020 Series UPS Installation and Operation Manual – 94861-000
G2020 Series UPS Installation and Operation Manual – 94861-000
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G2020 Series UPS Installation and Operation Manual – 94861-000
SOCIAL INFRASTRUCTURE SYSTEMS GROUP
POWER ELECTRONICS DIVISION
13131 West Little York Rd., Houston, TX 77041
Tel: 713/466-0277 Fax 713/896-5212
US 877-803-7087 Canada 800-872-2192
www.toshiba.com/tic/industrial-systems/uninterruptible-power-systems
Printed in Japan

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