G9000 Series 1000kVA Installation and Operation Manual

G9000 Series 1000kVA Installation and Operation Manual
UNINTERRUPTIBLE POWER SYSTEM (UPS)
G9000 SERIES
INSTALLATION AND
OPERATION MANUAL
480/480 V 1000kVA
Document No.: 91649-006
Reference: 4GBA0051 Rev. C
June 2015
G9000 1000kVA Installation and Operation Manual 91469-006
G9000 SERIES
INSTALLATION AND OPERATION MANUAL
480/480 V
1000 kVA
Document No. 91469-006
Reference: 4GBA0051 Rev. C
June 2015
G9000 1000kVA Installation and Operation Manual 91469-006
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 1-800-231-1412, 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:
G9000 1000kVA Installation and Operation Manual 91469-006
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 (855) 803-7087.
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/uninterruptible-power-systems
.
G9000 1000kVA Installation and Operation Manual 91469-006
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G9000 1000kVA Installation and Operation Manual 91469-006
Table of Contents
List of Figures .......................................................................................................... ii
List of Tables ........................................................................................................... iii
1 HOW TO USE THIS MANUAL............................................................................. 1
2 INTRODUCTION .................................................................................................. 2
2.1
2.2
2.3
2.4
3
4
SAFETY PRECAUTIONS ....................................................................................................... 2
GENERAL ............................................................................................................................... 5
DEFINITIONS.......................................................................................................................... 6
OPERATION OVERVIEW ....................................................................................................... 7
SPECIFICATIONS ............................................................................................. 14
OPERATOR CONTROLS AND INDICATORS .................................................. 18
4.1
LED DISPLAY ....................................................................................................................... 18
4.2
EPO BUTTON (Emergency Power Off Button) (7) ............................................................... 19
4.3
LIQUID CRYSTAL DISPLAY (8) ........................................................................................... 19
4.3.1 Test Mode Options ............................................................................................................ 19
4.3.2 Menu ................................................................................................................................. 20
4.3.3 Input Power Failure ........................................................................................................... 23
4.3.4 Fault Indication .................................................................................................................. 23
EXTERNAL SIGNAL TERMINAL BLOCK ............................................................................ 25
4.4
5
RemotEye 4 Introduction ................................................................................. 29
5.1
5.2
6
INSTALLATION AND OPERATION .................................................................. 32
6.1
6.2
6.3
7
8
9
Purpose ................................................................................................................................. 29
Instalation Overview .............................................................................................................. 29
TRANSPORTATION AND INSTALLATION.......................................................................... 32
PROCEDURE FOR CABLE CONNECTIONS * .................................................................... 33
OPERATING PROCEDURES............................................................................................... 44
RESPONSE TO UPS FAILURE......................................................................... 48
MAINTENENACE AND PARTS REPLACEMENT ............................................ 49
FAULT CODES .................................................................................................. 50
9.1
9.2
BYPASS MODULE FAULT CODES ..................................................................................... 50
UPS MODULE FAULT CODES ............................................................................................ 54
10 DAILY INSPECTION....................................................................................... 57
APPENDIX A – Installation Planning Guide (IPG) ................................................ 59
G9000 1000kVA Installation and Operation Manual 91469-005
i
List of Figures
Figure 2-1
Single Line Diagram – Normal Operation: Load powered by UPS inverter .................... 7
Figure 2-2
Single Line Diagram – Bypass Operation: Load fed through static bypass line ............. 9
Figure 2-3
Single Line Diagram - Battery Operation ...................................................................... 10
Figure 2-4
UPS Parts Location ....................................................................................................... 12
Figure 2-5
UPS Parts Location – Front Inside View ....................................................................... 13
Figure 4-1
Operation/Display Panel (Front panel) .......................................................................... 18
Figure 4-2
Main Screen .................................................................................................................. 20
Figure 4-3
Start/Stop Guidance ...................................................................................................... 21
Figure 4-4
Start Guidance .............................................................................................................. 21
Figure 4-5
Stop Guidance ............................................................................................................... 21
Figure 4-6
Input Values .................................................................................................................. 22
Figure 4-7
Output values ................................................................................................................ 22
Figure 4-8
Remote/Local operation and Date & Time adjustment select ....................................... 22
Figure 4-9
Log menu....................................................................................................................... 23
Figure 4-10
Event Log .................................................................................................................... 23
Figure 4-11
Battery log ................................................................................................................... 23
Figure 4-12
Main Screen
Figure 4-13
Measurement screen (Battery Operation) ................................................................... 23
Figure 4-14
Main screen (Fault indication) ..................................................................................... 24
Figure 4-15
Message Screen ......................................................................................................... 24
Figure 4-16
External Signal Terminal Block TN21-25 (NEC Class2) ............................................. 25
Figure 4-17
External Signal Terminal Block TN11-14 (NEC Class2) ............................................. 25
Figure 4-18
Control Wiring for External Contacts ........................................................................... 26
Figure 4-19
Remote "Start" Contact Connections .......................................................................... 27
Figure 5-1
Location of RemotEye 4 Option in Bypass Module ....................................................... 29
Figure 5-2
Detailed Configuration of RemotEye 4 Options ............................................................ 30
(Battery Operation) .............................................................................. 23
Figure 5-3
IOAU-19 (IO1) and RemotEye 4 Connection - Detail ................................................... 31
Figure 5-4
External Communications Connector (NEC Class 2) ................................................... 31
Figure 6-1
UPS Terminal Designation ............................................................................................ 38
Figure 6-2
Diagram of input/output bus bars and terminal blocks .................................................. 39
Figure 6-3
Diagram of Power Wire & Control Wire Interconnections between UPS and Battery .. 39
Figure 6-4
Diagram of power wire connections (Parallel Operation system connection) ............... 41
Figure 6-5
Diagram of Power Wire & Control Wire Connect (Parallel Operation system connection
2x to 8x) ............................................................................................................................................. 42
ii
Figure 6-6
Detail: IFAU-16A Control Wire Connections for N units in MMS Configuration ............ 43
Figure 6-7
LCD Screen (MMS Operation) ...................................................................................... 47
G9000 1000kVA Installation and Operation Manual 91469-006
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 ..................................................................................................... 14
Table 3–2
UPS Cabinet Information ............................................................................................... 14
Table 3–3
UPS Shipping Dimensions............................................................................................. 14
Table 3–4
Specifications ................................................................................................................. 14
Table 3–5
Typical UPS Efficiencies at Various Load ..................................................................... 16
Table 3–6
MTBF of 1000kVA ......................................................................................................... 16
Table 3–7
Rating of Contactors, Breaker and Fuses ..................................................................... 16
Table 5–1
Parts List for RemotEye 4 UPS Monitoring Options ...................................................... 30
Table 6–1
How to transport and install the system ......................................................................... 32
Table 6–2
List of UPS weights ........................................................................................................ 32
Table 6–3
Maximum Permitted Fault Current ................................................................................. 33
Table 6–4
Recommended Cable Sizes .......................................................................................... 36
Table 6–5
Recommended Hardware .............................................................................................. 36
Table 6–6
Crimp Type Compression Lug ....................................................................................... 37
Table 6–7
Jumper Status on IFAU16A (Parallel Interface Board) .................................................. 43
Table 8–1
Standard Replacement Parts List .................................................................................. 49
Table 8–2
Ait Filters ........................................................................................................................ 50
Table 9–1
Bypass Module Fault Code List ..................................................................................... 50
Table 9–2
UPS Module Faults Code List........................................................................................ 54
Table 10–1
How to Perform Daily Inspection ................................................................................. 57
G9000 1000kVA Installation and Operation Manual 91469-005
iii
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iv
G9000 1000kVA Installation and Operation Manual 91469-006
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.
G9000 1000kVA Installation and Operation Manual – 91469-006
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
This manual contains important instructions for the G9000 SERIES Uninterruptible Power
Supply System that should be followed during installation and maintenance of the UPS and
batteries.
WARNING
1
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.
WARNING
2
In no event will TOSHIBA be responsible or liable for either indirect or
consequential damage or injury that may come from the use of this
equipment.
Any modifications without authorization by TOSHIBA could result in personal
injuries, death or destruction of the UPS.
2.1
SAFETY PRECAUTIONS
APPLICATION
2
G9000 1000kVA Installation and Operation Manual – 91469-006
This UPS shall NOT be applied to support equipment (*) that could affect human
lives.
* • Life support equipment in medical operation rooms (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.
**
!
• 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.
NOTE
!
WARNING
3
NOTE
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:
G9000 1000kVA Installation and Operation Manual – 91469-006
3
Table 2–1 UPS Installation Environment
No
4
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
Relative
Humidity
The relative humidity must be held between 5 and 95%. There must be
no condensation due to temperature changes.
4
Altitude
This equipment must not be applied at altitude that exceeds 1980m
(6500ft) 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
Part 4
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
G9000 1000kVA Installation and Operation Manual – 91469-006
WARNING
4
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)
1000
Bypass Voltage
(Vac)
480
Bypass Rating
(Aac)
1203
Breaker (A)
1600
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 1.6.
2.2
GENERAL
The TOSHIBA G9000 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, back up 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 G9000 SERIES UPS is available in 100, 160, 225, 300, 500, 750, and 1000 kVA. This
manual covers the 1000 kVA mode only. Specifications are shown in Section 1.5.
This manual provides an overview of the G9000 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.
G9000 1000kVA Installation and Operation Manual – 91469-006
5
2.3
DEFINITIONS
UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS
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 CABINET – The metal enclosure which is the main part of UPS and composed of the
Bypass module, the 3 UPS modules, and the Cable Entry Section.
UPS MODULE – The metal enclosure which contains the Converter / Inverter, Charger, and
internal control systems required to provide specified AC power to a load.
CONVERTER / INVERTER – The UPS components which contain the equipment and controls
necessary to convert input AC power to output AC power required by the critical load.
CHARGER – The UPS components which contain the equipment and controls necessary to
regulate DC power required for battery charging and for supplying power to the Inverter.
BYPASS MODULE – The metal enclosure which contains the Bypass line, the Static transfer
switch, UPS operator controls, and internal control systems.
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.
STATIC TRANSFER SWITCH – The device which connects the critical load to the bypass line
when the Inverter cannot supply continuous power.
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.
6
G9000 1000kVA Installation and Operation Manual – 91469-006
2.4
OPERATION OVERVIEW
The UPS provides two power paths between the utility source and the critical load.
Figure 1.1 shows the path for normal operation, with the load powered from the inverter. Figure
1.2 shows the path for bypass operation, with the load supplied through the static bypass line.
A)
Normal operation: Load power supplied by each system UPS inverter.
CB
Bypass
Input
52 S
Bypass Module
Output
supplied
MCCB
CB 3
Static Transfer
Switch
CONVERTER / INVERTER
CB
AC
input
CB1
52 C
Output
User
supplied
MCCB
CB2
CHARGER
UPS Module
CB
Battery
CONVERTER / INVERTER
CB1
Cabinet
52 C
External
BATTERY
Power Flow
CB2
CHARGER
UPS Module
Not in Use
CONVERTER / INVERTER
CB1
CB2
52 C
CHARGER
UPS Module
UPS
CABINET
Figure 2-1 Single Line Diagram – Normal Operation: Load powered by UPS inverter
During normal operation, the path through the UPS inverters is used to power the load.
Referring to Figure 2-1: 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 whenever the system
G9000 1000kVA Installation and Operation Manual – 91469-006
7
is in the Parallel Operation. (Refer to Figure 3.4 that shows a sample of Parallel Operation
System Configuration.)
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 circuit breaker (MCCB) for protection of the UPS and cables are
field supplied and field installed. (See WARNING 4 on page 5).
8
G9000 1000kVA Installation and Operation Manual – 91469-006
B) Bypass Operation: Load Power supplied through UPS internal static bypass line.
CB
Bypass
Input
52 S
Bypass Module
User
supplied
MCCB
CB 3
Static Transfer
Switch
CONVERTER / INVERTER
CB
AC
input
CB1
52 C
Output
User
supplied
MCCB
CB2
CHARGER
UPS Module
CB
Battery
CONVERTER / INVERTER
CB1
Cabinet
52 C
External
BATTERY
Power Flow
CB2
CHARGER
UPS Module
Not in Use
CONVERTER / INVERTER
CB1
CB2
52 C
CHARGER
UPS Module
UPS
CABINET
Figure 2-2 Single Line Diagram – Bypass Operation: Load fed through static bypass line
Referring to Figure 1.2: 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.
G9000 1000kVA Installation and Operation Manual – 91469-006
9
Each UPS internal static bypass line will equally share the power supplied to the critical load
whenever the system is in the Parallel Operation.
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.
C) Battery operation: Load Power supplied by UPS battery.
CB
52 S
Bypass Module
Bypass
Input
supplied
MCCB
CB 3
Static Transfer
Switch
CONVERTER / INVERTER
CB
AC
input
CB1
52 C
Output
User
supplied
MCCB
CB2
CHARGER
UPS Module
CB
CONVERTER / INVERTER
Battery
CB1
Cabinet
52 C
External
BATTERY
Power Flow
CB2
CHARGER
UPS Module
Not in Use
CONVERTER / INVERTER
CB1
CB2
52 C
CHARGER
UPS Module
UPS
CABINET
Figure 2-3 Single Line Diagram - Battery Operation
10
G9000 1000kVA Installation and Operation Manual – 91469-006
Referring to Figure 1.3: 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:
(s)* : In the case of the Parallel Operation
a) The battery capacity expires and the inverter turns off, or
b) Input power is restored after which the converter will power the inverter and critical load
and simultaneously recharge the batteries.
A fully charged battery will provide power for the specified time at the rated load, or longer, at
a reduced load.
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.
G9000 1000kVA Installation and Operation Manual – 91469-006
11
1) UPS cabinet – Front View
.
LCD Touch Panel
Monitor Display
Bypass Module
UPS Module
Cable
Entry
Section
2) Backside of Bypass Module Door
LCD Touch Panel
Monitor Display
Display PCB
DPAU-89A
Main PCB
UPHR-SA
Figure 2-4 UPS Parts Location
12
G9000 1000kVA Installation and Operation Manual – 91469-006
3) UPS cabinet – Front Inside View
External I/F PCB
IOAU-19
52S
CB2
CB1(left), 52C(right)
(Back Side of PCB Unit)
CB3
Figure 2-5 UPS Parts Location – Front Inside View
G9000 1000kVA Installation and Operation Manual – 91469-006
13
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 Bypass Module door.
Table 3–1 Power Specifications
Rated output
Power
Input Voltage
3 phase / 3 wire
1000kVA / 1000kW
Bypass Input Voltage
3 phase / 3 wire
480V
Output Voltage
3 phase / 3 wire
480V
480V
Table 3–2 UPS Cabinet Information
UPS
[kVA]
1000
Width
in (mm)
Cable Entry
118.2
(3003.2)
BOTTOM / TOP /
LEFT SIDE
Depth
in (mm)
35.5
(901.6)
Height
in (mm)
80.7
(2048.6)
Weight
lb. (kg)
Heat Loss
kBTU / h
6283
(2850)
127.6
Table 3–3 UPS Shipping Dimensions
UPS
[kVA]
Section
Main Cabinet
1000
Landing Cabinet
Width
in (mm)
Depth
in (mm)
Height
in (mm)
91
(2311)
55
(1397)
44
(1118)
44
(1118)
90
(2286)
90
(2286)
Gross Weight
lb. (kg)
5304
(2406)
1612
(731)
Table 3–4 Specifications
Rated Output kVA
Rated Output kW
Configuration
Voltage
Frequency
Power Factor
Input kVA
(Max Input kVA)
Walk-in Function
Start-up Delay
Input Current Limiter
Reflected Current THD
Input Current
(Max Input Current)
No-Load Static Loss
Configuration
Voltage
Frequency
Bypass Overload
14
G9000 1000 kVA SPECIFICATIONS
1000 kVA
1000 kW
AC INPUT
3 phase, 3 wire
480 V +15% to -20%
60 Hz +/-10%
>.99 Lagging at 25% – 115% Load
1043 kVA
(1127 kVA)
1 –30 Seconds (in 1 second increments)
1 –3600 seconds (selectable in 1 second increments)
~108% Full Load Input Current
<3% at 100% load (No Input Filter Required)
1255 A
(1356 A)
7.4 kW
STATIC BYPASS INPUT
3 phase, 3 wire
480 V
+/-10%
60 Hz +/-5%
500% for 1 cycle
G9000 1000kVA Installation and Operation Manual – 91469-006
G9000 1000 kVA SPECIFICATIONS
BATTERY
Type
Lead Acid
Ride Through
Application Specific
Nominal Voltage
480 Vdc
Minimum Voltage
400 Vdc
Float Voltage
Up to 545 Vdc
Number of Cells
240
Max DC Ripple Current while
42 A
Charging
DC Ripple Current (% of Full
2.7%
Load Current)
Max DC Charge Current
200 A
Max. Discharge Current
2586 A
Batt. Capacity Required at
1036 kW
Full Load Output
AC OUTPUT
Configuration
3 phase, 3 wire
Voltage
480 V
Voltage Regulation
+/-1%
Voltage Unbalance
2% maximum at 100% unbalanced load
Voltage THD (VOUT)
2% maximum THD at 100% Linear Load
5% maximum THD at 100% Non-linear Load
Voltage Adjustment
±3% (User selectable)
Crest Factor
2.3
Transient Response
+/-2% maximum at 100% load step
+/-1% maximum at loss/return of AC power
+/-5% maximum at load transfer to/from static bypass
Transient Recovery
Less than 20ms
Output Current
1203 A
Frequency
60 Hz
Frequency Synch. Range
±1% to ± 5% (selectable in 1% increments)
Frequency Slew Rate
1 Hz/s to 5 Hz/s (selectable in 1 Hz/s increments)
Frequency Regulation
+/-0.01% in free running mode
Phase Displacement
1deg. maximum at 100% load
Power Factor
1.0 (unity)
Power Factor Range
0.7 lagging to 0.8 leading
Inverter Overload
125% for 10 minutes
150% for 60 seconds
System Overload
500% for 1 cycle
(with bypass available)
MTBF
w/ Bypass
2,600,000 hrs.
w/o Bypass
100,000 hrs.
Withstand Rating
100,000 AIC with Optional Fuses
ENVIRONMENTAL
Cooling
Forced Air
Operating Temperature
32゚F to 104゚F ( 0゚C to 40゚C).
Recommended : 68゚F to 86゚F ( 20゚C to 30゚C)
Relative Humidity
5% ~ 95% Non-Condensing
Altitude
0 to 6500 feet (1981 M) No Derating at 40゚C
Location
Indoor (free from corrosive gases and dust)
Paint Color
Munsell N1.5 (Black)
Clearance Required
Top: 24 in. (610 mm)
Front: 39 in. (991 mm)
Rear: 0 in. (0 mm)
Sides: 0 in. (0 mm) with sidecars,
1 in. (25 mm) if no sidecars used.
G9000 1000kVA Installation and Operation Manual – 91469-006
15
G9000 1000 kVA SPECIFICATIONS
NEMA 1
< 73 dB @ 1 m
ENERGY STAR® certified UPS, UL 1778; cUL; IEC 62040-2 Cat.
C3; ISO 9001; ISO14001; ANSI C62.41 (IEEE 587 Cat. B)
3 Years Parts and Labor
Included
MONITORING
Yes, for Input and Output Signals
Included
SNMP; MODBus RTU; MODBus TCP; BACNET; METASYS
Enclosure
Audible Noise
Listings/Standards
Warranty
Emergency Power Off
Dry Contacts Included
RS232 Port
Intelligent Monitoring
(Optional)
Display
LCD Touch Panel for Local Monitoring, Operation, and Control
Table 3–5 Typical UPS Efficiencies at Various Load
UNIT
25%
96.3
1000 kVA
% Full Load
50%
75%
97.0
97.1
100%
96.8
Table 3–6 MTBF of 1000kVA
UNIT
With Bypass
Without Bypass
Mean Time Between Failure
2,633,910 hrs.
101,687 hrs.
Table 3–7 Rating of Contactors, Breaker and Fuses
Breakers
Contactors
IDENTIFICATION
16
APPLICATION
OUTPUT CAPACITY OF EQUIPMENT
1000kVA / 1000kW
CB1
AC input contactor
452A
CB2
Battery contactor
285A
CB3
STS contactor
452A
52C
Inverter output contactor
452A
52S
Bypass contactor
1278A
88RC
Control circuit contactor
20A
User supply
Battery disconnect breaker
(Recommended)
3000A
User supply
AC input breaker
(Recommended)
1600A
User supply
Bypass input breaker
(Recommended)
1600A
FP, FC, FN
DC fuse
315A / 690V
FBP, FBN
DC fuse
1000A / 600V
G9000 1000kVA Installation and Operation Manual – 91469-006
IDENTIFIAPPLICATION
CATION
FBR1, FBR2, FBR3
FBR, FBS, FBT
Control power fuse
FBO1, FBO2, FBO3
FOA, FOB, FOC
FIA, FIB
Control power fuse
FUA, FUB, FUC
(OPTION)
Bypass input fuse
FSU, FSV, FSW
(OPTION)
Parallel control
FDU, FDV, FDW
circuit fuse (optional)
* Rating would be changed.
OUTPUT CAPACITY OF EQUIPMENT
1000kVA / 1000kW
G9000 1000kVA Installation and Operation Manual – 91469-006
30A / 600V
12A / 600V
2000A / 550V
3A / 600V
17
4
OPERATOR CONTROLS AND INDICATORS
The G9000 Series operator controls and indicators are located on the Bypass Module door exterior.
8
3
4
2
5
1
6
7
Figure 4-1 Operation/Display Panel (Front panel)
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".)
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G9000 1000kVA Installation and Operation Manual – 91469-006
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) (7)
When 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.
4.3
LIQUID CRYSTAL DISPLAY (8)
The Liquid Crystal Display (LCD) touch panel 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 LCD ERROR indicator is cleared after 24 hours and can be reproduced by pressing any key on
the panel.
4.3.1
Test Mode Options
Several parameters and functions are available if they are enabled by a Toshiba Field
Representative while the UPS is in Test Mode.
4.3.1.1
Battery Equalize Charge
The UPS "Equalize Charge" parameter is disabled by default unless the unit is sold with a wet cell
battery system.
The "Equalize Charge" button can be enabled by a Toshiba Service Representative while the UPS
is in Test Mode (Battery Run Setup).
Once enabled, the "Equalize ON/OFF" button is located
under OPERATION / SETUP.
To Initiate the Equalize Charge battery function, press the "Equalize ON/OFF" button.
Equalize
Charge will boost the charge voltage (500-640V) for the length of time (0-100 hrs.) specified during
setup.
G9000 1000kVA Installation and Operation Manual – 91469-006
19
4.3.1.2 Battery Self Check
The UPS "Battery Self Check" function provides a periodic battery self-check at preset intervals.
The parameter is disabled by default.
The adjustable Self Check cycle ships with a default setting of 720hrs.
hrs.
The minimum interval is 5
When the Self Check is initiated, the converter contributes 5% of the load to the inverter for up to
200ms. If the batteries cannot reach and contribute 5% of the load or if the battery voltage falls out
of tolerance, the unit will end the test and set an alarm.
4.3.2 Menu
A) MAIN MENU (Figure 4-2)
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)
Start/Stop Guidance (Figure 4-3 to Figure 4-5)
The display indicates the Start/Stop operation 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.
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G9000 1000kVA Installation and Operation Manual – 91469-006
-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.
Meaning of Icons in SMS (Single Module System)
INV START;
INV STOP:
START:
STOP:
UPS Module Startup
UPS Module Stop
Output Transfer from Bypass Line to Inverter.
Output Transfer from Inverter to Bypass Line.
Figure 4-3 Start/Stop Guidance
Figure 4-4
Start Guidance
Figure 4-5 Stop Guidance
Follow Start/Stop guidance accordingly.
G9000 1000kVA Installation and Operation Manual – 91469-006
21
B) MEASUREMENT MENU (Figure 4-6 and Figure 4-7)
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
C) OPERATION MENU (Figure 4-8)
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 4-8
Remote/Local operation and Date & Time adjustment select
D) LOG MENU (Figure 4-9 to Figure 4-11)
This LOG MENU displays two Touch icons in EVENT LOG and BATTERY LOG.
Pressing the EVENT LOG icon will display up to 50 condition/operation records. Press ▲ or ▼
button for turning pages.
Press the BATTERY LOG icon to display the Number of battery operations and Summed (Total)
battery operation time.
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G9000 1000kVA Installation and Operation Manual – 91469-006
Figure 4-9 Log menu
Figure 4-10 Event Log
Figure 4-11 Battery log
4.3.3 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 4-12 Main Screen (Battery
Figure 4-13 Measurement screen (Battery
Operation)
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.
4.3.4 Fault Indication
“MESSAGE” and “SILENCE ALARM” icons will appear on the main menu when UPS failure condition has
occurred.
G9000 1000kVA Installation and Operation Manual – 91469-006
23
Figure 4-14 Main screen (Fault indication)
The following will be displayed when the MESSAGE icon on the main menu is pressed.
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 4-15 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.
24
G9000 1000kVA Installation and Operation Manual – 91469-006
4.4
EXTERNAL SIGNAL TERMINAL BLOCK
The UPS is equipped with a series of input/output terminals for external annunciation of alarms and
for remote access of certain UPS functions. The layout of terminals is shown in Figure 4-16 with a
functional description of the input/output port presented. OUT1 to OUT8 are user programmable, but
are factory default set being also shown in Figure 4-16.
Adding same external I/F PCB “IOAU-19”, doubling signal outputs is applicable for OUT1 to OUT8.
Figure 4-16
External Signal Terminal Block TN21-25 (NEC Class2)
Figure 4-17
External Signal Terminal Block TN11-14 (NEC Class2)
G9000 1000kVA Installation and Operation Manual – 91469-006
25
A)
Output Contacts (for external alarm annunciation)
Output contacts consist of form “A” dry type contacts. Rated capacity of all output contacts is
NEC Class2 (30Vdc/1Adc). All dry contacts should be operated at their rated values or lower.
Figure 4-18 illustrates a typical installation. The external relay can also be a lamp, LED, computer,
etc.
UPS Cabinet
External to UPS
Cabinet
Terminal
Relay
Coil
Relay
Contact
Terminal
NEC Class 2
Power Source
User supplied
Figure 4-18
Control Wiring for External Contacts
Details of output alarm contacts : TN21-25
Terminals 1 to 2 "Summary Alarm" contact
Activated when a major fault has occurred with the system.
Terminals 3 to 4 "Load on Bypass" contact (OUT1)
Activated when the power is supplied from the static bypass input.
Terminals 5 to 6 "Load on Inverter" contact (OUT2)
Activated when the power is supplied by the inverter.
Terminals 7 to 8 "Battery Operation" contact (OUT3)
Activated when the battery is operating following an AC power failure.
Terminals 9 to 10 "Converter Operation" contact (OUT4)
Activated when the converter is operating.
Terminals 11 to 12 "Battery Low Voltage" contact (OUT5)
Activated when the battery voltage drops below discharge end voltage level during
inverter operation (i.e. During AC fail condition).
Terminals 13 to 14 "Overload" contact (OUT6)
Activated when an overload has occurred to the system.
Terminals 15 to 16 "Spare" contact (OUT7)
Terminals 17 to 18 "Total Alarm" contact (OUT8)
Activated during major fault, minor fault and alarm events.
Terminals 19 to 20 "52C Close" contact (OUT9)
Activated when the inverter output contactor 52C has closed.
26
G9000 1000kVA Installation and Operation Manual – 91469-006
NOTE: The UPS is equipped with a selectable output contact feature.
The above alarms are the default settings.
Contact TOSHIBA International Corporation for setup information.
B)
Input Contacts (for remote access to UPS)
External contacts are provided by the user of the UPS system. Terminal voltage at the UPS is
12Vdc. Provide external dry contact accordingly.
CAUTION:
Do not apply voltages to remote access input terminals.
Damage to UPS may result.
Refer to Figure 4-19 for a typical wiring configuration. Although this figure applies to the remote
start/stop terminals, the same wiring arrangement is used for emergency stop; power demand;
and battery temperature high.
External to
UPS Cabinet
UPS Cabinet
Relay
Coil
Start
Start
Switch
Common
0.5s – 4s
ON
OFF
24 VDC
Relay Coil current: 16.7 mA
Use Momentary
Switches Only
User supplied
Figure 4-19
Remote "Start" Contact Connections
G9000 1000kVA Installation and Operation Manual – 91469-006
27
Details of input contacts for remote access : TN11-14
Terminals 25 to 26 Remote "Inverter Start" input terminal (IN1)
Used to start inverter from a remote location. UPS must be programmed for remote
operation. Refer to Operations Menu for procedure.
Terminals 27 to 28 Remote "Inverter Stop" input terminal (IN2)
Used to stop inverter from a remote location. UPS must be programmed for remote
operation. Refer to Operations Menu for procedure.
Terminals 29 to 30 "Battery Temp. High" contact input (IN3)
Input fed by a thermocouple that monitors battery temperature. The converter float
voltage level is reduced for battery over-temperature conditions. External thermocouple
is user supplied
Terminals 31 to 32 "Power Demand” Command contact input (IN4)
This contact is used to control the input power. Power demand is turned ON when the
contact is closed, and power demand is turned OFF when the contact is open.
Terminals 33 to 34 "Remote EPO" contact input
Used to perform a remote UPS Emergency Power Off (EPO).
The load will be dropped.
NOTE:
The UPS is equipped with a selectable input contact item.
The above items are the default settings. Contact TOSHIBA International Corporation
for setup information.
CAUTION : In all cases, a switch having a protective cover is recommended in order to
reduce the possibility of accidental operation.
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G9000 1000kVA Installation and Operation Manual – 91469-006
5
RemotEye 4 Introduction
5.1
PURPOSE
The “RemotEye 4”* is available as a UPS system monitoring tool. The RemotEye 4 supplies a network
function to monitor UPS units via Simple Network Management Protocol (SNMP) and Hypertext Transfer
Protocol (HTTP) methods.
5.2
INSTALATION OVERVIEW
The RemotEye 4 module is installed on an option panel in the inside of Bypass Module. The location of the
RemotEye 4 option is shown in Figure 5-1 and Figure 2.14 shows the detailed configuration of the option.
RemotEye 4 Option
Figure 5-1 Location of RemotEye 4 Option in Bypass Module
G9000 1000kVA Installation and Operation Manual – 91469-006
29
RemotEye 4
CN84
CN85
IOAU-19
(IO1)
Cables (Provided
with RemotEye 4)
Figure 5-2 Detailed Configuration of RemotEye 4 Options
Table 5–1 Parts List for RemotEye 4 UPS Monitoring Options
Parts Number
1
2
Part Name
RemotEye 4 Module
Cable
Quantity
1
1
The Cable between RemotEye-IV and IOAU-19 PCB is included in the RemotEye-IV package.
cable can pass through under the option panel.
The
The RemotEye-IV communicates with the UPS via a cable. The connection is described in Figure
2.15 below. Figure 2.16 shows the detail of D-sub 9Pin on IOAU-19 PCB.
The UPS must be de-energized when installing the RemotEye-4 module.
CAUTION
* Consult Toshiba International Corporation for details on “RemotEye-IV” monitoring software
and its capabilities.
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G9000 1000kVA Installation and Operation Manual – 91469-006
RemotEye 4
Figure 5-3 IOAU-19 (IO1) and RemotEye 4 Connection - Detail
DB9
Description
Pin 1
-
Not Used
Pin 2
RXD
Receive Data
Pin 3
TXD
Transmit Data
Pin 4
-
Not Used
Pin 5
GND
Signal Ground
Pin 6
-
Not Used
Pin 7
-
Not Used
Pin 8
-
Not Used
Pin 9
-
Not Used
Figure 5-4 External Communications Connector (NEC Class 2)
G9000 1000kVA Installation and Operation Manual – 91469-006
31
6
6.1
INSTALLATION AND OPERATION
TRANSPORTATION AND INSTALLATION
Table 6–1 How to transport and install the system
Transportation
Installation
Transport unit with forklift or pallet
Use the pre-drilled 2 or 4 holes in the each UPS
jack ONLY.
channel base*, anchor the unit using appropriate
hardware. (Not provided)
* 4x 4-holes bases and 3x 2-holes bases
CAUTION : Do not attempt to lift cabinets using lifting eyes.
CAUTION : Do not transport in a horizontal position. Cabinets must be maintained
upright within +/- 15° of the vertical during handling.
CAUTION : Be sure to firmly anchor the UPS on level ground.
3.2
INSTALLATION PROCEDURE
A)
Note the load tolerance of the floor
Refer to Table 3.2 for list of UPS weights.
Table 6–2 List of UPS weights
UPS Capacity (kVA)
Weight (lb.)
B)
C)
1000
6283
Minimum clearance required for ventilation
Right side
25 mm (1 inch) (not required when sidecars are used)
Left side
25 mm (1 inch) (not required when sidecars are used)
Back side
0.0 mm (0 inch)
Top side
600 mm (24 inches) (for air flow)
Space requirement for routine maintenance
Allow for the following space at the time of installation.
32
Front
1000 mm (39 inches)
Sides
0.0 mm (0 inch)
Back side
0.0 mm (0 inch)
Top side
500 mm (20 inches)
G9000 1000kVA Installation and Operation Manual – 91469-006
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 Table
3.3.
Table 6–3 Maximum Permitted Fault Current
UPS Capacity
DC Voltage
Maximum Fault
(kVA)
Rating (V)
Current Permitted (A)
1000
6.2
1.
2.
480
25,000
PROCEDURE FOR CABLE CONNECTIONS *
Identify the input/output power terminal blocks as shown in Figure 3.1.
Connect the internal control wire and power wire.
(1) Control wire interconnections
1.
Battery CB ON Auxiliary to terminal TN11-14-21,22 of external I/F PCB IOAU-19.
(2) Power wire (AC input, Bypass input, AC output) interconnections
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
1.
Positive cable to BP bus bar in UPS
2.
Negative cable to BN bus bar in UPS
CAUTION : 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 → B → C.
G9000 1000kVA Installation and Operation Manual – 91469-006
33
3.
Connect the grounding conductor from the input service entrance to the UPS Grounding Bar (E).
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 3.1.
• 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 1-4).
• Connect the bypass input power cables from the input service entrance to the bypass
input power terminals, identified as A40, B40 and C40 in Figures 3.1 to 3.2. Bypass
input cables must be sized for an ampere rating larger than the maximum output current
capacity of the UPS. Refer to Table 3.4 for recommended cable sizes.
(2) Connect the external signal terminal block as desired. Refer to section 2.4 and Figure 2.10
2
for functional description. 14 AWG (2 mm ) 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 Figures 3.1 to 3.2.
• Input cables must be sized for an ampere rating larger than the maximum current
capacity of the UPS. Refer to Table 3.4 for recommended cable sizes.
(2) Using adequately sized conductors and referring to the appropriate figure identified in Figures
3.1 to 3.2, connect jumper bypass terminals A40, B40, C40 to AC input power terminals A, B,
C as identified in Figures 3.1 to 3.2.
(3) Connect the external signal terminal block as desired. Refer to section 2.4 and Figure 2.10
2
for functional description. 14 AWG (2 mm ) or less, shielded conductor is recommended.
CAUTION : UPS power terminals are supplied with stud type fittings.
It is recommended that compression lugs be used to fasten all
input/output power cables.
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G9000 1000kVA Installation and Operation Manual – 91469-006
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 Figures 3.4 and 3.5.
(2) Connect the external control wire and power wire.
a.) Control wire connections
Parallel configuration wiring (Refer to Figure 3.5.)
- 52L control signal from Toshiba Tie Cabinet (TTC) to UPS-n IOAU-19 (TN11-14 –
23, 24).
- Parallel control signals for TLAIN, TLAOUT, TLBIN, TLBOUT, CAIN, CAOUT,
CBIN, CBOUT, DIAIN, DIAOUT, DIBIN, DIBOUT as shown in Fig. 3.5.
b.) Power wire connections
From UPS AC Output Terminals to Toshiba Tie Cabinet (TTC) (Refer to Figure
3.4 and 3.5.)
!
Straight through, shielded CAT5 or better cables with metal shrouded RJ-45
heads on both sides are to be used for the parallel control signal cables. Use
of any other cables could cause erroneous communication failures.
NOTE
G9000 1000kVA Installation and Operation Manual – 91469-006
35
Table 6–4 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
1000kVA
480V
480V
5 x 600MCM or
347 - 469
5 x 600MCM or
347 - 469
5 x 600MCM or
347 - 469
8 x 600MCM or
347 - 469
6 x 500MCM
in. lbs
6 x 500MCM
in. lbs
6 x 500MCM
in. lbs
10 x 400MCM
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 6–5 Recommended Hardware
UPS Capacity
Bolt size
Flat washer
size
Split lockwasher
size
Nut size
1000kVA
M12 x 40mm
M12
M12
M12
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G9000 1000kVA Installation and Operation Manual – 91469-006
Table 6–6 Crimp Type Compression Lug
WIRE
SIZE
(CODE)
300 MCM
WIRE
STRAND
CLASS
B
350 MCM
I
B
400 MCM
I
B
500 MCM
I
B
600 MCM
I
B
750 MCM
I
B
RECOMMENDATION
VENDOR
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
ILSCO
BURNDY
BURNDY
CAT. NO.
YA30
CRA-300L
YA32-LB
YA31
CRA-350L
YA34-LB
YA32
CRA-400L
YA36-LB
YA34
CRA-500L
YA38-LB
YA36
CRA-600L
YA39-LB
YA39
ILSCO
CRA-750L
CRIMP TOOL REQUIRED
BURNDY TYPE Y35 OR Y46
COLOR KEY
DIE INDEX
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
GREEN
22 / 472
GREEN
22 / 472
--1030
BLACK
24
BLACK
24
NOTE: 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.
G9000 1000kVA Installation and Operation Manual – 91469-006
37
Bypass
Input
Terminals
A40
B40
C40
52 S
Bypass Module
CB 3
Static Transfer
Switch
AC
input
Terminals
A
B
C
Battery
Cabinet
Terminals
BP
BN
CONVERTER / INVERTER
CB1
CB2
Terminals
A50
Output
B50
C50
52 C
CHARGER
UPS Module
CONVERTER / INVERTER
CB1
CB2
52 C
CHARGER
UPS Module
CONVERTER / INVERTER
CB1
CB2
52 C
CHARGER
UPS Module
UPS
CABINET
Figure 6-1 UPS Terminal Designation
38
G9000 1000kVA Installation and Operation Manual – 91469-006
Figure 6-2 Diagram of input/output bus bars and terminal blocks
Location of bus bars and terminal blocks (Bottom/Top/ Entry)
118.1”(3003.2)
35.5”(901.6)
External
signal line
access※1
E
BP
80.7”(2048.6)
DC
Input
BN
E
Detailed AC Power Terminals
Grounding Bar
※3
For power terminals, use 1/2”
(12mm) diameter bolts.
※2
※3
Cable Entry Section – Left Side View
※2
UPS cabinet – Front View
※1. Signal lines should be separated to the main circuit cables with more than 100mm insulating distance.
The wiring also should fix to the frame to ensure the insulating distance satisfied the condition.
※2. 3x 2-holes bases
※3. 4x 4-holse bases
G9000 1000kVA Installation and Operation Manual – 91469-006
39
※2
※3
Figure 6-3 Diagram of Power Wire & Control Wire Interconnections between UPS and Battery
External signal
terminal
IOAU-19 - [TN1]
User supplied
DC circuit breaker
Auxiliary
Power terminal
21
BN BP
22
“-” Negative
“+” Positive
User supplied
UPS module
40
Wall mounted DC breaker
for Battery
G9000 1000kVA Installation and Operation Manual – 91469-006
Figure 6-4 Diagram of power wire connections (Parallel Operation system connection)
TOSHIBA TIE CABINET
52MB
Bypass input
AC input
UPS-1
Bypass
52S
Converter / Inverter
Charger
CB1
52C
CB2
Bypass input
52L 1
AC output
Battery
UPS-2
Bypass
52S
52L
AC input
Converter / Inverter
Charger
CB1
52L 2
AC output
52C
CB2
Battery
UPS-n
Bypass input
*1
52S
Bypass
CB1
AC input
Converter / Inverter
Charger
52L n *1
AC output
52C
CB2
*1
Battery
G9000 1000kVA Installation and Operation Manual – 91469-006
41
n : Maximum = 8
Figure 6-5
Diagram of Power Wire & Control Wire Connect (Parallel Operation system connection 2x to 8x)
UPS- 1
23 24
IOAU- 19
TN11-14
UPS- 2
23 24
IOAU- 19
TN11-14
*3
*3
CN95-20P
GNDA
B
GNDB
CN95
A
OFF
IFAU-16
GNDC
CN94
J-10P
B
A
CN94
CN95-20P
CN96
J-16P
GNDA
CN96
B
GNDB
CN95
CN952
TLAIN
TLBOUT TLAOUT
CN951
CN954
CN953
A
OFF
GNDD
SW1
GNDC
IFAU-16
CN94
J-10P
B
A
CN94
CN96
J-16P
CN96
GNDD
SW1
8 ...1
ON
TLBIN
UPS-N
23 24
IOAU- 19
TN11-14
8 ...1
ON
CA1IN
CA1OUT
DIBIN
DIAIN
DIBOUT
DIAOUT
TLBIN
CN941
CN942
CN962
CN961
CN964
CN963
CN952
TLAIN
CN951
TLBOUT TLAOUT
CN954
CN953
CA1IN
CA1OUT
DIBIN
DIAIN
DIBOUT
DIAOUT
CN941
CN942
CN962
CN961
CN964
CN963
Toshiba Tie Cabinet
*3
Total cable length
from UPS-1 to UPS-N
should be within
100m (330ft).
CN95-20P
GNDA
B
GNDB
CN95
A
OFF
IFAU-16
GNDC
CN94
J-10P
B
A
CN96
J-16P
CN96
CN94
35
36
37
38
.
.
.
49
50
GNDD
SW1
8 ...1
ON
TLBIN
CN952
TLAIN
CN951
TLBOUT TLAOUT
CN954
CN953
CA1IN
CA1OUT
DIBIN
DIAIN
DIBOUT
DIAOUT
CN941
CN942
CN962
CN961
CN964
CN963
UPS-3 CN951(TLAIN)
UPS-3 CN952(TLBIN)
52L1-AX
52L2-AX
.
.
.
52LN-AX
*1
UPS-3 CN961(DIAIN)
UPS-3 CN962(DIBIN)
UPS-3 CN941(CA1IN)
*1 : N(maximum) =8
UPS-(n-1) CN953(TLAOUT)
*2 : Return from the last UPS
module to the first UPS
module (continuous loop)
UPS-(n-1) CN954(TLBOUT)
UPS-(n-1) CN963(DIAOUT)
*2
UPS-(n-1) CN964(DIBOUT)
*2
*3 : DIP switch S1-1, S1-2
UPS1 and UPSn : ON
Otherwise : OFF
UPS-(n-1) CN942(CA1OUT)
UPS-1
A
B
C
Use Ethernet STP(Shield
Twisted Pair) cable for all
communication cabling.
The use of UTP (Unshield
Twisted Pair) cable may
cause malfunction)
...
UPS-2
A
B
C
AC OUTPUT
A50
B50
C50
42
AC OUTPUT
A50
B50
C50
G9000 1000kVA Installation and Operation Manual – 91469-006
AC OUTPUT
A50
B50
C50
UPS-n
A
B
C
AC OUTPUT
•
•
•
Use Ethernet STP (Shielded Twisted Pair) Cable (Cat 5 or Cat 6) with RJ45 modular connecto4rs for
all communication cabling.
Use of UPT (Unshielded Twisted Pair) Cable may cause malfunctions.
Total cable length from UPS #1 to UPS 3N should be within 100m.
IFAU-16A
IFAU-16A
IFAU-16A
CN961 DIAIN
CN961 DIAIN
CN961 DIAIN
CN962 DIBIN
CN962 DIBIN
CN962 DIBIN
CN963 DIAOUT
CN963 DIAOUT
CN963 DIAOUT
CN964 DIBOUT
CN964 DIBOUT
CN964 DIBOUT
CN941 CAIN
CN941 CAIN
CN941 CAIN
CN942 CBIN
CN942 CBIN
CN942 CBIN
CN943 CAOUT
CN943 CAOUT
CN943 CAOUT
CN944 CBOUT
CN944 CBOUT
CN944 CBOUT
CN951 TLAIN
CN951 TLAIN
CN951 TLAIN
CN952 TLBIN
CN952 TLBIN
CN952 TLBIN
CN953 TLAOUT
CN953 TLAOUT
CN953 TLAOUT
CN954 TLBOUT
CN954 TLBOUT
CN954 TLBOUT
UPS #1
1 – 8 ON
(All On)
UPS #2 – UPS #(N-1)
1 – 8 OFF
(All OFF)
UPS #N
1 and 2 ON
3 – 8 OFF
Figure 6-6 Detail: IFAU-16A Control Wire Connections for N units in MMS Configuration
Table 6–7 Jumper Status on IFAU16A (Parallel Interface Board)
No.
Device
Status
1
JP1
SHORT
2
JP6
SHORT
3
JP11
OPEN
G9000 1000kVA Installation and Operation Manual – 91469-006
43
6.3
OPERATING PROCEDURES
For Parallel Operation system, refer to section “D) MMS Start-up Procedure”.
(Parallel Operation system is herein after MMS [Multi Module System])
A)
Start-up Procedure
CAUTION : Before the UPS startup, the internal Bypass line starts to supply the
unconditioned bypass input power to the critical load if the External input
(or Bypass) Circuit Breaker is closed. Be extremely careful with closing the
External input (or Bypass) Circuit Breaker.
a)
b)
c)
d)
e)
f)
Verify that the External Bypass Input Circuit Breaker for each unit is closed (user supplied).
Verify that Battery Disconnect Circuit Breaker is opened or in tripping position.
If a dual source is feeding the UPS, close the External AC Input Circuit Breaker manually (user
supplied).
The LCD panel boots up automatically, and the screen will show that the Load is powered by
bypass line.
On the LCD panel, select “OPERATION” tab, and then press the “START OPERATION” button to
proceed UPS start-up. (Refer to Figure 2.3).
Follow the “START OPERATION” guidance accordingly until the completion of the inverter startup.
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.
44
G9000 1000kVA Installation and Operation Manual – 91469-006
B)
Shutdown Procedure
If a total UPS shutdown is required, verify that the critical load is OFF.
a.)
b.)
c.)
On the LCD panel, select “OPERATION” tab, and then press the “STOP OPERATION”
icon to proceed UPS shutdown. (Refer to Figure 2.3)
Follow the “STOP OPERATION” guidance accordingly. During the procedure, UPS will
transfer the power feeding from the Inverter supply to the Bypass line supply.
Both Converter and Inverter will remain energized until complete disconnection from all
power sources.
NOTE : 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.
d.)
If stopping both the Inverter and Converter is required, open the Battery Disconnect
circuit breaker manually in accordance with guidance.
WARNING : Verify the load is OFF if the next step is to be performed .
NOTE :
e.)
f.)
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.
If a dual source is feeding the UPS, open the External AC Input Circuit Breaker (user
supplied) manually.
If turning off all power to the critical load is desired, open the External Bypass Input
Circuit Breaker (user supplied) manually.
CAUTION : In bypass mode, all UPS power terminals are still live. 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 for the devices even when the UPS has been
de-energized, still internal devices may be hot.
G9000 1000kVA Installation and Operation Manual – 91469-006
45
C)
Bypass Operation Procedure
** Transfer from Inverter to Bypass
1. Check for “SYNC” on the LCD.
2. Press the "START/STOP” icon on the LCD.
3. Follow the “STOP OPERATION” guidance and Press the "STOP" icon on the LCD.
** Transfer from bypass to inverter.
1. Press the "START/STOP" icon on the LCD.
2. Follow the “START OPERATION” guidance and Press the "START" icon on the LCD..
NOTE : When "REMOTE OPERATION MODE" is displayed on the LCD panel, the inverter
start operation can only be performed remotely. If local inverter start or stop
operation is required (at the UPS), select "LOCAL ONLY" or “REMOTE & LOCAL”
in the OPERATION MENU.
D)
MMS Start-up Procedure
External Circuit Check
1. Verify that Toshiba Tie Cabinet (TTC) Circuit Breaker 52MB is closed.
2. Verify that TTC System Output Circuit Breaker 52L is open.
3. Verify that TTC UPS Circuit 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 Operation* ”. Each UPS will start Inverter
Operation in synchronization with the bypass input.
*Meaning of the icons in Figure 2.3(a) in MMS
INV. START: UPS Module Startup
INV. STOP: UPS Module Stop
START: Parallel-in**
**No effect in MMS Bypass Operation
STOP: Parallel-off
46
G9000 1000kVA Installation and Operation Manual – 91469-006
Transfer from Maintenance Bypass to MMS Bypass Operation
1. Close the TTC System Output Circuit Breaker 52L.
2. Open the TTC Circuit 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 Fig. 3.6.
Figure 6-7 LCD Screen (MMS Operation)
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 Fig. 3.6.
*Meaning of the icons in Figure 3.6
START: MMS Inverter Operation
STOP: MMS Bypass Operation
G9000 1000kVA Installation and Operation Manual – 91469-006
47
7
RESPONSE TO UPS FAILURE
UPS FAULT
Annunciator Silence
Recording of Fault
Primary Action
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.
When faults happen, contact the Authorized TOSHIBA Service
Information to Service Center
Representatives or call TOSHIBA International Corporation at
1-877-867-8773.
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.
48
G9000 1000kVA Installation and Operation Manual – 91469-006
8
MAINTENENACE AND PARTS REPLACEMENT
Contact Toshiba International Corporation or its authorized service representatives on all issues regarding
the replacement of parts.
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 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.
Replace battery if its capacity is within this percentage.
B)
UPS Component Parts
UPS components have a defined life expectancy (Fan, Capacitors, Air-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, and on all issues regarding the replacement of parts.
Table 8–1 Standard Replacement Parts List
Parts name
Cooling fans
Electrolytic Capacitors
AC filter Capacitors
Control Relays
Contactors
PCB
Control power supply
LCD
Fuses
Thermal relays
Replace interval
5 years*
15 years
15 years
15 years
15 years
15 years
15 years
10 years*
10 years*
10 years
Service Method
Replace with new one
Replace with new one
Replace with new one
Replace with new one
Replace with new one
Renew UPS
Replace with new one
Replace with new one
Replace with new one
Replace with new one
* Periodic replacements are needed.
NOTE : Any parts replacements (including modification) without authorized by
TOSHIBA International Corporation could result in personal injuries, death or
destruction of the UPS.
G9000 1000kVA Installation and Operation Manual – 91469-006
49
C)
Air Filters
D)
Air filters can be obtained in bulk quantities from Toshiba International Corporation. Use only air filters
specified by Toshiba.
Table 8–2 Ait Filters
UNIT
1000 kVA
9
Toshiba Part Number
T90-AF-15x30x1
5 ea. 15”x30”
Quantity (per unit)
5
FAULT CODES
This section covers fault codes, their description and required action.
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.
9.1
BYPASS MODULE FAULT CODES
Table 9–1 Bypass Module Fault Code List
BYPASS MODULE FAULT CODE LIST
Code
indication
(Note 2)
50
Status
Message
Meaning
Guidance
Audible
Alarm
External
relay
contact
(Note 1)
UA805
OVERLOAD
The output load current has
exceeded 100% of the rated
current.
WARNING:
DECREASE
LOAD
Intermittent
sound
Overload
UA806
INVERTER
OVERLOAD
The output load current peak has
exceeded 220% of the rated
current.
WARNING:
DECREASE
LOAD
Intermittent
sound
Overload
UA807
INVERTER
OVERLOAD
The output load current has
exceeded 105% of the rated
current.
WARNING:
DECREASE
LOAD
Intermittent
sound
Overload
UA808
OVERLOAD
The output load current has
exceeded 100% of the rated
current during bypass supply.
WARNING:
DECREASE
LOAD
Intermittent
sound
Overload
UA810
OVERLOAD
Short time over-current has
exceeded 150% of the rated
current.
WARNING:
DECREASE
LOAD
Intermittent
sound
Overload
UA812
BYPS.VOLT.OUT
RNG.
Bypass line voltage is out of the
specific range.
CHECK
BYPASS
INPUT
Intermittent
sound
Bypass
Input
Abnormal
UA813
BYPS.PHASE ABNL.
Bypass line power conductors
are not wired in a proper phase
sequence.
CHECK
BYPASS
INPUT
Intermittent
sound
Bypass
Input
Abnormal
UA814
BYPS.FREQ.OUT
RNG.
Bypass line frequency is out of
the specific range.
CHECK
BYPASS
INPUT
Intermittent
sound
Bypass
Input
Abnormal
G9000 1000kVA Installation and Operation Manual – 91469-006
BYPASS MODULE FAULT CODE LIST
Code
indication
(Note 2)
Status
Message
Meaning
Guidance
Audible
Alarm
External
relay
contact
(Note 1)
UA817
EMERG.STOP ACTIV.
The emergency stop was
activated by the EPO switch or
an external contact.
-
Continuous
sound
-
UA821
REM. BUTTON
CLOSE
The UPS cannot transfer to the
bypass because the inverter
output is not synchronized to the
bypass.
-
Intermittent
sound
-
UA822
LOC. BUTTON ABNL.
The UPS cannot transfer to the
bypass because of backup
generator operation.
CALL
SERVICE
ENGINEER
Intermittent
sound
-
UA824
CB2 OPEN
The battery disconnect contactor
CB2 in power converter module
is opened.
CB2 OPEN
Intermittent
sound
-
UA831
EMERG.BYPS.SW.ON
Emergency bypass switch has
been turned on.
CALL
SERVICE
ENGINEER
Intermittent
sound
-
UA833
52L OPEN
The load circuit breaker(52L) is
turned off.
-
Intermittent
sound
-
UA834
BATTERY DEPLETED
The battery voltage has reached
the depleted level.
CALL
SERVICE
ENGINEER
-
End-ofDischarge
UA835
TRANS.INHIBITED
The UPS could not transfer to the
bypass because the bypass
source has an abnormality.
-
-
-
UA861
MODULE ALARM
A power converter module has
detected an alarm condition.
CALL
SERVICE
ENGINEER
Intermittent
sound
-
UA862
MODULE MINOR
FAULT
A power converter module has
detected a minor fault condition.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UA863
MOD.IN.VOLT.
A power converter module has
detected input voltage abnormal.
CHECK
INPUT
POWER
SOURCE
Intermittent
sound
-
UA864
MODULE OVERLOAD
A power converter module has
detected output overload.
WARNING :
DECREASE
LOAD
Intermittent
sound
Overload
UA865
MOD.BAT.END
CALL
SERVICE
ENGINEER
-
Alarm
UA866
BATT.END WA
A power converter module issues
a warning on eminent battery
depletion.
-
Intermittent
sound
Alarm
UA890
EXTERNAL ALARM
External alarm relay turned on.
-
Intermittent
sound
Alarm
UF055
CONVERTER
ABNORMAL
Mixed operation (20 seconds)
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF151
BAT.VOLTAGE ABNL.
All power converter modules
have detected battery float
voltage abnormal.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF156
CHG.STOPPED
UF157 failure persisted for over
two(2) hours.
CHECK
BATTERY
Intermittent
sound
Battery
abnormal
UF157
BATTERY
OVERTEMP.
Detection of overtemperature at
the batteries.
CHECK
BATTERY
Intermittent
sound
Battery
abnormal
UF158
BATTERY LIQUID
LOW
Low level of battery electrolyte
solution.
CHECK
BATTERY
Intermittent
sound
Battery
abnormal
A power converter module has
detected battery depleted.
G9000 1000kVA Installation and Operation Manual – 91469-006
51
BYPASS MODULE FAULT CODE LIST
Code
indication
(Note 2)
52
Status
Message
Meaning
Guidance
Audible
Alarm
External
relay
contact
(Note 1)
UF161
CHG.STOPPED
UF151 failure is running for over
24 hours.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF162
BATTERY
ABNORMAL
Failure detection based on
battery self-check.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF163
BAT.VOLTAGE ABNL.
All converter modules have
detected battery voltage
abnormal.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF172
BATTERY
ABNORMAL
The external relay detected the
battery fault.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF202
INVERTER ABNL.
Output voltage dropped.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF253
CTRL.CIRCUIT ERR.
Discrepancy between output
voltage and bypass voltage
during bypass operation.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF254
CTRL. CIRCUIT ERR.
Inverter voltage is out of the
specification level during transfer.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF256
O/P VOLTAGE ABNL.
Output voltage is out of the
specified range.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF258
LOAD ABNL.
Load transfer due to overload for
over 4 times within 5 minutes.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF301
CTRL.CIRCUIT ERR.
AD reference has an abnormal
value.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF302
CTRL.CIRCUIT ERR.
Detection of an external
interruption during the software
execution.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF303
CTRL.CIRCUIT ERR.
Timer does not reset in the
specified period (WDT settings)
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF305
CTRL.CIRCUIT ERR.
Detection of an abnormal clock
speed in the CPU or FPGA.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF306
CTRL.CIRCUIT ERR.
Control power supply voltage is
below the specified level.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF320
CTRL.CIRCUIT ERR.
Cable disconnection in the
parallel interface board during
load supply (SMS).
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF321
CTRL.CIRCUIT ERR.
Cable disconnection in the
parallel interface board during
load supply (Individual Bypass
System).
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF322
CTRL.CIRCUIT ERR.
Major communication error
during parallel operation (ΔI).
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF323
CTRL.CIRCUIT ERR.
Major communication error
during parallel operation (CAN).
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF324
CTRL.CIRCUIT ERR.
Major communication error in
both of the CAN signals during
certain period.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
G9000 1000kVA Installation and Operation Manual – 91469-006
BYPASS MODULE FAULT CODE LIST
Code
indication
(Note 2)
Status
Message
Meaning
Guidance
Audible
Alarm
External
relay
contact
(Note 1)
UF326
CTRL.CIRCUIT ERR.
Communication integrity error or
No communication (SMS).
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF327
CTRL.CIRCUIT ERR.
Communication integrity error or
No communication (Individual
Bypass).
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF340
MODULE MINOR
FAULT
A power converter module has
detected major fault condition.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF341
#1 MAJOR FAULT
Power converter module #1 has
detected major fault condition.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF342
#2 MAJOR FAULT
Power converter module #2 has
detected major fault condition.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF343
#3 MAJOR FAULT
Power converter module #3 has
detected major fault condition.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF344
#4 MAJOR FAULT
Power converter module #4 has
detected major fault condition.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF349
MODULE MAJOR
FAULT
All Power converter modules
have detected major fault
condition.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF371
CTRL.CIRCUIT ERR.
Major communication error in
either of the CAN signals during
certain period.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF372
CTRL.CIRCUIT ERR.
Unable to synchronize the
inverter output and the bypass
voltage.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF374
CTRL.CIRCUIT ERR.
Cable disconnection in the
parallel interface board.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF375
CTRL.CIRCUIT ERR.
Unable to achieve
synchronization for parallel
operation.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF376
CTRL.CIRCUIT ERR.
No control response from another
UPS although its detection is
possible.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF377
CTRL. CIRCUIT ERR.
Logic signal abnormal (Supply
OFF).
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF378
CTRL.CIRCUIT ERR.
No answer for sending
synchronizing signal.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF381
CTRL.CIRCUIT ERR.
No module supply answer during
UPS operation.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF382
CTRL.CIRCUIT ERR.
Module supply answer during
UPS halt.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF383
CTRL.CIRCUIT ERR.
Module overcurrent answer
continued for 10 seconds or
more.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF401
52S ABNORMAL
Error to close the contactor 52S.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF402
52S ABNORMAL
Error to open the contactor 52S.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
G9000 1000kVA Installation and Operation Manual – 91469-006
53
BYPASS MODULE FAULT CODE LIST
Code
indication
Status
Message
(Note 2)
9.2
Meaning
Guidance
Audible
Alarm
External
relay
contact
(Note 1)
UF420
52L OPERATION
ERR.
Load circuit breaker 52L opened
during inverter operation.
CALL
SERVICE
ENGINEER
Continuous
sound
Major
UF451
52S ABNORMAL
Error to open the contactor 52S.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UF452
CB3 ABNORMAL
Contactor CB3 is not working
properly.
CALL
SERVICE
ENGINEER
Intermittent
sound
Minor
UPS MODULE FAULT CODES
Table 9–2 UPS Module Faults Code List
UPS MODULE FAULTS CODE LIST
Code
indication
(Note 2)
54
Status
message
Meaning
External relay
contact
(Note 1)
MA801
I/P VOLT.OUT RNG.
Input line voltage is out of the specific range.
Alarm
AC input
abnormal
MA802
I/P FREQ.OUT RNG.
Input line frequency is out of the specified range.
Alarm
AC input
abnormal
MA803
I/P PHASE ABNL.
Input line power conductors are not wired in a proper
phase sequence.
Alarm
AC input
abnormal
MA806
INVERTER OVERLOAD
The inverter output current has exceeded 110% for 1
min. or 130% for 30sec. of the rated current.
Alarm
Overload
MA807
INVERTER OVERLOAD
The inverter output current has exceeded 110% of the
rated current.
Alarm
Overload
MA810
INVERTER OVERLOAD
Short time over-current has exceeded 150% of the
rated current
Alarm
Overload
MA817
EMERG.STOP ACTIV.
The emergency stop was activated by the EPO switch
or an external contact.
Alarm
MA824
CB2 OPEN
The battery disconnect contactor CB2 open.
Alarm
MA834
BATTERY DEPLETED
The battery voltage has reached the depleted level.
Major
End-ofDischarge
MA836
INVERTER OVERLOAD
The output load active power has exceeded 110% of
the rated current.
Alarm
Overload
MA870
BALANCER OVERLOAD
The UPS detected a neutral point voltage unbalance.
Alarm
Overload
MF001
I/P CIRCUIT ABL.
Detection of a large variation of the reference error
signal.
Major
MF002
CONV OVERCURRENT
Detection of converter overcurrent.
Major
MF003
CONVERTER ABNL.
Pre-charging circuit is not working properly.
Major
MF102
DC OVERVOLTAGE
DC voltage surpasses the overvoltage level.
Major
MF103
DC UNDERVOLTAGE
DC voltage dropped below the undervoltage level.
Major
MF104
DISCHARGE FAULT
Capacitor voltage is higher than 100V at 5 minutes
after module stop.
Minor
MF108
CHOP OVERCURRENT
Detection of DC overcurrent.
Major
MF109
DC UNBALANCED
Major unbalance of the neutral point voltage.
Major
G9000 1000kVA Installation and Operation Manual – 91469-006
UPS MODULE FAULTS CODE LIST
Code
indication
(Note 2)
Status
message
Meaning
External relay
contact
(Note 1)
MF110
ZERO PHASE OC.
Major unbalance of the neutral point voltage.
Major
MF111
CTRL.CIRCUIT ERR.
Battery current unbalance.
Major
MF112
DC CIRCUIT ABNL.
Sudden change of the DC voltage level.
Major
MF119
DC GROUND FAULT
Detection of DC ground fault.
Major
MF128
CTRL.PWR. ABNL.
Power supply voltage to IGBT driver PCB is below the
specified level.
Major
MF154
CB2 ABNORMAL
During UVT, status signal from CB2 is ON.
Minor
MF159
DC GROUND FAULT
Detection of DC ground fault.
Minor
MF160
CTRL.CIRCUIT ERR.
Abnormal behavior of DC current sensor.
Minor
MF162
BATTERY ABNORMAL
Failure detection based on battery self-check.
Minor
MF163
BAT.VOLTAGE ABNL.
Battery voltage is abnormal.
Minor
MF179
DC GROUND FAULT
Detection of DC ground fault continued for 5 minutes.
Minor
MF201
INVERTER OV.
Detection of output overvoltage.
Major
MF202
IINVERTER UV.
Output voltage dropped.
Major
MF203
INVERTER OC.
Detection of inverter overcurrent.
Major
MF204
O/P CIRCUIT ABNL.
Detection of a large variation of the reference error
signal (current reference and actual current).
Major
MF207
ZERO PHASE OC.
Inverter zero-sequence overcurrent.
Major
MF208
CTRL.CIRCUIT ERR.
Cross current is abnormal.
Major
MF210
52C ABNORMAL
Error to open the contactor 52C.
Major
MF213
OVERTEMPERATURE
Heatsink temperature exceeds thermal settings.
Major
MF214
COOLING FAN ABNL.
Thermal relay activated protection.
Major
MF217
INVERTER OV.
Detection of inverter output phase overvoltage.
Major
MF230
ZERO PHASE OC.
Detection of zero-sequence overcurrent.
Major
MF253
CTRL.CIRCUIT ERR.
Discrepancy between output voltage and inverter
voltage, or between output voltage and bypass
voltage.
Minor
MF254
COOLING FAN ABNL.
Thermal relay of cooling fan worked.
Minor
MF256
O/P VOLTAGE ABNL.
Output voltage is out of the specified range.
Minor
MF301
CTRL.CIRCUIT ERR.
AD reference has an abnormal value.
Major
MF302
CTRL.CIRCUIT ERR.
Detection of an external interruption during the
software execution.
Major
MF303
CTRL.CIRCUIT ERR.
Timer does not reset in the specified period (WDT
settings)
Major
MF305
CTRL.CIRCUIT ERR.
Detection of an abnormal clock speed in the DSP or
FPGA.
Major
MF306
CTRL.CIRCUIT ERR.
Control power supply voltage is below the specified
level.
Major
MF309
INV.VOLTAGE ABNL.
Inverter voltage is out of the specified range.
Major
MF320
CTRL.CIRCUIT ERR.
Cable disconnection in the parallel interface board
during load supply.
Major
MF331
CTRL.CIRCUIT ERR.
Cable disconnection in the main driver PCB (Phase A)
Major
MF332
CTRL.CIRCUIT ERR.
Cable disconnection in the main driver PCB (Phase B)
Major
MF333
CTRL.CIRCUIT ERR.
Cable disconnection in the main driver PCB (Phase C)
Major
MF334
CTRL.CIRCUIT ERR.
Cable disconnection in the main driver PCB
(Chopper))
Major
MF376
CTRL.CIRCUIT ERR.
Logic signal abnormal (Supply ON)
Minor
MF552
DUMMY FAULT
Bypass Module send fault simulation signal.
Major
(Note 1) 1) "Major" is defined as a major failure. Load transferred from the inverter circuit to the static
bypass line;
G9000 1000kVA Installation and Operation Manual – 91469-006
55
2) "Minor" is defined as a minor failure. UPS continues to operate normally, but the cause of
alarm must be identified;
(Note 2) Code indication means:
#A+++ --------------------- Alarm
#F+++ ---------------------- Failure
#%0++ --------------------- Rectifier circuit failure
#%1++ --------------------- DC circuit failure
#%2++ --------------------- Inverter circuit failure
#%3++ --------------------- Control circuit failure
#%4++ --------------------- Bypass system failure
#%8++ --------------------- Alarm
“#” Bypass Module “U”, UPS Module “M”
“+” denotes any numeral from 0 to 9
“%” denotes either “A” or “F”
56
G9000 1000kVA Installation and Operation Manual – 91469-006
10 DAILY INSPECTION
Please perform the daily inspection while the UPS is running. The daily inspection items are shown in
Table 10–1.
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 10–1 How to Perform Daily Inspection
No. Subject
Procedure
Term
1.
2.
3.
4.
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 77 °F or about 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.
G9000 1000kVA Installation and Operation Manual – 91469-006
57
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58
G9000 1000kVA Installation and Operation Manual – 91469-006
APPENDIX A – Installation Planning Guide (IPG)
Installation Planning Guide for 1000kVA UPS
Standard System: 480V Input, 480V Output
General Mechanical Information
Dimensions
(W x D x H)
Inches
Lbs.
Floor
Loading
Lbs./ft. 2
Approximate Full-Load
Heat Rejection
kBtu/Hr
6613
227
112.8
Weight
118.2” x 35.5” x 80.7”*
Mechanical Clearance (Inches)from UPS for
Ventilation and Maintenance Access
Top
Front
Bottom Sides**
Back
24”
39”
0”
0”
0”
* Height includes removable an housing – Frame height is 78.7.”
** 0” clearance for peripheral equipment, 1” clearance for walls.
Primary AC Input (480V 3-Phase / 3-Wire)
Maximum Input Power Demand
Normal Mode (Recharge Mode)
Suggested External
Overcurrent Protection
kVA
PF
Amps
Amps
1045 (1113)
> 0.99
1256 (1340)
1600 AT
External Feeder Wire Size: Min. – Max. Per Phase
AWG or kcmil at 75º C Temp. Rating
(5) 600 kcmil – (6) 500 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
1000
1.0
1203
1600 AT
(5) 600 kcmil – (6) 500 kcmil
Battery Input (480VDC Nominal)
Battery Capacity Required
for Full Load Output
Maximum Discharge
at Full Load Output
Suggested External
Overcurrent Protection
External Feeder Wire Size: Min. – Max.
kWB
Amps DC
Amps
AWG or kcmil at 75º C Temp. Rating
1036 @ 1.0 PF
2715
3000 AT
(8) 600 kcmil – (10) 400 kcmil
Rated Output Power
Suggested External
Overcurrent Protection
AC Output (480V 3-Phase / 3-Wire)
External Feeder Wire Size:
Min. – Max. Per Phase
kVA
PF
Amps
Amps
AWG or kcmil at 75º C Temp. Rating
1000
1.0
1203
1600 AT
(5) 600 kcmil – (6) 500 kcmil
Important Notes:
1.
Maximum input current is limited to 108% 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.
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
13131 West Little York Road
Houston, TX 77041
Telephone: (800) 231-1412
Fax: (713) 896-5212
Web Site: www.toshiba.com/ind
G9000 1000kVA Installation and Operation Manual – 91469-006
59
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G9000 1000kVA Installation and Operation Manual – 91469-006
G9000 1000kVA Installation and Operation Manual – 91469-006
61
62
G9000 1000kVA Installation and Operation Manual – 91469-006
SOCIAL INFRASTRUCTURE SYSTEMS GROUP
POWER ELECTRONICS DIVISION
13131 West Little York Rd., Houston, TX 77041
Tel: 713/466-0277 Fax 713/466-8773
US 877/867-8773
Canada 800/872-2192
Mexico 01/800/527-1204
www.toshiba.com/tic/industrial/uninterruptible-power-systems
Printed in Japan
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