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UNINTERRUPTIBLE POWER SYSTEM (UPS) G9000 SERIES INSTALLATION AND OPERATION MANUAL 480/480 V 1000/1330/1500/1660/2000kVA Document No.: 91649-007 Reference: 4GBH0118 Rev. A August 2017...
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G9000 SERIES INSTALLATION AND OPERATION MANUAL 480/480 V 1000/1330/1500/1660/2000 kVA Document No. 91469-007 Reference: 4GBH0118 Rev. A August 2017 G9000 1000-2000kVA Installation and Operation Manual 91469-007...
The sales contract contains the entire obligation of TOSHIBA INTERNATIONAL CORPORATION. The warranty contained in the contract between the parties is the sole warranty of TOSHIBA, and any statements contained herein do not create new warranties or modify the existing warranty.
TOSHIBA shall not be liable for technical or editorial omissions or mistakes in this manual. Nor shall it be liable for incidental or consequential damages resulting from the use of information contained in this manual.
Table of Contents List of Tables ............................v How To Use This Manual ......................1 Introduction ........................... 2 Safety Precautions ......................3 General ............................6 Definitions ..........................7 Operation Overview......................8 3.2.1 Normal Operation: Load Power Supplied By Each System UPS Inverter ......8 3.2.2 Bypass Operation: Load Power Supplied Through UPS Internal Static Bypass Line.
List of Tables Table 2–1 UPS Installation Environment ....................4 Table 2–2 Rating of Bypass Input Circuit Breaker (100% Rated) ............5 Table 3–1 Power Specifications ......................18 Table 3–2 UPS Cabinet Information ....................18 Table 3–3 Specifications ........................19 Table 3–4 Rating of Contactors, Breakers, and Fuses ..............
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List of Figures Figure 3-1 Single Line Diagram - Normal Operation: Load fed by UPS inverter ......... 8 Figure 3-2 Single Line Diagram - Bypass Operation: Load Fed Through Static Bypass Line ....10 Figure 3-3 Single Line Diagram - Battery Operation – Load Fed by Battery ........11 Figure 3-4 Typical Battery Charging Curve ..................
Prohibit: A prohibit symbol shows the act the user or the service personnel should NEVER perform during the UPS installation, operation or service work. PROHIBIT Safety Recommendations: If any problems are encountered while following this manual, Toshiba field service group assistance and correspondence is recommended. G9000 1000-2000kVA Installation and Operation Manual 91469-007...
Introduction The Toshiba Uninterruptible Power Supply System (UPS) is designed to provide many years of reliable protection from power failure, brown-outs, line noise, and voltage transients. To ensure optimum performance of the equipment, follow the manufacturer's instructions. This manual contains instructions required to operate the UPS. Please read this manual carefully and retain it for future reference.
WARNING 2 WARNING In no event will TOSHIBA be responsible or liable for either indirect or consequential damage or injury that may come from the misuse of this equipment. Do not modify the UPS entirely or partially. Any modifications without authorization by TOSHIBA could result in personal injuries, death or destruction of the UPS.
WARNING 3 WARNING The UPS is to be installed in a controlled environment. Improper storage and installation environment may deteriorate insulation, shorten component life and cause malfunctions. Keep the installation environment per standard described as follows: Table 2–1 UPS Installation Environment Item Environment standard Installation...
WARNING 4 WARNING This UPS does not include a Bypass input circuit breaker (MCCB) to protect bypass circuit. The Bypass input circuit breaker (MCCB) is to be field supplied and installed. Recommended Breaker (MCCB)'s Specifications are as follows: Table 2–2 Rating of Bypass Input Circuit Breaker (100% Rated) Capacity Bypass Voltage Bypass Rating...
UPS. The UPS is simple to start-up, operate and maintain. The G9000 SERIES UPS is available in models ranging from 100 to 2000kVA capacities. This manual covers the 1000-2000 kVA units only. Specifications are shown in Section 3.3.
3.1 Definitions UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS Cabinet, ancillary cabinets, and associated batteries that function as a system to provide continuous, conditioned AC power to a load. This is sometimes referred to as the "System". UPS CABINET –...
3.2 Operation Overview The UPS provides two power paths between the utility source and the critical load. Figure 3-1 shows the path for normal operation, with the load powered by the inverter. Figure 3-2 shows the path for bypass operation, with the load supplied through the static bypass line.
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The conversion - inversion process eliminates any voltage transients or fluctuations existing in the input power before it reaches the critical load. The power drawn by the critical load is equally shared between all UPS systems when multiple UPSs are in Parallel Operation. (Refer to Figure 5-6 that shows a sample of Parallel Operation System Configuration.) When in Parallel Operation, the rectifier inputs to all G9000 UPS Systems in the Multi-Module System (MMS)-must be fed from a single source at...
In the event of a load overcurrent, the UPS transfers to bypass without interruption to the critical load. In the case of the Parallel Operation, all UPS will transfer to bypass without interruption to the critical load. The internal control system determines the operation of the two paths, with the load powered from the inverter being the normal operation.
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a reduced load. * (s) : In the case of the Parallel Operation When power is restored after a low battery shutdown, the UPS converter(s) automatically restarts operation, the charger(s) recharges the batteries and the Inverter(s) is automatically restarted without operator intervention. Load is automatically assumed by the inverter without operator intervention.
(see the Battery section of Table 3–3) or a lower current limit set via the LCD screen to comply with the battery manufacturer recommendations. This current limit adjustment should only be performed by a Toshiba Authorized Service Provider. Period (B): This period begins when the Charging Voltage reaches the float voltage of the batteries.
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Description of Parts Location Figures: LCD Touch Panel Monitor Display The liquid crystal display (LCD) touch panel monitor display indicates power flow, measured values, fault codes, and error messages via user selectable display screens. Refer to Figure 4-1 for details. Display PCB DPAU-89 Switches on DPAU-89 board: FOR SERVICE PERSONNEL ONLY - SW1 (RESET switch)
3.3 Specifications The UPS nameplate displays the rated kVA as well as nominal voltages and currents. The nameplate is located on the backside of the Bypass module door. Table 3–1 Power Specifications Rated output Input voltage Bypass input voltage Output voltage Power 3 phase / 3 wire 3 phase / 3 wire...
Table 3–3 Specifications Rated Output kVA 1000 1330 1500 1660 2000 Rated Output kW 1000 1330 1500 1660 2000 AC INPUT Configuration 3 phase, 3 wire Voltage 480 V +15% to -20% Frequency 60 Hz ±10% Reflected Current THD 3% typ. at 100% load Walk-In Function 1-30 Seconds (in 1 second increments) STATIC BYPASS INPUT...
Operator Controls and Indicators The G9000 Series operator controls and indicators are located as follows (Door exterior): Figure 4-1 Operation/Display Panel (Front Panel) G9000 1000-2000kVA Installation and Operation Manual 91469-007...
4.1 LED Display Load on inverter [ LOAD ON INVERTER ](green) Illuminates when power is supplied from inverter to the critical load. (Indicates the state of inverter transfer switch "52C".) Battery operation [ BATTERY OP. ](yellow) Illuminates when power is supplied from batteries. Load on bypass [ LOAD ON BYPASS ](yellow) Illuminates when power is supplied to load devices by static bypass.
4.3 Liquid Crystal Display The Liquid Crystal Display (LCD) touch panel (8) indicates power flow, measured values, operational guidance, data records and error messages. The LCD panel has a back-light which facilitates viewing in different ambient lighting conditions. The LCD will automatically clear and turn off, if the screen is not activated within 3 minute period.
*Meaning of the icons in SMS (Single Modular System) INV. START : Turns on UPS Converter and Inverter INV. STOP : Turns off UPS Converter and Inverter START : Output Transfer from Bypass Line to Inverter STOP : Output Transfer from Inverter to Bypass Line Figure 4-3 Start/Stop Operation Follow Start/Stop operation guidance accordingly.
OPERATION MENU This screen prompts the user to select: (a) whether the start & stop operation will be performed by local or remote operation; (b) date & time adjustment; (c) battery equalizing charge. The battery equalizing charge operation key will appear when battery equalizing charge is set up (Setup is based on battery type).
4.3.2 Input Power Failure During an Input Power Failure, the UPS inverter will be powered by the UPS batteries. The following will be displayed on the main and measurement screen (Indication of battery operation and remaining battery time). Figure 4-12 Main Screen (On Battery) Figure 4-13 Measurement Screen ( On Battery) The LCD will display a battery low voltage message when the battery capacity is near...
4.3.3 Fault Indication “MESSAGE” and “SILENCE ALARM” icons will appear on the main menu when UPS failure condition has occurred. Figure 4-14 Main Screen (Fault Indication) The following will be displayed when the MESSAGE icon on the main menu is pressed. MESSAGE The display shows a fault code, the description of the fault and a guidance of what action is to be taken by the user.
4.4 External Aux Contact Input and Output Terminal Blocks The UPS is equipped with a series of input/output terminals for external annunciation of alarms and for remote access of certain UPS functions. The layout of terminals is shown in Figure 4-17 and Figure 4-19 with a functional description of the input/output port presented.
Stops UPS module from remote location. Use momentary (0.5 to 4 sec.) REMOTE MOD.STOP switches only. For use with the internal wave capture tool; for use by Authorized Toshiba TRACE TRIGGER Service Providers. *: Default Settings from Factory.
4.4.2 Aux Contacts - Output The Output terminal provides eight (OUT1 thru OUT8) form "A" NO (Normally Open) dry type programmable contacts to drive annunciation signals sourced or "wetted" by external monitoring devices. All output contacts are rated for NEC Class 2 operation (30VDC / 1ADC.) The output dry contacts should be operated at their rated values or lower.
BATTERY LOW VOLTAGE 1 Level 1 during inverter operation. This level is set in the TEST MENU by an Authorized Toshiba Service Provider. Activated when the battery voltage drops below Discharge Warning Voltage Level 2 during inverter operation. This level is set in the TEST MENU by an BATTERY LOW VOLTAGE 2 Authorized Toshiba Service Provider.
RemotEye® 4 is shown in Figure 4-20 and Figure 4-22 shows detailed connection Remoteye4 Option BYPASS MODULE with Doors open Figure 4-20 RemotEye® 4 Installation (Overview) ® ” monitoring software * Consult Toshiba International Corporation for details on“RemotEye and its capabilities. G9000 1000-2000kVA Installation and Operation Manual 91469-007...
Figure 4-23 shows the detail of D-sub 9Pin on N002. The UPS has to be de-energized when the RemotEye® 4 module is installed for safety reason. CAUTION * Consult Toshiba International Corporation for details on “RemotEye® 4” monitoring software and its capabilities. G9000 1000-2000kVA Installation and Operation Manual 91469-007...
Installation And Operation 5.1 Transportation and Installation Table 5–1 How to Transport and Install the System Transportation Installation Transport unit with forklift or pallet Using the 2 or 4 pre-drilled holes in the each UPS jack ONLY. channel base*, anchor the unit using appropriate hardware.
D) External Battery Supply Please refer to the following when installing and maintaining batteries: 1. The customer shall refer to the battery manufacturer's installation manual for battery installation and maintenance instructions. 2. The maximum permitted fault current from the remote battery supply and the DC voltage rating of the battery supply over-current protective device are NOTE shown in Table 5–3.
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Two (2) sources feeding the UPS: (1) Before connection of alternate source, ensure that input bus bar jumper is removed. Connect the AC input power cables from the input service entrance to the AC input power terminals, identified as A, B, C in Figure 5-1 through Figure 5-4. Input cables must be sized for an ampere rating larger than the maximum input drawn by the converter.
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NOTE Control wire connection Parallel configuration wiring (Refer to Figure 4-17 and Figure 5-7) 52L control signal from Toshiba Tie Cabinet (TTC) to UPS-n IOAU-19 (TN11-23, 24). Parallel control signals, for TLAIN, TLAOUT, TLBIN, TLBOUT, CAIN, CAOUT, CBIN, CBOUT, DIAIN, DIAOUT, DIBIN, DIBOUT as shown in Figure 5-7 and...
Table 5–4 Recommended Cable Quantities at 500kcmil Input Side Output Side Bypass Side DC Input Side Input Output Cable Torque Cable Torque Cable Torque Cable Torque Capacity Voltage Voltage Size in. lbs. Size in. lbs. Size in. lbs. Size in. lbs. 347 - 469 347 - 469 347 - 469...
118.1”(3003.2) 35.5”(901.6) External signal line access ※ Input Detailed AC Power Terminals Grounding Bar ※2 ※2 ※3 ※3 ※2 ※3 For power terminals, use 1/2” Cable Entry Section – Left Side View UPS cabinet – Front View (12mm) diameter bolts. *1.
External signal line access (* 35.5”(900) 190.9”(4,850) Detailed Power Terminals Cable Entry Section Left Side View UPS cabinet – Front View Last Module for 1500kVA System Only For power terminals, use 1/2” (12mm) diameter bolts. 1: Signal lines should be separated to the main circuit cables with more than 100mm insulating distance. The wiring also should fix to the frame to ensure the insulating distance satisfied the condition.
External signal line access (* 222.4”(5,650) 35.5”(900) Grounding Bar Input Input Detailed AC Power Terminals Grounding Bar Cable Entry Section UPS cabinet – Front View Left Side View Last Module for 2000kVA System Only For power terminals, use 1/2” (12mm) diameter bolts. 1: Signal lines should be separated to the main circuit cables with more than 100mm insulating distance.
User DC circuit breaker External signal supplied terminal IOAU-19 - [TN11] Auxiliary DC Power “-” Negative “+” Positive Terminals User supplied DC breaker for UPS cabinet Battery Cabinet User User DC circuit breaker DC circuit breaker External signal supplied supplied terminal IOAU-19 - [TN11] Auxiliary...
*1: N(maximum) = 6 *2: Return from the last UPS module to the first UPS module (continuous loop) *3: DIP SWITCH UPS-1: All ON UPS-2~UPS-(N-1): All OFF UPS-N: ON / S1-1, S1-2 OFF / S1-3 to S1-8 Figure 5-7 Diagram of Power Wire & Control Wire Connection (Parallel system connection 2x to 6x) G9000 1000-2000kVA Installation and Operation Manual 91469-007...
Use Ethernet STP (Shielded Twisted Pair) Cable (Cat 6) with shielded RJ45 modular connectors for all communication cabling. Use of UTP (Unshielded Twisted Pair) Cable may cause malfunction. Total cable length from UPS-1 to UPS-n should be within 100m (330ft). UPS-1 UPS-2 UPS-n...
5.4 Operating Procedures NOTE: To avoid inadvertently placing the UPS online or offline the START and STOP switches must be pressed and held for a period of several seconds to execute the command. START – Press and hold the START switch for approximately 2 seconds. ...
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B) Stop Operation If a total UPS shutdown is required, verify that the critical load is OFF. Verify the load is OFF if the next step is to be performed. Power to the load has been supplied through the bypass line. Power to load will be lost after execution of the next step.
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C) Bypass Operation Procedure ** Transfer from Inverter to Bypass Check for “SYNC” on the LCD. Press the "START/STOP” icon on the LCD. Follow the “STOP OPERATION” guidance and Press the "STOP" icon on the LCD. ** Transfer from bypass to inverter. Press the "START/STOP"...
Transfer from Maintenance Bypass to MMS Bypass Operation Close Tie cabinet breaker 52CS. Open Tie cabinet Breaker 52MB. When "REMOTE OPERATION MODE" is displayed on the LCD panel, the inverter start operation can only be performed remotely. If local inverter start operation is required (at the UPS), select "LOCAL ONLY"...
Refer to the list of fault codes in section 6.0 for error Recording of Fault description. Take necessary action according to display guidance. Primary Action When faults happen, contact the Authorized Toshiba Service Information to Service Representatives or call Toshiba International Corporation at 1-877-867-8773. Note The error code indicated on the LCD display panel when an UPS alarms is very important.
7.1 Recommended Maintenance Toshiba International Corporation recommends the UPS have regular preventative maintenance (PM) visits to ensure optimum operation and longevity. Toshiba recommends two Major PM’s per year, at six month intervals. A Major PM includes maintenance of the batteries and an offline inspection of the UPS. Contact Toshiba International Corporation Service Department at 1-877-867-8773 for further details.
7.4 Air Filters Air filters can be obtained in bulk quantities from Toshiba International Corporation. Use only air filters specified by Toshiba. Table 7–2 Replacement Air Filters Module Toshiba Part Number Quantity T90-AF-15x30x1 2: 1000kVA T90-AF-20x30x1 2: 1330-2000kVA 3: 1000kVA...
8.1 Bypass Module Fault Codes Table 8–1 Bypass Module Fault Code List External Code relay Status Audible indication Meaning Guidance contact Message Alarm (Note 2) (Note 1) The output load current has WARNING: Intermittent UA805 OVERLOAD exceeded 100% of the rated DECREASE Overload sound...
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Table 8–1 Bypass Module Fault Code List (cont.) External Code relay Status Audible indication Meaning Guidance contact Message Alarm (Note 2) (Note 1) CALL A power converter module has UA865 MOD.BAT.END SERVICE Alarm detected battery depleted. ENGINEER A power converter module issues Intermittent UA866 BATT.END WA...
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Table 8–1 Bypass Module Fault Code List (cont.) External Code relay Status Audible indication Meaning Guidance contact Message Alarm (Note 2) (Note 1) CALL Detection of an abnormal clock Continuous UF305 CTRL.CIRCUIT ERR. SERVICE Major speed in the CPU or FPGA. sound ENGINEER CALL...
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Table 8–1 Bypass Module Fault Code List (cont.) External Code relay Status Audible indication Meaning Guidance contact Message Alarm (Note 2) (Note 1) No control response from another CALL Intermittent UF376 CTRL.CIRCUIT ERR. UPS although its detection is SERVICE Minor sound possible.
8.2 Ups Module Fault Codes Table 8–2 UPS Module Fault Code List Code External relay Status indication contact Meaning message (Note 2) (Note 1) Alarm MA801 I/P VOLT.OUT RNG. Input line voltage is out of the specific range. AC input abnormal Alarm MA802...
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Table 8–2 UPS Module Fault Code List (cont.) Code External relay Status indication contact Meaning message (Note 2) (Note 1) MF119 DC GROUND FAULT Detection of DC ground fault. Major Power supply voltage to IGBT driver PCB is below the MF128 CTRL.PWR.
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Table 8–2 UPS Module Fault Code List (cont.) Code External relay Status indication contact Meaning message (Note 2) (Note 1) MF301 CTRL.CIRCUIT ERR. AD reference has an abnormal value. Major Detection of an external interruption during the MF302 CTRL.CIRCUIT ERR. Major software execution.
Please perform the daily inspection while the UPS is running. The daily inspection items are shown in Table 9–1. The customers can only inspect exterior or environment of cabinet. When the customers want to perform the detailed inspection, contact Toshiba International Corporation at 1-877-867-8773. NOTE Table 9–1 How to Perform Daily Inspection No. Subject...
13. All Overcurrent Protection Devices are assumed to be 100% 7. Nominal battery voltage based on the use of VRLA type rated. batteries (2.0 volts/cell nominal). TOSHIBA 8. Maximum battery discharge current based on lowest INTERNATIONAL CORPORATION permissible discharge voltage of 1.67 VPC.
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13. All Overcurrent Protection Devices are assumed to be 100% batteries (2.0 volts/cell nominal). rated. 8. Maximum battery discharge current based on lowest TOSHIBA INTERNATIONAL CORPORATION permissible discharge voltage of 1.67 VPC. 13131 West Little York Road 9. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current.
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13. All Overcurrent Protection Devices are assumed to be 100% batteries (2.0 volts/cell nominal). rated. 8. Maximum battery discharge current based on lowest TOSHIBA INTERNATIONAL CORPORATION permissible discharge voltage of 1.67 VPC. 9. DC wires should be sized to allow not more than a 2-volt 13131 West Little York Road drop at maximum discharge current.
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13. All Overcurrent Protection Devices are assumed to be 100% batteries (2.0 volts/cell nominal). rated. 8. Maximum battery discharge current based on lowest TOSHIBA INTERNATIONAL CORPORATION permissible discharge voltage of 1.67 VPC. 9. DC wires should be sized to allow not more than a 2-volt 13131 West Little York Road drop at maximum discharge current.
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13. All Overcurrent Protection Devices are assumed to be 100% batteries (2.0 volts/cell nominal). rated. 8. Maximum battery discharge current based on lowest TOSHIBA INTERNATIONAL CORPORATION permissible discharge voltage of 1.67 VPC. 9. DC wires should be sized to allow not more than a 2-volt 13131 West Little York Road drop at maximum discharge current.
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SOCIAL INFRASTRUCTURE SYSTEMS GROUP POWER ELECTRONICS DIVISION 13131 West Little York Rd., Houston, TX 77041 Tel: 713/466-0277 Fax 713/896-5212 US 877/867-8773 Canada 800/872-2192 Mexico 01/877/867-8773 www.toshiba.com/tic/industrial-systems/uninterruptible-power-systems Printed in Japan...