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UNINTERRUPTIBLE POWER SYSTEM (UPS)

G8000 SERIES

INSTALLATION and

OPERATION MANUAL

480/480 V 80/100/125/150/225/300/500 kW

Document: 61001-002 April 2013

UNINTERRUPTIBLE POWER SYSTEM (UPS)

G8000 SERIES

INSTALLATION and OPERATION MANUAL

480/480 V 80/100/125/150/225/300/500 kW

Document: 61001-002

April 2013

G8000 Series Installation and Operation Manual

The Toshiba products listed in this document are intended for usage in general electronics applications

(computer, personal equipment, ofce equipment, measuring equipment, industrial robotics, domestic

appliances, etc.). These Toshiba products are neither intended nor warranted for usage in equipment that requires extraordinarily high quality and/or reliability; nor are they intended to be used in equipment that, if a malfunction or failure occurs, may result in loss of human life or bodily injury (collectively referred to as “Unintended Usage”). Unintended Usage includes atomic energy control instruments, airplane or spaceship

instruments, transportation instruments, trafc signal instruments, combustion control instruments, life

support equipment, all types of safety devices, etc. Unintended Usage of Toshiba products listed in this document shall be made at the customer’s own risk.

NOTICE

PLEASE INFORM TOSHIBA INTERNATIONAL CORPORATION OR AUTHORIZED

REPRESENTATIVE IN CASE OF INCONSISTENCIES, OMISSIONS, OR QUESTIONS.

The instructions contained in this manual are not intended to cover all of the details or variations in equipment, nor to provide for every possible contingency concerning installation, operation, or maintenance. Should

further information be required or if problems arise which are not covered sufciently contact your Toshiba sales ofce.

The contents of this instruction manual shall not become a part of or modify any prior or existing agreement, commitment, or relationship. The sales contract contains the entire obligation of Toshiba International Corporation’s UPS Division. The warranty contained in the contract between the parties is the sole warranty of Toshiba International Corporation’s UPS Division and any statements contained herein DO NOT create new warranties or modify the existing warranty.

Any electrical or mechanical modications to this equipment without prior written consent of Toshiba International Corporation will void all warranties and may void the UL/CUL listing. Unauthorized modications

can also result in personal injury, death, or destruction of the equipment.

QUALIFIED PERSONNEL ONLY

Qualied Personnel is one that has the skills and knowledge relating to the construction, installation,

operation, and maintenance of the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of NFPA 70E for additional safety requirements).

G8000 Series Installation and Operation Manual

UNINTERRUPTIBLE POWER SYSTEM (UPS)

Please complete the following information and retain for your records.

Unless otherwise specied, the warranty period for the UPS or UPS part is 12 months from the shipment

date (see Toshiba International Corporation bill of lading).

Unless otherwise specied, the warranty period for a UPS battery is 36 months from the shipment date (see

Toshiba International Corporation Bill of Lading for shipping date).

JOB NUMBER

MODEL NUMBER

SERIAL NUMBER

APPLICATION

SHIPMENT DATE

INSTALLATION DATE

INSPECTED BY

G8000 Series Installation and Operation Manual

Purpose

This manual provides information on how to safely install and operate your Toshiba International Corporation power electronics product. This manual includes a section of general safety instructions that describes the warning labels and symbols that are used throughout the manual. Read the manual completely before installing, operating, or performing maintenance on this equipment.

This manual and the accompanying drawings should be considered a permanent part of the equipment and should be readily available for reference and review. Dimensions shown in the manual are in metric and/or the English customary equivalent.

Toshiba International Corporation reserves the right, without prior notice, to update information, make

product changes, or discontinue any product or service identied in this publication.

Toshiba is a registered trademark of the Toshiba Corporation. All other product or trade references appearing in this manual are registered trademarks of their respective owners.

Toshiba International Corporation shall not be liable for direct, indirect, special, or consequential damages resulting from the use of the information contained within this manual.

This manual is copyrighted. No part of this manual may be photocopied or reproduced in any form without the prior written consent of Toshiba International Corporation.

Toshiba’s Customer Support Center

Contact the Toshiba Customer Support Center for assistance with application information or for any problems that you may experience with your Uninterruptible Power System (UPS).

Toshiba Customer Support Center

8 a.m. to 5 p.m. (CST) - Monday through Friday USA Toll Free (877) 867-8773 Tel (713) 466-0277 Fax (713) 896-5212

You may also contact Toshiba by writing to:

Toshiba International Corporation

13131 West Little York Road Houston, Texas 77041-9990 Attn: UPS Product Manager

For further information on Toshiba’s products and services, please visit our website at:

www.toshiba.com/ind

G8000 Series Installation and Operation Manual

1 Introduction ..........................................................................................................................1

2 General Safety Instructions ................................................................................................2

2.1 Symbols .......................................................................................................................2

2.2 Signal Words ................................................................................................................3

2.3 Qualied Personnel ......................................................................................................3

2.4 Factory Authorized Personnel ......................................................................................4

3 Important Safety Instructions .............................................................................................4

4 Safety Precautions ..............................................................................................................5

4.1 Disclaimer ....................................................................................................................5

4.2 General Maintenance ...................................................................................................6

4.3 Transporting/Unpacking ...............................................................................................6

4.4 Inspection/Storage .......................................................................................................8

5 Installation Precautions ......................................................................................................9

5.1 Wiring/Connection ........................................................................................................13

6 Warning Labels ....................................................................................................................14

6.1 Warning Label Locations ..............................................................................................15

7 Weight and Dimensions .....................................................................................................18

8 Transporting .........................................................................................................................19

8.1 Transporting By Crane .................................................................................................20

8.2 Transporting By Forklift ................................................................................................21

9 Storage/Operating Environment ........................................................................................23

9.1 Operating Precautions .................................................................................................23

9.2 Maintenance Precautions ............................................................................................25

9.3 Disposal .......................................................................................................................26

10 Installation..........................................................................................................................27

10.1 Unpacking ..................................................................................................................28

10.2 UPS Clearance ..........................................................................................................28

10.3 Anchor Bolts ...............................................................................................................29

11 UPS Wiring .........................................................................................................................30

11.1 80/100/125 kVA Terminal Blocks and Power Cables ...................................................32

G8000 Series Installation and Operation Manual

11.2 150, 225, 300, and 500 kVA Buss Strip Terminals and Power Cables .......................34

11.3 UPS Power Cable Conduit Landing Plates ................................................................39

11.4 External Breakers .......................................................................................................42

11.5 Grounding Wire ..........................................................................................................42

11.6 Control Wires..............................................................................................................44

11.7 Grounding Conguration ............................................................................................45

12 UPS Specications ............................................................................................................49

12.1 Specication Table .....................................................................................................49

12.2 Typical Efciency vs. Load .........................................................................................52

13 Operator Interface .............................................................................................................53

13.1 Key-Switch and Buttons .............................................................................................54

13.2 LCD/LED Indicators ...................................................................................................55

13.3 LCD Indicators ...........................................................................................................56

13.4 Normal Display ...........................................................................................................57

13.5 Fault Display ..............................................................................................................59

13.6 LCD Scroll ..................................................................................................................60

14 Operating the UPS .............................................................................................................61

14.1 Operation Types .........................................................................................................62

14.2 Pre-operational Check ...............................................................................................62

14.3 Startup Procedures ....................................................................................................63

14.4 Switch Power Supply (UPS to Bypass) ......................................................................65

14.5 Stop ............................................................................................................................66

14.6 Complete Shutdown ...................................................................................................67

14.7 Changing Between Float Charge and Equalize Charge ............................................68

14.8 Changing to Float Charge from Protection Charge (If applicable) .............................69

14.9 Emergency Power Off (EPO) .....................................................................................70

15 Troubleshooting ................................................................................................................70

15.1 Types of Errors ...........................................................................................................70

15.2 Faults and Warnings Data Screen .............................................................................71

15.3 LCD Fault & Warning Displays ...................................................................................72

15.4 Fault Messages ..........................................................................................................73

15.5 LCD Scroll (w/ faults or warnings) ..............................................................................75

15.6 Restoring UPS Operation ..........................................................................................76

G8000 Series Installation and Operation Manual

16 Periodic Maintenance/Parts Replacement ......................................................................77

16.1 Scheduled Maintenance ............................................................................................77

16.2 Parts Replacement ....................................................................................................77

Appendix A - Installation Planning Guides .............................................................................79

80kVA IPG .............................................................................................................................79

100kVA IPG ...........................................................................................................................82

125kVA IPG ...........................................................................................................................85

150kVA IPG ...........................................................................................................................88

225kVA IPG ...........................................................................................................................91

300kVA IPG ...........................................................................................................................94

500kVA IPG ...........................................................................................................................97

Appendix B - Outline Drawings ................................................................................................101

Appendix C - 500kVA Input- and Output- Cabinet Joining Instructions ...............................105

G8000 Series Installation and Operation Manual

iii

G8000 Series Installation and Operation Manual

1 Introduction

This manual provides information on how to safely operate your G8000 Series Uninterruptible Power System (UPS). This manual includes a section of general safety instructions that describes the warning labels and symbols that are used throughout the manual. Read the manual completely before installing, operating, or performing maintenance on this equipment.

Qualied personnel should read this manual carefully before transporting, installing and wiring the UPS. In

addition have a thorough understanding of the information provided in the chapters titled:

• General Safety Instructions

• Important Safety Instructions

• Safety Precautions

• Installation Precautions

Please read the G8000 Series Operation Manual for important instructions on operating the UPS. This manual and the accompanying drawings should be considered a permanent part of the equipment and should be readily available for reference and review. Dimensions shown in the manual are in metric and/or the English customary equivalent.

Keep the Installation Manual and the Operation Manual near the UPS for necessary reference.

SAVE THESE INSTRUCTIONS

G8000 Series Installation and Operation Manual

2 General Safety Instructions

DO NOT attempt to transport, install, operate, maintain or dispose of this equipment until you have read and understood all of the product safety information provided in this manual.

2.1 Symbols

The symbols listed below are used throughout this manual. When symbols are used in this manual they will include important safety information that must be carefully followed.

Safety Alert Symbol indicates that a potential

personal injury hazard exists.

Prohibited Symbol indicates DO NOT take action.

Mandatory Symbol indicates that the following

instruction is required.

Ground Symbol indicates the location of the

equipment grounding conductor.

Electrical - Voltage & Shock Hazard Symbol

indicates parts inside may cause electric shock.

Explosion Hazard Symbol indicates parts may

explode.

G8000 Series Installation and Operation Manual

2.2 Signal Words

The signal words listed below are used throughout this manual. When the words DANGER, WARNING, CAUTION and ATTENTION are used in this manual they will include important safety information that must be carefully followed.

The word DANGER in capital letters preceded by

DANGER

WARNING

CAUTION

the safety alert symbol indicates that an imminently hazardous situation exists, and if not avoided will result in loss of life or serious injury to personnel.

The word WARNING in capital letters preceded by the safety alert symbol indicates that a potentially

hazardous situation exists, and if not avoided may result in loss of life or serious injury to personnel.

The word CAUTION in capital letters preceded by the safety alert symbol indicates that a potentially

hazardous situation exists, and if not avoided may result in minor or moderate injury.

The word NOTICE in capital letters without the safety

NOTICE

alert symbol indicates a potentially hazardous situation exists, and if not avoided may result in

equipment and property damage.

2.3 Qualied Personnel

Installation, operation, and maintenance shall be performed by Qualied Personnel Only. A Qualied

Person is one that has the skills and knowledge relating to the construction, installation, operation, and maintenance of the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of NFPA 70E for additional safety requirements).

Qualied Personnel shall:

• Have read the entire operation manual.

• Be familiar with the construction and function of the UPS, the equipment being driven, and the

hazards involved.

• Be trained and authorized to safely energize, de-energize, ground, lockout/tagout circuits and

equipment, and clear faults in accordance with established safety practices.

• Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves,

hard hats, safety glasses, face shields, ash clothing, etc., in accordance with established safety

practices.

G8000 Series Installation and Operation Manual

• Be trained in rendering rst aid.

For further information on workplace safety visit www.osha.gov.

2.4 Factory Authorized Personnel

Factory authorized personnel have been factory trained and certied to install, service, and repair the

UPS. Contact the Toshiba Customer Support Center for assistance in locating the factory authorized personnel nearest you.

3 Important Safety Instructions

The following contains important instructions that should be followed during the installation, operation, and maintenance of the G8000 Series UPS.

Please refer to the battery manufacturer’s instructions for details on operating, maintaining and/or replacing

the batteries for each system. Keep unauthorized personnel from batteries. Only a certied service

representative with battery experience should perform service on batteries.

CAUTION

Misuse of this equipment could result in personal injury and/or equipment damage. In no event will Toshiba Corporation be responsible or liable for either indirect or consequential damage or injury that may come from the use of this equipment.

The UPS system input and output is NOT equipped with an over-current protection device, or an output disconnection at the AC output. The user should provide circuit breakers between the UPS AC

input (or Bypass input) and the power sources and between the UPS output and the critical load input. The minimum device ratings are listed in Table 3.1.

TABLE 3.1 UPS MINIMUM DEVICE RATINGS

CapaCity Rated Output input BReakeR Rating Output BReakeR Rating

80 kVA 480 V/277 V 480 V – 150 A 480 V – 125 A

100 kVA 480 V/277 V 480 V – 200 A 480 V – 150 A

125 kVA 480 V/277 V 480 V – 200 A 480 V – 200 A

150 kVA 480 V/277 V 480 V – 300 A 480 V – 250 A

225 kVA 480 V/277 V 480 V – 400 A 480 V – 350 A

300 kVA 480 V/277 V 480 V – 600 A 480 V – 500 A

500 kVA 480 V/277 V 480 V – 800 A 480 V – 800 A

80/100/150/225/300 kVA Temperature restrictions: The maximum operating ambient temperature is 86 °F (30 °C) at 1.0 PF, and 104 °F (40 °C) at 0.8 PF. If the UPS is exposed to the same ambient temperature as the battery system, the maximum operating ambient temperature is 86 °F (30 °C) at 1.0 PF, 90 °F (32 °C) at 0.8 PF. Table 3.2 lists the nominal battery voltage.

G8000 Series Installation and Operation Manual

TABLE 3.2 UPS NOMINAL BATTERY VOLTAGE

CapaCity nOminal VOltage FlOat VOltage

80 kVA 360 Vdc 405 V

100 kVA 360 Vdc 405 V

125 kVA 360 Vdc 405 V

150 kVA 360 Vdc 405 V

225 kVA 360 Vdc 405 V

300 kVA 360 Vdc 405 V

500 kVA 480 Vdc 540 V

4 Safety Precautions

The Toshiba products listed in this document are intended for usage in general electronics applications

(computer, personal equipment, ofce equipment, measuring equipment, industrial robotics, domestic

appliances, etc.). These Toshiba products are neither intended nor warranted for use in equipment that, if a malfunction or failure occurs, may result in loss of human life or bodily injury (collectively referred to as “Unintended Usage”). Unintended Usage includes atomic energy control instruments, airplane or spaceship

instruments, transportation instruments, trafc signal instruments, combustion control instruments, medical

operating room or life support equipment, all types of safety devices, etc. Unintended Usage of Toshiba products listed in this document shall be made at the customer’s own risk.

The application of the UPS without special consideration for equipment that supports human safety and/or maintain public services may cause serious accidents.

4.1 Disclaimer

IN NO EVENT WILL TOSHIBA CORPORATION BE RESPONSIBLE OR LIABLE FOR EITHER INDIRECT OR CONSEQUENTIAL DAMAGE OR INJURY THAT MAY COME FROM THE MISUSE OF THIS EQUIPMENT. ANY MODIFICATIONS WITHOUT AUTHORIZATION BY TOSHIBA COULD RESULT IN PERSONAL INJURIES, DEATH OR DESTRUCTION OF THE UPS.

TOSHIBA RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION OR DESIGN. TOSHIBA DOES NOT ASSUME ANY LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR UPS DESCRIBED HEREIN; NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS.

G8000 Series Installation and Operation Manual

4.2 General Maintenance

DO NOT remove the rear/side panels, or any sheet metla not designed to be removed.

Removing rear/side panels may result in electric shock, burns, personal injuries or UPS failure.

Keep the area arround the UPS clean.

Use a vacuum cleaner to clean the UPS.

Only factory authorized personnel sould perform internal general maintenance on the UPS.

Contact the authorized Toshiba Customer Support Center or an authorized Toshiba representative for informaton on proper disposal of UPS components.

It is illegal to dispose of certain components without conforming to environmental regulations for indusrial/commercial waste.

WARNING

4.3 Transporting/Unpacking

When transporting the UPS by crane, follow the SPECIFIED WORK PROCEDURE. The suspension wire angle should be less than 60°.

The UPS falling or overturning may cause crushing, trapping or other personal injuries.

See Installation Manual: Chapter 8 - Transporting

DO NOT tilt the UPS more than 10° from upright position.

Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries.

WARNING

G8000 Series Installation and Operation Manual

CAUTION

DO NOT transport, move, store, or place the UPS on its side.

Forces due to heavy components inside may damage the UPS.

Avoid vibration or shock exceeding 0.5G.

Failing to observe this precaution may cause damage to the UPS.

DO NOT allow the UPS to suffer shock or impact when unpacking.

Tools used to remove packaging materials may cause damage to the UPS.

DO NOT push or pull on the sides of the packaging.or the UPS to move it. Always use a crane, forklift, or pallet jack for transporting and positioning the UPS.

Pushing/pulling on the sides of the unit to move it may result in damage to the UPS. See Figure 4.1 Exterior Handling label.

Fig. 4.1 Exterior Handling label

BY CRANE

-Cablesshouldhavesufficientrating

andequallength.

-KeepUPSleveledwhenlifting/lowering

andavoidimpacts.

BY FORKLIFT

Donotpushor pullfromsides

BACKSIDE

FORKS (4Ft.Minimumlength)

WARNING: Riskoftipping. Forsafehandling,lift frombackandsidesonly(asshownabove)

UPS

-Verifyforkliftmaximumloadcapacity.

-Ensurethattheforksarelongenough

tosupporttheUPSandareinserted

properly.

-DonotswingortilttheUPSwhen

liftingand/ortransporting.

Seemanualforcompletedetails.

G8000 Series Installation and Operation Manual

4.4 Inspection/Storage

Inspection

Upon receipt of the UPS, an inspection for shipping damage should be performed. Use caution when removing the unit from the pallet. Refer to labels or documentation attached to packing material.

Unpacking

Check the unit for loose, broken, bent or otherwise damaged parts. If damage has occurred during shipping, keep all original crating and packing materials for return to the shipping agent.

NOTE: The factory warranty does not apply to damage incurred during shipping!

Ensure that the rated capacity and the model number specied on the nameplate conform to the order specications.

Storage

During periods of non-use, the following guidelines are recommended for storage.

Storage Preparation

1) Power up the UPS and allow it to operate with no load for 24 hours to fully charge the batteries.

2) Stop the unit.

3) Place the Main Circuit Breaker switch in the “OFF” position.

Storage Conditions

• For best results, store the UPS in the original shipping container and place on a wood

or metal pallet

• Storage temperature range: -4 to 104 °F (-20 to 40 °C)

• The optimum storage temperature is 70 °F (21 °C). A higher ambient temperature will

require recharging more frequently during storage

Avoid the following storage locations:

• Locations that are subject to extreme temperature changes or high humidity

• Locations that are subject to high levels of dust or metal particles

• Locations that are subject to excessive vibration

• Inclined oor surfaces

G8000 Series Installation and Operation Manual

5 Installation Precautions

CAUTION

Install the UPS in a controlled environment.

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

See Table 5.1 - UPS Installation Environment Standards

DO NOT tilt the UPS more than 10° from upright position.

Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries and cause physical damage to internal components.

WARNING

Keep the SPECIFIED CLEARANCE around the UPS.

Inadequate space around the UPS makes it difcult to perform maintenance/inspections, will lead to insufcient ventilation, and/or

cause malfunctions.

Install anchor bolts to secure the UPS to the installation oor.

The UPS may fall during an earthquake if the anchor bolts are not installed and secured.

Only factory authorized personnel should relocate, modify, or replace parts in the UPS after initial installation.

Electrical shock, injury or UPS failure may occur if non-authorized technicians attempt to modify or relocate the UPS. Please contact Toshiba Customer Support Center if you plan to move

or make modications to the UPS

G8000 Series Installation and Operation Manual

DO NOT block air vents.

Blocking the vents will increase the internal temperatures and may

result in UPS failure or re.

DO NOT install the UPS where water may fall on it.

Water may cause electrical shock, personal injury or UPS failure.

DO NOT use oor wax that contains silicon in the UPS storage

area and/or nearby rooms.

Floor wax that contains silicon may cause static electricity.

WARNING

The UPS should be installed per local and/or national electric codes

by qualied personnel.

Faults or improper operation may occur if the UPS is not installed properly.

When an external maintenance bypass is installed for the UPS, before switching to external bypass, ensure that the UPS unit is switched to AC Bypass mode and the UPS control panel display

veries the unit is Bypass mode.

Switching to the external bypass while the unit is in UPS mode may damage the UPS.

G8000 Series Installation and Operation Manual

TABLE 5.1 - UPS INSTALLATION ENVIRONMENT STANDARDS

Item Environment standard

Installation Location Indoors

Minimum operating temperature: 32 °F (0 °C).

Maximum operating temperature: 86 °F (30 °C) at 1.0 PF (UPS with/without battery system).

Ambient Temperature

Relative Humidity

Altitude

Vibration and Mechanical Shock

Dust

Maximum operating temperature: 90 °F (32 °C) at 0.8 PF (UPS with battery system).

Maximum operating temperature: 104 °F (40 °C) at 0.8 PF (UPS only).

Average 24-hour operating temperature: 86 °F (30 °C) at 1.0 PF and 41 – 95 °F

(5 – 35 °C) at 0.8 PF.

The relative humidity must be between 30 and 90% noncondensing due to temperature changes.

These specications are for altitudes up to 3240 ft. (1000 m) above sea level.

Consult with the factory to determine the derating factor for installations above 3240 ft. (1000 m).

Installation environment must not have vibration frequencies 10 Hz – 20 Hz.

The acceleration due to vibrations less than 10 Hz must not exceed 0.5 G.

The acceleration due to vibrations 20 Hz – 50 Hz must not exceed 0.5 G.

The total amplitude due to vibrations 50 Hz – 100 Hz must not exceed 0.1 mm.

Dust must not exceed normal atmospheric levels and must not include conductive particles, silicone or oils.

No ammable and/or explosive gas.

Hydrogen sulde (H2S) Less than or equal to 0.0001 PPM

Sulfurous acid gas (SO2) Less than or equal to 0.05 PPM

Chlorine gas (Cl2) Less than or equal to 0.002 PPM

Flammable Gas

Ammonia gas (NH3) Less than or equal to 0.1 PPM

Nitrous acid gas (NO2) Less than or equal to 0.02 PPM

Nitrous oxides (NOx) Less than or equal to 0.02 PPM

Ozone (O3) Less than or equal to 0.002 PPM

Hydrochloric acid mist (HCl) Less than or equal to 0.1 mg/m

Installation Precautions

1) Install the unit in a stable, level and upright position that is free of excessive vibration.

2) Install the unit where the ambient temperature is within the specied range.

3) DO NOT install the UPS in areas that are subject to high humidity.

4) DO NOT install the UPS in areas that allow exposure to direct sunlight.

5) DO NOT install the UPS in areas that allow exposure to high levels of airborne dust,

metal particles, or ammable gases.

6) DO NOT install the UPS in areas near sources of electrical noise. Ensuring a proper earth ground will reduce the effects of electrical noise and will reduce the potential for electrical shock.

G8000 Series Installation and Operation Manual

7) The UPS generates and can radiate radio-frequency energy during operation. Although

RFI noise lters are installed inside of the unit, there is no guarantee that the UPS will not inuence some sensitive devices that are operating near by. If such interference

is experienced, the UPS should be installed further away from the affected equipment and/or powered from a different source than that of the installed equipment.

8) The user should provide over-current protection for hardwired UPS systems between the UPS output and the load input.

9) After ensuring that all power sources are turned “OFF” and isolated in accordance with established lockout/tagout procedures, connect the power source wiring of the correct voltage to the input terminals of the UPS.

NOTE: Ensure the input phasing is connected in clockwise rotation (CW). UPS internal

circuitry is designed to disable further UPS operation if the input phasing is installed in counter-clockwise rotation (CCW).

10) Connect the output terminals of the UPS to the load (refer to NEC Article 300 - Wiring Methods and Article 310 - Conductors For General Wiring). Size the branch circuit conductors in accordance with NEC Table 310.16 as published 9/2007.

WARNING

METAL CONDUIT IS NOT AN ACCEPTABLE GROUND.

Conductor Routing and Grounding

1) Use separate metal conduits for routing the input power, output power, and control circuits.

2) Follow the wire size and tightening torque specications.

3) Always ground the unit to reduce the potential for electrical shock and to help reduce electrical noise.

4) A separate ground cable should be run inside the conduit with the input power, output power, and control circuits.

G8000 Series Installation and Operation Manual

5.1 Wiring/Connection

Perform wiring and connections with correct polarity.

Be careful when connecting the UPS to the battery system. A wrong connection may cause damage to the UPS, battery, or charger.

Connect ONLY one (1) ground wire to the earth ground terminal.

A missing ground wire may cause an electrical shock hazard. Connecting to more than one ground may cause a ground loop.

See Chapter 8 - UPS Wiring

DO NOT force, bend, or pull wires. DO NOT damage wire insulation. DO NOT place heavy objects on top of UPS.

Observe the above precautions when making wire connections or handling the wires. Failing to observe these precautions may damage

the insulation of the wires or may cause a re or an electric shock

hazard.

WARNING

Follow the torque criteria for tightening screws.

Loose connections may cause re due to heating.

See Chapter 11 - UPS Wiring

G8000 Series Installation and Operation Manual

NOTICE

6 Warning Labels

Below are representative warning labels and their location on the UPS. Exterior Handling labels shown in section 4.3, Transporting/Unpacking, are in the manual packet, and attached to the UPS shipping covering and shipping pallet.

NOTICE

Make sure all the warning labels are installed in the appropriate locations.

If a label is missing or illegible, contact Toshiba Customer Support Center or an authorized representative.

(B) 40308(A) 48082

DANGER

AC VOLTAGE

This UPS receives power from more than one source. Disconnect all AC sources before performing any service or testing inside this unit

48082

56875 FOR 80, 100, 150, 225 KVA

REFER TO INSTRUCTION MANUAL FOR WIRE SIZE AND TIGHTENING TORQUE

2V3W4

480V

AC INPUT

REFER TO INSTRUCTION MANUAL FOR WIRE SIZE AND TIGHTENING TORQUE

AC INPUT

58708

USE COPPER CONDUCTORS ONLY!

5V6W7N8U9V10W11

480V

BYPASS INPUT

USE COPPER CONDUCTORS ONLY !

2V3

480V

400V

BATTERY

480V

AC OUTPUT

7V8W9N10U11V12

480V

BYPASS INPUT

400V

BATTERY

480V

AC OUTPUT

DANGER

HAZARDOUS VOLTAGES

Hazardous voltages are used in the operation of this equipment and could cause severe personal injury or loss of life. The following precautions should be observed to reduce the risk of injury or death.

Only qualified technicians familiar with this equipment and the information supplied with it should be permitted to install and operate this equipment.

Installation of electrical equipment must be done in accordance with National Electrical Code and any other state or local codes. Proper grounding and conductor sizing mu st be installed for safe operation.

During operation, keep all covers in place and cabinet doors shut.

When performing visual inspections and maintenance, if possible, be sure the UPS is turned off and the incoming AC feed is turned off and locked out.

The UPS and Battery Cabinet will have hazardous voltages present even after the AC feed is turned off.

If i t i s ne ces s ary to make meas ur eme nts with t he power on, do not touch any electrical connection points. Rem ov e all j ewelry from wrists and finge rs. Make s ure te st equipment

is in good, safe operating condition.

While servicing, stand on some type of insulation, and be sure not to be grounded.

Follow the safety instructions given in the equipment manual carefully and observe all danger, warning and caution notices.

4030 8

(D) 40830

WARNING

CRITICAL FUSE S IZING

Incorrect fuse replacement size may res ul t in fire or ina deq uate equ ip men t pr ot ecti on .

Replace only with same type and rating of fuse.

PN 40830

G8000 Series Installation and Operation Manual

DANGER

HAZARDOUS VOLTAGES

Only qualified technicians familiar with this equipment and the information supplied with it should be permitted to install and operate this equipment.

During operation, keep all covers in place and cabinet doors shut.

When performing visual inspections and maintenance, if possible, be sure the UPS is turned off and the incoming AC feed is turned off and locked out.

If i t is ne ces sar y to ma ke mea surem en ts with th e power on, do not touch any electrical connection points. Rem ov e all jewe lry from w rists and f ingers. Make sur e test equipment is in good, safe operating condition.

While servicing, stand on some type of insulation, and be sure not to be grounded.

Follow the safety instructions given in the equipment manual carefully and observe all danger, warning and caution notices.

4030 8

The UPS and Battery Cabinet will have hazardous voltages present even after the AC feed is turned off.

DANGER

AC VOLTAGE

This UPS receives power from more than one source. Dis connect all AC sources before performing any service or testing inside this uni t

48082

2V3W4

REFER TO INSTRUCTION MANU AL FOR WIRE SIZE AND TIGHTENING TORQUE

480V

AC INPUT

480V

BYPASS INPUT

480V

AC OUTPUT

400V

BATTERY

5V6W7N8U9V10W11

USE COPPER CONDUCTORS ONLY!

(B) 40308(A) 48082

2V3

REFER TO INSTRUCTION MANU AL FOR WIRE SIZE AND TIGHTENING TORQUE

480V

AC INPUT

480V

BYPASS INPUT

480V

AC OUTPUT

400V

BATTERY

7V8W9N10U11V12

USE COPPER CONDUCTORS ONLY !

58708

PN 40830

Incorrect fuse replacement size may res ul t in fire or ina deq uate equ ipm ent pro tection .

Replace only with same type and rating of fuse.

CRITICAL FUSE S IZING

WARNING

(D) 40830

(E) 39561

DANGER

RISK OF ELECTRIC SHOCK

Capacitors stay charged after power has been shut off. Accidental contact with live parts can cause personal injury and death.

Turn off and lock out all power sources. Wait at least five (5) minutes for power to dissipate then check voltage before servici ng.

3956 1

(I) 40831

CAUTION

Heat sink not grounded.

Risk of electrical shock.

Disconnect UPS and electrically test heat sink before touching.

6.1 Warning Label Locations

(F) 58705 SERIAL LABEL

UNINT ERR UPT IBLE POW ER SUP PLY

58705

MFD . IN U.S .A. FR OM FO REIGN AN D DOMES TIC C OMPON ENTS

HOUSTON, TEXAS

PN 40831

LISTED

27E5

(J) 57053

(control power source sw itch)

Do no t turn off while ope rating.

(G) 57055

GND

CAUTION

FIGURE 6.2 – 80/100/125 KVA UPS WARNING LABELS

G8000 Series Installation and Operation Manual

FIGURE 6.3 – 150/225 KVA UPS WARNING LABELS

FIGURE 6.4 - 300 KVA UPS WARNING LABELS

G8000 Series Installation and Operation Manual

FINAL LAYOUT NOT AVAILABLE AT THIS TIME:

CONTACT THE FACTORY FOR ADDITIONAL

FIGURE 6.3 – 500 KVA UPS WARNING LABELS

INFORMATION

G8000 Series Installation and Operation Manual

7 Weight and Dimensions

Table 7.1 lists the unit and shipping weights for G8000 UPS models. See Appendix B for detailed outline and dimensioins of all models.

TABLE 7.1 G8000 UPS UNIT AND SHIPPING WEIGHTS

Model Unit Shipping

80 kVA 1390 lb. (630 kg) 1440 lb. (652 kg)

100 kVA 1740 lb. (789 kg) 1790 lb. (812 kg)

125 kVA 1740 lb. (789 kg) 1790 lb. (812 kg)

150 kVA 2467 lb. (1119 kg) 2556 lb. (1159 kg)

225 kVA 2980 lb. (1352 kg) 3069 lb. (1392 kg)

300 kVA 4575 lb. (2075 kg) 4725 lb. (2143 kg)

500 kVA (Input Cabinet) 1570 lb. (712 kg)1 ~1620 lb. (735 kg)

500 kVA (Output Cabinet) 4950 lb. (2245 kg)

 1-Weightsareapproximate.

~5100 lb. (2313 kg)

G8000 Series Installation and Operation Manual

8 Transporting

When transporting the UPS by crane, follow the SPECIFIED WORK PROCEDURE. The suspension wire angle should be less than 60°.

The UPS falling or overturning may cause crushing, trapping or other personal injuries.

DO NOT tilt the UPS more than 10° from upright position.

Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries.

DO NOT transport, move, store, or place the UPS on its side.

Excessive force applied from heavy components inside may damage the UPS.

WARNING

CAUTION

Avoid vibration or shock exceeding 0.5G.

Failing to observe this precaution may cause damage to the UPS.

DO NOT allow the UPS to suffer shock or impact when unpacking.

Tools used to remove packaging materials may cause damage to the UPS.

DO NOT install the UPS where water may fall on it.

Water may cause electrical shock, personal injury or UPS failure.

DO NOT push or pull on the sides of the packaging.or the UPS to move it. Always use a crane, forklift, or pallet jack for transporting and positioning the UPS.

Pushing/pulling on the sides of the unit to move it may result in damage to the UPS. (See Figure 4.1 Exterior Handling label.)

The UPS may be packed in a crate for extra protection during transportation. Avoid impact or vibration against the UPS during transportation. DO NOT expose the UPS directly to water.

G8000 Series Installation and Operation Manual

8.1 Transporting By Crane

Cables should have sufcient ratings and be of the same length. Make sure the suspension cables are

hooked at eyebolts. See Figure 8.1. Keep the angle less than 60° between cables.

Refer to Chapter 7 - Weight and Dimension for UPS cabinet weight.

Keep UPS leveled when lifting. DO NOT swing or tilt the UPS. Minimize the impact when lowering the UPS

to the oor. Figure 8.2 and 8.3 indicate unacceptable lifting.

Figure 8.4 and 8.5 show examples of acceptable and unacceptable operations.

Less than 60°

FIGURE 8.1 - CABLES AND EYEBOLTS TO LIFT THE UPS

More than 60°

FIGURE 8.2 - ANGLE MORE THAN 60°

FIGURE 8.2 - ANGLE MORE THAN 60° FIGURE 8.3 - UNEVEN CABLES

FIGURE 8.4 - ACCEPTABLE OPERATION FIGURE 8.5 - UNACCEPTABLE OPERATION

FIGURE 8.3 - UNEVEN CABLES

Uneven Cables

G8000 Series Installation and Operation Manual

8.2 Transporting By Forklift

Refer to Chapter 7 - Weight and Dimensions.

Verify forklift maximum load capacity and ensure that the forks are long enough to properly support the UPS. Insert the forks into the space shown in Figure 8.6. Spaces for the forks are provided underneath the UPS.

DO NOT swing or tilt UPS when lifting and/or transporting. Minimize the impact when lowering the UPS to

the oor.

80 - 225 kVA

Base

Insert the forks here

300 kVA

Base

Insert the forks here

FIGURE 8.6 -TRANSPORTING 80-300 KVA UPS BY FORKLIFT

Secure the forks against the base then lift

G8000 Series Installation and Operation Manual

Input Cabinet

500 kVA

(Ships in two parts, Input

and Output Cabinets)

Output Cabinet

Insert the forks here.

Secure forks against the base and then lift.

FIGURE 8.7 -TRANSPORTING 500 KVA UPS BY FORKLIFT

(See Appendix C for cabinet mating insturctions)

Insert the forks here.

Secure forks against the base and then lift.

G8000 Series Installation and Operation Manual

9 Storage/Operating Environment

Observe the following when storing the UPS.

• Store UPS indoors.

• Maximum storage time for the UPS between powered operation cycles is three years. If the UPS

has been stored for a period exceeding 36 months, contact your factory authorized represnetative of guidance in starting the unit.

• Temperature uctuations should be minimized.

• The optimal storage temperature range is 68 – 77 °F (20 – 25° C).

• A maximum temperature range of 32 – 104 °F (0 – 40 °C) should be observed.

• The optimal relative humidity at the storage location should be between 50 – 60%.

• Humidity must not exceed 90%.

• Avoid locations where UPS may be exposed to corrosive gas.

• Avoid locations with dirt and/or dust.

TABLE 9.1 - UPS STORAGE/OPERATING ENVIRONMENT STANDARDS

Item Environment standard

Storage Location Indoors

Ambient Temperature

Relative Humidity

Altitude

Dust

Minimum storage temperature: 32 °F (0 °C)

Maximum storage temperature: 104 °F (40 °C)

The relative humidity must be between 30 and 90% and without condensation due to temperature changes.

This equipment is rated for installations up to 3240 ft. (1000m) above sea level. Consult with the factory to determine the derating factor for installations above 3240 ft. (1000m).

Dust must not exceed normal atmospheric levels and must not include conductive particles, silicone or oils.

No ammable and/or explosive gas.

Hydrogen sulde (H2S) Less than or equal to 0.0001 PPM

Sulfurous acid gas (SO2) Less than or equal to 0.05 PPM

Chlorine gas (Cl2) Less than or equal to 0.002 PPM

Flammable Gas

Ammonia gas (NH3) Less than or equal to 0.1 PPM

Nitrous acid gas (NO2) Less than or equal to 0.02 PPM

Nitrous oxides (NOx) Less than or equal to 0.02 PPM

Ozone (O3) Less than or equal to 0.002 PPM

Hydrochloric acid mist (HCl) Less than or equal to 0.1 mg/m

9.1 Operating Precautions

Initial startup/comisioning of the UPS should be performed by factory authorized personnel.

1) The UPS should not be powered up until the entire operation manual has been read.

2) The voltage of the input power source must be within the rated input voltage range. The

G8000 Series Installation and Operation Manual

input frequency range must be within the rated input frequency range.

3) The UPS should not be used with a load that has a rated input that is greater than the rated output of the UPS.

4) If using the UPS to provide power to motors that require high starting current or with motors that require a long starting time, call Toshiba support for guidance in over sizing the UPS for lock rotor current.

5) DO NOT insert metal objects or combustible materials in the ventilation slots of the UPS.

6) DO NOT place, hang, or paste any objects on the exterior surfaces of the UPS.

7) The capacitors in the UPS maintain a residual charge for a while after turning the UPS off. The required discharge time for each UPS typeform is provided via a cabinet label and a CHARGE LED. Wait for at least the minimum time indicated on the label and ensure that the CHARGE LED has gone out before opening the door of the UPS once the UPS power has been turned off.

8) DO NOT attempt to disassemble, modify, or repair the UPS. Call your Toshiba sales representative for repair information.

9) Turn the power on only after installing ALL of the covers.

10) DO NOT remove any covers of the UPS when power is on.

11) If the UPS should emit smoke or an unusual odor or sound, turn the power off immediately.

12) Warning signs should be placed on or near the load as a notication that the load is

being powered by the UPS.

13) Additional warnings and notications shall be posted at the equipment installation

location as deemed required by Qualied Personnel.

WARNING

While operating in the inverter mode, placing the input breaker in the “OFF” position will switch the UPS to the battery backup mode.

The output of the UPS will continue uninterrupted to the load. The unit must be in the bypass mode at the time that the breaker is placed in the “OFF” position for the UPS to shutdown power to the load.

CAUTION

After an Emergency Power Off (EPO), DO NOT reset the breaker until the UPS internal circuits have been fully discharged.

The UPS could be damaged if the unit is not fully discharged before the breaker is reset.

G8000 Series Installation and Operation Manual

9.2 Maintenance Precautions

All internal maintenance sould be performed by factory authorized personnel.

1) Turn off, lockout, and tagout ALL power sources before connecting the power wiring to the equipment or when performing maintenance.

2) Hardwire type UPS units are not equipped with an over-current protection device, nor do they have an output disconnect for the AC output. A user-installed circuit breaker should be provided between the UPS output and the load input.

3) The maximum ambient operating temperature is 86 °F (30 °C) at 1.0 PF, and 104 °F (40 °C) at 0.8 PF.

4) Only factory authorized personnel should service the UPS. Contact Toshiba for the the nearest authorized service center.

5) Battery servicing should be performed by factory authorized personnel only. Contact your nearest factory authorized service center for battery replacement.

Qualied Personnel ONLY!

Qualied Personnel have the skills and knowledge relating to the construction, installation, operation, and

maintenance of the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of NFPA 70E for additional safety requirements).

Qualied Personnel shall:

1) Have read the entire operation manual.

2) Be trained and authorized to safely energize, de-energize, ground, lockout and tag circuits and equipment, and clear faults in accordance with established safety practices.

3) Be trained in the proper use and care of protective equipment such as safety shoes,

rubber gloves, hard hats, safety glasses, face shields, ash clothing, etc., in accordance

with established safety practices.

4) Be trained in rendering rst aid.

5) Be knowledgeable of batteries and the required handling and maintenance precautions.

For further information on workplace safety visit www.osha.gov.

Misuse of equipment could result in injury and equipment damage.

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

G8000 Series Installation and Operation Manual

WARNING

9.3 Disposal

CAUTION

DO NOT dispose of the batteries in a re.

The batteries may explode.

DO NOT open or mutilate the batteries.

Released electrolyte is harmful to the eyes and skin and could also be toxic.

DANGER

A battery can present a risk of electrical shock and high short circuit current.

Please contact your local or state environmental agency for details on disposal of electrical components and packaging in your particular area.

It is illegal to dump lead-acid batteries in landlls or dispose of them improperly.

Please help protect the Earth by contacting the environmental protection agencies in your area, the battery manufacturer, or call Toshiba toll-free at (877) 867-8773 for more information about recycling batteries.

G8000 Series Installation and Operation Manual

10 Installation

Keep the SPECIFIED CLEARANCE around the UPS.

Inadequate space around the UPS makes it difcult to perform maintenance/inspections, lead to insufcient ventilation, and/or will

cause malfunctions.

See Figure 10.1 - UPS Clearance

DO NOT tilt the UPS more than 10° from upright position.

Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries.

Install anchor bolts to secure the UPS to the installation oor.

The UPS may fall during an earthquake if the anchor bolts are not installed and secured.

DO NOT transport, move, store, or place the UPS on its side.

Forces due to heavy components inside may damage the UPS.

WARNING

DO NOT allow the UPS to suffer shock or impact when unpacking.

Tools used to remove packaging materials may cause damage to the UPS.

DO NOT push or pull on the sides of the packaging.or the UPS to move it. Always use a crane, forklift, or pallet jack for transporting and positioning the UPS.

Pushing/pulling on the sides of the unit to move it may result in damage to the UPS. See Figure 4.1 Exterior Handling label.

G8000 Series Installation and Operation Manual

10.1 Unpacking

Unpack the UPS indoors on a paved oor. The UPS should be as close as possible to its nal storage

location. Overhead traveling cranes should be used to unpack any G8000 Series UPS. If an overhead traveling crane is not available, allow enough space for forklift operations to unpack the UPS crate. Then remove the crate.

Points to observe

• Retain all small articles during unpacking and installation.

• Make sure that exterior paint is not scratched and that the UPS cabinet is not damaged.

• DO NOT damage the UPS when using tools to remove packaging materials.

• If provided, DO NOT remove the plastic sheet cover, until installation.

• Do not remove the fan covers until UPS start up. The fan covers should be removed by factory

authorized personnel. Packing materials should be disposed by the appropriate means.

• Immediately report any abnormalities to Toshiba Customer Support Center or an authorized

representative.

10.2 UPS Clearance

Maintain the indicated clearance during installation. See Figure 10.1. Ensure that the front and top air vents are NOT blocked.

Side 0 in. (0 mm)

Top 16 in. (400 mm)

Front 44 in.

(1100 mm)

Back 0 in. (0 mm)

FIGURE 10.1 - UPS CLEARANCE

G8000 Series Installation and Operation Manual

10.3 Anchor Bolts

Install the anchor bolts to secure the UPS on the oor. See Figure 10.2 for anchor bolt installation detail.

Use 12mm (1/2”) diameter anchor bolts. There are 16mm (5/8”) diameter holes provided in the UPS base.

See Figure 10.3 for the hole locations and dimensions for the specied UPS models.

150/225 kVA

(See Appendix B)

Back

21.7 in.

4 x 0.5 in. - Dia. (12 mm)

(551 mm)

4 x 5/16 in. (16 mm) diameter screw holes

Anchor Bolt

ANCHOR BOLT INSTALLATION DETAIL

FIGURE 10.2

80/100/125 kVA

(See Appendix B)

Back

21.7 in.

4 x 0.5 in. - Dia. (12 mm)

Front

(551 mm)

4 screw holes (Side View)

3.0 in. (76 mm)

Input Section

46.1 in. (1171 mm)

300 kVA

(See Appendix B)

8 x 0.5 in. - Dia. (12 mm)

22.5 in.

(571 mm)

22.5 in.

(571 mm)

500 kVA

(See Appendix B)

Back

Front

Back

Front

Output Section

25.6 in.

(650 mm)

22.5 in.

(571 mm)

30.0 in.

(762 mm)

29.7 in. (755 mm)

HOLE LOCATIONS/DIMENSIONS

G8000 Series Installation and Operation Manual

33.9 in.

(862 mm)

12 x 0.5 in. - Dia. (12 mm)

FIGURE 10.3

ON BOTTOM OF UPS

20.0 in.

(508 mm)

22.4 in.

(568 mm)

20.0 in.

(508 mm)

11 UPS Wiring

Figure 11.1 illustrates the external wiring of the G8000 UPS. See corresponding section to each wiring term.

• Power cable connection at terminal blocks/buses and external breaker provision for the AC input/output, Bypass Input and DC input.

• Earth ground wire at grounding terminal.

• Control wire terminal TB1 (battery cabinet and bypass breaker).

Note: Always consult your local and NEC electrical codes for wiring, cabling, and circuit protection device requirements.

Figure 11.1 illustrates the external wiring of the single-input G8000 UPS. See corresponding section to each wiring term.

• Power cable connection at terminal blocks/buses and external breaker provision for the AC

input/output, Bypass Input and DC input.

• Earth ground wire at grounding terminal.

• Control wire terminal TB1 (battery cabinet and bypass breaker)

< UPS >

Bypass

3φ4W

Bypass

Breaker

AC Input

3φ3W

Breaker

Input

Contactor

Input

Ground

Wire

Rectifier

Chopper

Charger

DC input

< Battery Cabinet >

Contactor + Thyristor

Inverter

Battery

Breaker

Bypass

Contactor

Inverter

Contactor

TB1

Output 3φ4W

Output

Breaker

FIGURE 11.1 - SINGLE INPUT EXTERNAL WIRING DIAGRAM

An external maintenance bypass may be installed in parallel with the UPS to allow servicing of the G8000 while maintaining power to the UPS load. Contact the Toshiba Customer Service for further information.

G8000 Series Installation and Operation Manual

Figure 11.2 illustrates the external wiring of the dual-input G8000 UPS. See corresponding section to each

11 UPS Wiring

Figure 11.1 illustrates the external wiring of the G8000 UPS. See corresponding section to each wiring term.

• Power cable connection at terminal blocks/buses and external breaker provision for the AC input/output, Bypass Input and DC input.

• Earth ground wire at grounding terminal.

• Control wire terminal TB1 (battery cabinet and bypass breaker).

wiring term.

• Power cable connection at terminal blocks/buses and external breaker provision for the AC

input/output, Bypass Input and DC input.

• Earth ground wire at grounding terminal.

• Control wire terminal TB1 (battery cabinet and bypass breaker)

< UPS >

Bypass 3φ4W

AC Input

3φ3W

Bypass

Breaker

Input

Breaker

Ground

Wire

Input

Contactor

Rectifier

Chopper

Charger

DC input

< Battery Cabinet >

Contactor + Thyristor

Inverter

Battery

Breaker

Bypass

Contactor

Inverter

Contactor

TB1

Output 3φ4W

Output

Breaker

FIGURE 11.2 - DUAL INPUT EXTERNAL WIRING DIAGRAM

G8000 Series Installation and Operation Manual

11.1 80/100/125 kVA Terminal Blocks and Power Cables

Note: Always consult your site specic, local, state, and NEC electrical codes for wiring, cabling, and circuit

protection device requirements.

The terminal blocks for the 80/100/125 kVA UPS are shown in Figure 11.3.

Recommended external cable sizes for both 75 °C and 90 °C copper wire for a single battery string are listed in Table 11.1–11.2. For two or more battery strings consult with Toshiba Technical Support. Ensure that your installation adheres to local and NEC electrical codes.

Use only copper wires for external cables.

1 2 3 4 5 6 7 8 9 10 11 12 13

Note: Contact the

factory if using more than one battery string.

+ –

U V W U V W U V W N

BATTERY

AC INPUT BYPASS INPUT AC OUTPUT

Cable Capacity of Terminal Blocks 1-11: 2 x #6 AWG to 2/0 Cable Capacity of Terminal Blocks 12-13: 2 x #6 AWG to 350 kcmil

FIGURE 11.3 - TERMINAL BLOCKS FOR 80/100/125 KVA UPS

TABLE 11.1 RECOMMENDED CABLE SIZE & TIGHTENING TORQUE FOR 80 KVA UPS

Block Number Cable Size (Min-Max)

Tightening Torque

75 °C Copper Wire 90 °C Copper Wire

1 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

2 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

3 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

4 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

5 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

6 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

8 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

9 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

10 1/0 – (2) 2/0 AWG #1 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

1,2

One battery string. (Consult factory if using more than one battery string.)

Maximum cable size for terminal lugs 1-11: (2) x #6 to #2 AWG; Battery Terminals 12-13: (2) x#6 AWG to 350 kcmil.

Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear.

(2) 1/0 – (2 ) 2/0 AWG (2) #1 – (2 ) 2/0 AWG 50 in.-lb. (5.6 N•m)

(2) 1/0 – (2 )2/0 AWG (2) #1 – (2 ) 2/0 AWG 50 in.-lb. (5.6 N•m)

(2) 1/0 - (2) 3/0 AWG (2) 2/0 - (2) 3/0 AWG 325 in.-lb. (36.7 N•m)

G8000 Series Installation and Operation Manual

TABLE 11.2 RECOMMENDED CABLE SIZE & TIGHTENING TORQUE FOR 100 KVA UPS

Block Number Cable Size (Min-Max)

Tightening Torque

75 °C Copper Wire 90 °C Copper Wire

1 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

2 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

3 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

4 (2) #1 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

5 (2) #1 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

6 (2) #1 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

8 (2) #1 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

9 (2) #1 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

10 (2) #1 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

1,2

One battery string. (Consult factory if using more than one battery string.)

Maximum cable size for terminal lugs 1-11: 2 x 6 to 2/0 AWG; Battery Terminals 12-13: 2 x 6 AWG to 350 kcmil.

Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear.

(2) 2/0 AWG (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

(2) 3/0 - (2) 4/0 AWG (2) 2/0 - (2) 3/0 AWG 325 in.-lb. (36.7 N•m)

TABLE 11.2 RECOMMENDED CABLE SIZE & TIGHTENING TORQUE FOR 125 KVA UPS

Block Number Cable Size (Min-Max)

Tightening Torque

75 °C Copper Wire 90 °C Copper Wire

1 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

2 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

3 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

4 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

5 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

6 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

8 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

9 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

10 (2) #3 – (2) 2/0 AWG 2/0 – (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

1,2

One battery string. (Consult factory if using more than one battery string.)

Maximum cable size for terminal lugs 1-11: 2 x 6 to 2/0 AWG; Battery Terminals 12-13: 2 x 6 AWG to 350 kcmil.

Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear.

(2) 2/0 AWG (2) 2/0 AWG 50 in.-lb. (5.6 N•m)

(2) 3/0 - (2) 4/0 AWG (2) 2/0 - (2) 3/0 AWG 325 in.-lb. (36.7 N•m)

G8000 Series Installation and Operation Manual

11.2 150, 225, 300, and 500 kVA Buss Strip Terminals and Power Cables

Note: Always consult your site specic, local, state, and NEC electrical codes for wiring, cabling, and circuit

protection device requirements.

The 150, 225, 300 and 500 kVA UPS units have buss strip power terminals.

Figure 11.4 is a typical buss strip for a 150/225 kVA UPS.

Figure 11.5 shows the arrangement of the terminal buss strips for the 150 and 225 kVA UPS units. The terminal buss strips are located inside, at the bottom of the UPS. The dashed line on terminals 1–13 indicates the side view of the bolt holes. Use 1/2 inch bolts to attach the lugs.

Figure 11.6 shows the arrangement of the terminal buss strips for the 300 kVA UPS. The buss strips are located inside at the top of the unit.

AC INPUT

BYPASS INPUT

AC OUTPUT

1.75 in.

(45 mm)

3 in.

(77 mm)

0.5 in. Dia. (1.27 mm)

1.97 in.

(50 mm)

5.3 in. (135 mm)

FIGURE 11.4 - TERMINAL BUS DETAIL

Flywheel Input (+)

Input fuse. Flywheel (-) connects to Battery (-))

–

BATTERY

Note: Contact the factory if using more than one battery string,

ywheel, or combination battery and ywheel.

1.77 in.

(45 mm)

(Optional Flywheel

FIGURE 11.5 - TERMINAL BUSS ARRANGEMENT FOR 150 AND 225 KVA UPS

Flywheel Input (+)

AC INPUT

3-phase 3-wire

FIGURE 11.6 - TERMINAL BUSS ARRANGEMENT FOR 300 KVA UPS

–

BATTERY

(Optional Flywheel Input fuse. Flywheel (-) connects to Battery (-))

Note: Contact the factory if using more than one battery string,

ywheel, or combination battery and ywheel.

BYPASS INPUT

3-phase 4-wire

AC OUTPUT

3-phase 4-wire

G8000 Series Installation and Operation Manual

Figure 11.7 shows the terminal mounting hole arrangement for the terminal buss strips for the 500 kVA UPS units.

Figure 11.8 shows the arrangement of the terminal buss strips for the 500 kVA UPS. The buss strips are located inside at the top of the unit. The dashed line on terminals 1–13 indicates the side view of the bolt holes. Use 1/2 inch bolts to attach the lugs.

3-Phase AC Power Lugs

3-Phase Neutral and

Battery (DC) Power Lugs

6 x 0.5625 in. Dia.

(14.3 mm)

0.875 in. (22 mm)

1.75 in.

(44.5 mm)

0.875 in. (22 mm)

0.75 in.

(19 mm)

G8000 500KVA - INPUT SECTION G8000 500KVA - OUTPUT SECTION

1 2

1.75 in.

(44.5 mm)

4 in. (102 mm)

FIGURE 11.7 - TERMINAL BUSS DETAILS FOR 500KVA UPS

4 5

(44.5 mm)

0.875 in. (22 mm)

1.75 in.

0.875 in. (22 mm)

0.75 in.

(19 mm)

9 10

1.75 in.

(44.5 mm)

5.5 in. (140 mm)

6 x 0.5625 in. Dia.

(14.3 mm)

1.75 in.

(44.5 mm)

–

BATTERY

AC INPUT

BYPASS INPUT

FIGURE 11.8 - TERMINAL BUSS ARRANGEMENT FOR 500 KVA UPS

GND

AC OUTPUT

For UPS’ equipped with buss strip terminals for the A/C INPUT, BYPASS INPUT, A/C OUTPUT and BATTERY connections, Toshiba recommends using the compression lugs listed in Table 11.3, or their equivalent, for cable terminations to be mounted on the bus strips.

G8000 Series Installation and Operation Manual

See Table 11.5 – Table 11.6 for recommended cable sizes for the 150, 225, 300 and 500 kVA UPS.

TABLE 11.3 RECOMMENDED CRIMP TYPE COMPRESSION LUGS FOR BUS STRIP TERMINALS

Wire Size Wire

Strand

Class

1/0 B

I B

2/0 B

I B

3/0 B

I B

4/0 B

I B

300 MCM B

I B

350 MCM B

600 MCM B

Recommendation Crimp tool Required

Burndy type Y35 or Y46

Vendor Cat. No. Color Key Die Index

Burndy Ilsco Burndy

Burndy Ilsco

YA25 CRA-1/OL YA25-LB

YA26 CRA-2/OL YA27-LB

YA-27 CRB-3/OL YA28-LB

YA28 CRB-4/OL YA29-LB

YA30 CRA-30OL YA32-LB

YA31L CRA-350

YA36L CRA-600

Pink Pink Black

Black Black Orange

Orange Orange Purple

Purple Purple Yellow

White White Red

Red Red

Green Green

12 / 348 12 / 348 13

13 13 14 / 101

14 / 101 14 / 101 15

15 15 16

17 / 298 17 / 298 18 / 324

18 18

22 22

TABLE 11.4 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 150 KVA UNIT

(USE 75 °C Copper Wire)

Recommended external cable sizes for both 75 °C and 90 °C copper wire for minimum battery congurations are listed in Table 11.4–11.7. For extended runtime battery strings congurations consult with Toshiba

Technical Support. Ensure that your installation adheres to local and NEC electrical codes.

G8000 Series Installation and Operation Manual

TABLE 11.4 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 150 KVA UNIT

(USE 75 °C Copper Wire)

Block Number Cable Size (Min-Max) Tightening Torque

75 °C Copper Wire 90 °C Copper Wire

1 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

2 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

3 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

4 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

5 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

6 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

8 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

9 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

10 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N•m)

Flywheel Input

(+)

One battery string. (Consult factory if using more than one battery string.)

Fastener torque specied for: 1/2 in. diameter grade 5 steel bolt.

Per ywheel unit

Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear.

(2) 300 kcmil – (6) #1 AWG (2) 250 kcmil – (6) #1 AWG 540 in.-lb. (61 N•m)

(2) 300 kcmil– (2) 350 kcmil (2) 250 kcmil – (2) 350 kcmil 540 in.-lb. (61 N•m)

(2) AWG 2/0 (2) AWG 2/0 300 in.-lb. (33.9 N•m)

TABLE 11.5 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 225 KVA UNIT

(USE 75 °C Copper Wire)

Block Number Cable Size (Min-Max) Tightening Torque

75 °C Copper Wire 90 °C Copper Wire

1 (2) 3/0– (2) 4/0 AWG (2) 2/0– (2) 3/0 AWG 540 in.-lb. (61 N•m)

2 (2) 3/0– (2) 4/0 AWG (2) 2/0– (2) 3/0 AWG 540 in.-lb. (61 N•m)

3 (2) 3/0– (2) 4/0 AWG (2) 2/0– (2) 3/0 AWG 540 in.-lb. (61 N•m)

4 (2) 4/0– (2) 250 kcmil (2) 3/0– (2) 4/0 AWG 540 in.-lb. (61 N•m)

5 (2) 4/0– (2) 250 kcmil (2) 3/0– (2) 4/0 AWG 540 in.-lb. (61 N•m)

6 (2) 4/0– (2) 250 kcmil (2) 3/0– (2) 4/0 AWG 540 in.-lb. (61 N•m)

8 (2) 4/0– (2) 250 kcmil (2) 3/0– (2) 4/0 AWG 540 in.-lb. (61 N•m)

9 (2) 4/0– (2) 250 kcmil (2) 3/0– (2) 4/0 AWG 540 in.-lb. (61 N•m)

10 (2) 4/0– (2) 250 kcmil (2) 3/0– (2) 4/0 AWG 540 in.-lb. (61 N•m)

Flywheel Input (+)

One battery string. (Consult factory if using more than one battery string.)

Fastener torque specied for: 1/2 in. diameter grade 5 steel bolt.

Per ywheel unit

(4) 4/0– (4) 250 kcmil (4) 3/0 – (4) 4/0 AWG 540 in.-lb. (61 N•m)

(4) 4/0 – (4) 250 kcmil (3) 250 kcmil – (4) 3/0 540 in.-lb. (61 N•m)

(2) AWG 2/0 (2) AWG 2/0 300 in.-lb. (33.9 N•m)

G8000 Series Installation and Operation Manual

Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear.

TABLE 11.6 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 300 KVA UPS

Bus Number Cable Size (Min-Max) Tightening

75 °C Copper Wire 90 °C Copper Wire

Torque

1 (2) 250 kcmil – (3) 2/0 (2) 4/0 – (3) 1/0 540 in.-lb. (61 N•m)

2 (2) 250 kcmil – (3) 2/0 (2) 4/0 – (3) 1/0 540 in.-lb. (61 N•m)

3 (2) 250 kcmil – (3) 2/0 (2) 4/0 – (3) 1/0 540 in.-lb. (61 N•m)

(4) 300 kcmil – (4) 350 kcmil (4) 300 kcmil – (4) 350 kcmil 540 in.-lb. (61 N•m)

6 (2) 300 kcmil – (3) 2/0 (2) 250 kcmil – (3) 1/0 540 in.-lb. (61 N•m)

7 (2) 300 kcmil – (3) 2/0 (2) 250 kcmil – (3) 1/0 540 in.-lb. (61 N•m)

8 (2) 300 kcmil – (3) 2/0 (2) 250 kcmil – (3) 1/0 540 in.-lb. (61 N•m)

(2) 300 kcmil – (3) 2/0 (2) 250 kcmil – (3) 1/0 540 in.-lb. (61 N•m)

10 (2) 300 kcmil – (3) 2/0 (2) 250 kcmil – (3) 1/0 540 in.-lb. (61 N•m)

11 (4) 300 kcmil – (4) 350 kcmil (4) 250 kcmil – (4) 300 kcmil 540 in.-lb. (61 N•m)

12 (4) 300 kcmil – (4) 350 kcmil (4) 250 kcmil – (4) 300 kcmil 540 in.-lb. (61 N•m)

Flywheel Input (+)

One battery string. (Consult factory if using more than one battery string.)

Fastener torque specied for: 1/2 in. diameter grade 5 steel bolt.

Per ywheel unit

Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear.

(2) AWG 2/0 (2) AWG 2/0 300 in.-lb. (33.9 N•m)

TABLE 11.7 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 500 KVA UPS

Bus Number Cable Size (Min-Max) Tightening

75 °C Copper Wire 90 °C Copper Wire

Torque

1 (3) 250 kcmil – (3) 400 kcmil (3) 4/0 kcmil – (3) 250 kcmil 540 in.-lb. (61 N•m)

2 (3) 250 kcmil – (3) 400 kcmil (3) 4/0 kcmil – (3) 250 kcmil 540 in.-lb. (61 N•m)

3 (3) 250 kcmil – (3) 400 kcmil (3) 4/0 kcmil – (3) 250 kcmil 540 in.-lb. (61 N•m)

4 (3) 400 kcmil – (3) 500 kcmil (4) 400 kcmil – (4) 500 kcmil 540 in.-lb. (61 N•m)

5 (3) 400 kcmil – (3) 500 kcmil (4) 400 kcmil – (4) 500 kcmil 540 in.-lb. (61 N•m)

6 (3) 400 kcmil – (3) 500 kcmil (3) 400 kcmil – (3) 500 kcmil 540 in.-lb. (61 N•m)

(6) 400 kcmil – (6) 500 kcmil (3) 400 kcmil – (3) 500 kcmil 540 in.-lb. (61 N•m)

1/0 1/0 540 in.-lb. (61 N•m)

9 (3) 400 kcmil – (3) 500 kcmil (3) 400 kcmil – (3) 500 kcmil 540 in.-lb. (61 N•m)

10 (3) 400 kcmil – (3) 500 kcmil (3) 400 kcmil – (3) 500 kcmil 540 in.-lb. (61 N•m)

11 (3) 400 kcmil – (3) 500 kcmil (3) 400 kcmil – (3) 500 kcmil 540 in.-lb. (61 N•m)

(6) 400 kcmil – (6) 500 kcmil (3) 400 kcmil – (3) 500 kcmil 540 in.-lb. (61 N•m)

13 (3) 400 kcmil – (3) 500 kcmil (3) 400 kcmil – (3) 500 kcmil 540 in.-lb. (61 N•m)

14 (3) 400 kcmil – (3) 500 kcmil (3) 400 kcmil – (3) 500 kcmil 540 in.-lb. (61 N•m)

Fastener torque specied for: 1/2 in. diameter grade 5 steel bolt.

Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear.

Ground cables

G8000 Series Installation and Operation Manual

11.3 UPS Power Cable Conduit Landing Plates

Cable conduit landing plates are provided at the bottom of the 80 kVA and100 kVA UPS, at the top and bottom of the 150/225 kVA UPS (Older models of the G8000 150/225 kVA UPS do not come equipped with an upper conduit landing plate.), and at the top only of the 300/500kVA. The recommended conduit landing arrangements are illustrated in Figure 11.9 thru 11.13.

The ve (5) holes must be punched during installation. The dashed rectangle indicates the UPS opening

behind the conduit landing plates.

Recommended

Conduit Placement

Order in Top Conduit

Landing Plate

23.11 in.

5.9 in.

7.48 in.

0.78 in.

INPUT

0.78 in.

BASE PLATES - DIMENSIONS

UPS BASE

BOTTOM ENTRY DIMENSIONS

FRONT OF UPS

23.73 in.

21.85 in.

BYPASS

AC OUT-

23.74 in.

PUT

3.37 in.

BATTERY

4.74 in.

CONTROL

WIRES

5.9 in.

FIGURE 11.9 - BOTTOM CONDUIT LANDING PLATES FOR 80/100/125 KVA

G8000 Series Installation and Operation Manual

21.85 in. 17.72 in.

3.35 in.

7.48 in.

Recommended

Conduit Placement

Order in Top Conduit

Landing Plate

FIGURE 11.10 - BOTTOM CONDUIT LANDING PLATES 100 KVA (T80S3K10KK6XSNH); 150/225 KVA

4.74 in.

0.7 in.

INPUT

23.11 in.

4.36 in.

0.7 in.

BYPASS

BASE PLATES - DIMENSIONS

UPS BASE

BOTTOM ENTRY DIMENSIONS

FRONT OF UPS

21.5 in.

42.126 in.

AC OUT-

PUT

BATTERY

4.74 in.

CONTROL

WIRES

5.9 in.

CONTROL

BATTERY

FRONT OF UPS

WIRES

AC OUT-

PUT

BYPASS

0.7 in.

INPUT

0.7 in.

Recommended

Conduit Placement

Order in Top Conduit

Landing Plate

21.5 in.

31.5 in.

4.27 in.

21.5 in.

4.36 in.

TOP ENTRY DIMENSIONS

FRONT OF UPS

FIGURE 11.11 - TOP ACCESS CONDUIT LANDING PLATE (150 AND 225 KVA ONLY)

G8000 Series Installation and Operation Manual

Figure 11.12 shows the four (4) cable landing plates provided at the top of the 300 kVA UPS. Seven (7) holes must be punched during installation. The dashed rectangle indicates the UPS opening behind the conduit landing plates.

3.93 in.

8.66 in.

GROUND

WIRE

Recommended

Conduit Placement

Order in Top Conduit

Landing Plates

7.09 in.

8.66 in.

0.76 in.

INPUT

FIGURE 11.12 - TOP ACCESS CONDUIT LANDING PLATES (300 KVA)

BATTERY

0.76 in.

CONDUIT LANDING PLATES - DIMENSIONS

BATTERY

56.70 in.

BYPASS

37.4 in.21.26 in.

AC OUT-

PUT

3.15 in.

8.66 in.

CONTROL

WIRES

7.09 in.

Figure 11.13 shows the three (3) conduit landing plates provided at the top of the 500 kVA UPS. The dashed rectangle indicates the UPS opening behind the conduit landing plates.

Ensure that your installation adheres to local and NEC electrical codes.

7.09 in.

CABLE ENTRY PLATE

(AC INPUT, BYPASS INPUT)

28.0” X 6.3” (711 MM X 161 MM)

FIGURE 11.13 - TOP CONDUIT LANDING PLATES FOR THE 500 KVA UPS

28.0” X 6.3” (711 MM X 161 MM)

G8000 Series Installation and Operation Manual

CABLE ENTRY PLATE

AC OUTPUT, DC INPUT

CABLE ENTRY PLATE

(CONTROL)

28.0” X 6.3” (711 MM X 161 MM)

11.4 External Breakers

The G8000 UPS units are not equipped with circuit breakers. Qualied personnel should provide the

external breakers for the AC input/output, bypass input and DC input.

See Figure 11.1 – External Wiring Diagram, for the circuit position of the breakers.

Table 11.7 shows the G8000 UPS minimum external breaker rating for each capacity. The Bypass, AC Input, and AC Output require 3-pole breakers.

TABLE 11.7 UPS MINIMUM DEVICE RATINGS

CapaCity Rated

Output

80 kVA 480 V/277 V 480 V – 150 A 480 V – 125 A 500 VDC – 300A

100 kVA 480 V/277 V 480 V – 200 A 480 V – 150 A 500 VDC – 350A

125 kVA 480 V/277 V 480 V – 200 A 480 V – 200 A 500 VDC – 400A

150 kVA 480 V/277 V 480 V – 300 A 480 V – 250 A 500 VDC – 600A

225 kVA 480 V/277 V 480 V – 400 A 480 V – 350 A 500 VDC – 900A

300 kVA 480 V/277 V 480 V – 600 A 480 V – 500 A 500 VDC – 1200A

500 kVA 480 V/277 V 480 V – 800 A 480 V – 800 A 600 VDC – 1200A

input BReakeR

Rating

Output BReakeR

Rating

dC input

BReakeR Rating

11.5 Grounding Wire

WARNING

Be sure to ground the UPS as specied.

Using the UPS without a proper ground will deteriorate the insulation, cause leakage of currents and electric shock.The resistance to ground should be less than or equal to 10 ohms.

The 80/100/150/225kVA earth grounding bus’ are located inside, at the bottom-front of the unit.

The 300 kVA earth grounding bus is located inside, at the top-left of the unit.

The 500 kVA earth grounding bus is located inside, at the bottom front of the units.

Use a AWG 2 (or 38 mm2) or larger cable for the grounding wire. Run the grounding wire through the opening at the bottom, or through a hole in the top conduit landing plate (if available). See Figure 11.12. Connect either the top or bottom earth ground bus, but not both, to the grounding wire.

The ground wire must have a crimp terminal with a 1/2 in. (12 mm) diameter bolt hole. The ground bus has 33/64 in. (13 mm) bolt hole. The connect the crimp terminal and ground bus together using a 7/16 in. (10 mm) diameter bolt.

G8000 Series Installation and Operation Manual

G8000 - 80/100 kVA

Groundbus

10 mm or 7/16 in. Bolt

G8000 - 300 kVA

Facility earth ground. Ground wire routing through top conduit landing plate.

10 mm or 7/16 in. Bolt

Through conduit landing plate on top (recommended)

AWG 2

(38 mm2)

ground

wire

G8000 - 500 kVA

12 mm or 1/2 in. Terminal

Feed-through opening

To facility

earth ground

Facility earth ground. Alternate ground wire routing through top conduit landing plate.

Note: Use either the top or the bottom access for the ground wire to connect to the ground buss, but use only one ground wire.

Note: Use either the top or the bottom grounding point, but not both. Doing so may degrade the performance of the unit.

G8000 - 150/225 kVA

AWG 2 (38 mm2)

ground wire

Groundbus

Alternate ground

wire location

10 mm or 7/16 in. Bolt

12 mm or 1/2 in. Terminal

Feed-through opening

To facility

earth ground

Ground

bus

AWG 1/0 (50 mm2)

ground wire

FIGURE 11.14 - EARTH GROUND WIRE CONNECTIONS

10 mm or 7/16 in. Bolt

12 mm or 1/2 in. Terminal

G8000 Series Installation and Operation Manual

11.6 Control Wires

The control wires terminal layouts at TB1 (terminal bus 1) are shown below in Table 11.8.

TABLE 11.8 EXTERNAL CONNECTIONS

No. I/O Signal Name Operation

1 Output Low Battery Closed at Low Battery

2 Output Backup Operation Closed during Backup Operation

3 Output Fault Closed if Faults present

4 Output Inverter Supply Closed during Normal Operation

5 Output Warning Closed if Warnings present

6 Input P24

7 Input Remote Run Close to run UPS

8 Input P24

9 Input Remote Stop Close to stop UPS

10 Output Bypass Supply Close during Bypass Operation

11 Output Output Signal Ground (Ground for pin #1 – 5 & #10)

12 Input P24 Battery’s

13 Input Battery Overheat Overheat B-contact

14 Output Bypass Breaker

15 Output 52C Trip Signal Shunt Trip Signal by EPO

16 Output Battery Breaker shunt trip

17 Output 72B Trip Signal by EPO or Battery shutdown

18 Output Battery breaker’s

19 Output 72B Aux. Contact Auxiliary A-contact

21 Output External EPO Ext EPO (Customer) N.O. Contacts

22 Output External EPO Ext EPO (Customer) N.O. Contacts

} }

}

 



Note: All control wiring should be #18 AWG (0.823 mm2) or larger.

G8000 Series Installation and Operation Manual

The UPS battery cabinet and bypass breaker should be wired as shown below in Figure 11.15.

Jumper wire if battery OH is not applied

15 16

TB1

UPS Cabinet

Power Source

To Bypass Input

Power Source for trip coil

To DC Input

Ext. EPO (Customer) N.O. Contacts

Bypass Breaker

Overheat B-Contact

Auxillary Acontact

Battery Cabinet

FIGURE 11.15 - CONNECTION BETWEEN UPS, BATTERY CABINET & BYPASS BREAKER

11.7 Grounding Conguration

This section describes the grounding conguration to be used with various AC service entrance congurations.

Inadequate grounding will cause problems at start-up. Connections for the ground line and the neutral line

must be made appropriately according to the system conguration.

11.7.1 Recommended conguration (for 4 wire input with Input Neutral

grounded)

Figure 11.16 shows recommended grounding conguration when the input neutral is grounded.

The neutral line at the input source is usually grounded. The neutral terminal in the UPS cabinet should be disconnected from the ground bus. The neutral connection for the UPS bypass input should be grounded.

G8000 Series Installation and Operation Manual

Input Source

3φ

< UPS Cabinet >

3φ

FIGURE 11.16 - GROUNDING CONFIGURATION WITH INPUT NEUTRAL GROUNDED

Remove

Jumper Cable

3φ

To the Load

A 2 AWG (or 38 mm2) jumper cable is provided between the neutral terminal and ground bus in the UPS

cabinet. The qualied personnel should remove the jumper cable in this conguration. The jumper cable

location is illustrated below.

Ground

Bus

80-225 kVA

Ground

Bus

Neutral

Terminal

Remove

Jumper

Cable

500 kVA

Neutral

Terminals

Ground

Bus

300 kVA

Remove

Jumper

Cable

Neutral

Terminal

Ground

Bus

Remove

Jumper

Cable

FIGURE 11.17 - JUMPER CABLE BETWEEN THE NEUTRAL TERMINAL & GROUND BUS

G8000 Series Installation and Operation Manual

11.7.2 Grounding Conguration (without input neutral)

φ3φ

< UPS Cabinet >

φ3φ

Remove

Jumper Cable

To the Load

φ3φ

< UPS Cabinet >

φ3φ

Remove

Jumper Cable

To the Load

φ3φ

< UPS Cabinet >

φ3φ

Input Source

Jumper Cable

Remains in Place

To the Load

When the input source is wye-connected, the neutral line out to the bypass input should be left open. The UPS is grounded by connecting the neutral terminal to the ground bus with the internal jumper cable. See Figure 11.18.

The jumper cable should stay in place. See Figure 11.17 for the jumper cable location.

If a ground fault interrupter is installed, the UPS is likely to trip the interrupter during transferring to/from the bypass circuit. It is recommended that the ground fault interrupter be set to a minimum delay of 0.5 seconds.

Input Source

3φ

FIGURE 11.18 - GROUNDING CONFIGURATION WITHOUT INPUT NEUTRAL

3φ

< UPS Cabinet >

3φ

Jumper Cable

Remains in Place

3φ

To the Load

11.7.3 Recommended Conguration (for delta-input)

If the input source is a delta-connection (3-phase 3-wire) without ground, the neutral terminal in the UPS cabinet must be connected to the ground bus with the internal jumper cable as shown in Figure 11.19.

The jumper cable should stay in place. See Figure 11.17 for the jumper cable location.

Input Source

3φ

< UPS Cabinet >

3φ

To the Load

FIGURE 11.19 - GROUNDING CONFIGURATION FOR NON-GROUNDED DELTA-INPUT

G8000 Series Installation and Operation Manual

Jumper Cable

Remains in Place

< UPS Cabinet >

φ3φ

Remove

Jumper Cable

To the Load

φ3φ

< UPS Cabinet >

φ3φ

Input Source

Jumper Cable

Remains in Place

To the Load

φ3φ

< UPS Cabinet >

φ3φ

Input Source

Jumper Cable

Remains in Place

To the Load

φ3φ

11.7.4 Grounding Conguration (with corner-grounded delta-input)

If one phase of delta-input source is grounded (B-phase for example), the ground bus in the UPS cabinet should NOT be connected to the neutral terminal of UPS output.

The jumper cable should be removed see Figure 11.17 for the jumper cable location.

During normal operation the UPS output is oating relative to the ground. An isolation transformer is

recommended at output distribution as shown in Figure 11.20.

Input Source

Bφ

3φ

< UPS Cabinet >

FIGURE 11.20 - GROUNDING CONFIGURATION WITH CORNER-GROUNDED DELTA-INPUT.

3φ

Remove

Jumper Cable

Output Distribution

To the Load

G8000 Series Installation and Operation Manual

12 UPS Specications

12.1 Specication Table

Model Number

Input

Normal (Charging)

Bypass

Battery

Rated Output

Capacity

Voltage 480 VAC (+10% to -15%)

Frequency 60 Hz (+/-5%)

Conguration 3 Phase; 3 Wire + GND

Input kVA

Power Factor > 0.99 PF Lagging

Walk-in Function EEPROM Upgrade

Maximum Input

Current

Reected THD < 5% @ 100% Load

Conguration 3-Phase; 4-Wire + Gnd

Voltage 480/277V (±10%)

Frequency 60 Hz (+/-5%)

Bypass Overload

Capacity

Number of Cells 180 240

Type Lead Acid (Contact factory for alternative options)

DC Nominal 360V 480V

DC Minimum 288V 408V

Float Charge 405V 540V

Ripple Current

(without batteries)

Back-up Time Application Specic

Max DC Charging

Current

Max Discharge 292 A 359 A 365 A 533 A 805 A 1073 A 1193 A

Battery Capacity Required for Full

Load Output

T80S3K08

KK6XSxx

80 kVA /

(100 kVA)

(120 A)

88 kWB 108 kWB 110 kWB 160 kWB 242 kWB 323 kWB 478 kWB

G8000 Specications

T80S3K10

KK6XSxx

100 kVA /

80 kW

89 kVA

107 A

30 A 30 A 30 A 30 A 30 A 30 A 45 A

100 kW

111 k VA

(122 kVA)

134 A

(147 A)

T80S3K12

KK6XSxx

125 kVA /

100 kW

112 kVA

(123 kVA)

135 A

(148 A)

1000% for 1 Cycle, 500% for 2 Cycle

AC Ripple on DC Bus: < 0.2% of DC Voltage

T80S3K15

KK6Xxx

150 kVA /

150 kW

163 kVA

(174 kVA)

196 A

(209 A)

< 6% @ 25% Load

T80S3K22

KK6XSxx

225 kVA /

225 kW

247 kVA

(258 kVA)

297 A

(311 A)

T80S3K30

KK6XSxx

300 kVA /

300 kW

329 kVA

(340 kVA)

396 A

(409 A)

T80S3K50

KK6XSxx

500 kVA /

450 kW

484 kVA

(505 kVA)

582 A

(608 A)

G8000 Series Installation and Operation Manual

Model Number

Output

Reliability

Environment

G8000 Specications

T80S3K08

KK6XSxx

Voltage 480Y/277V

Conguration 3-Phase; 4-Wire + Gnd

Voltage

Regulation

Voltage Adjust-

ment Range

Voltage

Unbalance

Crest Factor 2

Transient Voltage

Response

Transient

Recovery Time

Frequency 60 Hz

Frequency Syn-

chronous Range

Frequency Slew

Rate

Frequency Regu-

lation

Current 96 A 120 A 150 A 180 A 271 A 361 A 601 A

Power Factor 1.0 PF Lag: 32 - 86 °F (0

0.8 PF Lag: 86 - 104 °F (30 - 40 °C)

Overload

Capacity

Voltage THD <3% Max with 100% Linear Load / 5% Max with 100% Non-Linear Load

Withstanding

Rating

MTBF Module only - 200,000 Hrs. / 3,000,000 Hrs. in Bypass

Cooling Forced Air

Paint Color Sherwin Williams HHT2-7055, 079 Beige Texture

Weight 1740 lb.

Weight (Shipping) 1790 lb.

Floor Loading 210 Lbs/ft²

125% for 10 Minutes, 150% for 60 Seconds

(789 kg)

(812 kg)

(1023 kg/m2)

T80S3K10

KK6XSxx

±1% for 0-100%Balanced and Unbalanced Loads ±2% for

±3% for 100% Linear Loads ±5% for 100% Non-Linear Loads

±2% Max with a 100% Step Loads (without utilizing batteries)

- 30 °C)

(1023 kg/m2)

T80S3K12

KK6XSxx

±5% (in increments of 1V)

±1.5% Max with Loss/Return AC input

±2% Max when load transfers To/From Bypass

±0.5 Hz, ±1 Hz, + 1.5Hz (Selectable)

± 0.01% in free running mode

0.8 PF Lag: 32 - 104 °F

(0 - 40 °C)

110% for

5 Minutes,

120% for

60 Seconds

65 kA (with optional fuse)

1740 lb.

(789 kg)

1790 lb.

(812 kg)

210 Lbs/ft²

T80S3K15

KK6Xxx

<50 ms

1 Hz/Sec

1.0 PF Lag: 32 - 86 °F (0 - 30 °C)

0.8 PF Lag: 86 - 104 °F (30 - 40 °C)

125% for 10 Minutes, 150% for 60 Seconds

2467 lb.

(1119kg)

2556 lb.

(1159 kg)

203 Lbs/

ft² (990 kg/

m2)

T80S3K22

KK6XSxx

2980 lb.

(1352 kg)

3069 lb.

(1392 kg)

245 Lbs/ft²

(1196 kg/

m2)

T80S3K30

KK6XSxx

(2075 kg)

(2143 kg)

240 Lbs/ft²

(1173 kg/

4575 lb.

4725 lb.

m²)

T80S3K50

KK6XSxx

0-100%

Balanced

and Unbal-

anced Loads

0.9 PF Lag

32 - 104 °F

(0 - 40 °C)

6520 lb.

(2957 kg)

-TBD-

247 Lbs/ft²

(1204 kg/m²)

G8000 Series Installation and Operation Manual

Model Number

Environment (cont.)

Monitoring

EPO

Cong-

uration

Dimension - Width 36.8 in. (935 mm) 55.1 in. (1400 mm) 76.8 in.

Listings/Standards UL 1778; UL 17025, cUL 22.2, No. 107.1; ANSI C62.41 (IEEE 587 Cat B) NFPA 70; OSHA; ISO

Intelligent Monitor-

Emergency Power

G8000 Specications

T80S3K08

KK6XSxx

Depth 32.5 in. (826 mm) 31.8 in. (808 mm) 35.7 in.

Height 79.2 in. (2012 mm) 79.4 in.

Cable Access Bottom Access Top or Bottom Access Top Access

Minimum

Clearance

Enclosure NEMA 1

Heat Loss to be

Removed @ Full

Load

Audible Noise 65 dBA @ 1m Typical 68 dBA @ 1m Typical 72 dBA @

Operating Tem-

perature

Operating Humid-

ity

Operating Altitude 3200 ft. (1000 m)

Warranty 3 Years Parts and Labor

Dry Contacts

Included

RS232 Port Included

ing (Optional)

Display LCD Touch Panel for Local Monitoring, Operation and control

Off

Input Conv. 6-diode Bridge Rectier

Battery Cct IGBT Chopper

Out. Inv. IGBT Converter with PWM

28,321

BTUs/hr

T80S3K10

KK6XSxx

33,746

BTUs/hr

32˚F to 86˚F (0˚C to 30˚C) for 1.0PF 32˚F to 104˚F (0˚C to 40˚C) for 0.8 PF

SNMP; Modbus RTU; Modbus TCP; BACNET, METASYS

T80S3K12

KK6XSxx

Front: 43 7/16” (1100 mm) 37 in.

Back/Left/Right Sides: Zero

37,281

BTUs/hr

30% to 90% Non-Condensing

Yes, for input and output signals

T80S3K15

KK6Xxx

Top: 15.75” (400 mm)

38,524

BTUs/hr

9001; IEC298 IP20

Included

T80S3K22

KK6XSxx

67,667

BTUs/hr

T80S3K30

KK6XSxx

1951 mm)

(907 mm)

(2017 mm)

89,011

BTUs/hr

1m Typical

T80S3K50

KK6XSxx

101.8 in.

(2586 mm)

37.4 in.

(945 mm)

79.7 in.

(2024 mm)

(940 mm)

110,262 BTUs/hr

78 dBA @

1m Typical

G8000 Series Installation and Operation Manual

12.2 Typical Efciency vs. Load

UPS Efciency at Percent Full Load*

25% 50% 75% 100%

80 kVA 83.9% 85.3% 90.0% 90.6%

100 kVA 86.4% 90.1% 91.2% 91.0%

125 kVA 88.5% 90.9% 90.9% 90.2%

150 kVA 86.9% 91.7% 92.3% 93.3%

225 kVA 87.9% 91.9% 92.3% 91.9%

300 kVA 88.8% 91.6% 92.2% 92.8%

500 kVA 91.6% 91.1% 90.2% 93.3%

* Actual efciency may differ due to manufacturing variations and input power quality.

G8000 Series Installation and Operation Manual

13 Operator Interface

Table 13.1 shows the functions of the operating buttons on the graphic display panel.

NOTICE

Press an operating button for at least 0.5 seconds to change UPS modes. Press the reset button for at least 5 seconds to reset the UPS.

The UPS may not respond if the button press is too short.

TABLE 13.1 BUTTON AND INDICATOR FUNCTIONS (See g. 13.1 and 13.2)

# Name Function

1 OPERATION LOCK Enables/disables the buttons RUN, STOP, UPS, BYPASS, FLOAT/EQUAL, and RESET.

2 STOP BUTTON Stops the UPS. Transfers to bypass power if available.

3 RUN BUTTON Starts the UPS. Transfers the unit from bypass to UPS power.

4 FLOAT/EQUAL BUTTON Changes recharge mode between oat charge and equalize charge.

5 SCROLL UP BUTTON Scrolls the LCD screens up.

6 SCROLL DOWN BUTTON Scrolls the LCD screens down.

7 RESET BUTTON Reset UPS faults and warnings shown on the LCD. (See Section 13.5)

8 UPS BUTTON Transfers from bypass operation to normal operation.

9 BYPASS BUTTON Transfers from normal operation to bypass operation.

10 EPO BUTTON “ON” during Bypass Supply.

11 LCD DISPLAY Displays the operational, status, and warning/fault messages.

12 UPS SUPPLY LED “FLASHES” during START or STOP sequence “ON” when operating in inverter mode.

13 CONVERTER LED “ON” after DC bus capacitors are fully charged through the converter.

14 AC INPUT LED “ON” with nominal AC input. “FLASHES” with AC input under-voltage (85%).

15 FLOAT CHARGE LED “ON” during oat charge.

16 EQUALIZE CHARGE LED “ON” during equalize charge or protection charge while battery OH contact open.

17 BATTERY LED “ON” when battery is connected. (aux-contact on)

18 DISCHARGE LED “ON” during battery discharge.

19 BYPASS INPUT LED “ON” with nominal bypass input. “FLASHES” when bypass is under-voltage (85%).

20 WARNING LED Normally “OFF”. “ON” when warning displayed on LCD. “FLASHES” when AC input is abnormal.

21 FAULT LED Normally “OFF”. “ON” when faults occur.

22 INVERTER LED Lamp “FLASHES” during START or STOP sequence. “ON” when inverter is operating.

23 UPS LED “ON” when the inverter output is connected to the UPS output.

24 AC OUTPUT LED “ON” with AC output connected to the bypass/inverter sources.

25 BYPASS LED “ON” when the bypass power supplies the load

G8000 Series Installation and Operation Manual

13.1 Key-Switch and Buttons

The key-switch and operating buttons on the graphic display panel are shown in Figure 13.1. See the sections titled “Key-switch” and “Operating buttons” for each function.

4321

FIGURE 13.1 – GRAPHIC DISPLAY PANEL KEY-SWITCH/OPERATING BUTTONS

G8000 Series Installation and Operation Manual

EPO

13.2 LCD/LED Indicators

FIGURE 13.2 – GRAPHIC DISPLAY PANEL LCD/LED INDICATORS

G8000 Series Installation and Operation Manual

13.3 LCD Indicators

The operator can scroll through the following LCD display screens using the scroll buttons.

TABLE 13.2 - LCD DISPLAY SCREENS

Name Description

Normal Display Displays operational status, operational guidance, and measured

data.

Fault Display Displays detailed data when a fault occurs.

Warning Display Displays detailed data when a warning occurs.

NORMAL DISPLAY

FAULT DISPLAY

WARNIG DISPLAY

FIGURE 13.3 - CHANGING SCREENS WITH SCROLL BUTTONS

SCROLL UP

SCROLL DOWN

G8000 Series Installation and Operation Manual

13.4 Normal Display

The Normal Display screen indicates the UPS operational status and provides various screens: an operation guidance screens, mode screens and measured data screens. Table 13.3 shows these screens page by

page and illustrates the UPS Normal Display operational status screens.

TABLE 13.3 - NORMAL DISPLAY SCREEN EXAMPLES

OPERATIONAL STATUS SCREENS

BYPASS

PRESS ‘RUN’ SWITCH

UPS SUPPLY

AC-VO 480[V] AC- I O 50[%]

OPERATION MODE

NORMAL OPERATION MODE

SYNC.

MEASUREMENT SCREENS

Shows the UPS status at the top and guidance message or measured data underneath.

Shows a guidance message at start up.

Shows the output voltage and current after start up.

Shows the UPS Operation mode.

O/P VOLTAGE

VOLT. 480[V]

FREQ. 60.0[Hz]

O/P CURRENT (R.M.S.)

U 50[%] V 50[%] W 50[%]

G8000 Series Installation and Operation Manual

Output Voltage: Shows the output line-to-line output voltage.

Output Current: Shows the RMS output current (%) for each phase..

MEASUREMENT SCREENS

TABLE 13.3 - CONTINUED

O/P CURRENT (PEAK)

U 50[%] V 50[%] W 50[%]

AC INPUT

AC I/P-V 480[V] FREQ. 60.0[Hz]

BYPASS INPUT

BYP I/P-V 480[V] FREQ. 60.0[Hz]

DC INPUT

DC-V 632[V] BATT-V 400[V] BATT- I 0[A]

Shows the peak output current peak (%) for each phase.

Peak value of output current

x 100 [%]

RMS value for rated current x 1.41

Shows the AC Input Voltage (line-to-line) and frequency.

Shows the Bypass Input Voltage (line-to-line voltage) and frequency.

Shows the internal DC bus voltage, battery voltage and battery current.

The battery current value displayed is negative during recharge and positive during discharge.

MODE COUNT

UPS 35[H] BATTERY 56[MIN] 32[TIM]

CLOCK

TIME 03-24-06 13:58

Shows the cumulative UPS operation time, the cumulative battery backup time and the number of battery backup operations.

The current time is displayed if there are no faults recorded, or after the reset button is pressed.

Date is displayed in the mm-ddyyy format. The unit does not calculate daylight savings time.

Time is displayed in the 24-hour format (e.g. 1:58 P.M. = 1358 Hrs.)

G8000 Series Installation and Operation Manual

13.5 Fault Display

The Fault Display screen displays the fault records until they are reset. The Warning Display screen displays the warning records until they are reset. The fault records will remain in the memory until the reset button is pressed for at least 5 seconds, even after the actual cause of the fault has been resolved. Note that the fault records are not deleted when the UPS is turned off.

If the UPS is RESET while the system is in normal or bypass mode, the fault history is cleared and operation continues.

If the UPS is RESET while the system is on backup mode, the system will power down, re-initialize, and restart.

TABLE 13.4 FAULT & WARNING DISPLAY SCREEN EXAMPLES

FAULTS & WARNINGS

1 FUSE BLOWN

09-09-06 08:05:30

↓ANOTHER ITEM

FAULTS & WARNINGS

1 UPS OVERLOAD

09-09-06 08:05:30

↓ANOTHER ITEM

FAULTS & WARNINGS

NO ALARM NO WARNING

A fault record is shown with time stamp.

An arrow indicates that another record can be displayed by pressing the up/down buttons.

A warning record is shown with time stamp.

An arrow indicates that another record can be displayed by pressing the up/down buttons.

This screen is displayed if there are no warnings recorded, or after the reset button is pressed.

G8000 Series Installation and Operation Manual

13.6 LCD Scroll

Scroll through the LCD display screens (see Figure 13.5), in sequence, using the “SCROLL UP” and “SCROLL DOWN” buttons on the graphic display panel.

• SCROLL UP - Moves back to the previous screen

• SCROLL DOWN - Moves forward to the next screen

TABLE 13.5 DISPLAY SCREEN SCROLL SEQUENCE

UPS SUPPLY FAULTS & WARNINGS

AC-VO 480[V] AC- I O 50[%]

OPERATION MODE CLOCK

NORMAL OPERATION

MODE SYNC.

Abbreveations

AC – Alternating

Current

NO WARNING

TIME 03-24-06 13:58

DC – Direct Current

IO – Current

(The LCD displays a

diagram of the electrical

power ow.)

Output

I/P – Input

O/P – Output

VO – Voltage

MODE COUNT

UPS 35[H] BATTERY 56[MIN] 32[TIM]

Output

O/P VOLTAGE DC INPUT

VOLT. 480[V] FREQ. 60.0[HZ]

DC-V 632[V] BATT-V 400[V] BATT- I 0[A]

NO FAULT

O/P CURRENT (R.M.S.) BATTERY

U 50[%] V 50[%]

W 50[%]

O/P CURRENT (PEAK) AC INPUT

U 50[%] V 50[%]

W 50[%]

AC I/P-V 480[V]

FREQ. 60.0[HZ]

BACK-UP RATING 10[MIN] DISCHARGING 15[MIN]

G8000 Series Installation and Operation Manual

14 Operating the UPS

This section describes the basic procedures to operate the UPS. Figure 14.1 shows the location and functions of the operating switches to operate the UPS.

WARNING

If the UPS produces smoke or smells strange, immediately turn off all AC and DC input circuit breakers.

Continued operation may result in re. Contact Toshiba or Authorized

representatives.

DO NOT turn off the control power supply switch (8A) during UPS operation.

This may result in UPS faults.

FIGURE 14.1 - EPO AND CONTROL POWER SUPPLY OPERATING SWITCHES

G8000 Series Installation and Operation Manual

EPO Switch (Emergency Power Off Switch) See Section 14.9

Control Power Supply Switch

14.1 Operation Types

The operation types are summarized below.

TABLE 14.1 OPERATION TYPES

Operation Description

Complete Shutdown Turn off the control power supply. Shut down the UPS

completely.

Float / Equalize Charge Changing the battery recharge mode between oat charge and

equalize charge.

Protection Charge Automatic recharge mode transition from protection charge to

oat charge.

Startup Starting up and operating the UPS.

Stop Stop the inverter and chopper/charger.

Switch Power Supply Switching power supply source between UPS and Bypass.

14.2 Pre-operational Check

Perform the pre-operational check before operating the UPS.

Before operating the UPS:

1. Make sure all covers/panels are in place and secured.

2. Make sure the temperature in the UPS/Battery room is within specied limits.

3. Before starting the UPS, check the power source to make sure AC input power is on.

4. Make sure battery breaker’s auxiliary A-contact is connected to the terminal block TB1.

CAUTION

G8000 Series Installation and Operation Manual

14.3 Startup Procedures

The procedure to start the UPS is shown in Steps 1-5.

STEP 1

Turn on the control power supply switch. (Figure 14.1) and ensure the operation lock is set to OPERATION. (Figure 13.1 - 1)

AC INPUT

BATTERIES

BYPASS INPUT

STEP 2

Wait for a few seconds.

SYSTEM INITIALIZE

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

BYPASS

PRESS ‘RUN’ SWITCH

INVERTER

LED Key

- LED Off

- LED On

- LED Flash

UPS

SWITCH

BYPASS

AC OUTPUT

STEP 3

Press the “RUN” button for at least 0.5 seconds.

CONVERTER LED is “ON” and INVERTER

LED ashes.

AC INPUT

BATTERIES

BYPASS INPUT

AC INPUT

BATTERIES

BYPASS INPUT

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

BYPASS

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

UPS STARTING

WAIT FOR A WHILE

INVERTER

UPS

SWITCH

BYPASS

UPS

SWITCH

BYPASS

AC OUTPUT

G8000 Series Installation and Operation Manual

Step 4-5 continues the procedure to start the UPS.

LED Key

- LED Off

- LED On

- LED Flash

AC INPUT

BATTERIES

BYPASS INPUT

AC INPUT

BATTERIES

BYPASS

MOVE 72B TO ‘ON’ POSITION

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

SWITCH

BYPASS

UPS SUPPLY

AC - Vo 480 V AC - Io 50%

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

SWITCH

UPS

STEP 4

Turn on the DC Input Breaker (72B) on the external battery cabinet.

BATTERIES LED is “ON”.

AC OUTPUT

STEP 5

*Press the “UPS” button for at least 0.5 seconds. This completes UPS startup procedure

BYPASS LED is “OFF”.

UPS LED is “ON”.

AC OUTPUT

BYPASS INPUT

BYPASS

NOTE

*If the AC switch does not function, contact

Toshiba or authorized representatives.

If the bypass power source is out of

specication, this operation will be inhibited.

In order to switch manually, press the “UPS” button for 5 seconds or more.

G8000 Series Installation and Operation Manual

14.4 Switch Power Supply (UPS to Bypass)

The procedure to transfer between the UPS supply and the bypass supply is shown in Steps 1-3

LED Key

- LED Off

- LED On

- LED Flash

STEP 1

Check AC INPUT LED and BYPASS LED are on to make sure power is being delivered to the UPS.

STEP 2

Press the “BYPASS” button for at least 0.5 seconds.

UPS LED is “OFF”.

BYPASS LED is “ON”.

AC INPUT

BATTERIES

BYPASS INPUT

AC INPUT

BATTERIES

UPS SUPPLY

AC - Vo 480 v

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

BYPASS

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

AC - Io 50%

INVERTER

UPS

SWITCH

BYPASS

UPS

SWITCH

AC OUTPUT

STEP 3

Please wait until procedure is completed.

NOTE

To change from Bypass to UPS supply, follow the Startup Procedures - STEP 5.

If the AC switch does not function, contact Toshiba or authorized representatives.

G8000 Series Installation and Operation Manual

BYPASS INPUT

AC INPUT

BATTERIES

BYPASS INPUT

BYPASS

AC - Vo 480 V

AC - Io 50%

PRESS ‘UPS’ SWITCH

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

BYPASS

UPS

SWITCH

BYPASS

AC OUTPUT

14.5 Stop

The procedure to stop the UPS is shown in Steps 1-3.

LED Key

- LED Off

- LED On

- LED Flash

AC INPUT

BATTERIES

BYPASS INPUT

AC INPUT

BATTERIES

BYPASS INPUT

BYPASS

AC - Vo 480 V AC - Io 50%

PRESS ‘UPS’ SWITCH

UPS

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

SWITCH

BYPASS

MOVE #72B TO ‘OFF’ POSITION

UPS

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

SWITCH

BYPASS

AC OUTPUT

STEP 1

Transfer to Bypass supply as described in Switch Power Supply.

UPS LED is “OFF”.

BYPASS LED is “ON”.

STEP 2

Turn off the DC Input Breaker (72B) on the external battery cabinet, and, press the G8000 “STOP” button for at least 0.5 seconds.

BATTERIES LED is “OFF”.

INVERTER LED ashes then “OFF”.

FLOAT CHARGE LED and CONVERTER LED are “OFF”.

AC INPUT

BATTERIES

BYPASS INPUT

BYPASS

PRESS ‘RUN’ SWITCH

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

UPS

SWITCH

BYPASS

STEP 3

Wait until procedure is completed.

AC OUTPUT

G8000 Series Installation and Operation Manual

14.6 Complete Shutdown

The procedure to turn off the control power and shut down the UPS completely is shown in Steps 1-6.

STEP 1

Transfer to Bypass supply as described in Switch Power Supply.

UPS LED is “OFF”.

BYPASS LED is “ON”.

BYPASS

DC-V 0 [V] BATT-V 0 [V] BATT-I 0 [A]

STEP 2

Turn off the DC input breaker, and, press the “STOP” button for at least 0.5 sec.

BATTERIES LED is “OFF”.

INVERTER LED ashes then “OFF”.

FLOAT CHARGE LED and CONVERTER LED are “OFF”.

STEP 3

Please wait until procedure is completed.

STEP 4

Scroll the LCD screen to see the DC INPUT and make sure DC bus voltage is 0V.

STEP 5

*Turn off the control power supply switch (8A).

Nothing is displayed on the LCD.

All LED’s are “OFF”.

STEP 6

Turn off all breakers at AC Input, Bypass Input, and AC Output.

Shutdown is completed and UPS is isolated.

NOTICE

*STEP 5 - This operation is different from the instructions displayed on the screen.

Be sure to perform the procedure as

specied in this manual.

G8000 Series Installation and Operation Manual

14.7 Changing Between Float Charge and Equalize Charge

The procedure to change the recharge mode between oat charge and equalize charge is shown in Steps

1-3.

See the Note below for an explanation of Float and Equalize charge modes.

LED Key

- LED Off

- LED On

- LED Flash

STEP 1

Make sure that the FLOAT CHARGE LED is “ON”.

AC INPUT

BATTERIES

UPS SUPPLY

AC - Vo 480 V AC - Io 50%

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

UPS

SWITCH

AC OUTPUT

BYPASS INPUT

AC INPUT

BATTERIES

BYPASS INPUT

UPS SUPPLY

AC - Vo 480 V AC - Io 50%

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

BYPASS

UPS

SWITCH

BYPASS

AC OUTPUT

STEP 2

Press FLOAT/EQUAL button for at least 0.5 sec.

Change completed.

EQUAL CHARGE LED is “ON”.

FLOAT CHARGE LED is “OFF”

STEP 3

Please wait until procedure is completed.

NOTE

In equalize charge mode, the battery is charged for a programmed period at a

specied voltage (depending on the battery spec), rather than the oat charge, in order

to prevent voltage deviations among battery cells. This should be done once every six months if possible.

The G8000 UPS will automatically perform the equalize recharge after battery backup operation.

G8000 Series Installation and Operation Manual

14.8 Changing to Float Charge from Protection Charge (If applicable)

The manual procedure to change from protection charge to oat charge is shown in Step 1-3.This operation

applies to batteries after they have experienced over temperature condition.

See the Note below for an explanation of oat charge and protection charge.

LED Key

- LED Off

- LED On

- LED Flash

STEP 1

Make sure that the EQUAL CHARGE LED is “ON”.

STEP 2

Make sure that the “BATT FAULT1” warning goes away.

STEP 3

Press “FLOAT/EQUAL” button for at least 0.5 seconds.

Procedure completed.

NOTE

The battery is normally being charged at oat

charge mode. To prevent thermal runaway of the battery, this mode will automatically be changed to protection charge when a “BATT FAULT1” (Battery over temperature) warning occurs.

In protection charge mode, the battery is automatically charged at a voltage about 5%

lower than oat charge.

If the “BATT FAULT1” warning message goes away and a programmed duration is elapsed (about 24 hours), this mode will automatically

be changed back to oat charge. Thus, it is not

usually required to change the recharge mode

manually back to the oat charge.

AC INPUT

BATTERIES

BYPASS INPUT

AC INPUT

BATTERIES

BYPASS INPUT

UPS SUPPLY

AC - Vo 480 V AC - Io 50%

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

UPS SUPPLY

AC - Vo 480 V AC - Io 50%

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

UPS

SWITCH

BYPASS

UPS

SWITCH

BYPASS

AC OUTPUT

G8000 Series Installation and Operation Manual

14.9 Emergency Power Off (EPO)

Press the EPO switch for immediate shutdown of all power through the UPS. The signal from the EPO is processed as a “hard fault” by the UPS and results in gate-blocks on the transistors and opens all the internal contactors.

To Reset the UPS after triggering the EPO, do the following:

1. Shut Down the UPS as described in section 14.6.

2. Restart the UPS as described in section 14.3.

15 Troubleshooting

When an error occurs in the UPS, error data is displayed on the LCD screen. This section will describe the types of errors, the error messages displayed on the LCD screen and the procedures to correct the errors.

15.1 Types of Errors

The following types of errors may occur in the UPS:

TABLE 15.1 OPERATION TYPES

Name Description

Fault

Warning

Fault (Trip) The UPS has been tripped and has stopped operating.

The UPS is in Bypass mode.

Warning-1 (Input Power Failure) Power is supplied from the battery. When the warning is

corrected, power will automatically be supplied from the AC input.

Warning-2 (Stop and Restart) The UPS transfers to Bypass supply and the UPS stops

operating. When the warning is corrected, the UPS will automatically be restarted and revert to UPS supply.

Warning (Operation Control) An error or a phenomena related to an error occurred.

Since this problem does not directly affect operation, the system switches to synchronized mode.

(Guidance) An error or indication of an error has occurred, but

operation was not affected.

G8000 Series Installation and Operation Manual

15.2 Faults and Warnings Data Screen

This screen appears when a trip error is detected. Up to 10 screens of fault data can be displayed. Figure

15.1 and Table 15.2 show a sample screen and describe the data shown in the screen.

FAULTS & WARNINGS

1 UPS OVERLOAD

09-09-06 08:05:30

↓ANOTHER ITEM

FIGURE 15.1 - SAMPLE FAULT DATA SCREEN

TABLE 15.2 - FAULT AND WARNING DATA SCREEN DESCRIPTIONS

# Name Description

1 Number

2 Message Shows the type of the fault or warning message.

3 Time

4 Scroll Indicator

The number of the message in the order that it was detected (1 - 10). (Up to 10 screens of fault data can be displayed.)

The date (mm-dd-yy) and time (in 24-hour format) the fault was detected.

Indicates whether there is a fault screen before or after this screen.

Indicates there is a fault screen before this screen.

↓ Indicates there is a fault screen after this screen.

↓ Indicates there are fault screens before and after this screen.

G8000 Series Installation and Operation Manual

15.3 LCD Fault & Warning Displays

When a fault occurs, a screen is shown as in Figure 15.2. When a warning occurs, a screen is shown as in Figure 15.3. Select the desired fault or warning data to be displayed using the scroll buttons.

BYPASS

FAULT STOP

FAULTS & WARNINGS

1 FUSE BLOWN

09-09-06 08:05:30

FIGURE 15.2 - FAULT DISPLAY

UPS SUPPLY

AC-VO 480[V]

AC- I O 50[%]

FAULTS & WARNINGS

1 UPS OVERLOAD

09-09-06 08:05:30

FIGURE 15.3 - WARNING DISPLAY

G8000 Series Installation and Operation Manual

15.4 Fault Messages

Figure 15.4 show the locations for fault detection. Tables 15.3 through 15.7 gives details for the fault and warning messages referred to in section “Fault Data Screen.” The “item” code associated with each fault or warning message may be used to determine the physical location of the fault or warning by referring to

Figure 15.4. The UPS unit may be shipped with different protective congurations from the standard shown in Figure 15.4, if specied by the customer. See the protective conguration indicated on the single line

diagram for each UPS.

47S 95S 27S

59S

52R

51I

Inverter

59I 271

83MC1

Battery

83MC

Chopper

30U

5E 80PS 30ST 48

80B1

80B2

95C

76C

26B

71F

59C 47C 27C

FIGURE 15.4 - PROTECTIVE DETECTOR LOCATIONS

TABLE 15.3 - FAULT (TRIP)

83BF

ITEM LCD MESSAGE INDICATION DESCRIPTION

26 OVER HEAT HIGH TEMP IN THE CABINET.

30ST (NO INDICATION) AN ERROR OCCURRED IN THE MAIN CONTROL MICROPROCESSOR (CPU).

48 STARTUP ERR STARTUP WAS NOT COMPLETED WITHIN THE NORMAL TIME FRAME.

5E EMG.STOP AN EMERGENCY STOP WAS ACTIVATED VIA THE EXTERNAL CONTACT.

71F FUSE BLOWN RECTIFIER, DC, OR INVERTER MAIN CIRCUIT FUSE BLOWN.

76 DC OC DC OVER-CURRENT - EXCESSIVE CURRENT IN DC CIRCUIT.

80B2 BATT. UV BATTERY VOLTAGE IS BELOW CUTOFF VOLTAGE.

80PS CONT. PS. ERR THE CONTROL POWER SUPPLY VOLTAGE FAILED.

TABLE 15.4 - WARNING – 1 (CONVERTER STOP/INPUT POWER ERROR)

ITEM LCD MESSAGE INDICATION DESCRIPTION

27S AC I/P UV AC INPUT UNDERVOLTAGE - AC INPUT VOLTAGE IS TOO LOW.

47S AC PHASE ERR AC INPUT PHASE ROTATION ERROR.

59S AC I/P OV AC INPUT OVERVOLTAGE - AC INPUT VOLTAGE IS TOO HIGH.

95S I/P FREQ. ERR AC INPUT FREQUENCY ERROR.

G8000 Series Installation and Operation Manual

TABLE 15.5 - WARNING - 2 (STOP AND RESTART)

Item LCD Message Indication Description

27I

AC O/P UV AC output voltage is low.

30U UNIT FAULT IGBT Stack Failure.

45 DC OV Over-voltage in DC circuit.

49 AC O/P OL Output overload

51I

59I

INV. OC Inverter over-current.

AC O/P OV AC output voltage is high.

76C BATT. OC Over-current in Battery section.

TABLE 15.6 - WARNING (OPERATION CONTROL)

Item LCD Message Indication Description

27C BYPASS UV Bypass input voltage is low.

47C BYPASS ERR. Bypass input phase rotation error.

59C BYPASS OV Bypass input voltage is high.

95C BYPASS ASY. Bypass input frequency error.

TABLE 15.7 - WARNING (GUIDANCE)

Item LCD Message Indication Description

26B BATT. OVER HEAT Battery temperature is too high.

80B1 BATT. UV (ALM) Battery voltage is near cutoff voltage.

G8000 Series Installation and Operation Manual

15.5 LCD Scroll (w/ faults or warnings)

This section describes how to scroll through the LCD screens when a fault has occurred (when Fault Data screens exist).

Figure 15.5 shows the locations of the buttons to scroll the LCD screens. See Table 15.8 for details of the scroll buttons and how they are used for screen scrolling.

FIGURE 15.5 - POSITION OF SCROLL AND RESET BUTTONS

TABLE 15.8 - BUTTON FUNCTIONS

# Name Function

5 SCROLL UP Scrolls to the previous screen.

6 SCROLL DOWN Scrolls to the following screen.

7 RESET

Resets the UPS faults and warnings shown on the LCD and deletes fault history data stored in memory.

G8000 Series Installation and Operation Manual

15.6 Restoring UPS Operation

Contact Toshiba in the event of malfunction or fault.

This UPS should be repaired only by factory authorized personnel. Servicing by untrained personnel may extend the fault or result in electric shock or personal injury.

Do NOT attempt to modify or relocate the UPS.

Electric shock, personal injury or fault may result if unauthorized personnel attempt to modify or relocate the UPS. Be sure to contact toshiba customer service if you need to modify or relocate the UPS.

Do not open the front and/or rear panels.

The parts inside carry energy-high current. Touching them may result in electric shock, burns or fault.

WARNING

The procedure to restore UPS operation is shown in Steps 1-2. The example shows the UPS restored after a trip fault occurred on inverter over current with the message “INV. OC.”

STEP 1

AC INPUT

BATTERIES

BYPASS INPUT

LED Key

- LED Off

- LED On

BYPASS

1 INV. OC

07-15-07 08:05:30 ↓ ANOTHER ITEM

CONVERTER

FLOAT CHARGE

EQUAL CHARGE

DISCHARGE

INVERTER

UPS

SWITCH

BYPASS

AC OUTPUT

Check the LCD screen.

Also check other fault data screens with scroll buttons graphic panel.

STEP 2

Contact Toshiba Customer Support and follow the directions given by the service personnel.

G8000 Series Installation and Operation Manual

16 Periodic Maintenance/Parts Replacement

The G8000 is designed to provide long-term trouble-free power conditioning and backup. Optimum performance can be best maintained by regular, periodic, preventive maintenance.

16.1 Scheduled Maintenance

The G8000 UPS should have scheduled maintenance performed on it annually by a factory-authorized service provider. The preventive maintenance should include at minimum:

• Clean UPS exterior

• Clean UPS interior

• Verify power supply voltages

• Check for loose/overheated connections

• Scan error log and correct potential UPS-related issues

16.2 Parts Replacement

The following list shows the recommended intervals for periodic replacement of certain UPS parts.

• Aluminum electrolytic capacitors: Replace once every 7-10 years.

• Fuses: Replace once every 7-10 years

• Cooling fan: Replace once every 7-10 years

• Batteries (If applicable): See the Backup Battery Cabinet manual for specic test, maintenance and

replacement instructions.

G8000 Series Installation and Operation Manual

Appendix A - Installation Planning Guides

General Mechanical Information

(W x D x H)

Heat Rejection

for Ventilation and Maintenance Access

Inches

Lbs.

Lbs./ft.2Btu/Hr

Top

Front

Bottom

Sides

Back

36.8” x 32.5” x 79.2”

1,740

210

28,321

15.75”

43.5”0”0”

0”

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

Normal Mode (Recharge Mode)

Overcurrent Protection

89(100)

>0.99

107 (120)

150 A

1/0 – (2) x 2/0

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Demand

Overcurrent Protection

Min. – Max. Per Phase // Min. – Max. for Neutral

1.096125 AT

1/0 – (2) x 2/0 // (2) x 1/0 – (2) x 2/0

DC Backup Input (Battery - 360VDC Nom./Flywheel 550VDC Nom.)

DC Capacity for Full

Load Output

Maximum Discharge

at Full Load Output

Suggested External

Overcurrent Protection*

External Feeder Wire Size:

Min. – Max.

Battery88292

300 A

(2) x 1/0 – (2) x 3/0

Flywheel88158

175 A

2/0

AC Output (480/277V 3-Phase / 4-Wire)

Suggested External

Overcurrent Protection

External Feeder Wire Size:

Min. – Max. Per Phase // Min. – Max. for Neutral

1.096125 A

1/0 – (2) x 2/0 // (2) x 1/0 – (2) x 2/0

Important Notes:

80kVA IPG

Dimensions

kVA PF Amps A mps AWG or kcmil at 75º C Temp. Rating

Maximum Input Power

kVA PF Amps Amp s AWG or kcmil at 75º C Temp. Rating

Backup System

TOSHIBA G8000 Series UPS

Installation Planning Guide for 80kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx)

Weight

Maximum Input Power Demand

Suggested External

kWB Amps DC Amps AWG or kcmil at 75º C Temp. Rating

Floor

Approximate Full-Load

Suggested External

Mechanical Clearance (Inches)from UPS

External Feeder Wire Size: Min. – Max. Per Phase

External Feeder Wire Size:

* If required. Most Battery and Flywheel Cabinets are equipped with built-in breakers.

Rated Output Power

kVA PF Amps Amps AWG or kcmil at 75º C Temp. Rating

1. CABLE ACCESS – Bottom only.

2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current.

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

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

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

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

7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15.

- Primary AC Input: 3φ, 3-wire + ground.

- Alternate AC Input: 3φ, 4-wire + ground.

- AC Output: 3φ, 4-wire + ground.

- DC Input: 2-wire (Positive/Negative) + ground.

8. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal).

9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC.

10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current.

11. Weights do not include batteries or other auxiliary equipment external to the UPS.

12. 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.

- Neutral sized for 2X phase current.

- Not m ore than 3 current-carrying conductors installed in

conduit in ambient temperature of 30 °C.

- Temperature rating of copper conductors/terminals: 75 °C.

- Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONALCORPORATION

13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

G8000 Series Installation and Operation Manual

Rev. 2.2 Page 1 of 3 G8000-IPG-80kVA

TOSHIBA G8000 Series UPS

Top

Front

Right Side

Bottom Access Only

Installation Planning Guide for 80kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx)

Power Terminals: Two 2/0 AWG max. per terminal

G8000 80KVA OUTLINE DRAWING

G8000 80kVA UPS Cabling Connection Dimensions

Rev. 2.2 Page 2 of 3 G8000-IPG-80kVA

G8000 Series Installation and Operation Manual

TOSHIBA G8000 Series UPS

Installation Planning Guide for 80kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx)

Anchorage pattern:

Install anchor bolts to secure the UPS to the floor.

Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 80kVA UPS

Rev. 2.2 Page 3 of 3 G8000-IPG-80kVA

G8000 Series Installation and Operation Manual

General Mechanical Information

Dimensions

Floor

Approximate Full-Load

Mechanical Clearance (Inches)from UPS

Inches

Lbs.

Lbs./ft.2Btu/Hr

Top

Front

Bottom

Sides

Back

36.8” x 32.5” x 79.2”

1,740

210

33,746

15.75”

43.5”0”0”

0”

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

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External

Overcurrent Protection

110 (122)

>0.99

134 (147)

200 AT

(2) x #3 – (2) x 2/0

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Maximum Input Power

Demand

Suggested External

Overcurrent Protection

External Feeder Wire Size:

Min. – Max. Per Phase // Min. – Max. for Neutral

100

1.0

120

150 AT

(2) x #3 – (2) x 2/0 // (2) 2/0

DC Backup Input (Battery - 360VDC Nominal)

DC Capacity for Full

Maximum Discharge

Suggested External

External Feeder Wire Size:

Battery

108

359

350 A

(2) x 3/0 – (2) x 4/0

AC Output (480/277V 3-Phase / 4-Wire)

Suggested External

External Feeder Wire Size:

100

1.0

120

150 AT

(2) x #3 – (2) x 2/0 // (2) 2/0

100kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 100kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx)

(W x D x H)

kVA PF Amps A mps AWG or kcmil at 75º C Temp. Rating

kVA PF Amps Amp s AWG or kcmil at 75º C Temp. Rating

Backup System

* If required. Most Battery Cabinets are equipped with built-in breakers.

Rated Output Power

kVA PF Amps Amps AWG or kcmil at 75º C Temp. Rating

Weight

Load Output

kWB Amps DC A mps AWG or kcmil at 75º C Temp. Rating

at Full Load Output

Overcurrent Protection

Heat Rejection

Overcurrent Protection*

for Ventilation and Maintenance Access

External Feeder Wire Size: Min. – Max. Per Phase

Min. – Max.

Min. – Max. Per Phase // Min. – Max. for Neutral

Important Notes:

1. CABLE ACCESS – Bottom only.

2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current.

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

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

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

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

7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15.

- Primary AC Input: 3φ, 3-wire + ground.

- Alternate AC Input: 3φ, 4-wire + ground.

- AC Output: 3φ, 4-wire + ground.

- DC Input: 2-wire (Positive/Negative) + ground.

8. Nominal battery voltage based on the use of VRLA type

batteries (2.0 volts/cell nominal).

9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC.

10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current.

11. Weights do not include batteries or other auxiliary equipment external to the UPS.

12. 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.

- Neutral sized for 2X phase current.

- Not m ore than 3 current-carrying conductors installed in

conduit in ambient temperature of 30 °C.

- Temperature rating of copper conductors/terminals: 75 °C.

- Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONALCORPORATION

13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Rev. 2.2 Page 1 of 3 G8000-IPG-100kVA

G8000 Series Installation and Operation Manual

TOSHIBA G8000 Series UPS

Top

Front

Right Side

Bottom Access Only

Installation Planning Guide for 100kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx)

Power Terminals: Two 2/0 AWG max. per terminal

G8000 100kVA UPS Cabling Connection Dimensions

Rev. 2.2 Page 2 of 3 G8000-IPG-100kVA

G8000 100KVA OUTLINE DRAWING

G8000 Series Installation and Operation Manual

TOSHIBA G8000 Series UPS

Installation Planning Guide for 100kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx)

Anchorage pattern:

Install anchor bolts to secure the UPS to the floor.

Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 100kVA UPS

Rev. 2.2 Page 3 of 3 G8000-IPG-100kVA

G8000 Series Installation and Operation Manual

General Mechanical Information

(W x D x H)

Heat Rejection

for Ventilation and Maintenance Access

Inches

Lbs.

Lbs./ft.2Btu/Hr

Top

Front

Bottom

Sides

Back

36.8” x 32.5” x 79.2”

1,740

210

33,746

15.75”

43.5”0”0”

0”

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

Maximum Input Power Demand

Suggested External

112 (123)

>0.99

135 (148)

200 AT

(2) x #3 – (2) x 2/0

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Maximum Input Power

Suggested External

External Feeder Wire Size:

125

0.8

150

200 AT

(2) x #1 – (2) x 2/0 // (2) 2/0

DC Backup Input (Battery - 360VDC Nominal)

Load Output

at Full Load Output

Overcurrent Protection*

Min. – Max.

Battery

110

365

400 A

(2) x 3/0 – (2) x 4 /0

AC Output (480/277V 3-Phase / 4-Wire)

Suggested External

External Feeder Wire Size:

125

0.8

150

200 AT

(2) x #1 – (2) x 2/0 // (2) 2/0

125kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 125kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx)

Dimensions

Normal Mode (Recharge Mode)

kVA PF Amps Amp s AWG or kcmil at 75º C Temp. Rating

Demand

kVA PF Amps Amp s AWG or kcmil at 75º C Temp. Rating

Backup System

* If required. Most Battery Cabinets are equipped with built-in breakers.

Rated Output Power

kVA PF Amps A mps AWG or kcmil at 75º C Temp. Rating

DC Capacity for Full

Weight

kWB Amps DC Amps AWG or kcmil at 75º C Temp. Rating

Floor

Overcurrent Protection

Maximum Discharge

Overcurrent Protection

Approximate Full-Load

Overcurrent Protection

Mechanical Clearance (Inches)from UPS

External Feeder Wire Size: Min. – Max. Per Phase

Min. – Max. Per Phase // Min. – Max. for Neutral

Suggested External

Min. – Max. Per Phase // Min. – Max. for Neutral

External Feeder Wire Size:

Important Notes:

1. CABLE ACCESS – Bottom only.

2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current.

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

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

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

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

7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15.

- Primary AC Input: 3φ, 3-wire + ground.

- Alternate AC Input: 3φ, 4-wire + ground.

- AC Output: 3φ, 4-wire + ground.

- DC Input: 2-wire (Positive/Negative) + ground.

8. Nominal battery voltage based on the use of VRLA type

batteries (2.0 volts/cell nominal).

9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC.

10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current.

11. Weights do not include batteries or other auxiliary equipment external to the UPS.

12. 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.

- Neutral sized for 2X phase current.

- Not m ore than 3 current-carrying conductors installed in

conduit in ambient temperature of 30 °C.

- Temperature rating of copper conductors/terminals: 75 °C.

- Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONALCORPORATION

13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

G8000 Series Installation and Operation Manual

Rev. 0 Page 1 of 3 G8000-IPG-125kVA 0.8PF

TOSHIBA G8000 Series UPS

Top

Front

Bottom Access Only

Installation Planning Guide for 125kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx)

Right Side

Power Terminals: Two 2/0 AWG max. per terminal

G8000 100kVA UPS Cabling Connection Dimensions

G8000 125KVA OUTLINE DRAWING

Rev. 0 Page 2 of 3 G8000-IPG-125kVA 0.8PF

G8000 Series Installation and Operation Manual

TOSHIBA G8000 Series UPS

Installation Planning Guide for 125kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx)

Anchorage pattern:

Install anchor bolts to secure the UPS to the floor.

Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 100kVA UPS

Rev. 0 Page 3 of 3 G8000-IPG-125kVA 0.8PF

G8000 Series Installation and Operation Manual

General Mechanical Information

Dimensions

Floor

Approximate Full-Load

Mechanical Clearance (Inches)from UPS

Inches

Lbs.

Lbs./ft.2Btu/Hr

Top

Front

Bottom

Sides

Back

55.1” x 31.8” x 79.2”

2,467

203

38,754

15.75”

43.5”0”0”

0”

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

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External

Overcurrent Protection

167 (183)

>0.99

196 (209)

300 AT

300 kcmil - (2) x #1

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Maximum Input Power

Suggested External

External Feeder Wire Size:

150

1.0

180

250 AT

300 kcmil - (2) x #1 // (2) x 300 kcmil - (4) x #1

DC Backup Input (Battery - 360VDC Nom./Flywheel 550VDC Nom.)

Load Output

at Full Load Output

Overcurrent Protection*

Min. – Max.

Battery

160

533

600 A

(2) x 300 kcmil – (2) x 350 kcmil

AC Output (480/277V 3-Phase / 4-Wire)

Overcurrent Protection

Min. – Max. Per Phase // Min. – Max. for Neutral

150

1.0

180

225 AT

300 kcmil - (2) x #1 // (2) x 300 kcmil - (4) x #1

Important Notes:

150kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 150kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx)

(W x D x H)

kVA PF Amps A mps AWG or kcmil at 75º C Temp. Rating

Demand

kVA PF Amps Amp s AWG or kcmil at 75º C Temp. Rating

Backup System

* If required. Most Battery and Flywheel Cabinets are equipped with built-in breakers.

Rated Output Power

kVA PF Amps Amps AWG or kcmil at 75º C Temp. Rating

1. CABLE ACCESS – Top and Bottom.

2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current.

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

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

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

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

7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15.

- Primary AC Input: 3φ, 3-wire + ground.

- Alternate AC Input: 3φ, 4-wire + ground.

- AC Output: 3φ, 4-wire + ground.

- DC Input: 2-wire (Positive/Negative) + ground.

8. Nominal battery voltage based on the use of VRLA type

batteries (2.0 volts/cell nominal).

9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC.

10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current.

11. Weights do not include batteries or other auxiliary

equipment external to the UPS.

DC Capacity for Full

Weight

kWB Amps DC A mps AWG or kcmil at 75º C Temp. Rating

Overcurrent Protection

Maximum Discharge

Suggested External

Heat Rejection

Min. – Max. Per Phase // Min. – Max. for Neutral

Suggested External

12. 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.

- Neutral sized for 2X phase current.

- Not m ore than 3 current-carrying conductors installed in

conduit in ambient temperature of 30 °C.

- Temperature rating of copper conductors/terminals: 75 °C.

- Reference: 2005 NEC Handbook, Table 310.16.

for Ventilation and Maintenance Access

External Feeder Wire Size: Min. – Max. Per Phase

External Feeder Wire Size:

NOTE: Consult latest edition of applicable national and local codes for possible variations.

13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

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13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Rev. 2.2 Page 1 of 3 G8000-IPG-150kVA

G8000 Series Installation and Operation Manual

TOSHIBA G8000 Series UPS

Top

Front

Right Side

Top/Bottom Access

Installation Planning Guide for 150kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx)

G8000 150kVA UPS Cabling Connection Dimensions

Rev. 2.2 Page 2 of 3 G8000-IPG-150kVA

G8000 Series Installation and Operation Manual

G8000 150KVA OUTLINE DRAWING

TOSHIBA G8000 Series UPS

Installation Planning Guide for 150kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx)

Anchorage pattern:

Install anchor bolts to secure the UPS to the floor.

Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 150kVA UPS

Rev. 2.2 Page 3 of 3 G8000-IPG-150kVA

G8000 Series Installation and Operation Manual

Toshiba 100, 125, 225, 300, 480 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 Introduction

2 General Safety Instructions

2.1 Symbols

2.2 Signal Words

2.4 Factory Authorized Personnel

3 Important Safety Instructions

4 Safety Precautions

4.1 Disclaimer

4.2 General Maintenance

4.3 Transporting/Unpacking

4.4 Inspection/Storage

5 Installation Precautions

5.1 Wiring/Connection

6 Warning Labels

6.1 Warning Label Locations

7 Weight and Dimensions

8 Transporting

8.1 Transporting By Crane

8.2 Transporting By Forklift

9 Storage/Operating Environment

9.1 Operating Precautions

9.2 Maintenance Precautions

9.3 Disposal

10 Installation

10.1 Unpacking

10.2 UPS Clearance

10.3 Anchor Bolts

11 UPS Wiring

11.1 80/100/125 kVA Terminal Blocks and Power Cables

11.2 150, 225, 300, and 500 kVA Buss Strip Terminals and Power Cables

11.3 UPS Power Cable Conduit Landing Plates

11.4 External Breakers

11.5 Grounding Wire

11.6 Control Wires

13 Operator Interface

13.1 Key-Switch and Buttons

13.2 LCD/LED Indicators

13.3 LCD Indicators

13.4 Normal Display

13.5 Fault Display

13.6 LCD Scroll

14 Operating the UPS

14.1 Operation Types

14.2 Pre-operational Check

14.3 Startup Procedures

14.4 Switch Power Supply (UPS to Bypass)

14.5 Stop

14.6 Complete Shutdown

14.7 Changing Between Float Charge and Equalize Charge

14.8 Changing to Float Charge from Protection Charge (If applicable)

14.9 Emergency Power Off (EPO)

15 Troubleshooting

15.1 Types of Errors

15.2 Faults and Warnings Data Screen

15.3 LCD Fault & Warning Displays

15.4 Fault Messages

15.5 LCD Scroll (w/ faults or warnings)

15.6 Restoring UPS Operation

16 Periodic Maintenance/Parts Replacement

16.1 Scheduled Maintenance

16.2 Parts Replacement

Appendix A - Installation Planning Guides

80kVA IPG

100kVA IPG

125kVA IPG

150kVA IPG