installation and operation manual

Document: 94861-001

Ref: 4GBH0099 Rev. B

December 2016

UNINTERRUPTIBLE POWER SYSTEM (UPS)

INSTALLATION AND

OPERATION MANUAL

480/480 V 500kVA

This Page Left Intentionally Blank

G2020 Series UPS Installation and Operation Manual

– 94861-001

INSTALLATION AND OPERATION MANUAL

480/480 V 500kVA

Document No. 94861-001

Ref: 4GBH0099 Rev. B

December 2016


– 94861-001

IMPORTANT NOTICE

The Instructions contained in this manual are not intended to cover all of the details or variations in equipment or to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be required or should particular problems arise which are not covered sufficiently the matter should be referred to the local TOSHIBA sales office.

The contents of this instruction manual shall not become a part of or modify any prior or existing equipment, commitment, or relationship. The sales contract contains the entire obligation of

TOSHIBA INTERNATIONAL CORPORATION. The warranty contained in the contract between the parties is the sole warranty of TOSHIBA, and any statements contained herein do not create new warranties or modify the existing warranty.

Any Electrical or mechanical modifications to this equipment without prior written consent of TOSHIBA will void all warranties and may void UL/CUL listing.

Unauthorized modifications may also result in equipment damage, personal injury, or loss of life.

UNINTERRUPTIBLE POWER SYSTEM

If additional information or technical assistance is required call TOSHIBA Customer Support Center toll free at 1- 877-867-8773, or write to: Toshiba International Corporation, 13131 West Little York Road,

Houston, TX 77041-9990: Attn: UPS Product Manager.

Please complete the following information for your records. Unless otherwise specified on the warranty card, the warranty period for the UPS or UPS part is 36 months from the shipment date (see bill of lading).

Unless otherwise specified on the warranty card, the warranty period for a UPS battery is 36 months full replacement, and an additional 7 years pro-rated from the shipment date (see bill of lading).

Keep this manual with the UPS equipment.

Job Number:

Model Number:

Serial Number:

Application:

Shipping Date:

Date of Installation:

Inspected By:


– 94861-001

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 2016 TOSHIBA INTERNATIONAL CORPORATION

All rights reserved.

Printed in Japan

Contacting TOSHIBA Customer Support Center

The TOSHIBA Customer Support Center can be contacted to obtain help in resolving any Uninterruptible

Power System problem that you may experience or to provide application information.

The center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Support Center’s toll free number in USA is (877) 867-8773.

You may contact TOSHIBA by writing to:

TOSHIBA INTERNATIONAL CORPORATION.

SOCIAL INFRASTRUCTURE SYSTEMS GROUP

POWER ELECTRONICS DIVISION

13131 West Little York Rd.

Houston, TX 77041-9990

Attn: UPS Product Manager

www.toshiba.com/tic/industrial-systems/uninterruptible-power-systems


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Table of Contents

List of Tables ............................................................................................................................................... ii

List of Figures ............................................................................................................................................ iii

1 How to use this Manual ....................................................................................................................... 1

2 INTRODUCTION ................................................................................................................................... 2

3 GENERAL ............................................................................................................................................. 6

3.1

3.2

DEFINITIONS................................................................................................................................ 7

OPERATION OVERVIEW ............................................................................................................. 7

3.2.1

Normal Operation: Load power supplied by each system UPS inverter ....................................... 8

3.2.2

Bypass Operation: Load power supplied through UPS internal static bypass line. ...................... 9

3.2.3

Battery operation: Load Power supplied by UPS battery. ........................................................... 10

3.2.4

UPS Parts Location ..................................................................................................................... 12

3.3

SPECIFICATIONS ...................................................................................................................... 16

4 OPERATOR CONTROLS AND INDICATORS ................................................................................... 19

4.1

4.2

LED DISPLAY ............................................................................................................................. 20

EPO BUTTON (Emergency Power Off button) ........................................................................... 20

4.3

LIQUID CRYSTAL DISPLAY ...................................................................................................... 21

4.3.1

MENU .......................................................................................................................................... 21

4.3.2

Input Power Failure ..................................................................................................................... 26

4.3.3

Fault Indication ............................................................................................................................ 26

4.4

EXTERNAL AUX CONTACT INPUT AND OUTPUT TERMINAL BLOCKS ............................... 27

4.4.1

Aux Contacts

– Input ................................................................................................................... 28

4.4.2

Aux Contacts

– Output ................................................................................................................ 31

4.5

RemotEye

®

INTRODUCTION ..................................................................................................... 33

4.6

CONNECTOR DEFINITION ........................................................................................................ 36

5 INSTALLATION AND OPERATION ................................................................................................... 38

5.1

5.2

TRANSPORTATION AND INSTALLATION ................................................................................ 38

INSTALLATION PROCEDURE ................................................................................................... 38

5.3

5.4

PROCEDURE FOR CABLE CONNECTIONS ............................................................................ 39

OPERATING PROCEDURES ..................................................................................................... 53

6 RESPONSE TO UPS FAILURE .......................................................................................................... 59

7 PARTS REPLACEMENT .................................................................................................................... 60

8 FAULT CODES ................................................................................................................................... 61

9 DAILY INSPECTION ........................................................................................................................... 68

APPENDIX A Installation Planning Guides (IPG) .............................................................................. 69


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List of Tables

Table 2

–1 UPS Installation Environment ........................................................................................................... 4

Table 2

–2 Rating of Bypass Input Circuit Breaker ............................................................................................. 5

Table 3

–1 Power Specifications ...................................................................................................................... 16

Table 3

–2 UPS Module Information................................................................................................................. 16

Table 3

–3 UPS Module Information (Packing Dimension) .............................................................................. 16

Table 3

–4 Specifications .................................................................................................................................. 17

Table 3

–5 Rating of Contactors, Breakers, and Fuses ................................................................................... 18

Table 4

–1 External Input Functions ................................................................................................................. 30

Table 4

–2 External Output Functions .............................................................................................................. 32

Table 4

–3 Parts List for UPS Monitoring ......................................................................................................... 35

Table 5

–1 Transport by Overhead Crane ........................................................................................................ 38

Table 5

–2 List of UPS Weights ........................................................................................................................ 38

Table 5

–3 Maximum Permitted Fault Current .................................................................................................. 39

Table 5

–4 Recommended Cable Sizes ........................................................................................................... 42

Table 5

–5 Recommended Hardware ............................................................................................................... 42

Table 5

–6 Crimp Type Compression Lug ........................................................................................................ 43

Table 7

–1 Standard Replacement Parts List ................................................................................................... 60

Table 7

–2 Replacement Air Filters .................................................................................................................. 61

Table 8

–1 Fault Code ...................................................................................................................................... 62

Table 9

–1 How to Perform Daily Inspection .................................................................................................... 68

ii G2020 Series UPS Installation and Operation Manual

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List of Figures

Figure 3-1 Single Line Diagram

– Normal Operation: Load fed by UPS inverter .............................................. 8


– Bypass Operation: Load fed through static bypass line .............................. 9


– Battery Operation: Load fed by Battery................................................... 10

Figure 3-4 UPS Parts Location (500kVA) ........................................................................................................ 12

Figure 3-5 Display PCB DPAU-81 ................................................................................................................... 13

Figure 3-6 MAIN PCB UPHR-W ...................................................................................................................... 13

Figure 3-7 External I/F PCB IOAU-09.............................................................................................................. 13

Figure 4-1 Operation/Display Panel (Front panel) ........................................................................................... 19

Figure 4-2 Main Screen ................................................................................................................................... 21

Figure 4-3 Startup/Shutdown Screen .............................................................................................................. 22

Figure 4-4 Startup Guidance ........................................................................................................................... 22

Figure 4-5 Shutdown Guidance ....................................................................................................................... 22

Figure 4-6 Input Values ................................................................................................................................... 23

Figure 4-7 Output Values ................................................................................................................................. 23

Figure 4-8 Values in Battery operation ............................................................................................................ 23

Figure 4-9 Remote/Local Operation Select ..................................................................................................... 24

Figure 4-10 Date & Time Adjustment .............................................................................................................. 24

Figure 4-11 Log Menu ..................................................................................................................................... 25

Figure 4-12 Event Log ..................................................................................................................................... 25

Figure 4-13 Battery Log ................................................................................................................................... 25

Figure 4-14 Main Screen (Battery Operation) ................................................................................................. 26

Figure 4-15 Measurement Screen (Battery Operation) ................................................................................... 26

Figure 4-16 Main Screen (Fault Indication) ..................................................................................................... 26

Figure 4-17 Message Screen .......................................................................................................................... 27

Figure 4-18 Location of External Signal Terminal Block on IOAU-09 PCB ..................................................... 27

Figure 4-19 Control Wiring for Aux Input Contacts .......................................................................................... 28

Figure 4-20 External Signal Input Terminal Block (with default settings) ........................................................ 29

Figure 4-21 Control Wiring for Aux Output Contacts ....................................................................................... 31

Figure 4-22 External Signal Output Terminal Block (with default settings) ..................................................... 31

Figure 4-23 RemotEye® Installation (Overview 500kVA) ............................................................................... 33

Figure 4-24 Connection between Display Control PCB (SW1) and RemotEye

®

Module ............................... 34

Figure 4-25 PSAU-60 (PS1) ............................................................................................................................ 35

Figure 4-26 DPAU-81 (SW1) ........................................................................................................................... 35

Figure 4-27 Cable1 (3BBA0083P001) ............................................................................................................. 35

Figure 4-28 Connector (CN1) of PSAU-60 (PS1) ............................................................................................ 36

Figure 4-29 Terminal Block (TN) and VH connector (CN2) of PSAU-60 (PS1) .............................................. 36


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Figure 4-30 Connector (CN44) of PSAU-60 (PS1) .......................................................................................... 36

Figure 4-31 Connector (CN27) of DPAU-81 (SW1) ......................................................................................... 37

Figure 4-32 Connector (CN26) of DPAU-81 (SW1) ......................................................................................... 37

Figure 5-1 UPS Terminal Designation ............................................................................................................. 43

Figure 5-2 Diagram of input/output bus bars and terminal blocks ................................................................... 44

Figure 5-3 Diagram of Power Wire & Control Wire Inter-Connect between UPS and Battery ........................ 45

Figure 5-4 Diagram of Power Wire Connections (Parallel System Configuration) .......................................... 46

Figure 5-5 Diagram of Power & Control Wire Connections for 2 units in MMS Configuration ........................ 47

Figure 5-6 Detail of IFAU-09 Control Wire Connections for 2 units in MMS Configuration ............................. 48

Figure 5-7 Diagram of Power & Control Wire Connections for 3-4 units in MMS Configuration ..................... 49

Figure 5-8 Detail of IFAU-09 Control Wire Connections for 3 or 4 units in MMS Configuration ..................... 50

Figure 5-9 Diagram of Power Wire & Control Wire Connections for 5 to 8 units in MMS Configuration ......... 51

Figure 5-10 Detail of IFAU-09 Control Wire Connections for 5 to 8 units in MMS Configuration .................... 52

Figure 5-11 Circuit Protectors Location ........................................................................................................... 53

Figure 5-12 Automatic Startup of Inverter and Converter ............................................................................... 54

Figure 5-13 Close Battery Breaker .................................................................................................................. 54

Figure 5-14 Press and Hold START Button .................................................................................................... 54

Figure 5-15 Transfer from Online to Bypass ................................................................................................... 55

Figure 5-16 Transfer from Bypass to Online ................................................................................................... 55

Figure 5-17 Initiate Shutdown .......................................................................................................................... 56

Figure 5-18 UPS Transfers to Bypass ............................................................................................................. 56

Figure 5-19 Open Battery Breaker................................................................................................................... 57

Figure 5-20 LCD Screen (MMS Operation) ..................................................................................................... 58

iv G2020 Series UPS Installation and Operation Manual

– 94861-000

1 How to use this Manual

This manual is designed for ease of use, giving the user easy and quick reference to information.

This manual uses notice icons to draw attention to the user important information regarding the safe operation and installation of the UPS. The notice icons used in this manual are explained below, and should be taken into account and adhered to whenever they appear in the text of this manual.

Warning: A warning symbol shows potentially hazardous situation or condition which could result in personal injury or death, if not avoided.

WARNING

Caution: A caution symbol shows potentially hazardous situation or condition which could result in personal injury or equipment damage, if not avoided.

CAUTION

!

Note: A Note symbol shows the information the user or the service personnel should observe during the UPS operation or service work.

NOTE

Prohibit: A prohibit symbol shows the act the user or the service personnel should

NEVER perform during the UPS installation, operation or service work.

PROHIBIT

Safety Recommendations: If any problems are encountered while following this manual, Toshiba field service group assistance and correspondence is recommended.


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1

2 INTRODUCTION

The TOSHIBA Uninterruptible Power Supply System (UPS) is designed to provide many years of reliable protection from power failure, brown-outs, line noise, and voltage transients. To ensure optimum performance of the equipment, follow the manufacturer's instructions. This manual contains descriptions required to operate the UPS. Please read this manual carefully and retain it for future reference.

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

CAUTION

This manual contains important instructions for the G2020 SERIES Uninterruptible Power Supply

System that should be followed during installation and maintenance of the UPS and batteries.

WARNING

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.

2 G2020 Series UPS Installation and Operation Manual

– 94861-000

WARNING 2

WARNING

In no event will TOSHIBA be responsible or liable for either indirect or consequential damage or injury that may come from the misuse of this equipment.

Don

’t modify the UPS entirely or partially.

Any modifications without authorization by TOSHIBA could result in personal injuries, death or destruction of the UPS.

PROHIBIT

1.1 SAFETY PRECAUTIONS

APPLICATION

This UPS shall NOT be applied to support equipment (*) that could affect human lives.

*



Medical operation room equipment



Life support equipment (artificial dialysis, incubators, etc.)



Toxic gas or smoke eliminators

PROHIBIT



Equipment that must be provided under fire laws, construction standards or other ordinances



Equipment equivalent to the above

Special considerations are required when applying this UPS to the equipment

(**) that affect human safety and/or maintain public services.

!

NOTE

**



Equipment to supervise or control airways, railways, roads, sea-lanes or other transportation.



Equipment in nuclear power plants.



Equipment to control communications.



Equipment equivalent/similar to the above mentioned.


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3

WARNING 3

WARNING

4

The UPS is to be installed in a controlled environment.

Improper storage and installation environment may deteriorate insulation, shorten component life and cause malfunctions.

Keep the installation environment per standard described as follows:

Table 2

–1 UPS Installation Environment

No

1

2

3

4

5

6

Item

Installation

Location

Ambient temperature

Relative humidity

Altitude

Dust

Inflammable gas following

IEC654-4

Part 4

Environment standard

Indoors

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).

The relative humidity must be held between 5 and 95%.

There must be no condensation due to temperature changes.

This equipment must not be applied at altitude that exceeds

6500 ft. (1981 m) above sea level.

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.

There should be no inflammable/explosive gas.

Hydrogen sulfide (H

2

S)

Sulfurous acid gas (SO

2

)

Chlorine gas (Cl

2

)

Ammonia gas (NH

3

)

No more than 0.003 PPM



No more than 1 PPM

Nitrous oxides (NO x

)

Ozone (O

3

)




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WARNING 4

WARNING

This UPS does not include a Bypass input circuit breaker (MCCB) to protect bypass circuit. The Bypass input circuit breaker (MCCB) is to be field supplied and installed. Recommended Breaker (MCCB)'s Specifications are as follows:

Capacity

(kVA)

500

Table 2

–2 Rating of Bypass Input Circuit Breaker

Bypass Voltage

(Vac)

Bypass Current

(Aac)

Breaker

(A)

480 601 800

AC input and AC output overcurrent protection and disconnect devices shall be field supplied and installed. The DC circuit breaker (MCCB) shall be field supplied and installed. The overcurrent protection device should be installed in the Battery cabinet and rated as indicated

in Table 3

–5.

!

NOTE

The DC input overcurrent protection (Battery disconnect breaker) hereinafter will be referred as “CB2”.


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5

3 GENERAL

The TOSHIBA G2020 SERIES UPS is designed to provide continuous and clean electrical power to a critical load. Additionally the UPS monitors power conditions affecting the load.

In the event of an input power failure, the UPS will supply power to the critical load for the specified battery time.

If the input power is not restored promptly, backup power from the UPS battery permits the orderly shutdown of equipment supported by the UPS. The UPS is simple to start-up, operate and maintain.

The G2020 SERIES UPS is available in 500 kVA. Specifications are shown in Section 3.3.

This manual provides an overview of the G2020 SERIES components and their functions. The appearance and purpose of operator controls and indicators is described with procedures for operation, start-up, shutdown and basic maintenance included.


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3.1 DEFINITIONS

UNINTERRUPTIBLE POWER SYSTEM (UPS)

– All components within the UPS Module Cabinet and associated batteries that function as a system to provide continuous, conditioned AC power to a load.

This is sometimes referred to as the "System".

UPS MODULE CABINET

– The metal enclosure which contains the Converter / Charger, Inverter,

Static Transfer Switch, Internal Bypass line, operator controls, and internal control systems required to provide specified AC power to a load.

UPS MODULE

– The Converter / Charger and Inverter assemblies which, under the direction of the internal control system and operator controls, provide specified AC power to a load.

INVERTER

– The UPS components which contain the equipment and controls necessary to convert

DC power from the Converter / Charger, or the battery, to AC power required by the critical load.

CONVERTER / CHARGER

– The UPS components which contain the equipment and controls necessary to convert input AC power to regulated DC power required for battery charging and for supplying power to the Inverter.

STATIC TRANSFER SWITCH

– The device which connects the critical load to the bypass line when the Inverter cannot supply continuous power.

BYPASS LINE

– The line which conducts electricity directly from the input power source to the critical load during Maintenance or whenever the UPS is not completely operational.

AC INPUT POWER

– Power provided by the electrical utility company, or auxiliary generator, which is connected to the UPS for supplying the critical load.

BATTERY

– The rechargeable battery strings which supply DC power to the inverter to maintain continuous AC power to the load during AC input power failure conditions.

3.2 OPERATION OVERVIEW

The UPS provides two power paths between the utility source and the critical load.

Figure 3-1

shows the path for normal operation, with the load powered by the inverter.

Figure 3-2 shows the path for bypass operation, with the load supplied through the static bypass line.

Figure 3-3 shows the path for battery operation, with the load powered by the inverter.


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7

3.2.1 Normal Operation: Load power supplied by each system UPS inverter

Bypass input

CB

UPS Module

52S

CB3

User supplied

MCCB

CB

CB1

CONVERTER

/ CHARGER INVERTER

Static Transfer

Switch

52C

AC input

User supplied

MCCB

Power Flow

Not in Use

Battery Cabinet

CB2

External

BATTERY


–

Normal Operation: Load fed by UPS inverter

Output

During normal operation, the path through the UPS inverter is used to power the load.

In Figure 3-1 input AC power is converted to DC by the Converter. DC power is utilized to charge the UPS

battery and to provide power to the Inverter. The Inverter converts the DC power to clean AC power to supply the critical load.

The conversion-inversion process eliminates any voltage transients or fluctuations existing in the input power before it reaches the critical load.

The power drawn by the critical load is equally shared between all UPS systems when multiple UPSs are

in Parallel Operation. (Refer to Figure 5-4 that shows a sample of Parallel Operation System

Configuration.)


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In the event of a UPS module failure during Parallel Operation, the critical load power will be continually supplied and shared by all other UPS.

!

The Bypass Input breaker and cables are to be supplied and installed by the user or the contractor. (See WARNING 4 on page 5)

NOTE

3.2.2 Bypass Operation: Load power supplied through UPS internal static bypass line.

Bypass input

AC input

CB

User supplied

MCCB

CB

User supplied

MCCB

UPS Module

CB1

CONVERTER

/ CHARGER INVERTER

Battery Cabinet

CB2

CB3

52S

Static Transfer

Switch

52C

Power Flow

Not in Use

Output

External

BATTERY


– Bypass Operation: Load fed through static bypass line

Figure 3-2 shows the Internal Bypass line is a Hard-wired line through 52S which supplies the critical load

with unconditioned bypass input power. Upon switching to the Internal Bypass line, the Static Transfer

Switch line through CB3 (herein after STS contactor CB3) supplies the power immediately, and then the

Internal Bypass line through 52S supplies the power. In the event of a switching to the Bypass line, the power to the critical load will be uninterrupted. The purpose of this Internal Bypass line is to route power to the critical load while the UPS module is de-energized (converter and inverter), and during Start-up before the system is fully operational.

Each UPS internal static bypass line will equally share the power supplied to the critical load whenever the system is in the Parallel Operation.


– 94861-000

9

In the event of a load overcurrent, the UPS transfers to bypass without interruption to the critical load. In the case of the Parallel Operation, all UPS will transfer to bypass without interruption to the critical load.

The internal control system determines the operation of the two paths, with the load powered from the inverter being the normal operation.

3.2.3 Battery operation: Load Power supplied by UPS battery.

CB

UPS Module

Bypass input

User supplied

MCCB

CB3

CB

CB1

CONVERTER

/ CHARGER INVERTER

AC input

User supplied

MCCB

Battery Cabinet

CB2

52S

Static Transfer

Switch

52C

Power Flow

Not in Use

External

BATTERY


– Battery Operation: Load fed by Battery

Output

Figure 3-3 shows that in the event of AC input source failure or interruption, the UPS Converter(s)* will

de-energize and the UPS battery(s)* will immediately discharge and supply DC power to the Inverter to maintain continuous AC power to the load. This operation will continue until: a) The battery capacity expires and the inverter turns off, or b) Input power is restored. (When input power is restored the converter will simultaneously power the inverter and critical load, and recharge the batteries.)

A fully charged battery will provide power for the specified time at the rated load, or longer, at a reduced load.

* (s) : In the case of the Parallel Operation


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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.


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11

3.2.4 UPS Parts Location

See

Figure 3-4

for parts location in the UPS.

1. LCD Touch Panel

Monitor Display

Cable

Entry

Section

Left

Door

Right

Door

1) UPS cabinet

– Front View 2) Back side of right door

CB3 52S

CPMC

CPMS

EMB

52C

5. External I/F PCB

(IOAU-09)

CB1

Converter

Unit

Chopper

Unit

AC Capacitor

Inverter

Unit

1. LCD Touch Panel

Monitor Display

3. External

Communication

Connector

2. Display PCB

DPAU-81

4. Main PCB

UPHR-W

2) Backside of

Bypass Module door

Figure 3-4 UPS Parts Location (500kVA)


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3. External

Communication

Connector

16.

52L S/W switch

15.

BOOT switch

11. SW1

RESET switch

Figure 3-5 Display PCB DPAU-81

14.

RESET switch

13. SW6

MAINTENANCE switch

12. SW5

TEST switch

Figure 3-6 MAIN PCB UPHR-W

17. External contact signal terminal block

Figure 3-7 External I/F PCB IOAU-09


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13

Description of Figure 3-4 to

Figure 3-7

:

1.

LCD Touch Panel Monitor Display

The liquid crystal display (LCD) touch panel monitor display indicates power flow, measured values and fault and error messages via user selectable display screens.

Refer to Figure 4-1 for details.

2. Display PCB DPAU-81

Switches on DPAU-81 board: FOR SERVICE PERSONNEL ONLY

- (11) SW1 (RESET switch)

- (12) SW5 (TEST switch)

- (13) SW6 (MAINTENANCE button)

3. External Communication Connector

RS232C connector on DPAU-81 board: FOR SERVICE PERSONNEL ONLY

Refer to Figure 4-32 for details.

4. Main PCB UPHR-W

Switches on UPHR-W board: FOR SERVICE PERSONNEL ONLY

- (14) RESET switch

- (15) BOOT switch

- (16) 52L S/W switch

5. External I/F PCB IOAU-09

Signal I/F on IOAU-09 board

- (17) External contact signal terminal block

Refer to

Figure 4-20

and Figure 4-22 for details.

6.

Control Relay PCB PSAU-80 (not shown)

7. Parallel control PCB TLCR-E (not shown)

For use in Parallel Operation system application: Option

8. Parallel I/F PCB IFAU-09 (not shown)

For use in Parallel Operation system application: Option

Refer to

Figure 5-5

thru Figure 5-10 for details.

9. AC input, AC output, DC input terminal (not shown)

Refer to

Figure 5-2

for details

10. Grounding Bar (E) (not shown)

Refer to

Figure 5-2

for details


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Switches on Display PCB DPAU-81

11. "RESET" switch (FOR SERVICE PERSONNEL ONLY)

This switch resets errors resulting from alarm conditions.

12. "TEST" switch (FOR SERVICE PERSONNEL ONLY)

This switch changes system operation to the test-mode.

13. "MAINTENANCE" button (FOR SERVICE PERSONNEL ONLY)

This switch sets the UPS menu parameters.

Switches on MAIN PCB UPHR-W

14. "RESET" switch (FOR SERVICE PERSONNEL ONLY)

This switch resets the processor on the main control circuit board

15. "BOOT" switch (FOR SERVICE PERSONNEL ONLY)

This switch boots the processor on the main control circuit board following alarm conditions.

16. "52L S/W" switch (FOR SERVICE PERSONNEL ONLY)

This switch prohibits turning on the AC output contactor

“52C” during test/maintenance in Parallel

Operation system application.

TB on External I/F PCB IOAU-09

17. External contact signal terminal block

Terminal block to connect contact signal input/output lines to and from external dry contacts. Refer to

Figure 4-20

and Figure 4-22 for details.


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15

3.3 SPECIFICATIONS

The UPS nameplate displays the rated kVA as well as nominal voltages and currents. The nameplate is located on the backside of the UPS front left door..

Table 3

–1 Power Specifications

Rated output

Power

500 kVA / 500 kW

Input voltage

3 phase / 3 wire

480 V

Bypass input voltage


480 V

Output voltage


480 V

Table 3

–2 UPS Module Information

UPS

[kVA]

Width

[in. (mm)]

Depth

[in. (mm)]

Height

[in. (mm)]

Net Weight

[lbs. (kg)]

Typ. Heating at 100% load

[kBTU/h]

Cable

Knockout

500

59.1

(1500)

33.5

(850)

80.6

(2,047)

2,756

(1250)

31.2

BOTTOM

TOP

LEFT SIDE

Table 3

–3 UPS Module Information (Packing Dimension)

UPS

[kVA]

500

Width

[in. (mm)]

78.4

(1990)

Depth

[in. (mm)]

40.2

(1020)

Height

[in. (mm)]

Gross Weight

[lbs. (kg)]

87.4

(2220)

3086

(1400)


– 94861-000

Table 3

–4 Specifications

Rated Output kVA 500

Rated Output kW

AC INPUT

Configuration

Voltage

Frequency

Reflected Current THDi

500

3 phase, 3 wire

480 V +15% to -20%

60 Hz ±10%

3% typ. at 100% load (no input filter required)

STATIC BYPASS INPUT

Configuration 3 phase, 3 wire

Voltage

Frequency

480 V ±10%

60 Hz ±5%

BATTERY

Type

Ride Through

Nominal Voltage

Minimum Voltage

Number of Cells

AC OUTPUT

Configuration

Voltage

Voltage Regulation

Frequency

Frequency Regulation

Power Factor

Power Factor Range

Voltage THD

Transient Response

Transient Recovery Time

Voltage Unbalance

Phase Displacement

Inverter Overload

Bypass Overload

Lead Acid

Application Specific

480 Vdc

400 Vdc

240

3 phase, 3 wire

480 V

±1%

60 Hz

±0.01% in free running mode

Unity (nominal)

0.7 Lagging to 0.8 Leading (within output kW rating)

2% maximum THD at 100% linear load

5% maximum THD at 100% non-linear load

±2% maximum at 100% load step

±1% maximum at loss/return of AC power

±5% maximum at load transfer to/from static bypass

Less than 20ms

1% maximum at 100% unbalanced load

1 deg. maximum at 100% Load

125% for 1 minutes

150% for 10 seconds

500% for 1 cycle

(with bypass available)

ENVIRONMENTAL**

Cooling

Operating Temperature

Relative Humidity

Altitude

Location

Forced Air

32



F to 104



F (0



C to 40



C).

Recommended : 68ﾟF to 86ﾟF ( 20



C to 30



C)

5%

– 95% Non-Condensing

0 to 65 ft. (1981 m) No Derating at 104ﾟF (40ﾟC)

Indoor (free from corrosive gases and dust)

Paint Color Munsell N1.5 (Black)

Clearance Required Top : 24 in. (610 mm)

Front : 40 in. (1016 mm)

Rear : 0 in. (0 mm)

Sides: 0 in. (0 mm) if sidecars used, 1 in. (25 mm) if no sidecars used.

**Indication that the unit is intended for installation in a temperature-regulated,

indoor area that is relatively free of conductive contaminants.


– 94861-000

17

Table 3

–5 Rating of Contactors, Breakers, and Fuses

NUMBER APPLICATION

CB1

CB3

52C

52S

88RC

CB2

User supply

AC input contactor

STS contactor

Inverter output contactor

Bypass contactor

Control circuit contactor

Battery disconnect breaker

(Recommended)

AC input breaker

(Recommended)

Bypass input breaker

(Recommended)

User supply

FCR, FCS, FCT

FIU, FIV, FIW

FUA, FUB, FUC

AC fuse

Control power fuse

FBS1, FBS2, FBS3 Control power fuse

FOA, FOB, FOC

(OPTION)

FSU, FSV, FSW

Control power fuse

Bypass input fuse

OUTPUT CAPACITY OF EQUIPMENT

500kVA

500kW

680A

260A

680A

680A

20A

1400A

800A

800A

400A / 690V

30A / 600V

30A / 600V

30A / 600V

315A / 690V


– 94861-000

4 OPERATOR CONTROLS AND INDICATORS

The G2020 Series operator controls and indicators are located as follows (Door exterior):

8

3

2

1

7

4

5

6

Figure 4-1 Operation/Display Panel (Front panel)


– 94861-000

19

4.1 LED DISPLAY

1) Load on inverter [ LOAD ON INVERTER ](green)

Illuminates when power is supplied from inverter to the critical load.

(Indicates the state of inverter transfer switch "52C".)

2) Battery operation [ BATTERY OP. ](yellow)

Illuminates when power is supplied from batteries following a power failure.

3) Load on bypass [ LOAD ON BYPASS ](yellow)

Illuminates when power is supplied to load devices by static bypass.

(Indicates the state of bypass transfer switch "52S".)

4) Overload [ OVERLOAD ](yellow)

Illuminates in overload condition.

5) LCD fault [ LCD FAULT ](red)

Illuminates when an error occurs.

6) UPS fault [ UPS FAULT ](red) [Annunciator: intermittent or constant tones]

Illuminates when an error occurs in the system. In this case, the details of the error are indicated on the display panel.

4.2 EPO BUTTON (Emergency Power Off button)

When EPO button (7) activated, the Emergency Power Off (EPO) function shuts down the UPS module. The critical load will lose power and also shutdown. The EPO function can be performed both locally and remotely.


– 94861-000

4.3 LIQUID CRYSTAL DISPLAY

The Liquid Crystal Display (LCD) touch panel (8) indicates power flow, measured values, operational guidance, data records and error messages. The LCD panel has a back-light which facilitates viewing in different ambient lighting conditions. The LCD will automatically clear and turn off, if the screen is not activated within 3 minute period. The LCD is turned back on when it is touched again. The

ERROR indicator is cleared after 24 hours and can be reproduced by pressing any key on the panel.

4.3.1 MENU

A) MAIN MENU

The LCD panel indicates power flow and measured values, while also operating the start/stop function. The LCD panel also allows the user to verify the status and operation of the UPS Module.

Figure 4-2 Main Screen

The following will be displayed when the START/STOP key on the MAIN MENU is pressed

(Jump into OPERATION MENU):

1) Startup/Shutdown Guidance

The display indicates the Startup and Shutdown guidance for the UPS system. If this operation is

PIN protected, the user is required to enter the security PIN before the screen can be accessed.

When in remote mode, the message “REMOTE operating model” will appear on this Screen. The user cannot operate the start and stop functions without changing the setup from remote mode to local mode.

When bypass voltage is abnormal, the message “Bypass voltage abnormal” will appear.

- Start: When the bypass voltage is abnormal, the LCD asks the operator if an interrupted transfer is acceptable (Load may be lost).

- Stop: When the bypass voltage is abnormal, the user cannot transfer from inverter to bypass line.


– 94861-000

21

Figure 4-3 Startup/Shutdown Screen

Figure 4-4 Startup Guidance Figure 4-5 Shutdown Guidance

Follow Startup/Shutdown guidance accordingly


– 94861-000

B)

MEASUREMENT MENU

This screen shows details of measured values. Input and Output values are displayed. During

Battery operation, Remaining battery power and Run time are also displayed.

Figure 4-7 Output Values

Figure 4-6 Input Values

Figure 4-8 Values in Battery operation


– 94861-000

23

C)

OPERATION MENU

This screen prompts the user to select: (a) whether the start & stop operation will be performed by local or remote operation; (b) date & time adjustment; (c) battery equalizing charge. The battery equalizing charge operation key will appear when battery equalizing charge is set up (Setup is based on battery type).

Figure 4-9 Remote/Local Operation Select

Figure 4-10 Date & Time Adjustment


– 94861-000

D)

STATUS MENU

This LOG MENU displays two Touch icons in EVENT LOG and BATTERY LOG.

Pressing the EVENT LOG icon, up to 50 condition/operation records will be displayed.

Press ▲ or ▼ button for page turning.

Pressing the BATTERY LOG icon, Number of battery operations and Summed battery operation time are displayed.

Figure 4-11 Log Menu

Figure 4-12 Event Log Figure 4-13 Battery Log


– 94861-000

25

4.3.2 Input Power Failure

During an Input Power Failure, the UPS inverter will be powered by the UPS batteries. The following will be displayed on the main and measurement screen (Indication of battery operation and remaining battery time).

Figure 4-14 Main Screen (Battery Operation) Figure 4-15 Measurement Screen (Battery

Operation)

The LCD will display a battery low voltage message when the battery capacity is near depletion. The

End of Battery Discharge announcement is displayed when the battery end voltage is reached. At this time, the inverter will perform an electronic shutdown to prevent battery loss of life typical from extreme deep discharge conditions. When the input power is restored, the inverter will automatically restart to power the load, and the batteries will be simultaneously recharged. The End of Battery announcement is shown at the bottom of the screen.

4.3.3 Fault Indication

“

MESSAGE” and “SILENCE ALARM” icons will appear on the main menu when UPS failure condition has occurred.

Figure 4-16 Main Screen (Fault Indication)

The following will be displayed when the MESSAGE icon on the main menu is pressed.


– 94861-000

1) MESSAGE

The display shows a fault code, the description of the fault and a guidance of what action is to be taken by the user. A maximum of 10 faults are displayed at one time. If an input power failure occurs during a fault condition, the fault indication and input power failure announcement are alternatively displayed at 5 second intervals.

Figure 4-17 Message Screen

2)

SILENCE ALARM

This icon will appear when a failure occurs. The audible alarm (announcing the failure) can be silenced by pressing this icon.

4.4 EXTERNAL AUX CONTACT INPUT AND OUTPUT TERMINAL BLOCKS

The UPS is equipped with terminals strips TN1 (Input) and TN2 (Output) on the Auxiliary Connection

Board, IOAU-09. Some of these terminals are user-assignable to a variety of functions. These can be programmed to:



Inputs (TN1): Control the UPS remotely, or report environmental data to the UPS.



Outputs (TN2): Report status data from the UPS to external annunciation/monitoring devices.

TN1: INPUT (NEC Class2) TN2: OUTPUT (NEC Class2)

1 3 5 7 9 11 13 15 17 19 1 3 5 7 9 11 13 15 17 19

2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12 14 16 18 20

Figure 4-18 Location of External Signal Terminal Block on IOAU-09 PCB


– 94861-000

27

4.4.1 Aux Contacts

– Input

The Input terminal provides four (IN1 thru IN4) programmable contacts that can be set to any of the

functions in Table 4

–1.

Do not apply voltages to remote access input terminals.

Damage to UPS may result.

PROHIBIT

Inputs require a dry NO (Normally Open) contact to be wired on the corresponding terminals on

TN1 of IOAU-09. Closing this contact activates the selected functionality set for that input. The

Inputs provide a signal or "wetting" voltage of 24VDC / 8.3 mA. See Figure 4-19. The function

takes effect immediately upon contact closure, and is removed immediately upon opening.

External block IOAU-09

UPS Cabinet

Relay

Coil

24VDC

Relay Coil current: 8.3mA

Signal

External to

UPS Cabinet

Switch

Common

0.5s

– 4s

Wire Size: #14AWG

(2 mm

2

) or less

User supplied

ON

OFF

Use Momentary

Switches only

Figure 4-19 Control Wiring for Aux Input Contacts


– 94861-000

See

Figure 4-20

, and

Table 4

–1

.

TN1

1

+

2

TN1 Setting

1(+)-2(-) CB2 UVR* (Battery Breaker Panel)

3

4

3-4 CB2 AX (Battery Breaker Panel)

6

5

5-6 52L AX (Load Circuit Switch)

8

7

7-8 IN1: REMOTE INVERTER START

9

10

9-10 IN2: REMOTE INVERTER STOP

11

12

11-12 IN3: BATTERY TEMP. HIGH

13

14

13-14 IN4: POWER DEMAND

15

16

18

17

15-16 REMOTE EPO

17-18 N/A

19

20

19-20

N/A

UPS

Remarks

User supplied dry contact

Figure 4-20 External Signal Input Terminal Block (with default settings)

NOTE: For multiple battery cabinets, the UVR signals must be connected in parallel with UPS TN1-1 &-2.

For multiple battery cabinets, the Auxiliary Switches must be wired in series with UPS TN1-3 & -4.

CAUTION

* UVR is required for proper operation of system. If the UVR is not present or it is not properly installed, the system warranty is voided. If you encounter this condition, stop and do not continue with start-up. (See Figure 4-20 and

Figure 5-3 for connection.)

The input logic can be reversed by setting the Active Level to "Neg" when selecting the input function.

This will be annunciated on the Setup screen for the inputs by an "R" next to the Input Port.

For Example:

"IN1 1" indicates the UPS will remote start when contact closes.

"IN1 R1" indicates the UPS will remote start when contact opens.

In all cases, a switch having a protective cover is recommended in order to reduce the possibility of accidental operation.

CAUTION


– 94861-000

29

Table 4

–1 External Input Functions

Code Function Description

0

1 *

2 *

6 *

3 *

NONE

REMOTE INVERTER START

REMOTE INVERTER STOP

BATTERY TEMP ABNORMAL

POWER DEMAND 1

Starts UPS inverter from remote location. Use momentary (0.5 to 4 sec.) switches only.

This is the default setting on IN1

Stops UPS inverter from remote location. Use momentary (0.5 to 4 sec.) switches only.


Driven by any customer-provided NO (Normally Open) dry contact thermal detection device installed in the UPS's Battery Cabinet(s). When the contact closes, the UPS decreases its battery charging maximum limit to

95% of the set charging voltage. If the contacts stay closed (the battery temp is still abnormal) for two hours, the UPS will shut off its battery charger. (Battery operation will still possible)


Driven by any customer-provided NO (Normally Open) dry contact.

Closing the contact limits the input current to a value (10-150% of the UPS's rated input) set in the TEST MENU

– ”Power Demand Level 1" by an

Authorized Toshiba Service Provider. Opening the contact returns the

UPS to its normal operation parameters.

This is the default setting on IN4.

*Default Settings from Factory.


– 94861-000

4.4.2 Aux Contacts

– Output

The Output terminal strip TN2 provides eight (OUT1 thru OUT8) Form "A" NO (Normally Open) dry type programmable contacts to drive annunciation signals sourced or "wetted" by external monitoring devices. All output contacts are rated for NEC Class 2 operation (30VDC / 1ADC.)

The output dry contacts should be operated at their rated values or lower.

Figure 4-21

illustrates a

typical installation. The external relay can be a lamp, LED, computer, etc.

External block IOAU-09

UPS Cabinet

Relay

Contact

Terminal

Terminal

Wire Size: #14AWG

(2 mm

2

) or less

User supplied

Relay

Coil

External to

UPS Cabinet

NEC Class 2

Power Source

Figure 4-21 Control Wiring for Aux Output Contacts

2

TN2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

TN2 Setting

1-2 SUMMARY ALARM

3-4 OUT1: LOAD ON BYPASS

5-6 OUT2: LOAD ON INVERTER

7-8 OUT3: BATTERY OPERATION

9-10 OUT4: CONVERTER OPERATION

11-12 OUT5: BATTERY LOW VOLTAGE

13-14 OUT6: OVERLOAD

15-16 OUT7: TOTAL ALARM

17-18 OUT8: SPARE

19-20

52C CLOSE

* Relay contactor (52C close): Normally Closed

UPS

Figure 4-22 External Signal Output Terminal Block (with default settings)


– 94861-000

31

These contacts can be programmed to provide any of the functions shown in Table 4

–2. The default

programmed values are indicated with an asterisk (*).

Table 4

–2 External Output Functions

Code

0 NONE

Function

18 * LOAD ON BYASS

17 * LOAD ON INVERTER

20 * BATTERY OPERATION

21 * CONVERTER OPERATION

8 *

10 * OVERLOAD

1 *

BATTERY LOW VOL.2

TOTAL ALARM

Description

Activated when the power is supplied from the bypass.

This is the default setting on OUT1.

Activated when the power is supplied from the inverter.


Activated when the battery is operating following an AC power failure.


Activated when the converter is operating.

This is the default setting on OUT4

Activated when the battery voltage drops below Discharge Warning Voltage

Level 2 during inverter operation. This level is set in the TEST MENU by an

Authorized Toshiba Service Provider.

This is the default setting for OUT5.

Activated when an overload of 105% or more had occurred to the system.


Summary alarm; activated when any minor, major, fault or alarm has occurred with the system.


*Default output settings


– 94861-000

4.5 RemotEye

®

INTRODUCTION

The RemotEye4 is available as a UPS system monitoring tool. The RemotEye4 supplies a network function to monitor UPS units via Simple Network Management Protocol (SNMP) and Hypertext Transfer

Protocol (HTTP) methods.

The RemotEye4 module is installed at the rear of the front door in G2020 UPS units. The

configuration of the RemotEye4 is shown in Figure 4-23 and Figure 4-24 shows detailed connection.

Bushing, Support

RemotEye

(Installed here)

Cable2

(provided with

RemotEye4)

PSAU-60

(PS1)

Cable1

(provided)

UPHR-W

(UP1)

DPAU-81

(SW1)

Back of the front left door (Main cabinet)

Figure 4-23 RemotEye® Installation (Overview 500kVA)

* Consult Toshiba International Corporation for details on

“RemotEye

®

” monitoring software and its capabilities.


– 94861-000

33

The Power Supply PCB (PSAU-60, designated as PS1) and the Cable1 (designated as 3BBA0083P001) are equipped with G2020 UPS units.

The Cable2 between RemotEye4 and PSAU-60 PCB is included in the RemotEye 4 package.

The Power Supply PCB (PS1) provides connectivity between the Display Control PCB (DPAU-81, designated as SW1) and the RemotEye 4 module in G2020 UPS units.

The RemotEye 4 communicates with the UPS via a Cable2. The connection is described in Figure 4-24

below.

The UPS has to be de-energized when the RemotEye 4 module is installed

for safety reason.

CAUTION

* Consult Toshiba International Corporation for details on

“RemotEye 4” monitoring software and its capabilities.

DPAU-81

SW1

Cable1

3BBA0083P001

PSAU-60

PS1

(male)

12V Power Cable2

UPS Gold Finger Connector(GF1)

RemotEye4

NETWORK (RJ45) EMD (RJ45)

Communication

Figure 4-24 Connection between Display Control PCB (SW1) and RemotEye

®

Module


– 94861-000

The parts for UPS monitoring are listed below.

Table 4

–3 Parts List for UPS Monitoring

Parts No. Part name

Qt’y

1

2

3

Power supply PCB (PS1): PSAU-60*

Cable1: 3BBA0083P001

RemotEye 4 module

4 Cable2 (included in the RemotEye 4 package) 1

*

– PCB revision suffix may be applied.

1

1

1

Connector CN44 to be connected with

CN27 of DPAU-81(SW1).

D-sub connector CN1 to be connected with

RemotEye.

Connected with

3BBA0083P001(Cable1)

Shown in

Figure 4-27

.

Figure 4-25 PSAU-60 (PS1)

Terminal block TN to feed 12VDC power to RemotEye.

(12V across P to N)

Optional interface CN2 to feed 12VDC power

(12V Pin#1 to #2)

(Note 12VDC exposed)

Connector CN27 to be connected with

CN44 of PSAU-60(PS1).

Figure 4-26 DPAU-81 (SW1)

D3200 5pin

(Housing)

Figure 4-27 Cable1 (3BBA0083P001)


– 94861-000

35

4.6 CONNECTOR DEFINITION

5

4

3

2

1

9

8

7

6

D-SUB 9Pin (male)

DB9

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

Pin 6

Pin 7

Pin 8

Pin 9

Description

- Not used

RXD Receive Data

TXD Transmit Data

- Not used

GND Signal Ground

-

-

-

-

Not used

Not used

Not used

Not used

Figure 4-28 Connector (CN1) of PSAU-60 (PS1)

1

P

N

2

Terminal Block 2Pin

2

1

VH 2Pin

TB2

Pin 1

Pin 2

Description

+12VS +12VDC

GND(S) +12VDC ground

Figure 4-29 Terminal Block (TN) and VH connector (CN2) of PSAU-60 (PS1)

1

2

3

4

5

D5

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

Description

RXD Receive data

TXD Transmit data

GND Signal ground

+24VS +24VDC


D3200 5Pin (contact)

Figure 4-30 Connector (CN44) of PSAU-60 (PS1)


– 94861-000

1

2

3

4

5

D5

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

Description

RXD Receive data

TXD Transmit data

GND Signal ground

+24VS +24VDC


D3200 5Pin (contact)

Figure 4-31 Connector (CN27) of DPAU-81 (SW1)

FOR SERVICE PERSONNEL ONLY

DB9 Description

6

7

8

9

1

2

3

4

5

D-SUB 9Pin (male)

Pin 1

Pin 2

Pin 3

Pin 4

Pin 5

Pin 6

Pin 7

Pin 8

Pin 9

- Not used

RXD Receive Data

TXD Transmit Data

- Not used

GND Signal Ground

-

-

-

-

Not used

Not used

Not used

Not used

Figure 4-32 Connector (CN26) of DPAU-81 (SW1)


– 94861-000

37

5 INSTALLATION AND OPERATION

5.1 TRANSPORTATION AND INSTALLATION

Transport with forklift. If carry by overhead crane, use four eyebolts (Not provided)

Table 5

–1 Transport by Overhead Crane

Model

500 kVA

UPS Cabinet

4 x M20 Lifting Eyes

Landing Cabinet *

4 x M16 Lifting Eyes

* Use lifting eyes on landing cabinet only to lift landing cabinet by itself, not as part of assembled unit.

Install the unit using the four pre-drilled holes in the UPS channel base. Anchor the unit using appropriate hardware. (Not provided).

Do not transport UPS cabinet laid horizontally.

PROHIBIT

!

Cabinets must be maintained upright within ± 15° of the vertical during handling.

NOTE

5.2 INSTALLATION PROCEDURE

A) Note the load tolerance of the floor

Refer to Table 5

–2 for list of UPS weights.

Table 5

–2 List of UPS Weights

UPS Capacity (kVA)

Weight (lb.)

500

2,756

B) Minimum clearance required for ventilation

Right side 1 in. (25 mm) (not required when sidecars are used)

Left side

Back side

Top side

1 in. (25 mm) (not required when sidecars are used)

0.0 in. (0 mm)

24 in. (610 mm) (for air flow)

C) Space requirement for routine maintenance

Allow for the following space at the time of installation.

Front

Sides

Back side

Top side

40 in. (1016 mm)

0.0 in. (0 mm)

0.0 in. (0 mm)

20 in. (500 mm)


– 94861-000

38

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 5

–3.

NOTE

Table 5

–3 Maximum

Permitted

Fault Current

UPS Capacity

(kVA)

DC Voltage

Rating (V)

Maximum Permitted

Fault Current (A)

500 480

5.3 PROCEDURE FOR CABLE CONNECTIONS

25,000

1. Confirm the capacity of the UPS being installed. Identify the input/output power

Terminal blocks accordingly as shown in the Figure 5-1 and

Figure 5-2

.

2. Connect the internal control wire and power wire.

(1) Control wire Inter-connect

1. CB2 UVR to terminal TN1 1, 2 of external I/F PCB IOAU-09.

UVR is required for proper operation of system. If the UVR is not present or it is not properly installed, the system warranty is voided. If you encounter this

CAUTION

condition, stop and do not continue with start-up. (See Figure 4-20 and Figure

5-3 for connection.)

2. CB2 ON Auxiliary to terminal TN1 3, 4 of external I/F PCB IOAU-09.

(2) Power wire (AC input, Bypass input, AC output) Inter-connect a.) Fro m 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

!

NOTE

After the completion of the input power cables connection:

With a phase rotation meter, check that the phase rotation of the AC Input power terminals A, B and C as well as the Bypass Input power terminals A40,

B40 and C40 are correct.

The proper phase rotation is clockwise A(R)

→ B(S) → C(T).

REQUIRED


– 94861-000

39

3. Connect the grounding conductor from the input service entrance to the UPS Ground 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 5-1 and

Figure 5-2

. Input cables must be sized for

an ampere rating larger than the maximum input drawn by the converter. (Refer to equipment nameplate for current ratings.) Confirm that an external bypass input circuit breaker (MCCB) is installed (refer to WARNING 4, page 10). Connect the bypass input power cables from the input service entrance to the bypass input power terminals, identified as A40, B40 and C40 in

Figure 5-1 and

Figure 5-2

. Bypass input cables must be sized for an ampere rating larger

than the maximum output current capacity of the UPS. Refer to Table 5

–4 for recommended

cable sizes.

(2) Connect the external signal terminal block as desired. Refer to Section 4.4 and Figure 4-19

thru Figure 4-22 for functional description. 14 AWG (2mm

2

), or less, shielded conductor is recommended.

5. One (1) source feeding the UPS:

(1) Confirm that an external input circuit breaker sized to protect both the AC input and the bypass line is installed. (Refer to equipment nameplate for current ratings.) Connect the bypass input power cables from the input service entrance to the bypass input power

terminals, identified as A40, B40 and C40 in Figure 5-1 and

Figure 5-2

. Input cables must be

sized for an ampere rating larger than the maximum current capacity of the UPS. Refer to

Table 5

–4 for recommended cable sizes.

(2) Using adequately sized conductors and referring to the appropriate figure identified in Figure

5-1 and

Figure 5-2

, connect jumper bypass terminals A40, B40, C40 to AC input power terminals A, B, C as identified in Figure 5-1 and

Figure 5-2

.

(3) Connect the external signal terminal block as desired. Refer to Section 4.4 and Figure 4-19

thru Figure 4-22 for functional description. 14 AWG (2mm

2

), or less, shielded conductor is recommended.

!

NOTE

1. Confirm that all UPS internal contactors (breakers) "CB1", "CB2", and

"CB3" are open before energizing UPS.

2. UPS power terminals are supplied with stud type fittings.

It is recommended that compression lugs be used to fasten all input/output power cables.


– 94861-000

40

6. Procedure for Cable Connections for Parallel Operation System

(1) Confirm the number of units to be connected in parallel. Identify the input/output power terminal blocks and control wire connections for parallel operation systems as shown in the

appropriate Figure 5-1 and

Figure 5-2

.

(2) Connect the external control wire and power wire.

!

Straight through, shielded CAT5 cables with metal shrouded RJ-45 plugs on both sides are to be used for the parallel control signal cables. Use of any

NOTE

other cables could cause erroneous communication failures.

a.) Control wire connection

Parallel configuration wiring (Refer to

Figure 5-4

to Figure 5-10)

- 52L control signal from Toshiba Tie Cabinet (TTC) to UPS-n IOAU-09

(TN1

– 5, 6).

- Parallel control signal for TLAx, TLBx, CAx, and CBx as shown in

Figure 5-5

to

Figure 5-10.

b.) Power wire connection

From UPS AC Output Terminals to Toshiba Tie Cabinet (TTC) (Refer to Figure 5-1 and

Figure 5-2)


– 94861-000

41

Table 5

–4 Recommended Cable Sizes

Input Side Output Side Bypass Side kVA

Capacity

Input

Voltage

Output

Voltage

Cable

Size

Torque in. lbs

Cable

Size

Torque in. lbs

Cable

Size

Torque in. lbs

Cable

Size

3 x 250MCM 347 - 469 3 x 250MCM 347 - 469 3 x 250MCM 347 - 469

500kVA 480V 480V 4 x 400MCM or larger in. lbs or larger in. lbs or larger in. lbs

*1

– Use 75 degree C copper wire.

*2

– The cables must be selected to be equal or larger to the sizes listed in the table.

*3

– Voltage drop across power cables not to exceed 2% of nominal source voltage.

*4

– Allowable ampere-capacities based on copper conductors with 75 degree C. insulation at ambient temperature of 40 degree C.

Table 5

–5 Recommended Hardware

UPS Capacity

500kVA

Bolt size

M12 x 40mm

Flat washer size

M12

Split lockwasher size

M12

Nut size

M12

DC Input Side

Torque in. lbs

347 - 469 in. lbs


– 94861-000

Table 5

–6 Crimp Type Compression Lug

WIRE

SIZE

(CODE)

1

1/0

2/0

3/0

4/0

250 MCM

300 MCM

350 MCM

400 MCM

500 MCM

WIRE

STRAND

CLASS

B

I

B

I

B

I

B

I

B

I

B

I

I

B

I

B

I

B

B

I

RECOMMENDATION

VENDOR

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

BURNDY

ILSCO

BURNDY

CAT. NO.

YA1C

CRA-1L

YA25-LB

YA25

CRA-1/OL

YA25-LB

YA26

CRA-2/OL

YA27-LB

YA27

CRB-3/OL

YA28-LB

YA28

CRB-4/OL

YA29-LB

YA29

CRA-250L

YA30-LB

YA30

CRA-300L

YA32-LB

YA31

CRA-350L

YA34-LB

YA32

CRA-400L

YA36-LB

YA34

CRA-500L

YA38-LB

CRIMP TOOL REQUIRED

BURNDY TYPE Y35 OR Y46

COLOR KEY

GREEN

GREEN

---

PINK

PINK

---

BLACK

BLACK

---

ORANGE

ORANGE

---

PURPLE

PURPLE

---

YELLOW

YELLOW

---

WHITE

WHITE

---

RED

RED

---

BLUE

BLUE

---

BROWN

BROWN

---

DIE INDEX

11 / 375

11 / 375

1019

12 / 348

12 / 348

1020

13

13

1021

14 / 101

14 / 101

1022

15

15

1023

16

16

1024

17 / 298

17 / 298

1026

18 / 324

18 / 324

1027

19 / 470

19 / 470

1027

20 / 299

20 / 299

1029

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.

Bypass

Input

Terminals

A40

B40

C40

CB3

52S

Static Transfer

Switch

AC

Input

Terminals

A

B

C

CB1

Converter

/Charger

/ CHA

Inverter

52C Terminals

A50

B50

C50

AC

Output

Terminals

BP

BN

CB2

External

Battery

Figure 5-1 UPS Terminal Designation


– 94861-000

43

44

Location of bus bars and terminal blocks (Bottom/Top/Left Side entry)

D=33.5

” (850mm)

59.2

”(1500)

AC Input

A , B , C

Bypass Input

A 40 , B 40 , C 40

AC Output

A 50 , B 50 , C 50

DC Input

BP , BN

Grounding Bar

( not shown )

Detailed Power Terminals

For power terminals, use 1/2

” (12mm) diameter bolts.

E

Grounding

Bar

AC Input

A

B

C

A 40

Bypass

Input

B 40

C 40

A 50

AC

Output

B 50

C 50

DC Input

BP

BN

15.7

” (400)

UPS module (500kVA)

Figure 5-2 Diagram of input/output bus bars and terminal blocks


– 94861-000

NOTE

!

UVR is required for proper operation of system. If the UVR is not present or it is not properly installed, the system warranty is voided. If you encounter this condition, stop and do not continue with start-up. (See Figure

4-20 and Figure 5-3 for connection.)

External signal terminal

IOAU-09

– [TN1]

3

4

1

2

DC Power

Terminals

BN BP

User

Supplied

User

Supplied

CB2 (DC Circuit Breaker

UVR

“–” Negative

Auxiliary

“+” Positive

UPS Module

DC Breaker for

Battery Cabinet

External signal terminal

IOAU-09

– [TN1]

1

2

3

4

DC Power

Terminals

BN BP

User

Supplied

User

Supplied


UVR

“–” Negative

Auxiliary

“+” Positive

User

Supplied


UVR

Auxiliary

User

Supplied

“–” Negative

“+” Positive

UPS Module

DC Breaker for

Battery Cabinet 1

DC Breaker for

Battery Cabinet n

Figure 5-3 Diagram of Power Wire & Control Wire Inter-Connect between UPS and Battery


– 94861-000

45

46

Toshiba Tie Cabinet (TTC)

Bypass input

AC input

Bypass input

AC input

UPS-1

Bypass

52S

CB1

Converter

/Charger Inverter

52C

UPS-2

Bypass

CB1

CB2 Battery

52S

Converter

/Charger

Inverter

52C

CB2 Battery

AC output

AC output

52L1

UPS

Breaker

52L2

52MB

Maintenance

Bypass Breaker

UPS

Breaker

Output

Breaker

52CS

Bypass input

UPS-n

Bypass

CB1

Converter

/Charger

52S

Inverter

UPS

Breaker

52Ln (*1)

AC input AC output

52C

(*1) n: Maximum=8

CB2 Battery

Figure 5-4 Diagram of Power Wire Connections (Parallel System Configuration)


– 94861-000

NOTE

!

Use Ethernet STP (Shielded

Twisted Pair) Cable (Cat 5 or better) with shielded RJ45 modular connectors for all communication cabling.

Use of UTP (Unshielded Twisted Pair)

Cable may cause malfunction.

Communication

Cabling

*1

*1

NOTE

TLAx and TLBx are redundant signal lines. CAx and CBx are redundant signal lines.

Redundant lines provide reduced vulnerability to cable damage when

TLAx/CAx circuits are installed in separate conduit from TLBx/CBx circuits.

UPS-1

IFAU-09

CN99

TLBIN

CN98

TLAIN

CN97

TLBOUT

CN96

TLAOUT

*2

CN954

CB2IN

CN953

CB1IN

CN952

CA2IN

CN951

CA1IN

ON

CN944

CB2OUT

CN943

CB1OUT

CN942

CA2OUT

CN941

CA1OUT

*2 ON

NOTE

!

Total cable length from UPS-1 to UPS-2 should be within 100m.

*1 Return from the last

UPS module to the first UPS module (continuous loop).

*2 DIP switch position

UPS-1 and UPS-2: ON

UPS-2

IFAU-09

CN99

TLBIN

CN98

TLAIN

CN97

TLBOUT

CN96

TLAOUT

*2

CN954

CB2IN

CN953

CB1IN

CN952

CA2IN

CN951

CA1IN

ON

CN944

CB2OUT

CN943

CB1OUT

CN942

CA2OUT

CN941

CA1OUT

*2 ON

IOAU-09

TN1

5

6

AC

OUTPUT

A50

B50

C50

IOAU-09

TN1

5

6

AC

OUTPUT

A50

B50

C50

Toshiba Tie Cabinet (TTC)

Signal

Cabling

47

48

49

50

52L1-AX

52L2-AX

Power

Cabling

AC OUTPUT

UPS-1

A

B

C

UPS-2

A

B

C

Figure 5-5 Diagram of Power & Control Wire Connections for 2 units in MMS Configuration


– 94861-000

47

No.1 UPS

IFAU-09

CN99 TLBIN

CN98 TLAIN

CN97 TLBOUT

CN96 TLAOUT

CN954 CB2IN

CN953 CB1IN

CN952 CA2IN

CN951 CA1IN

CN944 CB2OUT

CN943 CB1OUT

CN942 CA2OUT

CN941 CA1OUT

No.2 UPS

IFAU-09

CN99 TLBIN

CN98 TLAIN

CN97 TLBOUT

CN96 TLAOUT

CN954 CB2IN

CN953 CB1IN

CN952 CA2IN

CN951 CA1IN

CN944 CB2OUT

CN943 CB1OUT

CN942 CA2OUT

CN941 CA1OUT

IOAU-09

~~~~~

IOAU-09

~~~~~

Figure 5-6 Detail of IFAU-09 Control Wire Connections for 2 units in MMS Configuration


– 94861-000

Communication

Cabling

NOTE

!





NOTE

TLAx and TLBx are redundant signal lines. CAx and CBx are redundant signal lines.



NOTE

!


*1

*1

UPS-1

IFAU-09

CN99

TLBIN

CN98

TLAIN

CN97

TLBOUT

CN96

TLAOUT

*2

ON

CN954

CB2IN

CN953

CB1IN

CN952

CA2IN

CN951

CA1IN

CN944

CB2OUT

CN943

CB1OUT

CN942

CA2OUT

CN941

CA1OUT

*2 ON

IOAU-09

TN1

5

6

AC

OUTPUT

A50

B50

C50

UPS-2

IFAU-09

CN99

TLBIN

CN98

TLAIN

CN97

TLBOUT

CN96

TLAOUT

*2

CN954

CB2IN

CN953

CB1IN

CN952

CA2IN

CN951

CA1IN

OFF

CN944

CB2OUT

CN943

CB1OUT

CN942

CA2OUT

CN941

CA1OUT

*2 OFF

IOAU-09

TN1

5

6

AC

OUTPUT

A50

B50

C50


Signal

Cabling

35

36

37

38

.

.

.

49

50

52L1-AX

52L2-AX

52Ln-AX

*3




UPS-1 and UPS-n: ON

Otherwise: OFF

*3 n = 3-4 (maximum) for this cabling configuration

UPS-n

*3

IFAU-09

CN99

TLBIN

CN98

TLAIN

CN97

TLBOUT

CN96

TLAOUT

*2

CN954

CB2IN

CN953

CB1IN

CN952

CA2IN

CN951

CA1IN

ON

CN944

CB2OUT

CN943

CB1OUT

CN942

CA2OUT

CN941

CA1OUT

*2

ON

IOAU-09

TN1

5

6

AC

OUTPUT

A50

B50

C50

Power

Cabling

AC OUTPUT

UPS-1

A

B

C

UPS-2

A

B

C

.

.

.

UPS-n

*3

A

B

C

Figure 5-7 Diagram of Power & Control Wire Connections for 3-4 units in MMS Configuration


– 94861-000

49

No.1 UPS

IFAU-09

CN99 TLBIN

CN98 TLAIN

CN97 TLBOUT

CN96 TLAOUT

CN954 CB2IN

CN953 CB1IN

CN952 CA2IN

CN951 CA1IN

CN944 CB2OUT

CN943 CB1OUT

CN942 CA2OUT

CN941 CA1OUT

No.2 UPS

IFAU-09

CN99 TLBIN

CN98 TLAIN

CN97 TLBOUT

CN96 TLAOUT

CN954 CB2IN

CN953 CB1IN

CN952 CA2IN

CN951 CA1IN

CN944 CB2OUT

CN943 CB1OUT

CN942 CA2OUT

CN941 CA1OUT

No.N UPS

IFAU-09

CN99 TLBIN

CN98 TLAIN

CN97 TLBOUT

CN96 TLAOUT

CN954 CB2IN

CN953 CB1IN

CN952 CA2IN

CN951 CA1IN

CN944 CB2OUT

CN943 CB1OUT

CN942 CA2OUT

CN941 CA1OUT

IOAU-09

~~~~~

IOAU-09

~~~~~

IOAU-09

~~~~~

Figure 5-8 Detail of IFAU-09 Control Wire Connections for 3 or 4 units in MMS Configuration


– 94861-000

NOTE

TLAx and TLBx are redundant signal lines. CAx and CBx are redundant sgnal lines.



NOTE

!


Communication

Cabling

*1

NOTE

!





*1

UPS-1

IFAU-09

CN99

TLBIN

CN98

TLAIN

CN97

TLBOUT

CN96

TLAOUT

*2

CN954

CB2IN

CN953

CB1IN

CN952

CA2IN

CN951

CA1IN

ON

CN944

CB2OUT

CN943

CB1OUT

CN942

CA2OUT

CN941

CA1OUT

*2 ON

UPS-2

IFAU-09

CN99

TLBIN

CN98

TLAIN

CN97

TLBOUT

CN96

TLAOUT

*2

CN954

CB2IN

CN953

CB1IN

CN952

CA2IN

CN951

CA1IN

OFF

CN944

CB2OUT

CN943

CB1OUT

CN942

CA2OUT

CN941

CA1OUT

*2 OFF

IOAU-09

TN1

5

6

AC

OUTPUT

A50

B50

C50

IOAU-09

TN1

5

6

AC

OUTPUT

A50

B50

C50


35

36

37

38

.

.

.

49

50

Signal

Cabling

52L1-AX

52L2-AX

52Ln-AX

*3

Power

UPS-1

A

B

C

UPS-n

*3

IFAU-09

CN99

TLBIN

CN98

TLAIN

CN97

TLBOUT

CN96

TLAOUT

*2

CN954

CB2IN

CN953

CB1IN

CN952

CA2IN

CN951

CA1IN

ON

IOAU-09

TN1

5

6

UPS-2

A

B

C

.

.

.

UPS-n

*3

A

B

C




UPS-1 and UPS-n: ON

Otherwise: OFF

*3 n = 5-8 (maximum) for this cabling configuration

CN944

CB2OUT

CN943

CB1OUT

CN942

CA2OUT

CN941

CA1OUT

*2 ON

AC

OUTPUT

A50

B50

C50

Figure 5-9 Diagram of Power Wire & Control Wire Connections for 5 to 8 units in MMS Configuration


– 94861-000

51

No.1 UPS

IFAU-09

CN99 TLBIN

CN98 TLAIN

CN97 TLBOUT

CN96 TLAOUT

CN954 CB2IN

CN953 CB1IN

CN952 CA2IN

CN951 CA1IN

CN944 CB2OUT

CN943 CB1OUT

CN942 CA2OUT

CN941 CA1OUT

No.2 UPS

IFAU-09

CN99 TLBIN

CN98 TLAIN

CN97 TLBOUT

CN96 TLAOUT

CN954 CB2IN

CN953 CB1IN

CN952 CA2IN

CN951 CA1IN

CN944 CB2OUT

CN943 CB1OUT

CN942 CA2OUT

CN941 CA1OUT

No.N UPS

IFAU-09

CN99 TLBIN

CN98 TLAIN

CN97 TLBOUT

CN96 TLAOUT

CN954 CB2IN

CN953 CB1IN

CN952 CA2IN

CN951 CA1IN

CN944 CB2OUT

CN943 CB1OUT

CN942 CA2OUT

CN941 CA1OUT

IOAU-09

~~~~~

IOAU-09

~~~~~

IOAU-09

~~~~~

Figure 5-10 Detail of IFAU-09 Control Wire Connections for 5 to 8 units in MMS Configuration


– 94861-000

5.4 OPERATING PROCEDURES

NOTE: To avoid inadvertently placing the UPS online or offline the START and STOP switches must be pressed and held for a period of several seconds to execute the command.



START

– Press and hold the START switch for approximately 2 seconds.



STOP

– Press and hold the STOP switch for approximately 5 seconds.

For Parallel Operation system, refer to section

“E) MMS Start-up Procedure”.

(Parallel Operation system is herein after referred to as a MMS [Multi Module System])

On-screen guidance for Starting and Stopping the UPS can be obtained by pressing the OPERATION tab icon.

A) Start-up Procedure

Before the UPS startup, the internal Bypass line starts to supply the unconditioned bypass input power to the load if the External input (or Bypass)

!

NOTE

Circuit Breaker is closed. Be extremely careful with closing the External input

(or Bypass) Circuit Breaker.

Confirm the position of the circuit protectors (CPMC, CPMS and EMB) located

at the upper right part of the cabinet (Figure 5-11).

1) CPMC and CPMS: ON;

2) EMB: OFF.

CPMC CPMS EMB

Figure 5-11 Circuit Protectors Location

a.) Verify the Battery Disconnect Circuit Breaker (CB2) is open or in the tripped position. (user supplied) b.) Verify the External Input /Bypass Circuit Breaker for each unit is closed. (user supplied) c.) If a dual source is feeding the UPS, close the External AC Input Circuit Breaker manually (user supplied). d.) The LCD panel boots up automatically and opens up in the “MAIN” Tab; the Converter and

Inverter will start automatically (Figure 5-12).

NOTE: On the initial startup of the G2020, both the Bypass (52S) and the Inverter (52C)

contactors will be open (Figure 5-12b). After the initial startup, the UPS will subsequently

startup in Bypass mode (Figure 5-16).

e.) FOR GUIDANCE IN STARTING THE UPS, select

“OPERATION” tab on the LCD panel, then press the

“STARTUP GUIDANCE” icon (Figure 4-3) and follow the on-screen directions to continue UPS start-up (

Figure 4-4

). (The directions are the same as given in the following

steps.)

OR remain on the “MAIN” tab and continue with step f).


– 94861-000

53

a.

b.

Figure 5-12 Automatic Startup of Inverter and Converter

f) Close the Battery Breaker. (The START/STOP icon will not work until the battery breaker is closed.)

The display will show CB2 is closed and the battery backup is now online. (Figure 5-13)

Figure 5-13 Close Battery Breaker

g) Press the STOP/START icon on the display, then press and hold the START button (Figure 5-14a) for two (2) seconds until the UPS transfers to load on INV. (Figure 5-14b)

a.

54

b.

Figure 5-14 Press and Hold START Button


– 94861-000

When "REMOTE OPERATION MODE" is displayed on the LCD panel, the inverter

! start operation can only be performed remotely. If local inverter start operation is required (at the UPS), select "LOCAL ONLY" or “REMOTE & LOCAL” in the

OPERATION MENU.

NOTE

B) Transfer from Online to Bypass Procedure

Transfer to Bypass to remove power from the inverter but continue to provide utility power to the critical load. a.) Press the "START/STOP" icon from the “MAIN” Menu on the LCD.

b.) On the LCD panel, press and hold STOP for five (5) seconds. (Figure 5-14a)

c.) The UPS transfers to Bypass. (Figure 5-15) The Bypass contactor (52S) closes and the

Inverter contactor (52C) opens. (Figure 5-15b)

a.

. b.

Figure 5-15 Transfer from Online to Bypass

C) Transfer from Bypass to Online Procedure

Transfer from Bypass to Online to provide the load with conditioned, reliable power. a.) Press the "START/STOP" icon from the “MAIN” Menu on the LCD. b.) On the LCD panel, press and hold START for two (2) seconds. c.) The UPS transfers to Online. The Bypass contactor (52S) opens and the Inverter contactor

(52C) closes. (Figure 5-16b)

a.

b.

Figure 5-16 Transfer from Bypass to Online


– 94861-000

55

D) Shut-down Procedure

If a total UPS shutdown is required, verify that the critical load is OFF.

Verify the load is OFF if the next step is to be performed.

Power to the load has been supplied through the bypass line. Power to load will be lost after execution of the next step. The load will drop.

CAUTION

a.) Press the "START/STOP" icon from the Main Menu or the Operation Menu on the LCD. b.) On the LCD panel, press

“START/STOP” icon, and then press and hold STOP for 5 seconds.

(Figure 5-17b)

a.

b.

Figure 5-17 Initiate Shutdown

c.) The UPS transfers to Bypass. The Bypass contactor (52S) closes and the Inverter contactor

(52C) opens. (Figure 5-18)

56

Figure 5-18 UPS Transfers to Bypass

d.) In Bypass, both of the Inverter and the Converter remain energized until complete disconnection from all power sources.

In bypass mode, all UPS power terminals are still alive. Lethal voltages are present. De-energize all external sources of AC and DC power. Before removing the covers, wait 5 minutes after de-energizing. Check no-voltage before handling UPS. Be careful of the devices even when the

UPS has been de-energized, since internal devices may be energized.

WARNING


– 94861-000

e.) If stopping both the Inverter and Converter is required, open the Battery Disconnect circuit

breaker CB2. (Figure 5-19)

Figure 5-19 Open Battery Breaker

!

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.

Verify the load is OFF if the next step is to be performed.

WARNING

!

NOTE

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.

f.) If a dual source is feeding the UPS, open the External AC Input Circuit Breaker (user supplied) manually. g.) If turning off all power to the critical load is required, open the External Bypass Input Circuit

Breaker (user supplied) manually.


– 94861-000

57

E) MMS Start-up Procedure

External Circuit Check (Ensure System is in Maintenance Bypass)

1.

Verify that Tie cabinet Maintenance bypass breaker 52MB is closed.

2.

Verify that Tie cabinet Output breaker 52CS is open.

3.

Verify that Tie cabinet UPS breakers

52L1, 52L2…and 52Ln are closed.

Start-up from UPS-1 to UPS-n

1.

Start-up each UPS in accordance with

“A) Start-up Procedure”. Each UPS will start Inverter

Operation synchronized with the bypass input. The Maintenance Bypass Switch is synchronized with the Static Transfer Switch.

Transfer from Maintenance Bypass to MMS Bypass Operation

1.

Close Tie cabinet breaker 52CS.

2.

Open Tie cabinet Breaker 52MB.

!

NOTE

When "REMOTE OPERATION MODE" is displayed on the LCD panel, the inverter start operation can only be performed remotely. If local inverter start operat ion is required (at the UPS), select "LOCAL ONLY" or “REMOTE

& LOCAL” in the OPERATION MENU.

Transfer from UPS MMS Bypass Operation To UPS MMS Inverter Operation

1. Transfer MMS Bypass Operation to MMS Inverter Operation from Operation Menu on any UPS

LCD as shown in Figure 5-20.

Transfer from UPS MMS Inverter Operation To UPS MMS Bypass Operation

1. Transfer MMS Inverter Operation to MMS Bypass Operation from Operation Menu on any UPS

LCD as shown in Figure 5-20.

58

Figure 5-20 LCD Screen (MMS Operation)


– 94861-000

6 RESPONSE TO UPS FAILURE

UPS FAULT

Annunciator Silence

Recording of Fault

Primary Action

Information to Service

Center

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

Representatives or call Toshiba International Corporation at

1-877-867-8773.

!

NOTE

Note

The error code indicated on the LCD display panel when an UPS alarms is very important.

In order to reduce repair time, please include this information, along with the operation and load status for all correspondence to

Toshiba field service group.


– 94861-000

59

7 PARTS REPLACEMENT

A) Recommended Maintenance

Toshiba International Corporation recommends the UPS have regular preventative maintenance (PM) visits to ensure optimum operation and longevity. Toshiba recommends two

Major

PM’s per year, at six month intervals.

A Major PM includes maintenance of the batteries and an offline inspection of the UPS.

Contact Toshiba International Corporation Service Department at 1-877-867-8773 for further details.

B) Battery

Battery lifetime may vary according to the frequency of use and the average ambient operating temperature. The end of battery life is defined as the state of charge resulting in an ampere-hour capacity less than, or equal to, 80% of nominal capacity.

Battery replacement is recommended if its capacity is within this percentage.

C) UPS Component Parts

UPS components have a defined life expectancy (Fans, Capacitors, Filters, etc.)

Contact Toshiba International Corporation or its authorized service representatives for a complete parts replacement schedule. Recommended replacement time interval varies with operating environment.

Contact Toshiba International Corporation or its authorized service representatives for application specific recommendations.

Table 7

–1 Standard Replacement Parts List

Parts name

Cooling fans

Electrolytic Capacitors

AC filter Capacitors

Control Relays

Contactors

PCB

Control power supply

LCD

Fuses

Thermal relays

Life Expectancy

5 years

15 years

15 years

15 years

15 years

15 years

15 years

10 years

10 years

10 years

Any parts replacements (including modification) without authorized by

Toshiba could result in personal injuries, death or destruction of the UPS.

WARNING


– 94861-000

D) Air Filters

Air filters can be obtained in bulk quantities from Toshiba International Corporation. Use only air filters specified by Toshiba.

Table 7

–2 Replacement Air Filters

UNIT

500kVA

Toshiba Part Number

T90-AF-20x30x1

T90-AF-15x30x1

Quantity

1 (Left Door)

1 (Right Door)

8 FAULT CODES

This section covers fault codes, their description and required action at time of error.

In the event of a fault occurring:

A) Verify and record the occurrence of the alarm. Note details of alarm message displayed on the LCD display panel.

Contact Toshiba International Corporation at 1-877-867-8773.

B) If a circuit breaker (MCCB) has tripped, depress the toggle to reset the breaker before closing it again.


– 94861-000

61

62

Table 8

–1 Fault Code

Code indication

(Note 3)

Status message

Meaning Guidance

UA801

UA802

UA803

UA804

UA805

UA806

UA807

UA808

UA810

UA812

UA813

UA814

UA815

UA817

UA821

UA822

AC INPUT

VOLTAGE OUT

OF RANGE

AC INPUT

FREQUENCY

OUT OF

RANGE

AC INPUT

PHASE

ROTATION

ERROR

CONVERTER

OPE.

INHIBITED

INVERTER

OVERLOAD

INVERTER

OVERLOAD

INVERTER

OVERLOAD

INVERTER

OVERLOAD

INVERTER

OVERLOAD

BYPASS

VOLTAGE OUT

OF RANGE

BYPASS

PHASE

ROTATION

ERROR

BYPASS

FREQUENCY

OUT OF

RANGE

TRANSFER

INHIBITED

EMERGENCY

STOP

ACTIVATED

TRANSFER

INHIBITED

TRANSFER

INHIBITED

UA824 CB2 OPEN

UA827

52C OPE.

INHIBITED

Input line voltage is out of the specific range.

Input line frequency is out of the specified range.

Input line power conductors are not wired in a proper phase sequence.

CHECK

INPUT

POWER

SOURCE

CHECK

INPUT

POWER

SOURCE

CHECK

INPUT

POWER

SOURCE

The converter interlock is active.

The output load current has exceeded 105% of the rated current.




Short time over-current has exceeded 150% of the rated current

Bypass line voltage is out of the specific range.

-

Bypass line power conductors are not wired in a proper phase sequence.

WARNING:

DECREASE

LOAD

WARNING:

DECREASE

LOAD

WARNING:

DECREASE

LOAD

WARNING:

DECREASE

LOAD

WARNING:

DECREASE

LOAD

CHECK

BYPASS

INPUT

CHECK

BYPASS

INPUT

Bypass line frequency is out of the specific range.

Transfer to bypass is not available due to bypass abnormality.

The emergency stop was activated by the EPO switch or an external contact.

The UPS cannot transfer to the bypass because the inverter output is not synchronized to the bypass.

The UPS cannot transfer to the bypass because of backup generator operation.

The battery circuit breaker

(CB2) is open.

The interlock for the inverter output contactor (52C) is active.

CHECK

BYPASS

INPUT

-

-

-

-

TURN ON

CB2

-

Buzzer

Intermittent sound

External relay contact

(Note 1)

Failure lamp

(Note 2)

AC input abnormal

-

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

-

-

-

Intermittent sound

Intermittent sound

AC input abnormal

AC input abnormal

-

Overload

Overload

Overload

Overload

Overload

Bypass

Input

Abnormal

Bypass

Input

Abnormal

Bypass

Input

Abnormal

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-


– 94861-000

Code indication

(Note 3)

Status message

UA831

EMERGENCY

BYPASS SWITCH

ON

UA833 52L OPEN

UA834

BATTERY

DEPLETED/AC

OUT STOPPED

UA835

UA841

UA860

UA861

UA870

UA890

UF001

UF002

UF003

UF004

UF011

UF052

UF056

UF057

UF059

UF102

UF103

TRANSFER

INHIBITED

CONVERTER

OPE. INHIBITED

REMOTE

BUTTON

ABNORMAL

LOCAL BUTTON

ABNORMAL

BALANCER

OVERLOAD

EXTERNAL

ALARM

INPUT CIRCUIT

ABNORMAL

CONVERTER

OVERCURRENT

CONVERTER

ABNORMAL

CONVERTER

OVERCURRENT

CB1 ABNORMAL

CB1 ABNORMAL

CONVERTER

OVERCURRENT

CONVERTER

OVERCURRENT

INPUT CIRCUIT

ABNORMAL

DC

OVERVOLTAGE

DC

UNDERVOLTAGE

Meaning

Emergency bypass switch has been turned on.

The load circuit breaker

(52L) is turned off.

The battery voltage has reached the depleted level.

The UPS could not transfer to the bypass because the bypass source has an abnormality.

The interlock for the converter input contactor

(CB1) is active on external input.

Remote start signal is being received continuously for a considerable time.

Local start or stop signal is being received continuously for a considerable time.

The UPS detected a neutral point voltage unbalance.

External Alarm relay turned on.

Detection of a large variation of the reference error signal.

Detection of converter overcurrent.

Pre-charging circuit is not working properly.


Major discrepancy between reference signal and actual state of contactor CB1.

Minor discrepancy between reference signal and actual state of contactor CB1.



Detection of a large variation of the reference error signal.

DC voltage surpasses the overvoltage level.

DC voltage dropped below the undervoltage level.

Guidance

-

-

-

-

-

-

-

-

-

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

Buzzer

Intermittent sound

Intermittent sound

-


(Note 1)

Failure lamp

(Note 2)

- -

-

End-of-

Discharge

-

Lit on

-

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Continuous sound

Continuous sound

-

-

-

-

-

-

Major

Major

Major

Major

Major

Minor

Minor

Minor

Minor

Major

Major

-

-

-

-

-

-

Lit on

Lit on

Lit on

Lit on

Lit on

Flicker

Flicker

Flicker

Flicker

Lit on

Lit on


– 94861-000

63

64

Code indication

(Note 3)

UF108

UF109

UF110

UF112

UF113

UF119

UF128

UF151

UF152

UF154

UF156

UF157

UF158

UF159

UF161

UF162

UF163

UF170

UF172

UF159

Status message

Meaning Guidance

CHOPPER

OVERCURRENT

DC UNBALANCED

ZERO PHASE

OVERCURRENT

DC CIRCUIT

ABNORMAL

DC CIRCUIT

ABNORMAL

DC GROUND

FAULT

CONTROL

POWER SUPPLY

ABNORMAL

DC VOLTAGE

ABNORMAL

DC VOLTAGE

ABNORMAL

CB2 ABNORMAL

Detection of DC overcurrent.

Major unbalance of the neutral point voltage.

Detection of converter zero-sequence overcurrent.

Sudden change of the DC voltage level.

Unit current unbalance.

Detection of DC ground fault.

Power supply voltage to SiC driver PCB is below the specified level.

24 hours after input power restoration, batteries do not reach float voltage level.

Unable to equalize the voltage of various batteries after 24 hours.

During UVR, status signal from CB2 is ON.

UF157 failure persisted for over 2 hours.

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CHECK

BATTERY

CHG.STOPPED

(BATTERY

OVERTEMP.)

BATTERY

OVERTEMPERA

TURE

BATTERY LIQUID

LOW

Detection of over temperature at the batteries.

CHECK

BATTERY

GROUND FAULT

CHG.STOPPED

(DC VOLT.

ABNORMAL)

BATTERY

ABNORMAL

BATTERY

VOLTAGE

ABNORMAL

VDB SENSOR

ABNORMAL

CHG.STOPPED

(DEVICE

STATUS)

GROUND FAULT

Low level of battery electrolyte solution.

Detection of DC ground fault

(L).

UF151 failure is running for over 24 hours.

Failure detection based on battery self-check.

CHECK

BATTERY

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

Battery voltage is abnormality.

Detection of a large variation of the difference between control-only and protection-only battery voltage.

Energy storage device abnormal

Detection of DC ground fault

(M).

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

Buzzer

Continuous sound

Continuous sound

Continuous sound

Continuouss ound


(Note 1)

Failure lamp

(Note 2)

Major Lit on

Major

Major

Major

Lit on

Lit on

Lit on

Continuous sound

Continuous sound

Continuous sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Major

Major

Major

Minor

Minor

Minor

Minor

Battery abnormal

Minor

Battery abnormal

Minor

Battery abnormal

Minor

Minor

Minor

Minor

Lit on

Lit on

Lit on

Flicker

Flicker

Flicker

Flicker

Flicker

Flicker

Flicker

Flicker

Flicker

Flicker

Intermittent sound

Intermittent sound

Intermittent sound

Minor

Minor

Minor

Flicker

Flicker

Flicker


– 94861-000

Code indication

(Note 3)

UF201

UF202

UF203

UF204

UF206

UF207

UF208

UF209

UF210

UF211

UF213

UF214

UF217

UF230

UF253

UF256

UF257

UF258

UF259

Status message

Meaning Guidance

INVERTER

OVERVOLTAGE

INVERTER

UNDERVOLTAGE

INVERTER

OVERCURRENT

OUTPUT

CIRCUIT

ABNORMAL

UPS CONTROL

CIRCUIT ERROR

ZERO PHASE

OVERCURRENT

UPS CONTROL

CIRCUIT ERROR

52C ABNORMAL

52C ABNORMAL

52C ABNORMAL

OVERTEMPERAT

URE

COOLING FAN

ABNORMAL

INVERTER

OVERVOLTAGE

ZERO PHASE

OVERCURRENT

UPS CONTROL

CIRCUIT ERROR

OUTPUT

VOLTAGE

ABNORMAL

52C ABNORMAL

LOAD

ABNORMAL

ANOTHER UPS

ABNORMAL

Detection of output overvoltage.

Output voltage dropped.

Detection of inverter overcurrent.

Detection of a large variation of the reference error signal

(current reference and actual current).

Discrepancy between output voltage and external voltage

(bypass, common ac bus)

Inverter zero-sequence overcurrent.

Cross current is abnormality.

Error to close the contactor

52C.

Error to open the contactor

52C.

No answer from contactor

52C during inverter operation.

Heat sinks temperature exceeds thermal settings.

Thermal relay activated protection.

Detection of inverter output phase overvoltage.

Detection of zero-sequence overcurrent.

Discrepancy between output voltage and inverter voltage, or between output voltage and bypass voltage.

Output voltage is out of the specified range.

Contactor 52C failed to open during load transfer from inverter to bypass.

Load transfer due to overload for over 4 times within 5 minutes.

No detection of another UPS voltage signal.

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

Buzzer

Continuous sound

Continuous sound

Continuous sound


(Note 1)

Failure lamp

(Note 2)

Major Lit on

Major

Major

Lit on

Lit on

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Major

Major

Major

Major

Major

Major

Major

Major

Major

Major

Major

Minor

Minor

Minor

Minor

Minor

Lit on

Lit on

Lit on

Lit on

Lit on

Lit on

Lit on

Lit on

Lit on

Lit on

Lit on

Flicker

Flicker

Flicker

Flicker

Flicker


– 94861-000

65

66

Code indication

(Note 3)

UF301

UF302

UF303

UF305

UF306

UF309

UF310

UF320

UF323

UF331

UF332

UF333

UF334

UF352

UF363

UF371

UF372

UF374

UF375

UF376

Status message

Meaning Guidance

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

INVERTER

VOLTAGE

ABNORMAL

CONTROL

POWER SUPPLY

ABNORMAL

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

CONTROL

POWER SUPPLY

ABNORMAL

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

AD reference has an abnormal value.

Detection of an external interruption during the software execution.

Timer does not reset in the specified period (WDT settings)

Detection of an abnormal clock speed in the DSP or

FPGA.

Control power supply voltage is below the specified level.

Inverter voltage is out of the specified range.

Backup control power supplies exhibit abnormal condition.

Cable disconnection in the parallel interface board during load supply.

Major communication error during parallel operation.

Major abnormal detected in the converter unit

Major abnormal detected in the inverter unit

Major abnormal detected in the chopper unit

Major abnormal detected in the converter unit

Backup control power supplies exhibit abnormal condition.

Synchronization status signal is being received for a considerable time.

Minor communication error during parallel operation.

Unable to synchronize the inverter output and the bypass voltage.

Cable disconnection in the parallel interface board.

Unable to achieve synchronization for parallel operation.

No control response from another UPS although its detection is possible.

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

Continuous sound

Continuous sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittent sound

Intermittents ound

Buzzer

Continuous sound

Continuous sound

Continuous sound

Continuous sound


(Note 1)

Failure lamp

(Note 2)

Major Lit on

Major

Major

Major

Lit on

Lit on

Lit on

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Continuous sound

Major

Major

Major

Major

Major

Major

Major

Lit on

Lit on

Lit on

Lit on

Lit on

Lit on

Lit on

Major

Major

Minor

Minor

Minor

Minor

Minor

Minor

Minor

Lit on

Lit on

Flicker

Flicker

Flicker

Flicker

Flicker

Flicker

Flicker


– 94861-000

Code indication

(Note 3)

Status message

Meaning Guidance Buzzer


(Note 1)

Failure lamp

(Note 2)

UF377

UF378

UF379

UF401

UF402

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

UPS CONTROL

CIRCUIT ERROR

52S ABNORMAL

52S ABNORMAL

Overload detection signal is being received continuously for a considerable time.

No answer for sending synchronizing signal.

Abnormal clock speed of the parallel control board processor.

Error to close the contactor

52S.

Error to open the contactor

52S.

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

Intermittent sound

Intermittent sound

Intermittent sound

Continuous sound

Continuous sound

Minor

Minor

Minor

Major

Major

Flicker

Flicker

Flicker

Lit on

Lit on

UF420

UF451

UF452

52L OPERATION

ERROR

52S ABNORMAL

CB3 ABNORMAL

Load circuit breaker 52L opened during inverter operation.

Contactor 52S failed during load transfer from inverter to bypass.

Contactor CB3 is not working properly.

CHECK 52L

CALL

SERVICE

ENGINEER

CALL

SERVICE

ENGINEER

Continuous sound

Intermittent sound

Intermittent sound

Major

Minor

Minor

Lit on

Flicker

Flicker

(Note 1) 1) "Major" is defined as a major failure. Load transferred from the inverter circuit to the static bypass line;

2) "Minor" is defined as a minor failure. UPS continues to operate normally, but cause of alarm must be identified;

(Note 2) Indicates one of two possible LED illumination patterns

–

continuously on (lit on) or intermittent

(flicker).

(Note 3) Code indication means:

UA+++ ----------------------- Alarm

UF+++ ----------------------- Failure

U%0++ ----------------------- Rectifier circuit failure

U%1++ ----------------------- DC circuit failure

U%2++ ----------------------- Inverter circuit failure

U%3++ ----------------------- Control circuit failure

U%4++ ----------------------- Bypass system failure

U%8++ ----------------------- Alarm

U%+00 - U%+49 --------- Major failure

U%+50 - U%+99 --------- Minor failure

*)

“+” denotes any numeral from 0 to 9

*)

“%” denotes either “A” or “F”


– 94861-000

67

2. Cabinet

Construction

3. Operation

No. Subject

1. Environmental ambient

9 DAILY INSPECTION

Please perform the daily inspection while the UPS is running. The daily inspection items are shown in

Table 9

–1.

!

NOTE

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.

Table 9

–1 How to Perform Daily Inspection

4. LEDs

2 fault LEDs

Procedure

Daily Visual check

Criteria and/or Action needed

Term Period Method/Tool

Dust or Gas

Dewdrops

Condensation

Temperature

Humidity

Vibration or

Audible noise

Daily

Daily

Daily

Daily

Visual check and smelling

Visual check

Ventilate room atmosphere if dusty or smelling gas.

Thermometer hygrometer

Fix the dripping source

Dehumidify upon necessity.

Temperature: 32

– 104



F Humidity: 30

– 90%

No condensation.

To be controlled at about 77



F by A/C.

Touch and hearing Check if fans have irregular sound.

Contact service representative in case of abnormalities.

Overheating

Air filter clog

LCD sharpness

Brightness

Left-bottom LED

Indication terms:

Output voltage

Output current

AC input voltage

Output frequency

Battery voltage

Battery current

DC voltage

Daily

When needed Touching exterior Contact service representative in case of abnormalities.

When needed Visual check

Daily Visual check

Clean/wipe if clogged or dusty.

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.

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.

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.


– 94861-000

68

APPENDIX A Installation Planning Guides (IPG)

Installation Planning Guide for 500kVA UPS

Standard System: 480V Input, 480V Output

General Mechanical Information

Dimensions Floor Approximate Full-Load

59.1

(W x D x H)

Inches

” x 33.5” x 80.6”*

Weight

Lbs.

2,756

Loading

Lbs./ft.

2

201

Heat Rejection

BTU/Hr

31,200

* Height includes removable fan housing

– Frame height is 78.7”.

** 0” clearance for peripheral equipment, 1” clearance for walls.

Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access

Top

24

”

Front Bottom Sides** Back

40

” 0” 0” 0” kVA

Primary AC Input (480V 3-Phase / 3-Wire)

Maximum Input Power Demand

Normal Mode (Recharge Mode)

Suggested External

Overcurrent Protection

External Feeder Wire Size: Min.

– Max. Per Phase

509 (560)

PF

>0.99

Amps

612 (673)

Amps

800 AT

AWG or kcmil at 75º C Temp. Rating

(3) x 300 kcmil

– (3) x 350 kcmil

Maximum Input Power Demand

Alternate (Bypass) AC Input (480V 3-Phase / 3-Wire)

Suggested External


External Feeder Wire Size:

Min.

– Max. Per Phase kVA

500

PF

1.0

Amps (Max.)

601

Amps

800 AT


(3) x 300 kcmil

– (3) x 350 kcmil

Battery Input (480VDC Nominal)

Battery Capacity Required for Full Load Output

Suggested External Overcurrent Protection

Three (3) Cabinets in parallel:

DC Cable Size per Cabinet*** kWB Amps AWG or kcmil at 75º C Temp. Rating

518 @ 1.0 PF

N/A

– Toshiba-Supplied Battery Cabinets equipped with built-in overcurrent Protection

1 x 500 kcmil (ea. Cabinet)

*** Contact Toshiba Factory Representative for different multiple Battery Cabinet Configurations.

Rated Output Power

AC Output (480V 3-Phase / 3-Wire)

Suggested External


External Feeder Wire Size:

Min.

– Max. Per Phase kVA

500

PF

1.0

Amps

601

Amps

800 AT


(3) x 300 kcmil

– (3) x 350 kcmil

Important Notes:

1. Maximum input current is limited to 106% of the full-load input current.

2. Output load conductors are to be installed in separate conduit from input conductors.

3. Control wires and power wires are to be installed in separate conduits.

4. Recommended AC input and output overcurrent protection based on continuous full load current per NEC.

5. Wiring shall comply with all applicable national and local electrical codes.

6. Grounding conductors to be sized per NEC Article 250-122.

Neutral conductors to be sized per NEC Article 310.15.



Primary AC Input: 3



, 3-wire + ground.



Alternate AC Input: 3



, 3-wire + ground.



AC Output: 3



, 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

Social Infrastructure Systems Group

Power Electronics Division

13131 West Little York Road

Houston, TX 77041

Telephone: (877) 867-8773

Fax: (713) 896-5212

Web Site: www.toshiba.com/tic/industrial/uninterruptible-power-systems


– 94861-000

69


– 94861-000


– 94861-000

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– 94861-000

SOCIAL INFRASTRUCTURE SYSTEMS GROUP

POWER ELECTRONICS DIVISION

13131 West Little York Rd., Houston, TX 77041

Tel: 713/466-0277 Fax 713/896-5212

US 877-803-7087 Canada 800-872-2192

www.toshiba.com/tic/industrial-systems/uninterruptible-power-systems

Printed in Japan

installation and operation manual

INSTALLATION AND

OPERATION MANUAL

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INSTALLATION AND OPERATION MANUAL

480/480 V 500kVA

Document No. 94861-001

Ref: 4GBH0099 Rev. B

December 2016

IMPORTANT NOTICE

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.

Purpose and Scope of Manual

Contacting TOSHIBA Customer Support Center

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Table of Contents

List of Tables

List of Figures

1 How to use this Manual

WARNING

CAUTION

NOTE

PROHIBIT

2 INTRODUCTION

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

CAUTION

WARNING

WARNING 1

WARNING 2

WARNING

PROHIBIT

This UPS shall NOT be applied to support equipment (*) that could affect human lives.

*

Medical operation room equipment

Life support equipment (artificial dialysis, incubators, etc.)

Toxic gas or smoke eliminators

PROHIBIT

Equipment that must be provided under fire laws, construction standards or other ordinances

Equipment equivalent to the above

Special considerations are required when applying this UPS to the equipment

(**) that affect human safety and/or maintain public services.

NOTE

**

Equipment to supervise or control airways, railways, roads, sea-lanes or other transportation.

Equipment in nuclear power plants.

Equipment to control communications.

Equipment equivalent/similar to the above mentioned.

WARNING 3

WARNING

Table 2

–1 UPS Installation Environment

No

Item

Environment standard

WARNING 4

WARNING

Capacity

(kVA)

Table 2

–2 Rating of Bypass Input Circuit Breaker

Bypass Voltage

(Vac)

Bypass Current

(Aac)

Breaker

(A)

NOTE

3 GENERAL

Figure 3-1 Single Line Diagram

Normal Operation: Load fed by UPS inverter

NOTE

Figure 3-2 Single Line Diagram

– Bypass Operation: Load fed through static bypass line

Figure 3-3 Single Line Diagram

– Battery Operation: Load fed by Battery

See

Figure 3-4 UPS Parts Location (500kVA)

Figure 3-5 Display PCB DPAU-81

Figure 3-6 MAIN PCB UPHR-W

**This UPS shall NOT be applied to support equipment (*) that could affect human lives.**

() that affect human safety and/or maintain public services.**