Toshiba 1500 Plus User Manual

TOSHIBA

UNINTERRUPTIBLE POWER SYSTEM

SINGLE PHASE - .6/.8/1.0 kVA 220V

1500 1500

1500 and 1500 PLUS SERIES

1500 1500

MANUFACTURED IN THE U.S.A.

OPERATION MANUAL

August, 1998
Part # 48449-000

TOSHIBA

TOSHIBA

NOTE

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
to be met in connection with installation, operation, or maintenance. Should further
information be desired or should particular problems arise which are not covered
sufficiently for the purchaser's purposes, the matter should be referred to the local
Toshiba sales office.

The contents of this instruction manual shall not become a part of or modify any
prior or existing 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 modifications to this equipment,
without prior written consent of Toshiba International
Corporation, will void all warranties and may void UL listing
or other safety certification. Unauthorized modifications also
can result in personal injury, death, or destruction of the
equipment.

UNINTERRUPTIBLE POWER SUPPLY

Please complete the Extended Warranty Card supplied with this UPS and return
it by prepaid mail to Toshiba. This activates the extended warranty. If additional
information or technical assistance is required call Toshiba's marketing department toll
free at [phone] or write to: Toshiba International Corporation,
13131 W. Little York Road, Houston, TX 77041-9990.

Please complete the following information for your records and to remain within this
equipment manual:

Model Number:
Serial Number:
Date of Installation:
Inspected By:

i

TOSHIBA

CONTENTS

SECTION PAGE

Disclaimer ..................................................................................................i

Contents .................................................................................................. ii-iii

Introduction...............................................................................................iv

General Safety Instructions..................................................................... v

Important Safety Instructions............................................................... vi-vii

1.0 Product Description ................................................................................1-1

1.1 Theory of Operation........................................................................1-1

1.2 Application and Use........................................................................1-1

1.3 Power Backup.................................................................................1-1

1.4 Power Conditioning.........................................................................1-1

2.0 Inspection/Storage/Disposal ..................................................................2-1

2.1 Inspection of the new UPS equipment............................................2-1

2.2 Storage of UPS equipment .............................................................2-1

2.3 Disposal..........................................................................................2-1

3.0 Precautions..............................................................................................3-1

3.1 Installation Precautions (General) ..................................................3-1

3.2 Prestart Precautions ....................................................................... 3-2

3.3 Operating Precautions ....................................................................3-2

4.0 Specifications .......................................................................................... 4-1

4.1 Standard Series Specifications.......................................................4-1

4.2 Plus Series Specifications...............................................................4-2

5.0 Operating the UPS ..................................................................................5-1

5.1 Operation Modes ............................................................................ 5-1

5.1.1 AC Input Mode (normal operation).........................................5-1

5.1.2 Battery Backup Mode ............................................................5-1

5.1.3 Circuit Bypass Mode..............................................................5-2

5.2 System Protection Features ...........................................................5-2

ii

TOSHIBA

CONTENTS (Cont'd)

SECTION PAGE

5.0 Operating the UPS (cont'd).....................................................................5-1

5.3 Operation Monitoring ...................................................................... 5-3

5.3.1 Visual Indicator Functions......................................................5-3

5.3.2 Audible Alarm Functions ........................................................5-3

5.3.3 Visual and Audible Indicator Function Chart ..........................5-3

5.4 Front Panel Layout .........................................................................5-4

5.5 UPS On Line Mode Display ............................................................5-4

5.6 Battery Recharging ......................................................................... 5-5

5.7 Battery Backup Time.......................................................................5-6

5.8 Battery Low Voltage Tolerances .....................................................5-6

5.9 Battery Check Function ..................................................................5-6

5.10 System Reset .................................................................................5-6

6.0 UPS Control Interface .............................................................................6-1

6.1 DB25 Connector Pinout ..................................................................6-1

6.2 RS-232C Communication Interface ................................................6-2

6.2.1 UPS Shutdown (via RS-232C)...............................................6-2

6.3 Dry Contact Interface......................................................................6-2

7.0 Troubleshooting Procedures.................................................................. 7-1

7.1 Non-Fatal Fault Mode .....................................................................7-1

7.2 Fatal Fault Mode.............................................................................7-2

8.0 Preventive Maintenance/Parts Replacement ........................................8-1

8.1 Preventive Maintenance .................................................................8-1

8.2 Parts Replacement .........................................................................8-1

8.3 Fuse Rating Chart...........................................................................8-2

9.0 External Dimensions/Panel Layout/Shipping Weights ......................... 9-1

9.1 External Dimensions.......................................................................9-1

9.2 Panel Layout .................................................................................. 9-2

9.3 Shipping Weights............................................................................ 9-2

iii

TOSHIBA

Thank you for purchasing the 1500/1500 Plus Series UPS. This Series features the very
latest state of the art microprocessor technology and also uses IGBT transistors for fast, high
power and low noise PWM (pulse width modulation) switching. Also, the Plus Series f eatures a
low impedance transformer to provide isolation even during bypass operation.

INTRODUCTION

It is the intent of this manual to provide a guide for
the UPS. This operation manual contains a section of general safety instructions and is marked
throughout with warning symbols.
and operation of this electrical equipment.

Read this operation manual

All safety warnings must be followed
Follow all precautions

to attain proper equipment performance and longevity.

safely

to ensure personal safety.

installing, operating, and maintaining

thoroughly before installation

General safety instructions are found on page v and important safety
instructions are found on pages vi, vii, and viii. Read and save these instructions
for future reference.

The manual is divided into major sections of interest. Section 1 contains the product description
with the theory of operation and applications. All of the initial inspection, stor age , installation,
operating, and prestart precautions can be found in Sections 2 and 3.

Section 4 contains the equipment standard specifications.
Section 5 outlines the operating modes, protective features, battery recharging, battery low

voltage tolerances, alarm and panel indicator functions.
Section 6 shows the control interface pin configurations.
Sections 7 and 8 are devoted to troubleshooting procedures, preventative maintenance

techniques and periodic parts replacement. A fuse rating chart is also shown.
Section 9 shows front, rear , and side panel layout views with dimensional data. Labels,

connector and switch placement, and shipping weights are also shown.
We hope that you find this oper ation manual informative and easy to use. If additional information

or technical assistance is needed, please call toll free [phone] or write to: Toshiba
International Corporation, 13131 W . Little York Road, Houston, TX 77041-9990.

Again, thank you for the purchase of this product.

TOSHIBA INTERNATIONAL CORPORATION

© Copyright 1994

iv

GENERAL SAFETY INSTRUCTIONS

TOSHIBA

Warnings

in this manual appear in any of four ways:

1)

Danger

the 3/16" high letters spelling the word "DANGER". The danger symbol is used to indicate
imminently hazardous situations, locations, and conditions which, if not avoided, WILL
result in death, serious injury , and/or se v ere property damage.

- The danger symbol is a lightning bolt mark enclosed in a triangle which precedes

DANGER

2)

Warning

precedes the 3/16" high letters spelling the word "W ARNING". The warning symbol is
used to indicate potentially hazardous situations and conditions which, if not avoided
COULD result in serious injury or death. Severe property damage COULD also occur.

- The w arning symbol is an exclamation mark enclosed in a triangle which

WARNING

3)

Caution

precedes the 3/16" high letters spelling the word "CA UTION". The caution symbol is used
to indicate potentially hazardous situations and conditions which, if not avoided may result
in injury. Equipment damage may also occur.

- The caution symbol is an exclamation mark enclosed in a triangle which

CAUTION

4)

Attention warnings

triangle which precedes the 3/16" high letters spelling the word "ATTENTION". The
Attention warning symbol is used to indicate situations and conditions that can cause
operator injury and/or equipment damage:

- The attention w arning symbol is an exclamation mark enclosed in a

ATTENTION

Other warning symbols may appear along with the
special hazards. These warnings describe particular areas where special care and/or procedures are
required in order to prevent serious injury and possible death:

1)

2)

Electrical warnings

a triangle. The Electrical warning symbol is used to indicate high voltage locations and
conditions that may cause serious injury or death if the proper precautions are not
observed:

Explosion warnings

a triangle. The Explosion warning symbol is used to indicate locations and conditions
where molten, exploding parts may cause serious injury or death if the proper
precautions are not observed:

- The electrical warning symbol is a lighting bolt mark enclosed in

- The explosion warning symbol is an explosion mark enclosed in

Danger

and

Caution

symbol and are used to specify

v

TOSHIBA

IMPORTANT SAFETY INSTRUCTIONS

SA VE THESE INSTRUCTIONS- This manual contains impor tant instr uctions

that should be followed during the installation and maintenance of the UPS and it's batteries. Use for
models UE1E1E006-5M, UE1E1E008-5M, UE1E1E010-5M.

- The maximum ambient temperature in which this UPS unit should be operated or stored is
104 °F (40 °C).

- The nominal battery voltage range is indicated in Section 5.6.

- Servicing of the batteries should only be performed by a qualified Toshiba Representative who is
knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from

batteries.

- When replacing batteries, use the same number and type of one of the following sealed, lead-acid
batteries (do not mix types of batteries):

Model Capacity Manufacturer T ype Quantity

600 VA
800 VA

1000 VA

CAUTION

either indirect or consequential damage or injury that may result from the use of this equipment.

Misuse of this equipment could result in human injury and equipment
damage. In no event will Toshiba Corporation be responsible or liable for

CAUTION

CAUTION

WARNING

flame. Annual preventative maintenance must be performed by an authorized, tr ained technician.

Do not open or mutilate the batteries. Released electrolyte is harmful
to the eyes and skin and could also be toxic.

This unit contains sealed lead acid batteries. Lack of preventative
maintenance could result in batteries exploding and emitting gasses and/or

Y uasa NPH5-12FR 5

Yuasa HPH5-12FR 5

Do not dispose of the batteries in a fire. The batteries may explode.

Failure to replace a battery before it becomes exhausted may cause the

WARNING

resulting in secondary faults such as odor, smoke, and fire.

case to crack, possibly releasing electrolytes from inside the battery, and

vi

IMPORTANT SAFETY INSTRUCTIONS

TOSHIBA

W ARNING

unauthorized personnel away from the batteries.

W ARNING

your UPS system. Refer to service manual.

DANGER

when working with batteries:

1) Verify that the UPS is off and that the power cord is disconnected from the power source.

2) Remove watches, rings or other metal objects.

3) Use tools with insulated handles to prevent inadvertent shorts.

4) Wear rubber gloves and boots .

5) Do not lay tools or metal parts on top of batteries.

6) Determine if the battery is inadvertently grounded. If inadvertently grounded, remove
source of ground.

electrical shock.

removed during installation and maintenance.

7) V erify circuit polarities prior to making connections.

8) Disconnect charging source and load prior to connecting or disconnecting terminals.

9) VRLA batteries contain an explosive mixture of hydrogen gas. Do not smoke, cause a flame
or spark in the immediate area of the batteries. This includes static electricity from the body.

10) Do not attempt to open the batteries in order to add water or sample the specific gravity of the
electrolyte. The batteries are valve regulated lead acid type and such servicing is not
possible without damaging the battery .

11 ) Use proper lifting means when moving batteries and wear all appropriate safety clothing and

equipment.

12) Do not dispose of lead acid batteries except through channels in accordance with local, state
and federal regulations.

Installation and servicing of batteries should be performed by personnel
knowledgeable of batteries and the required precautions. Keep

Proper maintenance to the battery system of this unit must be done by a
qualified service technician, this is essential to the safety and reliability of

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

Contact with any part of a grounded battery can result in

The likelihood of such shock will be reduced if such grounds are

The following precautions should be observed

vii

TOSHIBA

INSTRUCTIONS IMPORTANTES CONCERNANT

LA SÉCURITÉ

CONSERVER CES INSTRUCTIONS

Une battery peut présenter un risque de choc électrique, de brûlure par

ATTENTION

ATTENTION

Model Capacity Manufacturer Type Quantity

600 VA
800 VA

1000 VA

transfert d' énergie.

Pour le remplacement, utiliser le même nombre de batteries du modéle
suivant.

Y uasa NPH5-12FR 5

Yuasa NPH5-12FR 5

Cette notice contient des
instructions importantes concernant
la sécurité.

ATTENTION

L' élimination des batteries est règlementèe. Consulter les codes locaux
à cet effet.

© Copyright 1994

viii

1.0 Product Description

1.1 Theory of Operation

An uninterruptible power supply is a system that is installed between the commercial
power and the load equipment. It is used during short-term black outs or brownouts. The
UPS provides steady ac output power during these commercial power interruptions.
This power is provided for a long enough time so that the load can be shutdown in an
orderly fashion. This prevents loss of data and possible damage to both hardware and
software.

During normal operation the UPS uses commercial ac power. In addition, it also takes
in all of the high voltage spikes and transients caused by switching and faults, and all
of the common mode and normal mode noise which is associated with commercial ac
power. The UPS converts it all to flat dc power. From this dc power, the UPS charges
its batteries and generates its own extremely high quality ac waveform output. The
result of this process is maximum power conditioning.

If the ac power supplied to the UPS drops below a specified voltage level, the unit's
batteries automatically begin supplying power instead of receiving it. This insures that
the loads connected to the UPS continue to receive power with no interruption. When
ac input power becomes available again, operation returns to normal. The unit's
batteries begin to recharge so they will be ready for the next power interruption.

TOSHIBA

1.2 Application and Use

Toshiba's 1500 and 1500 Plus Series of on-line uninterruptible power supply (UPS)
systems provide continuous computer-grade ac power in a compact, high performance,
and energy efficient unit. The UPS unit assures safe and reliable operation of critical
office equipment. This can range from word processors and personal computers to
mini-computers and local area networks. All units f eature an audib le alarm which sounds
if the battery voltage drops below standard during use. This is an additional aid to help
in retaining the valuable office data banks. All units allow for computer interf acing and
an external battery pack option (see specifications).

1.3 Power Backup

When an electrical power failure occurs, the UPS unit's internal maintenance-free
batteries automatically supply back-up power to the load without interruption. For
example, when used to support a computer, the UPS back-up assures enough
additional time to complete the activity and store data. This allows an orderly shutdown
after a power failure has occurred.

1.4 Power Conditioning

When commercial power is present, the UPS supplies conditioned power to the load
while maintaining its batteries in a charged condition. The UPS protects against the
normal everyday problems associated with hea vy use of raw commercial ac power ,
including power sags, surges, signal interference, and spikes. This protection keeps
power-line problems from reaching the loads where they can cause equipment to
operate erratically, hard-disk crashes, or cause damage to hardware and software.

1 - 1

TOSHIBA

2.0 Inspection/Storage/Disposal

2.1 Inspection of the new UPS equipment

Upon receipt of the UPS, a careful inspection for shipping damage should be made.

After Uncrating:

1) Check the unit for loose, broken, bent or otherwise damaged parts. If damage
has occurred during shipment, keep all original crating and packing materials
for return to shipping agent. Warranty will not apply to units which are damaged
during shipment.

2) Check to see that the rated capacity and the model number specified on the
nameplate conform to the order specifications.

2.2 Storage of UPS equipment.

If the UPS equipment is to be subject to long or short term storage the following
guidelines should be used.

Av oid:

1) Storage in sites subject to extreme changes in temperature or high humidity.

2) Storage in sites subject to exposure of high levels of dust or metal particles

3) Storage on inclined floor surfaces or in sites subject to excessive vibration.

Before storing:

1) Charge the units batteries.

2) Place the STOP/RUN switch in the STOP position.

Storing:

1) Store within a temperature range of -20° to 40° C (-4° to 104° F).

2) For best results, store the UPS in the original shipping container and place on a

3) The optimum storage temperature is 21° C (70° F). Higher ambient

After storing:

1) If stored in an ambient temperature under 20° C (68° F); recharge the batteries

2) If stored in an ambient temperature of 20° to 30° C (68° to 86° F); recharge the

3) If stored in an ambient temperature of 30° to 40° C (86° to 104° F); recharge the

2.3 Disposal

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

wood or metal pallet.

temperatures cause UPS batteries to need recharging more frequently.

every 9 months.

batteries every 6 months.

batteries every 3 months.

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

Please help our Earth by contacting the environmental protection agencies in your area,
the battery manufacturer , or call Toshiba toll-free at [phone] for more inf ormation
about recycling.

2 - 1

3.0 Precautions

3.1 Installation Precautions (General)

1) Install the unit in a well ventilated location; allow at least 10 cm (4 inches) on

2) Install the unit in a stable, level, and upright position which is free of vibration.

3) Install the unit where the ambient temperature is within the correct operating

4) Do not install the UPS in areas that are subject to high humidity.

5) Do not allow direct sunlight to shine on the unit.

6) Do not install the UPS in areas which are subject to contamination such as

7) Av oid installation near sources of electrical noise and alw ays make sure that

TOSHIBA

CAUTION

all sides for air ventilation and for maintenance.

range (see Specifications Section 4.0).

high levels of airborne dust, metal particles, or inflammable gas.

the unit ground is intact to prevent electrical shock and to help reduce
electrical noise.

8) Do not install where water or any foreign object may get inside the UPS.

9) This UPS generates and can radiate radio-frequency energy during operation.
Although RFI noise filters are installed inside the unit, there is no guarantee
that the UPS will not influence some sensitive devices which are operating
close by. If such interference is experienced, the UPS should be installed farther
away from the affected equipment and/or powered from a different source than
that of the affected equipment.

3 - 1

TOSHIBA

3.0 Precautions

3.2 Prestart Precautions

1) Before connecting the UPS to a power source; move the operation switch

CAUTION

(STOP/RUN), on the front panel (See sections 9.1), to the STOP position.

3.3 Operating Precautions

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

2) The input power source voltage and frequency must be within the specified
ranges (See Specification sections 4.1 and 4.2). Voltages and frequencies
outside of the permissible tolerance ranges may cause internal protection
devices to activate.

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

4) Do not use the UPS to provide power to motors that require high starting current
or a long starting time such as vacuum cleaners and machine tools (oversizing
for lock rotor current required).

5) Do not insert metal objects or combustible materials in the unit's ventilation slots.

6) Do not place, hang, or paste any objects on the top or on the exterior surfaces
of the UPS.

7) Always use caution when connecting or disconnecting load equipment.

The UPS may be supplying power to the output load receptacles
through the bypass circuit.

switch is in the STOP position and the unit is connected to a source of
supply power (see Circuit-bypass Mode section 5.1.3).

CAUTION

This can occur when the STOP/RUN

3 - 2

4.0 Specifications

4.1 Standard Series Specifications

MODEL NUMBER UE1E1E008-5M UE1E1E010-5M

CAPACITY 800 VA (0.56 kW) 1000 VA (0.7 kW)

Input Input voltage Single phase, 220 Vac, +10% to -30% (*)

Input frequency 45 to 65 Hz

Input capacity 800 VA 1000 VA

Input power factor Approximate unity (0.95 to 1.0)

Battery Battery rated voltage 60 Vdc

Battery backup time when fully charged
with 0.7 power factor at 77° F (25° C)

Recharge time Maximum 24 hrs to 100% (90% recharge after 8 hrs) (***)

Type of batteries Sealed lead-acid

Output Output voltage Single-phase, 220 volts

Output voltage regulation Within +/- 3%, steady state

Output frequency 50/60 Hz +/- 0.5% in free-running mode (line sync range +/- 1Hz)

Output voltage waveform Computer-grade sine wave with less than 3.0% total harmonic

Rated load power factor 0.7 lagging (0.6 to 1.0)

Voltage transient characteristic +/- 8% under 100% load step change

Rated output current (rms) 3.6A 4.5A

8 min. at full load (**) 7 min. at full load (**)

20 min. at half load (**) 18 min. at half load (**)

distortion with linear load

TOSHIBA

Maximum output current (peak) 10.8A 13.5A

Inverter overload capacity 150% for 30 seconds

Crest factor 3.0

Environment Operating temperature 32 to 104° F (0 to 40° C), optimal at 77° F (25° C)

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

Operating humidity 30 to 90%, no condensation

Altitude(****) Less than 3000 ft (1000 m) above sea level

External dimensions 8.00W x 20.38D x 10.00H in (203W x 518D x 254H mm)

Net weight 58.8 lb (26.7 kg) 60.7 lb (27.5 kg)

Acoustical noise 50 dB at max. output, measured 3.3 ft (1 m) from front panel

Efficiency (ac-dc-ac) 85% 87%

Switches Bypass switch Automatic bypass is provided when the run switch is in the stop

position, if a fault occurs, or if an overload occurs (transfer time is
approximately 4 msec)

Interfaces IBM

Fault detect and input power loss

Options Software for unattended

External battery pack Contact Toshiba for details on this option

(TM)

AS/400

LAN Manager See section 6.0 for details.

RS232 ASCII

computer shutdown Contact Toshiba for details on this option

(*) Output capacity reduced when input voltage is between -15% and -30% of nominal.
(**) Battery backup time may vary depending on the operating conditions including ambient temperature at the
installation site.
(***) An initial charge time of 24 hrs. is necessary to obtain proper battery performance level before unit is used
for battery backup.
(****) Above 3000 ft (1000 m), output capacity reduced.

4 - 1

TOSHIBA

4.0 Specifications

4.2 Plus Series Specifications (w/ isolation transformer)

MODEL NUMBER UE1E1E006-5M

CAPACITY 600 VA (0.42 kW)

Input Input voltage Single phase, 220 Vac, +10% to -30% (*)

Input frequency 45 to 65 Hz

Input capacity 600VA

Input power factor Approximate unity (0.95 to 1.0)

Batte ry Battery rated voltage 60 Vdc

Battery backup time when fully charged

with 0.7 power factor at77° F (25° C)

Recharge time Maximum 24 hrs to 100% (90% recharge after 8 hrs) (***)

Type of batteries Sealed lead-acid

Output Output voltage Single-phase, 220 volts

Output voltage regulation Within +/- 3%, steady state

Output frequency 50/60 Hz +/- 0.5% in free-running mode (line sync range +/- 1Hz)

Output voltage waveform Computer-grade sine wave with less than 3.0% total harmonic

Common Mode Less than 0.5V peak

Normal Mode Less than 10V peak

Rated load power factor 0.7 lagging (0.6 to 1.0)

Voltage transient characteristic +/- 8% under 100% load step change

Rated output current (rms) 2.7A

12 min. at full load (**)
30 min. at half load (**)

distortion with linear load

Maximum output current (peak) 8.0A

Inverter overload capacity 150% for 30 seconds

Crest factor 3.0

Environment Operating temperature 32 to 104° F (0 to 40° C), optimal at 77° F (25° C)

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

Operating humidity 30 to 90%, no condensation

Altitude(****) Less than 3000 ft (1000 m) above sea level

External dimensions 8.00W x 20.38D x 10.00H in (203W x 518D x 254H mm)

Net weight 58.8 lb (26.7 kg)

Acoustical noise 50 dB at max. output, measured 3.3 ft (1 m) from front panel

Efficiency (ac-dc-ac) 85%

Switches Bypass switch Automatic bypass is provided when the run switch is in the stop

position, if a fault occurs, or if an overload occurs (transfer time is
approximately 4 mS)

Interfaces IBM

Fault detect and input power loss

Options Software for unattended

External battery pack Contact Toshiba for details on this option

(TM)

AS/400

LAN Manager See section 6.0 for details.

RS232 ASCII

computer shutdown Contact Toshiba for details on this option

(*) Output capacity reduced when input voltage is between -15% and -30% of nominal.
(**) Battery backup time may vary depending on the operating conditions including ambient temperature at the
installation site.
(***) An initial charge time of 24 hrs. is necessary to obtain proper battery performance level before unit is used
for battery backup.
(****) Above 3000 ft (1000 m), output capacity reduced.

4 - 2

5.0 Operating the UPS

5.1 Operation Modes

5.1.1 AC Input Mode (normal operation)

TOSHIBA

Power

input plug

IEC-320

Fuse

Bypass circuit

UPS

main

circuit

Input

Transformer

*Isolation only

for 1500 plus

series (600VA)

Output

Transformer

UPS
receptacles
(rear panel)

IEC-320

+

UPS batteries

= power flow

-

Power flow in AC input mode

The above illustration shows circuit power flow in the ac input mode. The UPS
unit's rectifier, included in a boost chopper circuit, converts ac input power to dc
power. This dc power runs the unit's transistor inverter and charges the batteries.
The boost chopper circuit maintains a constant voltage, with current limiting, for
charging the batteries and assures proper sine waveform generation for the
output current. The unit's batteries are maintained in a constantly charged state
when the UPS is in the normal operation mode. On the front panel, LED's labeled
"On Line" and "AC Input" should be on and the "Fault" LED should be off
(See Section 9.2 Panel Layout).

Power

input plug

IEC-320

5.1.2 Battery Backup Mode

Bypass circuit

Fuse

Input

Transformer

+

UPS batteries

Power flow in battery backup mode

The above illustration shows circuit power flow in battery backup mode. When
commercial ac power failures occur, the UPS's batteries instantly begin supplying
dc voltage to the UPS's main inverter circuit. This circuit changes (inverts) the dc
power into ac power. The ac power is available at the unit's output receptacles.
This back-up process will continue until the UPS's battery voltage drops below a
specific minimum level. When this occurs, the batteries will stop supplying power
to the load. This minimum level is the rated minimum voltage (Vmin). The rated
battery voltage chart in section 5.6 (See Section 5.7 for battery backup time)
shows (Vmin). On the front panel, LED's labeled “AC Input” and “Fault” should be
off. The “On Line” and “Backup” LED’s should be on (See Section 9.2 Panel
Layout).

-

UPS

main

circuit

*Isolation only

for 1500 plus

series (600VA)

Output

Transformer

UPS
receptacles
(rear panel)

IEC-320

= power flow

5 - 1

TOSHIBA

5.0 Operating the UPS

5.1 Operation Modes

5.1.3 Circuit-bypass mode

Power

input plug

IEC-320

Fuse

Input

Transformer

UPS batteries

Power flow in circuit-bypass mode.

If the UPS unit is severely overloaded or develops an internal fault, the power flow
is automatically switched from the unit's main circuit to the bypass circuit mode.
Power flow through the bypass is shown in the above illustrations. This change­over occurs automatically in approximately 4 milliseconds. The switching period
is not long enough to cause interruptions to occur in most UPS equipment loads.

The energy flow must be transferred manually from the UPS's bypass
circuit back to the inverter circuit after first correcting the fault.

STOP/RUN switch (on the unit's front panel) first to STOP and then back to RUN.
This procedure resets the UPS and transfers back to inverter. During circuit­bypass mode the AC-Input LED is ON, the On-Line LED is OFF, and the F ault
LED may be ON or OFF.(See Section 9.2 Panel Layout).

Bypass circuit

UPS

main

circuit

+

-

*Isolation only

for 1500 plus

series (600VA)

Output

Transformer

UPS
receptacles
(rear panel)

IEC-320

= power flow

T oggle the

5.2 System Protection Features

The schematic shown below depicts the electrical locations of the protection devices on
the UPS.

Input
Abnormal

Fuse

Input

Overcurrent

Input

Transformer

Low Battery
Level

Rectifier/
Charger/
Chopper

Overheating

Inverter

+

Batteries

Current Limit
Overload

*Isolation only

for 1500 plus

series (600VA)

Output

Output

Output

Transformer

Overvoltage/
Undervoltage

5 - 2

5.0 Operating the UPS

5.3 Operation Monitoring

5.3.1 Visual Indicator Functions

The following LED (light emitting diode) indicators are located on the front panel
(see Section 9.2 "Panel Layout"). Refer to these lamps for visual information
about the operating condition of the UPS (see Section 5.3.3 "Visual and Audible
Indicator Function Chart").

1) AC Input: This green LED lights when normal ac input power is being
supplied to the UPS unit.

2) On Line: This green LED lights when the inverter output voltage is normal.

3) Fault: This red LED lights when an abnormal operating condition is
detected. Operation of the unit's inverter is inhibited until the fault has been
corrected and the system reset (see Section 5.10 "System Reset").

5.3.2 A udible Alarm Functions

The UPS is equipped with an audible alarm system which activates under various
operating conditions. Sound patterns are used to indicate these conditions (see
Section 5.3.3 "Visual and Audible Indicator Function Chart"). Alarms for the
battery backup mode or low battery voltage will stop automatically when AC input
voltage is restored. Alarms for a fault condition will continue to sound until the
UPS has been reset (see Section 5.10 "System Reset").

TOSHIBA

5.3.3 Visual and A udible Indicator Function Chart

Condition Cause Visual

Audible

Alarm

Pattern

Indicators

UPS

Operation

Overcurrent (OC) Problem in chopper or 1) "Fault" LED 1) Auto

inverter circuit. is ON transfer

2) "On Line" to bypass

1.5s

ON

3) "AC Input" stopped

OFF

stopped

DC Bus Overvoltage (DCOV) DC Bus > 115% of rated. LED is OFF 2) Chopper

Ouput Overvoltage (OV) V out > 110% of rated. LED is ON 3) Inverter

2s

Undervoltage (UV) V out < 85% of rated.

Overheat (OH) Heatsink exceeds 90º C.

Overload (OL) Output current and over-

load specifications have
been exceeded.

.5s .5s

ON

OFF

ON

Battery problem Problem in battery 1) “Replace 1) Bypass or

circuit. Battery” On-Line

1s

OFF

2s

LED is ON mode.

70s

.5s

ON

OFF

2) "On Line" 2) Inverter
LED is ON running

3) "AC Input"

ON

OFF

LED is OFF

Normal battery backup Loss of AC power 1) "Fault" LED 1) Chopper

operation is OFF running

5s

Low battery voltage Battery voltage too low,

Shutdown imminent.

1s

5 - 3

TOSHIBA

5.0 Operating the UPS

5.4 Front Panel Layout

ON LINE (green lamp)
Lights

green

when the UPS’s inverter is supplying power to the load.

AC INPUT (green lamp)
Lights

green

when normal ac input power is being supplied to the UPS

Unit.
FAULT (red lamp)

Lights

red

when the UPS unit has tripped in the fault mode.

REPLACE BATTERY (red lamp)
Lights

red

to indicate batteries may need to be replaced.

5.5 UPS On-Line Mode Display

The following chart shows normal operating conditions when the UPS On-Line
lamp is

green

.

Output Display Stat us Explanation

When output current is
between 30% and 100%,
the

green

Normal bottom to top) to indicate

15% increments (from
relative output value

(This sample display
shows output current at
45% to 60% of rated
current).

All the
light and the
lamp will flash. If the load
exceeds 135% of the max.
rated output the red

Overload Overload lamp will light

continuously.

overload as quickly as
possible to prevent fault
(fault timeouts vary
depending on overload
condition).

lamps light in

green

lamps will

red

Remove

Overload

Output Display Status Explanation

During battery backup all

green

lamps flash and the

red

Backup lamp is lit

continuously. As the

Battery green lamps extinguish
Backup from top to bottom to

Low is lit continuously or

Battery flashing.

During
Battery
Backup

batteries discharge, the

indicate remaining battery
capacity (This sample
display shows battery
voltage between 75% and
90% of battery capacity).

All green lamps are off
and the

red

Backup lamp

= Flashing LED

= Steady-lit LED

5 - 4

5.0 Operating the UPS (Cont'd)

5.6 Battery Recharging

The graph below shows the typical voltage requirements for recharging the UPS unit's
batteries.

Current

V oltage

TOSHIBA

0.4 amp (A)

Charging
current

Vmax.

Vmin.

0

The recharge process usually consists of three periods. During the first period, the
current is maintained at approximately 0.4 amperes. In the second period, the constant­voltage control starts and the current gradually decreases as the batteries continue to
charge. In the third period, a slight current flows into the batteries to keep them fully
charged. After a complete discharge, a full recharge usually requires 24 hours (90%
recharge in 8 hours).

Discharge
shut-off point

0

Period 1

Time

Period 2 Period 3

Battery
charge
voltage

Fully
charged

The chart depicted below shows the rated maximum and minimum battery voltages,
and the charge current for each of the sizes.

Rated battery voltages

Model Vmax. Vmin. Charge
600 VA 68.2 48.0 0.4 (A)
800 VA 68.2 48.0 0.4 (A)

1000 VA 68.2 48.0 0 .4 ( A)

5 - 5

TOSHIBA

5.0 Operating the UPS

5.7 Battery Backup Time

The UPS unit's batteries provide about 5-12 minutes of back-up time depending on the
capacity of the UPS. These times are valid when a unit is operating under full load. When
the units are operating at half load, the batteries can power the load equipment about 3
times longer. The exact length of these times will depend on the UPS model used,
condition of the batteries, amount of load, temperature and other variables. See battery
backup time in the standard specifications Sections 4.1 through 4.2.

5.8 Battery Low Voltage Tolerances

Excessive discharge will cause the UPS unit's battery voltage to drop. The chart shown
below lists the voltage level at which each UPS unit's low-voltage alarm will sound and
also at what level the low-voltage condition will cause the unit to automatically shut down.

UPS Capacity 600VA 800VA 1000VA

Nominal voltage 60.0 60.0 60.0

in Vdc

Alarm voltage 52.8 52.8 52.8

in Vdc

Shutdown voltage 48.0 48.0 48.0

5.9 Battery Check Function

Part of the UPS start-up procedure is an automatic 'Battery Check' to see if a problem
exists in the battery circuit. When the UPS is started it will begin operation in the bypass
mode. An automatic voltage level test of the batteries is made while operating in the
bypass mode for five seconds. A failure of this first test will activate visual and audible
alarms (see section 5.3.3 "battery problem"). If this test is passed, then the UPS will auto­transfer from bypass mode to on line operating mode. A ten second automatic voltage
check of the batteries is made after the UPS has auto-transferred from bypass to on line
mode. Normal on line operation continues if the second test is passed. If the second test
fails, then the "Fault" LED will flash and up to three additional automatic battery voltage
checks are made at 3 hour intervals while the inverter continues to operate. If the
batteries are found to be normal during one of these three tests then the "Fault" LED
will stop flashing and normal inverter operation will continue. A f ailure of the third and
final check will activate visual and audible alarms (see section 5.3.3 "battery problem")
causing an auto-transfer back to bypass.

STOP the UPS and allo w a 24 hour c harge on the batteries before restarting.

If the batteries are indicated "bad" then

5.10 System Reset

The UPS is reset by moving the STOP/RUN switch from "run" to "stop" and then back
to "run". Use the reset procedure to transfer from bypass back to inverter after a fault
occurs. Some faults may only be cleared by shutting down the UPS, waiting for all LED's
on the front panel to go off, and then restarting the UPS.

5 - 6

6.0 UPS Control Interface

6.1 DB25 Connector Pinout

RS-232C serial communication and Dry Contacts are both standard features available
through a DB25 female connector located on the back panel of the UPS (see Section 9.1).
The RS-232C serial communication interface allows control of the UPS from a personal
computer running special Toshiba software. The computer is connected to the UPS
through a serial RS-232C communication port. The Dry Contact interf ace is a vailable as
open or closed contacts. An adapter is available from Toshiba for splitting the RS-232C
and Dry Contact interfaces into two separate DB9 connectors. Contact Toshiba for more
information on this option. The following chart shows the pin assignments for the DB25
connector.

Pin Symbol Description

1 0V Supply used by Slide-In Options cards (-)
2 +9V Supply used by Slide-In Options cards (+)
3 RXD_UPS UPS receive line
4 TXD_UPS UPS transmit line
5 TXD_AUX Auxiliary transmit line
6 RXD_AUX Auxiliary receive line
7 (not used)
8 SNMPSIG1 SNMP option card function

9 RS_Common Common line for RS-232C communication
10 SNMPSIG2 SNMP option card function
11 DTR UPS data terminal ready

RS-232C Serial Interface

12 DSR UPS request to send
13 RTS UPS clear to send
14 CTS UPS data set ready
15 (not used)
16 Dry_Common Common line for Dry Contact signals
17 Backup_O Open during Battery Backup
18 Backup_C Closed during Battery Backup
19 Low_Battery Closed during Low Battery
20 Inverter Closed during On-Line mode
21 Bypass Closed during Bypass mode

Dry Contacts

22 Fault Closed during Fault
23 (not used)
24 SD_Signal Shutdown command signal line
25 SD_Common Shutdown command common line

TOSHIBA

6 - 1

TOSHIBA

6.0 UPS Control Interface

6.2 RS-232C Serial Communication Interface

The available data from the UPS, via RS-232C communication, is shown below:

Operating conditions Battery voltage

UPS operating status UPS in BYPASS mode
(described as ‘yes’ or ‘no’) UPS in NORMAL mode

'Fault’ details Input overcurrent
(described as ‘occurred’ Overheat
or ‘not occurred’) Overload being timed

Output voltage
Output current

Input frequency
Output frequency

Utility power OK
Low battery voltage detected

Input and output frequency synchronized
UPS ‘fault’ occurred

DC bus overcurrent
DC bus overvoltage
DC bus undervoltage

Overload (allowable time exceeded)
Output overvoltage (during NORMAL mode)
Output undervoltage (during NORMAL mode)

6.2.1 UPS Shutdown (via RS-232C)

When the UPS is operating from its internal batteries, a ‘shutdown’ order can be
sent to the UPS telling it to turn OFF after a user-specified amount of time. This
function can allow you to stop discharging the UPS batteries after an orderly
system shutdown has been completed. The UPS can be programmed to turn
OFF up to 8 minutes after the ‘shutdown’ command is given. This command can
be cancelled before the specified time has elapsed.

6.3 Dry Contact Interface

The Dry Contact interface uses pins 16 trough 22. Pins 24 and 25 are used for the
shutdown function. The following schematic shows the contact state and pin assignments
for each signal output along with the associated DB25 connector pinout.

16 Dry Contact common
17

Battery Backup 1) Pin “switches are shown

}

18 in their
19 Battery voltage “low” low then pin 19 will be
20 UPS “on”
21 Bypass “on” follows:
22 Fault detect signal ac: 30Vrms (42V -peak)

Notes:

inactive states

(ex. if battery voltage is
connected to pin 16)

2) Contacts are rated as
dc: 48V, 0.1A

0.07A(0.1A-peak)

6 - 2

TOSHIBA

7.0 Troubleshooting Procedures

Faults are those abnormal conditions that can occur and cause the unit to shutdown normal
operation. The faults are detected by the protection circuitry (see System Protection F eatures
Section 5.2) in the unit. The UPS “Fault” lamp will light
the bar graph lamps on the front panel and then interpreting the readout by using the fault mode
display charts.

7.1 Non-Fatal Fault Mode

Non-fatal faults may or may not cause the unit to shut down. These f aults normally will
cause the UPS to transfer to bypass mode. Use "System Restart" procedures (see
Section 5.10) to transfer the UPS back to “On Line” mode. Use the following chart to
decode the display. All non-fatal faults will cause the red “Fault” LED to flash.

Non-Fatal Fault Mode Display Chart

Fault Display status Probable cause Corrective action

Output low Inverter fault or short short circuit. If none is

voltage circuit in UPS output found, contact your

red

. "Troubleshooting" involves monitoring

Remove cause of

Toshiba service
representative.

Output Resonance with load Remove load

overvoltage equipment equipment one piece

at a time.

DC Chopper fault Contact your Toshiba

undervoltage service representative.

Check for airflow

Cooling fin Cooling fan outage or restriction. If none is

overheating closed cooling airflow found, contact your

path Toshiba service

representative.

Battery damaged or

Battery something wrong in the Contact your Toshiba

problem battery circuit (battery may service representative.

not be connected)

Output Capacity of load Review UPS rating

overload equipment to high or reduce load

equipment.

7 - 1

TOSHIBA

7.0 Troubleshooting Procedures

7.2 Fatal Fault Mode

Fatal faults may or may not cause the UPS to shutdown. Use "System Reset" procedures
(see Section 5.10) to transfer UPS back to “On Line” mode. Use the following chart to
decode the display. All fatal faults will cause the red “Fault” LED to light continuously.

Fatal Fault Mode Display Chart

Fault Display status Probable cause Corrective action

DC Inverter fault

overcurrent

DC Chopper fault

overvoltage

Input Chopper fault

overcurrent

UPS system Trouble with the control

error PWB

= Flashing LED = Steady-lit LED

Contact your Toshiba
service representative.

7 - 2

8.0 Preventive and Scheduled Maintenance/Parts Replacement

8.1 Preventive Maintenance

Toshiba's 1500 and 1500 Plus Series of uninterruptible power systems have been
designed to provide years of trouble-free operation requiring a minimum of preventive
maintenance.

The best preventive measure that the UPS user can take is to keep the area around the
unit, particularly the air inlet vents, clean and free of moisture and dust accumulations.
If the atmosphere of the installation site is very dusty, use a vacuum cleaner to
periodically remove dust accumulations from the system. Schedule authorized service
centers to perform internal parts inspections annually.

Before performing any maintenance, the technician should

CAUTION

WARNING

be familiar with and follow the important safety instructions
located on pages vi and vii.

Proper maintenance of the battery system of this unit by a
qualified service technician is essential to the safety and
reliability of your UPS system. Refer to service manual.

TOSHIBA

8.2 Parts Replacement

The following list shows intervals for periodic maintenance and replacement of certain
UPS parts.

1) Batteries: VRLA batteries are maintenance free with respect to electrolyte only.
The charging voltage, temperature, performance and connection resistance must
be monitored periodically. Necessary corrective actions must be made in order to
assure safe reliable power is supplied by the UPS. The aforementioned items
affect the lif e of batteries, so replacement should be done once every 3 to 5 years
at a minimum. All of the batteries must be replaced at the same time.

Quarterly maintenance
a) Visual checks

1) Leakage

2) Corrosion on positive terminal
b) Check battery temperature at the negative terminal.
c) Measure and record the system float charging voltage.
d) Measure and record the individual units float charging voltage.

Semi-Annual maintenance
a) Repeat the quarterly checks.
b) Perform a 10 second high rate (e.g. 100 amp) load test on the

individual batteries.
c) Optionally test for the purpose of trending the battery over time.
d) Re-torque all inter-battery connecting hardware (if applicable).
e) Perform inter-battery connector resistance checks.

2) Aluminum electrolytic capacitors: Replace once every 5 years.

3) Fuses: Replace once every 7 years (see output fuse rating chart on the following
page).

4) Cooling fan: Replace once every 3 years.

8 - 1

TOSHIBA

8.0 Preventive and Scheduled Maintenance/Parts Replacement

8.3 Fuse Rating Chart

The following chart shows the recommended fuses for all UPS sizes.

Fuse rating

Model Amp rating Fuse model no.
600 VA 15.0A Bussmann MDL-8
800 VA 15.0A Bussmann MDL-8

1000 VA 15.0A Bussmann MDL-8

8 - 2

9.0 External Dimensions/Shipping Weights/Panel Layout

9.1 External Dimensions

TOSHIBA

8.00

Overload

On Line

AC Input

Fault

X

+-

Replace Battery

X

SERIES

1500

1000VA ON-LINE UPS

90%
75%

60%

45%

30%

Backup

Front
View

Air V ents

Input power
cord connector

Run/Stop
switch.
0: Stop
1: Run

10.00

20.38

Output
Receptacles

Fuse

Rear
View

Slide-in
Option
Card

Computer
Interface
Connector

Side
View

9 - 1

TOSHIBA

9.0 External Dimensions/Shipping Weights/Panel Layout

9.2 Panel Layout

9.3 Shipping Weights

UPS Shipping Weight

Model Pounds Kilograms

600 VA 48.8 22.2
800 VA 48.8 22.2

1000 VA 52.2 23.7

9 - 2

TOSHIBA

TOSHIBA INTERNATIONAL CORPORATION

INDUSTRIAL DIVISION
13131 West Little York Rd., Houston Texas 77041

Tel: [800] 231-1412 Fax: [713] 466-8773 Telex: 762078

Printed in U.S.A.