MaxPower Corp G9000 User Manual

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UNINTERRUPTIBLE POWER SYSTEM (UPS)

G9000 SERIES

INSTALLATION AND

OPERATION MANUAL

480/480 V 80/100/160/225 kVA

Document: GBH0016 Rev. 0.21 P/N 61480-000

April 2009

G9000 Installation and Operation Manual

G9000 SERIES

INSTALLATION AND OPERATION MANUAL

480/480 V 80/100/160/225 kVA

Document No. GBH0016 Rev. 0.21

P/N 61480-000

April 2009

G9000 Installation and Operation Manual

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.

IMPORTANT NOTICE

UNINTERRUPTIBLE POWER SYSTEM

If additional information or technical assistance is required call TOSHIBA Customer Support Center toll free at 1- 800-231-1412, or write to: Toshiba International Corporation, 13131 West Little York Road, Houston, TX 77041-9990 Attn: UPS Product Manager.

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

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

Keep this manual with the UPS equipment. Job Number: Model Number: Serial Number: Application: Shipping Date: Date of Installation: Inspected By:

G9000 Installation and Operation Manual

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.

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 (800) 231-1412.

You may contact TOSHIBA by writing to:

TOSHIBA INTERNATIONAL CORPORATION. INDUSTRIAL DIVISION 13131 West Little York Rd. Houston, TX 77041-9990 Attn: UPS Product Manager

G9000 Installation and Operation Manual

Table of Contents

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

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

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

1 INTRODUCTION ......................................................................................................................... 2

1.1 SAFETY PRECAUTIONS ....................................................................................................... 3

1.2 GENERAL ............................................................................................................................... 6

1.3 DEFINITIONS.......................................................................................................................... 7

1.4 OPERATION OVERVIEW ....................................................................................................... 8

1.5 SPECIFICATIONS ................................................................................................................ 16

2 OPERATOR CONTROLS AND INDICATORS ......................................................................... 20

2.1 LED DISPLAY ....................................................................................................................... 21

2.2 EPO BUTTON (Emergency Power Off button) (7) ................................................................ 21

2.3 LIQUID CRYSTAL DISPLAY (8) ........................................................................................... 22

2.3.1 Menu ................................................................................................................................. 22

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

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

2.4 EXTERNAL SIGNAL TERMINAL BLOCK ............................................................................ 28

2.5 RemotEyeII INTRODUCTION ............................................................................................... 33

3 INSTALLATION AND OPERATION .......................................................................................... 37

3.1 TRANSPORTATION AND INSTALLATION .......................................................................... 37

3.2 INSTALLATION PROCEDURE ............................................................................................. 37

3.3 PROCEDURE FOR CABLE CONNECTIONS ...................................................................... 38

3.4 OPERATING PROCEDURES ............................................................................................... 47

4 RESPONSE TO UPS FAILURE................................................................................................ 51

5 PARTS REPLACEMENT .......................................................................................................... 52

6 FAULT CODES ......................................................................................................................... 53

7 DAILY INSPECTION ................................................................................................................. 60

APPENDIX A Installation Planning Guides (IPG) ......................................................................... 61

G9000 Installation and Operation Manual i

List of Tables

Table 1.1 UPS Installation Environment ................................................................................... 4

Table 1.2 Rating of Bypass Input Circuit Breaker .................................................................. 5

Table 1.3 Power Specifications ................................................................................................ 17

Table 1.4 UPS Module Information .......................................................................................... 17

Table 1.5.a Detail of Specifications ............................................................................................. 18

Table 1.5.b Efficiency at Various Loads ...................................................................................... 19

Table 1.6 Rating of Contactors, Breakers and Fuses .............................................................. 20

Table 2.1 Parts list for UPS monitoring .................................................................................... 36

Table 3.1 How to Transport and Install the System ................................................................. 38

Table 3.2 List of UPS Weights (lb.) .......................................................................................... 38

Table 3.3 Maximum Permitted Fault Current ........................................................................... 39

Table 3.4 Recommended Cable Sizes ..................................................................................... 42

Table 3.5 Crimp Type Compression Lug .................................................................................. 43

Table 6.1 Fault Code ................................................................................................................ 56

Table 7.1 How to perform daily inspection ............................................................................... 60

ii G9000 Installation and Operation Manual

List of Figures

Figure 1.1 Single Line Diagram – Normal Operation................................................................. 8

Figure 1.2 Single Line Diagram – Bypass Operation ................................................................ 9

Figure 1.3 Single Line Diagram – Battery Operation ................................................................. 10

Figure 1.4.1 UPS Parts Location (80,100kVA) ............................................................................. 12

Figure 1.4.2 UPS Parts Location (160,225kVA) ........................................................................... 12

Figure 1.5 Display PCB DPAU-81 ............................................................................................. 13

Figure 1.6 External I/F PCB IOAU-09 ...................................................................................... 13

Figure 1.7 Parallel I/F PCB IFAU-08 ........................................................................................ 13

Figure 1.8 Main PCB UPGR-MA ............................................................................................. 14

Figure 2.1 Operation/Display Panel ........................................................................................... 20

Figure 2.2 Main Screen ............................................................................................................. 22

Figure 2.3.1 Startup/Shutdown Screen ........................................................................................ 23

Figure 2.3.2 Startup guidance ...................................................................................................... 23

Figure 2.3.3 Shutdown guidance .................................................................................................. 23

Figure 2.4.1 Input values .............................................................................................................. 23

Figure 2.4.2 Output values ........................................................................................................... 24

Figure 2.4.3 Values battery operation .......................................................................................... 24

Figure 2.5.1 Remote/Local operation select ................................................................................. 24

Figure 2.5.2 Date & Time adjustment ........................................................................................... 24

Figure 2.6.1 Log menu .................................................................................................................. 25

Figure 2.6.2 Event log ................................................................................................................... 25

Figure 2.6.3 Battery log ................................................................................................................ 25

Figure 2.7.1 Main Screen (Battery Operation) .............................................................................. 26

Figure 2.7.2 Measurement Screen (Battery Operation) ............................................................... 26

Figure 2.8 Main Screen (Fault Indication) ................................................................................. 26

Figure 2.9 Message Screen ....................................................................................................... 27

Figure 2.10.1 External Signal Terminal Block (TN2) .................................................................... 28

Figure 2.10.2 External Signal Terminal Block (TN1) .................................................................... 29

Figure 2.11 Control Wiring for External Contacts ........................................................................ 30

Figure 2.12 Remote "Start" Contact Connections ....................................................................... 31

Figure 2.13 Configuration of the RemotEyeII (overview) ............................................................ 33

Figure 2.14 Connection between Display Control PCB (SW1) and RemotEyeII module ........... 34

Figure 2.15 PSAU-60 PCB (PS1) ................................................................................................ 35

Figure 2.16 DPAU-81 PCB (SW1) ............................................................................................... 35

Figure 2.17 3BBA0083P001 (Cable1) ......................................................................................... 35

Figure 2.18 The connector (CN1) of PSAU-60 (PS1).................................................................. 36

Figure 2.19 The terminal block (TN) of PSAU-60 (PS1) ............................................................. 36

Figure 2.20 The connector (CN44) of PSAU-60 (PS1) ............................................................... 36

Figure 2.21 The connector (CN27) of DPAU-60 (SW1) .............................................................. 36

Figure 3.1 UPS Terminal Designation ..................................................................................... 42

Figure 3.2 Diagram of input/output bus bars and terminal blocks ........................................... 43

G9000 Installation and Operation Manual iii

Figure 3.3 Diag. of Power wire & Control wire Inter-connect between UPS and Battery .......... 44

Figure 3.4 Diag. of Power wire Connect (Parallel Connection) ................................................. 45

Figure 3.5 Diag. of Power and Control wire Connect (Parallel Connection) ............................. 46

Figure 3.6 LCD Screen (MMS Operation) ................................................................................. 50

iv G9000 Installation and Operation Manual

WARNING

CAUTION

NOTE

PROHIBIT

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.

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

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

Prohibit: A prohibit symbol shows the act the user or the service personnel should NEVER perform during the UPS installation, operation or service work.

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

G9000 Installation and Operation Manual 1

WARNING 1

WARNING

CAUTION

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

1 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.

1.1.1.1.1.1.1.1

This manual contains important instructions for the G9000 SERIES Uninterruptible Power Supply Systems that should be followed during installation and maintenance of the UPS and batteries.

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 G9000 Installation and Operation Manual

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

human lives.

* Medical operation room equipment Life support equipment (artificial dialysis, incubators, etc.) Toxic gas or smoke eliminators

Equipment that must be provided under fire laws, construction

standards or other ordinances

Equipment equivalent to the above

Special considerations are required when applying this UPS to the equipment

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

** Equipment to supervise or control airways, railways, roads,

sea-lanes or other transportation. Equipment in nuclear power plants. Equipment to control communications. Equipment equivalent/similar to the above mentioned.

WARNING 2

CAUTION

PROHIBIT

NOTE

In no event will TOSHIBA be responsible or liable for either indirect or consequential

damage or injury that may come from the use of this equipment.

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.

1.1 SAFETY PRECAUTIONS

APPLICATION

G9000 Installation and Operation Manual 3

No.

Item

Environment standard

Installation location

Indoors

Ambient temperature

Minimum temperature: 32 F(0 C), Maximum temperature: 104 F(40 C) The average temperature over any 24-hour period must be in the range 41 F (5 C) to 95 F(35 C).

Relative humidity

The relative humidity must be held between 5 and 95%. There must be no condensation due to temperature changes.

Altitude

This equipment must not be applied at altitude that exceeds 2250m(7400ft) above seal level.

Dust

Dust in the room where the UPS is installed must not exceed normal atmospheric dust levels. In particular, that dust should not include iron particles, oils or fats, or organic materials such as silicone.

Inflammable gas

following IEC654-4 Part 4

There should be no inflammable/explosive gas.

Hydrogen sulfate (H2S)

No more than 0.003 PPM

Sulfurous acid gas (SO2)

No more than 0.01 PPM

Chlorine gas (Cl2)

No more than 0.002 PPM

Ammonia gas (NH3)

No more than 1 PPM

Nitrous oxides (NOx)

No more than 0.05 PPM

Ozone (O3)

No more than 0.002 PPM

WARNING 3

NOTE

The UPS is to be installed in a controlled environment.

Improper storage and installation environment may deteriorate

insulation, shorten component life and cause malfunctions.

Keep the installation environment per standard described as follows:

TABLE 1.1 UPS Installation Environment

4 G9000 Installation and Operation Manual

Capacity (kVA)

Bypass Voltage (Vac)

Bypass Rating (Aac)

Breaker (A)

480

125

100

480

120

150

160

480

192

250

225

480

271

350

WARNING 4

NOTE

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

TABLE 1.2 Rating of Bypass Input Circuit Breaker

AC input and AC output overcurrent protection and disconnect devices shall be field supplied and installed. The DC circuit breaker (MCCB) shall be field supplied and installed. The overcurrent protection device should be installed in the Battery cabinet and rated as indicated in TABLE 1.6.

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

G9000 Installation and Operation Manual 5

1.2 GENERAL

The Toshiba G9000 UPS is designed to provide continuous and clean electrical power to a critical load. Additionally the UPS monitors power conditions affecting the load. In the event of an input power failure, the UPS will supply power to the critical load for the specified battery time.

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

The G9000 SERIES UPS is available in Four kVA sizes - 80, 100, 160 and 225 kVA. Specifications for each kVA model appear in Section 1.5. The principles of operation described herein are applicable to all models.

This manual provides an overview of the G9000 SERIES components and their functions. The appearance and purpose of operator controls and indicators is described with procedures for operation, start-up, shutdown and basic maintenance included.

6 G9000 Installation and Operation Manual

1.3 DEFINITIONS

UNINTERRUPTIBLE POWER SUPPLY 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.

G9000 Installation and Operation Manual 7

UPS Module

Power Flow

Not in Use

AC input

CB3

CONVERTER

/ CHARGER

INVERTER

Output

52C

CB1

External BATTERY

User Supplied

MCCB

Static Transfer

Switch

52S

CB2

Battery Cabinet

Bypass

input

User supplied

MCCB

1.4 OPERATION OVERVIEW

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

Figure 1.1 shows the path for normal operation, with the load powered by the inverter. Figure 1.2 shows the path for bypass operation, with the load supplied through the static bypass line.

A) Normal operation: Load power supplied by each system UPS inverter.

FIGURE 1.1 Single Line Diagram - Normal Operation: Load powered by UPS inverter

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

In Figure 1.1 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 3.4 that shows a sample of Parallel Operation System Configuration.)

8 G9000 Installation and Operation Manual

UPS Module

Power Flow

Not in Use

AC input

CB3

CONVERTER / CHARGER

INVERTER

Output

52C

CB1

External

BATTERY

User supplied

MCCB

Static Transfer

Switch

52S

CB2

Battery Cabinet

Bypass

input

User supplied

MCCB

NOTE

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 constructor. (See WARNING 4 on page 1-4)

B) Bypass Operation: Load Power supplied through UPS internal static bypass line.

FIGURE 1.2 Single Line Diagram - Bypass Operation: Load fed through static bypass

line.

Figure 1.2 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.

G9000 Installation and Operation Manual 9

UPS Module

Power Flow

Not in Use

input

CB3

CONVERTER / CHARGER

INVERTER

Output

52C

CB1

External

BATTERY

User Supplied

MCCB

Static Transfer

Switch

52S

CB2

Battery Cabinet

Bypass

input

User Supplied

MCCB

In the event of a load overcurrent, the UPS transfers to bypass without interruption to the critical

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

The internal control system determines the operation of the two paths, with the load powered from

the inverter being the normal operation.

C) Battery operation: Load Power supplied by UPS battery.

FIGURE 1.3 Single Line Diagram - Battery Operation

Figure 1.3 shows that in the event of AC input source failure or interruption, the UPS Converter(s)* will de-energize and the UPS battery(s)* will immediately discharge and supply DC power to the Inverter to maintain continuous AC power to the load. This operation will continue until:

a) The battery capacity expires and the inverter turns off, or

b) Input power is restored. (When input power is restored the converter will simultaneously

power the inverter and critical load, and recharge the batteries.)

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

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

10 G9000 Installation and Operation Manual

When power is restored after a low battery shutdown, the UPS converter(s) automatically restarts operation, the charger(s) recharges the batteries and the Inverter(s) is automatically restarted without operator intervention. Load is automatically assumed by the inverter without operator intervention.

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

The power drawn by the load is equally shared between all UPS regardless of the presence or absence of the UPS that is (are) in battery operation or not whenever the system is in the Parallel Operation.

G9000 Installation and Operation Manual 11

UPS module Front View

CPMC

CPMS

EMB

88F

Inverter, Converter, Charger Unit

5. Relay PCB RYAU-09

4. Main PCB UPGR-M

7. Parallel control PCB TLCR-C

Ground Fault Sensor FDAU-04

CB3

10. Grounding Bar (E)

52C

52S

CB1

3. External I/F PCB IOAU-09

2. Display PCB DPAU-81

1. LCD touch panel monitor display

6. External Communication Connector

8. Parallel I/F PCB IFAU-08

UPS module Front View

CPMC

CPMS

EMB

88F

Inverter, Converter, Charger Unit

5. Relay PCB RYAU-09

4. Main PCB UPGR-M

7. Parallel control PCB TLCR-C

Ground Fault Sensor FDAU-04

CB3

10. Grounding Bar (E)

52C

52S

CB1

3. External I/F PCB IOAU-09

2. Display PCB DPAU-81

1. LCD touch panel monitor display

6. External Communication Connector

8. Parallel I/F PCB IFAU-08

FIGURE 1.4.1 UPS Parts Location (80,100kVA)

* Item 9 (AC input, AC output, DC input terminal) is not shown in Figure 1.4.1. (Refer to Figure 3.2)

* Item 9 (AC input, AC output, DC input terminal) is not shown in Figure 1.4.2. (Refer to Figure 3.2)

FIGURE 1.4.2 UPS Parts Location (160, 225kVA)

12 G9000 Installation and Operation Manual

OFF

IOAU-0

TN1

TN2

External contact signal

IFAU-0

TLIN

CN96

TLOUT

CN95

CBIN

CAIN

CAOU

CN94

13. SW6 MAINTENANCE

12. SW5 TEST switch

START

button

STOP button

CNV. SW. switch

11. SW1 RESET switch

FIGURE 1.5 Display PCB DPAU-81

FIGURE 1.6 External I/F PCB IOAU-09

FIGURE 1.7 Parallel I/F PCB IFAU-08

G9000 Installation and Operation Manual 13

UPGR-M

11. SW1 RESET switch

14. SW2 BOOT switch

15. SW3 52L S/W

FIGURE 1.8 MAIN PCB UPGR-MA

Description of Figures 1.4 to 1.8:

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 2.1 for details.

2. Display PCB DPAU-81 (Figure 1.5): Switches on DPAU-81 board : FOR SERVICE PERSONNEL ONLY

- (11) SW1 (RESET switch)

- (12) SW5 (TEST switch)

- (13) SW6 (MAINTENANCE switch)

3. External I/F PCB IOAU-09 (Figure 1.6):

Signal I/F on IOAU-09 board

- (17) External contact signal terminal block Refer to FIGURE 2.10 for details.

4. Main PCB UPGR-M (Figure 1.8):

Switches on UPGR-M board : FOR SERVICE PERSONNEL ONLY

- (11) SW1 (RESET switch)

- (14) SW2 (BOOT switch)

14 G9000 Installation and Operation Manual

- (15) SW3 (52L S/W switch)

5. Relay PCB RYAU-09

6. External Communication Connector RS232C connector on DPAU-81 board : FOR SERVICE PERSONNEL ONLY Refer to FIGURE 2.18 for details.

7. Parallel control PCB TLCR-C For use in Parallel Operation system application : Option

8. Parallel I/F PCB IFAU-08 For use in Parallel Operation system application : Option (Figure 1.7): Refer to FIGURE 3.5 for details.

9. AC input, AC output, DC input terminal

Refer to Figure 3.2 for details

10. Grounding Bar (E)

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" switch (FOR SERVICE PERSONNEL ONLY) This switch sets the UPS menu parameters.

14. "BOOT" switch (FOR SERVICE PERSONNEL ONLY) This switch enables firmware to be loaded on the control board.

15. "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.

16. External contact signal terminal block Terminal block to connect contact signal input/output lines to and from external dry contacts. Refer to FIGURE 2.10 for details.

G9000 Installation and Operation Manual 15

Rated output

Power

Input voltage

3 phase / 3 wire

Bypass input voltage

3 phase / 3 wire

Output voltage

3 phase / 3 wire

80kVA / 72kW

100kVA / 90 kW

160kVA / 144kW

225kVA / 202.5kW

480V 480V 480V 480V

UPS

[kVA]

Width

[in.]

(mm)

Depth

[in.]

(mm)

Height

[in.]

(mm)

Net Weight

[lbs.]

(kg)

Heating

[kBTU/h]

Cable

Knockout

27.6

(700)

32.8

(832)

80.6

(2,047)

855

(388)

10.8

BOTTOM

100

27.6

(700)

32.8

(832)

80.6

(2,047)

855

(388)

13.5

BOTTOM

160

35.4

(900)

32.8

(832)

80.6

(2,047)

1,160

(526)

17.8

BOTTOM

225

35.4

(900)

32.8

(832)

80.6

(2,047)

1,230

(558)

25.1

BOTTOM

UPS

[kVA]

Width

[in.]

(mm)

Depth

[in.]

(mm)

Height

[in.]

(mm)

Gross Weight

[lbs.]

(kg)

35.4

(900)

41.3

(1,050)

88.6

(2,250)

990

(450)

100

35.4

(900)

41.3

(1,050)

88.6

(2,250)

990

(450)

160

43.3

(1,100)

41.3

(1,050)

88.6

(2,250)

1,320

(600)

225

43.3

(1,100)

41.3

(1,050)

88.6

(2,250)

1,430

(650)

1.5 SPECIFICATIONS

The UPS nameplate displays the rated kVA as well as nominal voltages and currents. The

nameplate is located on the inside of the UPS front door.

TABLE 1.3 Power Specifications

TABLE 1.4 UPS Module Information a) Cabinet Dimension

b) Packing Dimension

16 G9000 Installation and Operation Manual

Rated Output kVA

100

160

225

Rated Output kW

144

202.5

AC INPUT

Configuration

3 phase, 3 wire

Voltage

480 V +15% to -20%

Frequency

60 Hz +/-10%

Power Factor

>.99 Lagging at 25% - 115% Load

Reflected Current THD

3% max. at 60% - 100% load (no input filter required) 6% max. at 25% - 59% load.

STATIC BYPASS INPUT

Configuration

3 phase, 3 wire

Voltage

480 V +/-10%

Frequency

60 Hz +/-5%

BATTERY

Type

Lead Acid

Ride Through

Application Specific

Nominal Voltage

480 Vdc

Minimum Voltage

400 Vdc

DC Ripple

0.23%

0.29%

DC Charging Current

20 Adc

25 Adc

40 Adc

56 Adc

Number of Cells

240

AC OUTPUT

Configuration

3 phase, 3 wire

Voltage

480 V

Voltage Regulation

+/-1%

Frequency

60 Hz

Frequency Regulation

+/-0.01% in free running mode Power Factor

0.9 nominal

Power Factor Range

0.9 lagging to 0.95 leading (within output kW rating)

Voltage THD

2% maximum THD at 100% Linear Load 5% maximum THD at 100% non-linear load

Transient Response

+/-2% maximum at 100% load step +/-1% maximum at loss/return of AC power +/-5% maximum at load transfer to/from static bypass

Transient Settling (Recovery) Time

Less than 20ms Voltage Unbalance

1% maximum at 100% unbalanced load

TABLE 1.5.a Detail of Specifications

G9000 Installation and Operation Manual 17

Phase Displacement

1 deg. maximum at 100% load

Inverter Overload

125% for 2 minutes; 150% for 60 seconds

Crest Factor

2.3

Bypass Overload

1000% for 1 cycle (with bypass available)

Withstand Rating

65,000 A (with optional fuse)

ENVIRONMENTAL

Cooling

Forced Air

Operating Temperature

32 F to 104 F ( 0 C to 40 C). Recommended : 68ﾟF to 86ﾟF ( 20 C to 30 C)

Relative Humidity

5% – 95% Non Condensing

Altitude

0 to 7380 feet No Derating at 40ﾟC

Location

Indoor (free from corrosive gases and dust)

Paint Color

Munsell N1.5 (Black)

UNIT

% Full Load

20%

40%

60%

80%

100%

80 kVA

92.5%

94.3%

95.0%

95.2%

95.8%

100 kVA

92.5%

94.3%

95.0%

95.2%

95.8%

160 kVA

94.7%

95.7%

96.2%

96.5%

225 kVA

94.9%

96.2%

96.5%

TABLE 1.5.b UPS Efficiencies at Various Loads

18 G9000 Installation and Operation Manual

NUMBER

APPLICATION

OUTPUT CAPACITY OF EQUIPMENT

80kVA

100kVA

160kVA

225kVA

72kW

90kW

144kW

202.5kW

Contactor

CB1

AC input contactor

135A

200A

285A

CB3

STS contactor

80A

135A

150A

52C

Inverter output

contactor

135A

200A

285A

52S

Bypass contactor

135A

200A

285A

88RC

Control circuit contactor

20A

Breaker

CB2

Battery disconnect breaker

(Recommended)

225A

300A

400A

600A

User supply

(OPTION)

AC input breaker

(Recommended)

125A

150A

250A

350A

User supply

(OPTION)

AC bypass breaker

(Recommended)

125A

150A

250A

350A

User supply

(OPTION)

AC output breaker

(Recommended)

125A

150A

250A

350A

Fuses

FCU, FCV, FCW

FCR, FCS, FCT

DC fuse

315A / 690V

200A / 690V

FPU, FPV

FNU, FNV

DC fuse

200A / 690V

350A / 690V

FUA, FUB, FUC

Control power fuse

30A / 600V

FSU, FSV,

FSW(OPTION)

Bypass input fuse

250A / 690V

200A / 690V

250A / 690V

FZS1, 2, 3

Bypass input ZNR fuse

5A / 500V

FBS1, 2, 3

Control power fuse

30A / 600V

FZR1, 2, 3

AC input ZNR fuse

5A / 500V

FEA, FEB, FEC

Parallel control

circuit fuse

3A / 600V

TABLE 1.6 Rating of Contactors, Breaker and Fuses

G9000 Installation and Operation Manual 19

8 3 2 1 7

4 5 6

2 OPERATOR CONTROLS AND INDICATORS

The G9000 Series operator controls and indicators are located as follows (Door exterior) :

FIGURE 2.1 Operation/Display Panel (Front panel)

20 G9000 Installation and Operation Manual

2.1 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. ](orange)

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

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

Illuminates when power is supplied to load devices by static bypass. (Indicates the state of bypass transfer switch "52S".)

4) Overload [ OVERLOAD ](orange)

Illuminates in overload condition.

5) LCD fault [ LCD FAULT ](red)

Illuminates when LCD is not responding.

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.

2.2 EPO BUTTON (Emergency Power Off button) (7)

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

G9000 Installation and Operation Manual 21

2.3 LIQUID CRYSTAL DISPLAY (8)

The Liquid Crystal Display (LCD) touch panel indicates power flow, measured values, operational

guidance, data records and error messages. The LCD panel has a back-light which facilitates viewing in different ambient lighting conditions. The LCD will automatically clear and turn off, if the screen is not activated within 3 minute period. The LCD is turned back on when it is touched again. The LCD ERROR indicator is cleared after 24 hours and can be reproduced by pressing any key on the panel.

2.3.1 Menu

A) MAIN MENU (FIGURE 2.2)

The LCD panel indicates power flow and measured values, while also operating the start/stop

function. The LCD panel also allows the user to verify the status and operation of the UPS Module.

FIGURE 2.2 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 (FIGURE 2.3)

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.

22 G9000 Installation and Operation Manual

FIGURE 2.3.1 Startup/Shutdown Guidance

FIGURE 2.3.2 Startup guidance FIGURE 2.3.3 Shutdown guidance

Follow Startup/Shutdown guidance accordingly.

B) MEASUREMENT MENU (FIGURE 2.4)

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 2.4.1 Input values

G9000 Installation and Operation Manual 23

FIGURE 2.4.2 Output values FIGURE 2.4.3 Values in Battery operation

C) OPERATION MENU (FIGURE 2.5)

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 2.5.1 Remote/Local operation select

FIGURE 2.5.2 Date & Time adjustment

24 G9000 Installation and Operation Manual

D) LOG MENU (FIGURE 2.6)

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 2.6.1 Log menu

FIGURE 2.6.2 Event log FIGURE 2.6.3 Battery log

G9000 Installation and Operation Manual 25

2.3.2 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 2.7.1 Main screen FIGURE 2.7.2 Measurement screen

(Battery operation) (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.

2.3.3 Fault Indication “MESSAGE” and “SILENCE ALARM” icons will appear on the main menu when UPS failure

condition has occurred.

FIGURE 2.8 Main screen (Fault indication)

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

26 G9000 Installation and Operation Manual

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 2.9 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.

G9000 Installation and Operation Manual 27

SUMMARY ALARM

OUT2: LOAD ON INVERTER

OUT3:BATTERY OPERATION

OUT4: CONVERTEN OPERATION

OUT5: BATTERY LOW VOLTAGE

OUT6: OVERLOAD

OUT1: LOAD ON BYPASS

UPS

1 3 5

11 2 4 6 8

12 OUT7: SPARE

OUT8: TOTAL ALARM

52C CLOSE

*1 Relay contactor (52C close): Normal Closed

2.4 EXTERNAL SIGNAL TERMINAL BLOCK

The UPS is equipped with a series of input/output terminals for external annunciation of alarms and for remote access of certain UPS functions. The layout of terminals is shown in Figure 2.10.1 and

2.10.2 with a functional description of the input/output port presented. OUT1 to OUT8 are user programmable, but factory default settings are shown in Figure 2.10.1.

Adding same external I/F PCB “IOAU-09”, doubling signal outputs is applicable for OUT1 to OUT8.

FIGURE 2.10.1 External Signal Terminal Block (NEC Class2)

TN2

28 G9000 Installation and Operation Manual

(User supplied dry contact)

IN3: BATTERY TEMP. HIGH

IN1: REMOTE INVERTER START

IN2: REMOTE INVERTER STOP

REMOTE EPO

IN4: POWER DEMAND

UPS

CB2 UVT

CB2 AX

52L AX

1 3 5 7 9

11 2 4 6 8

Battery Breaker

Load Circuit Switch

FIGURE 2.10.2 External Signal Terminal Block (NEC Class2)

TN1

G9000 Installation and Operation Manual 29

Terminal

UPS Cabinet

External to UPS

Cabinet

Relay

Coil

NEC Class 2

Power Source

Relay

Contact

Terminal

User supplied

A) Output Contacts (for external alarm annunciation)

Output contacts consist of form “A” dry type contacts. Rated capacity of all output contacts is NEC

Class2 (30Vdc/1Adc). All dry contacts should be operated at their rated values or lower. Figure 2.11 illustrates a typical installation. The external relay can also be a lamp, LED, computer, etc.

FIGURE 2.11 Control Wiring for External Contacts

Details of output alarm contacts : TN1

Terminals 1 to 2 "Summary Alarm" contact

Activated when a major fault has occurred with the system.

Terminals 3 to 4 "Load on Bypass" contact (OUT1)

Activated when the power is supplied from the static bypass input.

Terminals 5 to 6 "Load on Inverter" contact (OUT2)

Activated when the power is supplied by the inverter.

Terminals 7 to 8 "Battery Operation" contact (OUT3)

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

Terminals 9 to 10 "Converter Operation" contact (OUT4)

Activated when the converter is operating.

Terminals 11 to 12 "Battery Low Voltage" contact (OUT5)

Activated when the battery voltage drops below discharge end voltage level during inverter operation (i.e. During AC fail condition).

Terminals 13 to 14 "Overload" contact (OUT6)

Activated when an overload has occurred to the system. Terminals 15 to 16 "Total Alarm" contact (OUT7) Activated during major fault, minor fault and alarm events. Terminals 17 to 18 "Spare" contact (OUT8) Terminals 19 to 20 "52C Close" contact (OUT9)

Activated when the inverter output contactor 52C has closed.

30 G9000 Installation and Operation Manual

Start

Relay Coil current : 8.3mA

Use Momentary Switches Only

UPS Cabinet

External to UPS

Cabinet

Relay

Coil

24 VDC

Start

Switch

Common

User

0.5S- 4S ON OFF

NOTE

PROHIBIT

The UPS is equipped with a selectable output contact feature. The above alarms are the default settings. Contact Toshiba International Corporation for setup information.

B) Input Contacts (for remote access of UPS)

External contacts are provided by the user of the UPS system. Terminal voltage at the UPS is

24Vdc. Provide external dry contact accordingly.

Do not apply voltages to remote access input terminals. Damage to UPS may result.

Refer to Figure 2.12 for a typical wiring configuration. Although this figure applies to the remote start/stop terminals, the same wiring arrangement is used for emergency stop; power demand; and battery temperature high.

FIGURE 2.12 Remote "Start" Contact Connections

G9000 Installation and Operation Manual 31

NOTE

CAUTION

Details of input contacts for remote access : TN2

Terminals 7 to 8 Remote "Inverter Start" input terminal (IN1)

Used to start inverter from a remote location. UPS must be programmed for remote operation. Refer to Operations Menu for procedure.

Terminals 9 to 10 Remote "Inverter Stop" input terminal (IN2)

Used to stop inverter from a remote location. UPS must be programmed for remote operation. Refer to Operations Menu for procedure.

Terminals 11 to 12 "Battery Temp. High" contact input (IN3)

Input fed by a thermocouple that monitors battery temperature. The converter float voltage level is reduced for battery over-temperature conditions. External thermocouple is user supplied

Terminals 13 to 14 "Power Demand” Command contact input (IN4)

This contact is used to control the input power. Power demand is turned ON when the contact is closed, and power demand is turned OFF when the contact is open.

Terminals 15 to 16 "Remote EPO" contact input

Used to perform a remote UPS Emergency Power Off (EPO).

The load will be dropped.

The UPS is equipped with a selectable input contact item.

The above items are the default settings. Contact Toshiba International Corporation for setup information.

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

32 G9000 Installation and Operation Manual

* Consult Toshiba International Corporation for details on“RemotEyeII” monitoring software

and its capabilities.

DPAU-81

(SW1)

PSAU-60

(PS1)

RemotEyeII

Back of the front door

Cable1

(provided)

Cable2 Cable3

(provided)

2.5 RemotEyeII INTRODUCTION

The “RemotEyeII”* is available as a UPS system monitoring tool. The RemotEyeII supplies a network function to monitor UPS units via Simple Network Management Protocol (SNMP) and Hypertext Transfer Protocol (HTTP) methods.

The RemotEyeII module is installed at the rear of the front door in G9000 UPS units. The configuration of the RemotEyeII is shown in FIGURE 2.13 below.

FIGURE 2.13 configuration of the RemotEyeII (overview)

G9000 Installation and Operation Manual 33

CAUTION

PSAU-60

RemotEyeII

DPAU-81

3BBA0083P001

Cable1

D-sub 9-pin Cable

Cable2

12V Power Cable

Cable3

(male)

(RJ45)

(receptacle)

The Power Supply PCB (PSAU-60, designated as PS1) and the Cable1 (designated as

3BBA0083P001) are equipped with G9000 UPS units.

The Cable2 (D-sub 9pin) and the Cable3 (12V power cable) are included in the RemotEyeII

package.

The Power Supply PCB (PS1) provides connectivity between the Display Control PCB

(DPAU-81, designated as SW1) and the RemotEyeII module in G9000 UPS units.

The RemotEye II communicates with the UPS via a Cable2. The connection is described in

FIGURE 2.14 below.

The UPS has to be de-energized when the RemotEyeII module is installed for safety reason.

FIGURE 2.14 Connection between Display Control PCB (SW1) and RemotEyeII module

34 G9000 Installation and Operation Manual

Parts No.

Part name

Qt’y

PSAU-60* :Power supply PCB (PS1)

3BBA0083P001 :Cable1

RemotEyeII module

D-sub 9-pin to RJ45 Cable:Cable2

12V Power Cable:Cable3

Connected with 3BBA0083P001(Cable1) Shown in FIGURE 2.17.

D-sub connector CN1 to be connected with RemotEyeII.

Terminal block TN to feed 12VDC power to RemotEyeII. (12V across P to N)

Optional interface CN2 to give 12VDC power (12V Pin#1 to #2)

(Note 12VDC exposed)

FIGURE 2.15 PSAU-60 PCB (PS1)

FIGURE 2.17 3BBA0083P001 (Cable1)

Connector CN44 to be connected with CN27 of DPAU-81(SW1).

FIGURE 2.16 DPAU-81 (SW1)

Connector CN27 to be connected with CN44 of PSAU-60(PS1).

D3200 5pin (housing)

The parts (included RemotEyeII) for UPS monitoring are listed below.

TABLE 2-1 Parts list for UPS monitoring

* – PCB revision suffix may be applied.

G9000 Installation and Operation Manual 35

Description

Pin 1

RXD

Receive data

Pin 2

TXD

Transmit data

Pin 3

GND

Signal ground

Pin 4

+24VS

+24VDC

Pin 5

GND(S)

+24VDC ground

D3200 5Pin (contact)

Description

Pin 1

RXD

Receive data

Pin 2

TXD

Transmit data

Pin 3

GND

Signal ground

Pin 4

+24VS

+24VDC

Pin 5

GND(S)

+24VDC ground

D3200 5Pin (contact)

TB2

Description

Pin 1

+12VS

+12VDC

Pin 2

GND(S)

+12VDC ground

Terminal Block 2Pin

D-SUB 9Pin (male)

DB9

Description

Pin 1

Not used

Pin 2

RXD

Receive data

Pin 3

TXD

Transmit data

Pin 4

Not used

Pin 5

GND

Signal ground

Pin 6

Not used

Pin 7

Not used

Pin 8

Not used

Pin 9

Not used

N 1 2

5 4 3 2 1

9 8 7 6

1 2 3 4 5

2.6 CONNECTOR DEFINITION

FIGURE 2.18 The connector (CN1) of PSAU-60 (PS1)

FIGURE 2.19 The terminal block (TN) of PSAU-60 (PS1)

FIGURE 2.20 The connector (CN44) of PSAU-60 (PS1)

FIGURE 2.21 The connector (CN27) of DPAU-60 (SW1)

36 G9000 Installation and Operation Manual

Transportation

Installation

Transport unit with forklift. If carry by overhead crane, use four M12 eyebolts. (Not provided)

Using the pre-drilled four holes in the UPS channel base, anchor the unit using appropriate hardware. (Not provided)

UPS Capacity (kVA)

100

160

225

Weight (lbs)

855

1160

1230

PROHIBIT

NOTE

3 INSTALLATION AND OPERATION

3.1 TRANSPORTATION AND INSTALLATION

TABLE 3.1 How to transport and install the system

Do not transport UPS cabinet laid horizontally.

Cabinets must be maintained upright within +/- 15° of the vertical during handling.

3.2 INSTALLATION PROCEDURE

A) Note the load tolerance of the floor

Refer to Table 3.2 for list of UPS weights.

TABLE 3.2 List of UPS weights

B) Minimum clearance required for ventilation

Right side 25 mm (1 inch) (not required when sidecars are used) Left side 25 mm (1 inch) (not required when sidecars are used) Back side 0.0 mm (0 inch) Top side 500 mm (20 inches) (for air flow)

C) Space requirement for routine maintenance

Allow for the following space at the time of installation. Front 1000 mm (40 inches) Sides 0.0 mm (0 inch) Back side 0.0 mm (0 inch) Top side 500 mm (20 inches)

G9000 Installation and Operation Manual 37

UPS Capacity

(kVA)

DC Voltage

Rating (V)

Maximum Fault

Current Permitted (A)

480

25,000

100

480

25,000

160

480

25,000

225

480

25,000

NOTE

D) External Battery Supply

Please refer to the following when installing and maintaining batteries:

1. The customer shall refer to the battery manufacturer's installation manual for battery installation and maintenance instructions.

2. The maximum permitted fault current from the remote battery supply, and the DC voltage rating of the battery supply over-current protective device are shown in Table 3.3.

TABLE 3.3 Maximum Permitted Fault Current

3.3 PROCEDURE FOR CABLE CONNECTIONS

1. Confirm the capacity of the UPS being installed. Identify the input/output power terminal blocks as shown in the appropriate Figures 3.1 through 3.3.

2. Connect the internal control wire and power wire. (1) Control wire Inter-connect

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

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

(2) Power wire (AC input, Bypass input, AC output) Inter-connect

a.) From user’s distribution panel

1. X1 (A-phase) to A bus bar in UPS

2. X2 (B-phase) to B bus bar in UPS

3. X3 (C-phase) to C bus bar in UPS

b.) DC Input to UPS

1. Positive cable to BP bus bar in UPS

2. Negative cable to BN bus bar in UPS

38 G9000 Installation and Operation Manual

NOTE

REQUIRED

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).

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 Figures 3.1 to 3.3. Input cables must be sized for an ampere rating larger than the maximum input drawn by the converter. (Refer to equipment nameplate for current ratings.) Confirm that an external bypass input circuit breaker (MCCB) is installed (refer to WARNING 4, page 1-4). Connect the bypass input power cables from the input service entrance to the bypass input power terminals, identified as A40, B40 and C40 in Figures 3.1 to 3.3. Bypass input cables must be sized for an ampere rating larger than the maximum output current capacity of the UPS. Refer to Table 3.4 for recommended cable sizes.

(2) Connect the external signal terminal block as desired. Refer to section 2.4 and Figure

2.10 for functional description. 2mm2, or less, shielded conductor is recommended.

5. One (1) source feeding the UPS:

(1) Confirm that an external input circuit breaker sized to protect both the AC input and the

bypass line is installed. (Refer to equipment nameplate for current ratings.) Connect the bypass input power cables from the input service entrance to the bypass input power terminals, identified as A40, B40 and C40 in Figures 3.1 to 3.3. Input cables must be sized for an ampere rating larger than the maximum current capacity of the UPS. Refer to Table 3.4 for recommended cable sizes.

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

Figures 3.1 to 3.3, connect jumper bypass terminals A40, B40, C40 to AC input power terminals A, B, C as identified in Figures 3.1 to 3.3.

G9000 Installation and Operation Manual 39

NOTE

(3) Connect the external signal terminal block as desired. Refer to section 2.4 and Figure

2.10 for functional description. 2mm2, or less, shielded conductor is recommended.

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.

6. Procedure for Cable Connections for Parallel Operation System (1) Confirm the number of units to be connected in parallel. Identify the input/output power

terminal blocks and control wire connections for parallel operation systems as shown in the appropriate Figures 3.4 and 3.5.

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

a.) Control wire connection

Parallel configuration wiring (Refer to Figure 3.4 and 3.5.)

- 52L control signal from Critical Load Cabinet (CLC) to UPS-n IOAU-09 (TN1– 5 , 6).

- Parallel control signal for CN94 as shown in Fig. 3.5.

- Parallel control signal for CN96 and CN95 as shown in Fig. 3.5.

b.) Power wire connection

From UPS AC Output Terminals to Critical Load Cabinet (CLC) (Refer to Figure 3.4

and 3.5.)

40 G9000 Installation and Operation Manual

Input Side

Output Side

Bypass Side

DC Input Side

kVA

Capacity

Input

Voltage

Output

Voltage

Cable

Size

Torque

in. lbs

Cable

Size

Torque

in. lbs

Cable

Size

Torque

in. lbs

Cable

Size

Torque

in. lbs

80kVA

480V

1 AWG – 1/0 AWG

100 - 135

in. lbs

1 AWG – 1/0 AWG

100 - 135

in. lbs

1 AWG – 1/0 AWG

100 - 135

in. lbs

250 MCM –

300 MCM

100 - 135

in. lbs

100kVA

480V

2/0 AWG –

3/0 AWG

100 - 135

in. lbs

2/0 AWG –

3/0 AWG

100 - 135

in. lbs

2/0 AWG –

3/0 AWG

100 - 135

in. lbs

350 MCM –

400 MCM

100 - 135

in. lbs

160kVA

480V

250 MCM –

300 MCM

100 - 135

in. lbs

250 AWG –

300 MCM

100 - 135

in. lbs

250 MCM –

300 MCM

100 - 135

in. lbs

2x350 MCM –

2x400 MCM

100 - 135

in. lbs

225kVA

480V

500 MCM

2x250 MCM

100 - 135

in. lbs

500 MCM

2x250 MCM

100 - 135

in. lbs

500 MCM

2x250 MCM

100 - 135

in. lbs

3x300 MCM –

3x350 MCM

100 - 135

in. lbs

TABLE 3.4 Recommended Cable Sizes

*1 - The cables must be selected to be equal to the sizes listed in the table. *2 - Voltage drop across power cables not to exceed 2% of nominal source voltage. *3 - Allowable ampere-capacities based on 75 C insulated copper conductor at ambient temperature of 40 C. *4 – All wiring to be in accordance with all applicable national and/or local electrical codes.

G9000 Installation and Operation Manual

WIRE

SIZE

WIRE

STRAND

RECOMMENDATION

CRIMP TOOL REQUIRED BURNDY TYPE Y35 OR Y46

(CODE)

CLASS

VENDOR

CAT. NO.

COLOR KEY

DIE INDEX

BURNDY

ILSCO

BURNDY

YA1C

CRA-1L

YA25-LB

GREEN GREEN

---

11 / 375 11 / 375

1019

1/0

BURNDY

ILSCO

BURNDY

YA25

CRA-1/OL

YA25-LB

PINK PINK

---

12 / 348 12 / 348

1020

2/0

BURNDY

ILSCO

BURNDY

YA26

CRA-2/OL

YA27-LB

BLACK BLACK

---

13 13

1021

3/0

BURNDY

ILSCO

BURNDY

YA27

CRB-3/OL

YA28-LB

ORANGE ORANGE

---

14 / 101 14 / 101

1022

4/0

BURNDY

ILSCO

BURNDY

YA28

CRB-4/OL

YA29-LB

PURPLE PURPLE

---

15 15

1023

250 MCM

BURNDY

ILSCO

BURNDY

YA29

CRA-250L

YA30-LB

YELLOW YELLOW

---

16 16

1024

300 MCM

BURNDY

ILSCO

BURNDY

YA30

CRA-300L

YA32-LB

WHITE WHITE

---

17 / 298 17 / 298

1026

350 MCM

BURNDY

ILSCO

BURNDY

YA31

CRA-350L

YA34-LB

RED RED

---

18 / 324 18 / 324

1027

400 MCM

BURNDY

ILSCO

BURNDY

YA32

CRA-400L

YA36-LB

BLUE BLUE

---

19 / 470 19 / 470

1027

500 MCM

BURNDY

ILSCO

BURNDY

YA34

CRA-500L

YA38-LB

BROWN BROWN

---

20 / 299 20 / 299

1029

AC input

CB3

CONVERTER

/ CHARGER

INVERTER

Output

52C

CB1

External BATTERY

Static Bypass

Transfer Switch

52S

CB2

Bypass

input

Terminals

A40 B40 C40

Terminals

A B C

Terminals

A50 B50 C50

Terminals

BP BN

TABLE 3.5 Crimp Type Compression Lug

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.

FIGURE 3.1 UPS Terminal Designation

42 G9000 Installation and Operation Manual

Location of bus bars and terminal blocks (Bottom entry)

Detailed Power Terminals

H=80.6” (2047mm) D=32.8” (832mm)

For power terminals, use 1/2” (12mm) Diameter bolts.

UPS module

160kVA to 225kVA : 35.4” (900mm)

80kVA to 100kVA : 27.6” (700mm)

AC A DC

AC Output

Bypass

C B A40

C40

B40

A50

C50

B50

Bypass Input A40,B40,C40

UPS

Battery Input BN,BP

AC Output A50,B50,C50

AC Input A,B,C

Grounding

Bar (E)

External Block IOAU-09

FIGURE 3.2 Diagram of input/output bus bars and terminal blocks

G9000 Installation and Operation Manual 43

FIGURE 3.3 Diagram of Power Wire & Control Wire Inter-Connect between UPS and Battery

44 G9000 Installation and Operation Manual

Bypass

CB2

52L1

UPS

Breaker

Inverter

CB1

UPS-

Battery

52L2

UPS

Breaker

52C

Tie

UPS

Breaker

52Ln (*1)

SMB

Maintenance

Bypass Breaker

Output

Breaker

52L

52S

Bypass

Converter

/Charger

UPS-

UPS-n (*1)

Bypas

Inverter

CB1

Battery

52C

52S

Converter

/Charger

Bypass

Inverter

CB1

Battery

52C

52S

Converter

/Charger

(*1) n: Maximum=4

FIGURE 3.4 Diagram of Power Wire Connect ( Parallel Operation system connection )

G9000 Installation and Operation Manual 45

UPS-1

IFAU-08

CN96

CN95

CN94

TLIN TLOUT CBIN CAIN

CBOUT CAOUT

TN1

IOAU-09

5 6

A50 B50 C50

AC OUTPUT

UPS-2

IFAU-08

CN96

CN95

CN94

TLIN TLOUT

TN1

IOAU-09

5 6

A50 B50 C50

AC OUTPUT

UPS-n

IFAU-08

CN96

CN95

CN94

TLIN TLOUT

TN1

IOAU-09

5 6

A50 B50 C50

AC OUTPUT

UPS-3 CN96 (TLIN)

UPS-3 CN94 (CAIN)

UPS-3 CN94 (CBIN)

UPS-(n-1) CN96 (TLOUT)

UPS-(n-1) CN94 (CAOUT)

UPS-(n-1) CN94 (CBOUT)

A B

UPS-1

A B C

UPS-2

A B C

UPS-n

AC OUTPUT

35 36 37 38

. .

. 49 50

OFF

52L1-AX

52L2-AX

. . .

52Ln-AX

Critical Load Cabinet

CBIN CAIN

CBOUT CAOUT

CBIN CAIN

CBOUT CAOUT

*1 n : Maximum = 4 *2 Return from the last

UPS module to the first

UPS

*1 **2 **

Use Ethernet STP (Shielded Twisted Pair) Cable for all communication cabling. Use of UTP (Unshielded Twisted Pair) Cable may cause malfunction.

Total cable length from UPS-1 to

FIGURE 3.5 Diagram of Power Wire & Control Wire Connect ( Parallel Operation system connection )

46 G9000 Installation and Operation Manual

NOTE

3.4 OPERATING PROCEDURES

For Parallel Operation system, refer to section “D) MMS Start-up Procedure”. (Parallel Operation system is herein after MMS [Multi Module System])

A) Start-up Procedure

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) Circuit Breaker is closed. Be extremely careful with closing the External input (or Bypass) Circuit Breaker.

a.) Verify that the External Bypass Input Circuit Breaker for each unit is closed.

(user supplied) b.) Verify that Battery Disconnect Circuit Breaker (CB2) is opened or in tripping position. 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 the screen will show that the Load is powered

by bypass line.

e.) On the LCD panel, select “OPERATION” tab, and then press the “STARTUP GUIDANCE”

button to continue UPS start-up. (Refer to Figure 2.3)

f.) Follow the “STARTUP GUIDANCE” accordingly until the completion of the inverter startup.

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.

G9000 Installation and Operation Manual 47

NOTE

CAUTION

WARNING

B) Shut-down Procedure

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

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 select “SHUTDOWN GUIDANCE”

icon. (Refer to Figure 2.3) c.) Follow the “SHUTDOWN GUIDANCE” until Inverter stops. The UPS will simultaneously

transfer to Bypass operation. d.) In general, only the Inverter will be stopped and the Converter will remain energized to

charge the batteries.

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.

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

breaker (CB2) manually in accordance with guidance.

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.

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 desired, open the External Bypass Input Circuit

Breaker (user supplied) manually.

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.

48 G9000 Installation and Operation Manual

NOTE

C) Bypass Operation Procedure

** Transfer from Inverter to Bypass

1. Check for “SYNC” on the LCD.

2. Press the "START/STOP” icon on the LCD.

3. Follow the “SHUTDOWN GUIDANCE” and Press the "STOP" icon on the LCD.

** Transfer from bypass to inverter.

UPS

1. Press the "START/STOP" icon on the LCD.

2. Follow the “STARTUP GUIDANCE” and Press the "START" icon on the LCD..

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

G9000 Installation and Operation Manual 49

NOTE

D) MMS Start-up Procedure

External Circuit Check (Ensure System is in Maintenance Bypass)

1. Verify that Tie cabinet Maintenance bypass breaker SMB is closed.

2. Verify that Tie cabinet Output breaker 52L 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 52L.

2. Open Tie cabinet Breaker SMB.

Transfer from UPS MMS Bypass Operation To UPS MMS Inverter Operation

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

any UPS LCD as shown in Fig. 3.6.

FIGURE 3.6 LCD Screen (MMS Operation)

50 G9000 Installation and Operation Manual

UPS FAULT

Annunciator Silence

Recording of Fault

Primary Action

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.

Information to Service

NOTE

4 RESPONSE TO UPS FAILURE

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 1-800-231-1412.

G9000 Installation and Operation Manual 51

WARNING

5 PARTS REPLACEMENT

Contact Toshiba International Corporation or its authorized service representatives on all issues regarding the replacement of parts.

A) Battery

Battery lifetime may vary according to the frequency of use and the average ambient

operating temperature. The end of battery life is defined as the state of charge resulting in an ampere-hour capacity less than, or equal to, 80% of nominal capacity.

Replace battery if its capacity is within this percentage.

B) UPS Component Parts

UPS components have a defined life expectancy (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.

Any parts replacements (including modification) without authorized by Toshiba could result in personal injuries, death or destruction of the UPS.

52 G9000 Installation and Operation Manual

6 FAULT CODES

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

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 1-800-231-1412.

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

closing it again.

G9000 Installation and Operation Manual 53

Note 3

Note 1

Note 2

Code

indication

Status message

Meaning

Guidance

Buzzer

External

relay

contact

Failure

lamp

UA801

AC INPUT VOLTAGE OUT OF RANGE

Input line voltage is out of the specified range.

CHECK INPUT POWER SOURCE

Intermittent

sound

Alarm

AC input

abnormal

UA802

AC INPUT FREQUENCY OUT OF RANGE

Input line frequency is out of the specified range.

CHECK INPUT POWER SOURCE

Intermittent

sound

Alarm

AC input

abnormal

UA803

AC INPUT PHASE ROTATION ERROR

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

CHECK INPUT POWER SOURCE

Intermittent

sound

Alarm

AC input

abnormal

UA804

CONVERTER OPE. PROHIBITED

The converter interlock is active.

Intermittent

sound

Alarm

UA805

INVERTER OVERLOAD

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

WARNING : DECREASE LOAD

Intermittent

sound

Alarm

Overload

UA806

INVERTER OVERLOAD

The output load current has exceeded 110% of the rated current.

WARNING : DECREASE LOAD

Intermittent

sound

Alarm

Overload

UA807

INVERTER OVERLOAD

The output load current has exceeded 125% of the rated current.

WARNING : DECREASE LOAD

Intermittent

sound

Alarm

Overload

UA808

INVERTER OVERLOAD

The output load current has exceeded 150% of the rated current.

WARNING : DECREASE LOAD

Intermittent

sound

Alarm

Overload

UA810

INVERTER OVERLOAD

Short time over-current has been detected during the inverter operation.

WARNING : DECREASE LOAD

Intermittent

sound

Alarm

Overload

UA812

BYPASS VOLTAGE OUT OF RANGE

Bypass line voltage is out of the specified range.

CHECK BYPASS INPUT

Intermittent

sound

Alarm

Bypass input

abnormal

UA813

BYPASS PHASE ROTATION ERROR

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

CHECK BYPASS INPUT

Intermittent

sound

Alarm

Bypass input

abnormal

UA814

BYPASS FREQUENCY OUT OF RANGE

Bypass line frequency is out of the specified range.

CHECK BYPASS INPUT

Intermittent

sound

Alarm

Bypass input

abnormal

UA815

TRANSFER PROHIBITED

Transfer to the bypass is not available due to bypass abnormality.

Intermittent

sound

Alarm

UA817

EMERGENCY STOP ACTIVATED

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

Alarm

UA821

TRANSFER PROHIBITED

The UPS could not transfer to the bypass because the inverter output was not synchronized to the bypass.

Alarm

UA822

TRANSFER PROHIBITED

The UPS could not transfer to the bypass because external “generator operation” signal indicates a backup generator is in operation.

Alarm

Failure Code List

Table 6.1 Fault Code

54 G9000 Installation and Operation Manual

Note 3

Note 1

Note 2

Code

indication

Status message

Meaning

Guidance

Buzzer

External

relay

contact

Failure

lamp

UA824

CB2 OPEN

The battery circuit breaker (CB2) is open.

TURN ON CB2

Intermittent

sound

Alarm

UA827

52C OPEN PROHIBITED

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

Intermittent

sound

Alarm

UA831

EMERGENCY BYPASS SWITCH ON

Emergency bypass switch has been turned on.

Intermittent

sound

Alarm

UA833

52L OPEN

The load circuit breaker(52L) is turned off.

Intermittent

sound

Alarm

UA834

BATTERY DEPLETED/AC OUT STOPPED

The battery voltage has reached the depleted level.

Major

End-of-

Discharge

Lit on

UA835

TRANSFER PROHIBITED

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

Alarm

UA860

REMOTE BUTTON ABNORMAL

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

Intermittent

sound

Alarm

UA861

LOCAL BUTTON ABNORMAL

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

Intermittent

sound

Alarm

UA870

BALANCER OVERLOAD

The UPS detected a neutral point voltage unbalance.

Intermittent

sound

Alarm

Overload

UA890

EXTERNAL ALARM

External Alarm relay turned on.

Intermittent

sound

Alarm

UF001

INPUT CIRCUIT ABNORMAL

The MMS input reference error signal exceeds specifications.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF002

CONVERTER OVERCURRENT

Detection of MMS converter overcurrent.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF003

CONVERTER ABNORMAL

Pre-charging circuit is not working properly.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF011

CB1 ABNORMAL

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

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF052

CB1 ABNORMAL

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF056

CONVERTER OVERCURRENT

Detection of SMS converter overcurrent.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF059

INPUT CIRCUIT ABNORMAL

The SMS input reference error signal exceeds specifications.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF102

DC OVERVOLTAGE

DC voltage surpasses the overvoltage level.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF103

DC UNDERVOLTAGE

DC voltage dropped below the undervoltage level.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF108

CHOPPER OVERCURRENT

Detection of DC overcurrent from backup battery.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

G9000 Installation and Operation Manual 55

Note 3

Note 1

Note 2

Code

indication

Status message

Meaning

Guidance

Buzzer

External

relay

contact

Failure

lamp

UF109

DC UNBALANCED

Major unbalance of the neutral point voltage.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF110

ZERO PHASE OVERCURRENT

Detection of converter zero-sequence overcurrent.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF111

UPS CONTROL CIRCUIT ERROR

Battery current unbalance.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF112

DC CIRCUIT ABNORMAL

Sudden change of the DC voltage level.

CALL SERVICE ENGINEER

Continuouss

ound

Major

Lit on

UF119

DC GROUND FAULT

Detection of DC ground fault UF159 exceeds 10 seconds. UPS transfers to bypass.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF128

CONTROL POWER SUPPLY ABNORMAL

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

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF151

DC VOLTAGE ABNORMAL

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF152

DC VOLTAGE ABNORMAL

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF154

CB2 ABNORMAL

During UVT, status signal from CB2 is ON.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF156

CHG.STOPPED(B ATTERY OVERTEMP.)

UF157 failure persisted for over 2 hours.

CHECK BATTERY

Intermittent

sound

Minor

Battery

abnormal

Flicker

UF157

BATTERY OVERTEMPERAT URE

Detection of overtemperature at the batteries.

CHECK BATTERY

Intermittent

sound

Minor

Battery

abnormal

Flicker

UF158

BATTERY LIQUID LOW

Low level of battery electrolyte solution.

CHECK BATTERY

Intermittent

sound

Minor

Battery

abnormal

Flicker

UF159

DC GROUND FAULT

Detection of DC ground fault. Chopper operation is stopped.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF160

UPS CONTROL CIRCUIT ERROR

Abnormal behavior of DC current sensor.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF161

CHG.STOPPED(D C VOLT. ABNORMAL)

UF151 failure is running for over 24 hours.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF162

BATTERY ABNORMAL

Failure detection based on battery self-check.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF163

BATTERY VOLTAGE ABNORMAL

Battery voltage is abnormal.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF170

VDB SENSOR ABNORMAL

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

56 G9000 Installation and Operation Manual

Note 3

Note 1

Note 2

Code

indication

Status message

Meaning

Guidance

Buzzer

External

relay

contact

Failure

lamp

UF201

INVERTER OVERVOLTAGE

Detection of output overvoltage.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF202

INVERTER UNDERVOLTAGE

Output voltage dropped.below specs.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF203

INVERTER OVERCURRENT

Detection of inverter overcurrent.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF204

OUTPUT CIRCUIT ABNORMAL

Detection of a large variation of the reference error signal (current reference and actual current).

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF206

UPS CONTROL CIRCUIT ERROR

Discrepancy between output voltage and external voltage (bypass, common ac bus)

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF207

ZERO PHASE OVERCURRENT

Inverter zero-sequence overcurrent.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF208

UPS CONTROL CIRCUIT ERROR

Cross current is abnormal.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF209

52C ABNORMAL

Error to close the contactor 52C.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF210

52C ABNORMAL

Error to open the contactor 52C.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF211

52C ABNORMAL

No answer from contactor 52C during inverter operation.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF213

OVERTEMP

Heatsinks temperature exceeds thermal settings.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF214

COOLING FAN ABNORMAL

Thermal relay activated protection.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF217

INVERTER OVERVOLTAGE

Detection of inverter output phase overvoltage.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF230

ZERO PHASE OVERCURRENT

Detection of zero-sequence overcurrent.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF253

UPS CONTROL CIRCUIT ERROR

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF256

OUTPUT VOLTAGE ABNORMAL

Output voltage is outside of the specified range.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF257

52C ABNORMAL

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF258

LOAD ABNORMAL

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF259

ANOTHER UPS ABNORMAL

No detection of another UPS voltage signal.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

G9000 Installation and Operation Manual 57

Note 3

Note 1

Note 2

Code

indication

Status message

Meaning

Guidance

Buzzer

External

relay

contact

Failure

lamp

UF301

UPS CONTROL CIRCUIT ERROR

AD reference has an abnormal value.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF302

UPS CONTROL CIRCUIT ERROR

Detection of an external interruption during the software execution.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF303

UPS CONTROL CIRCUIT ERROR

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

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF305

UPS CONTROL CIRCUIT ERROR

Detection of an abnormal clock speed in the DSP or FPGA.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF306

UPS CONTROL CIRCUIT ERROR

Control power supply voltage is below the specified level.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF309

INVERTER VOLTAGE ABNORMAL

Inverter voltage is out of the specified range.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF310

CONTROL POWER SUPPLY ABNORMAL

MMS backup control power supplies exhibit abnormal condition.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF320

UPS CONTROL CIRCUIT ERROR

Cable disconnection in the parallel interface board during load supply.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF323

UPS CONTROL CIRCUIT ERROR

Major communication error during parallel operation.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF352

CONTROL POWER SUPPLY ABNORMAL

SMS backup control power supplies exhibit abnormal.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF363

UPS CONTROL CIRCUIT ERROR

Synchronization error signal is being received for a considerable time.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF371

UPS CONTROL CIRCUIT ERROR

Minor communication error during parallel operation.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF372

UPS CONTROL CIRCUIT ERROR

Unable to synchronize the inverter output and the bypass voltage when the bypass is normal.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF374

UPS CONTROL CIRCUIT ERROR

Cable disconnection in the parallel interface board.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF375

UPS CONTROL CIRCUIT ERROR

Unable to achieve synchronization for parallel operation.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF376

UPS CONTROL CIRCUIT ERROR

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF377

UPS CONTROL CIRCUIT ERROR

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF378

UPS CONTROL CIRCUIT ERROR

No answer for sending synchronizing signal.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF379

UPS CONTROL CIRCUIT ERROR

Abnormal clock speed of the parallel control board processor.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

58 G9000 Installation and Operation Manual

Note 3

Note 1

Note 2

Code

indication

Status message

Meaning

Guidance

Buzzer

External

relay

contact

Failure

lamp

UF401

52S ABNORMAL

Error to close the contactor 52S.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF402

52S ABNORMAL

Error to open the contactor 52S.

CALL SERVICE ENGINEER

Continuous

sound

Major

Lit on

UF420

52L OPERATION ERROR

Load circuit breaker 52L opened during inverter operation.

CHECK 52L

Continuous

sound

Major

Lit on

UF451

52S ABNORMAL

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

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

UF452

CB3 ABNORMAL

Contactor CB3 is not working properly.

CALL SERVICE ENGINEER

Intermittent

sound

Minor

Flicker

(Note 1) 1) "Major" is defined as major failure. Inverter transferred 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) 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”

G9000 Installation and Operation Manual 59

No. Subject

Procedure

Criteria and/or Action needed

Term

Period

Method/Tool

Environmental ambient

Dust or Gas

Daily

Visual check and

smelling

Ventilate room atmosphere if dusty or

smelling gas.

Dewdrops Condensation

Daily

Visual check

Fix the dripping source

Dehumidify upon necessity.

Temperature Humidity

Daily

Thermometer

hygrometer

Temperature: 32 – 104 F Humidity: 30 –

90%

No condensation.

To be controlled at 77 F or about by

A/C.

Cabinet Construction

Vibration or Audible noise

Daily

Touch and

hearing

Check if fans have irregular sound.

Contact service representative in case

of abnormalities.

Overheating

When

needed

Touching exterior

Contact service representative in case

of abnormalities.

Air filter clog

When

needed

Visual check

Clean/wipe if clogged or dusty.

Operation

LCD sharpness Brightness Left-bottom LED

Daily

Visual check

No characters faded, illegible or any

other abnormalities.

Left-bottom LED should be green.

Contact service representative when

the LED shows red with the backlight

lost.

Indication terms: Output voltage Output current

AC input voltage Output frequency Battery voltage

Battery current DC voltage

Daily Visual check

Check indication terms/values if within

the adequate window.

Also check indication meters on

surface of optional cabinet, if installed.

LEDs

4 status LEDs

Daily

Visual check

Check if LEDs turn on, off or flash

according to the operation.

2 fault LEDs

Daily

Visual check

If UPS fault LED turns on, scroll the

screen to see fault codes and record

the codes.

Contact service representative to tell about fault codes and UPS symptom.

NOTE

7 DAILY INSPECTION

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

shown in Table 7.1.

The customers can only inspect exterior or environment of cabinet. When the customers want to perform the detailed inspection, contact the Authorized Toshiba Service Representatives or call Toshiba International Corporation at 1-800-231-1412.

TABLE 7.1 How to perform daily inspection

60 G9000 Installation and Operation Manual