Toshiba G9000 SERIES Installation And Operation Manual
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Toshiba G9000 SERIES Installation And Operation Manual

480/480 v 1000kva
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Download this manual See also: Operation & Installation Manual
UNINTERRUPTIBLE POWER SYSTEM (UPS)
G9000 SERIES
INSTALLATION AND
OPERATION MANUAL
480/480 V 1000kVA
Document No.: 91649-0041
Reference: 4GBA0051 Rev. A
September. 2014

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  • Page 1 UNINTERRUPTIBLE POWER SYSTEM (UPS) G9000 SERIES INSTALLATION AND OPERATION MANUAL 480/480 V 1000kVA Document No.: 91649-0041 Reference: 4GBA0051 Rev. A September. 2014...
  • Page 2 G9000 1000kVA Installation and Operation Manual 91469-004...
  • Page 3 G9000 SERIES INSTALLATION AND OPERATION MANUAL 480/480 V 1000 kVA Document No. 91469-004 Reference: 4GBA0051 Rev. A September. 2014 G9000 1000kVA Installation and Operation Manual 91469-004...

  • Page 4: Important Notice

    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.

  • Page 5: Purpose And Scope Of Manual

    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.
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  • Page 7: Table Of Contents

    Table of Contents List of Figures ....................... ii List of Tables ........................ iii HOW TO USE THIS MANUAL.................. 1 INTRODUCTION ....................... 2 SAFETY PRECAUTIONS ......................3 GENERAL ............................. 5 DEFINITIONS..........................6 OPERATION OVERVIEW ......................7 SPECIFICATIONS ....................14 OPERATOR CONTROLS AND INDICATORS ............18 LED DISPLAY ..........................

  • Page 8: List Of Figures

    List of Figures Figure 2-1 Single Line Diagram - Normal Operation: Load powered by UPS inverter ......7 Figure 2-2 Single Line Diagram - Bypass Operation: Load fed through static bypass line ....9 Figure 2-3 Single Line Diagram - Battery Operation ................10 Figure 2-4 UPS Parts Location ......................
  • Page 9 List of Tables Table 2-1 UPS Installation Environment ....................4 Table 2-2 Rating of Bypass Input Circuit Breaker .................. 5 Table 3-1 Power Specifications ......................14 Table 3-2 UPS Cabinet Information ...................... 14 Table 3-3 UPS Shipping Dimensions ....................14 Table 3-4 Specifications ........................
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  • Page 11: How To Use This Manual

    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 1000kVA Installation and Operation Manual – 91469-004...

  • Page 12: Introduction

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

  • Page 13: Safety Precautions

    SAFETY PRECAUTIONS APPLICATION This UPS shall NOT be applied to support equipment (*) that could affect human lives. • Life support equipment in medical operation rooms (artificial dialysis, incubators, etc.) • Toxic gas or smoke eliminators • Equipment that must be provided under fire laws, construction standards or other ordinances PROHIBIT •...

  • Page 14: Table 2-1 Ups Installation Environment

    Table 2-1 UPS Installation Environment Item Environment standard Installation Indoors Location Ambient Minimum temperature: 32°F(0°C), Maximum temperature: 104°F(40°C) temperature The average temperature over any 24-hour period must be in the range 41° F (5°C) to 95°F(35°C). Relative The relative humidity must be held between 5 and 95%. There must be humidity no condensation due to temperature changes.

  • Page 15: General

    UPS. The UPS is simple to start-up, operate and maintain. The G9000 SERIES UPS is available in 100, 160, 225, 300, 500, 750, and 1000 kVA. This manual covers the 1000 kVA mode onlyl. Specifications are shown in Section 1.5.

  • Page 16: Definitions

    DEFINITIONS UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS Cabinet and associated batteries that function as a system to provide continuous, conditioned AC power to a load. This is sometimes referred to as the "System". UPS CABINET – The metal enclosure which is the main part of UPS and composed of the Bypass module, the 3 UPS modules, and the Cable Entry Section.

  • Page 17: Operation Overview

    OPERATION OVERVIEW The UPS provides two power paths between the utility source and the critical load. Figure 1.1 shows the path for normal operation, with the load powered from the inverter. Figure 1.2 shows the path for bypass operation, with the load supplied through the static bypass line. Normal operation: Load power supplied by each system UPS inverter.
  • Page 18 power to clean AC power to supply the critical load. The conversion - inversion process eliminates any voltage transients or fluctuations existing in the input power before it reaches the critical load. The power drawn by the critical load is equally shared between all UPS whenever the system is in the Parallel Operation.

  • Page 19: Figure 2-2 Single Line Diagram - Bypass Operation: Load Fed Through Static Bypass Line

    B) Bypass Operation: Load Power supplied through UPS internal static bypass line. Bypass Module 52 S Bypass Input User supplied CB 3 Static Transfer MCCB Switch CONVERTER / INVERTER CB 1 52 C Output input User supplied MCCB CHARGER UPS Module Battery CONVERTER / INVERTER CB 1...

  • Page 20: Figure 2-3 Single Line Diagram - Battery Operation

    Each UPS internal static bypass line will equally share the power supplied to the critical load whenever the system is in the Parallel Operation. In the event of a load overcurrent, the UPS transfers to bypass without interruption to the critical load.
  • Page 21 Referring to Figure 1.3: In the event of AC input source failure or interruption, the UPS Converter(s)* will de-energize and the UPS battery(s)* will immediately discharge and supply DC power to the Inverter to maintain continuous AC power to the load. This operation will continue until: a) The battery capacity expires and the inverter turns off, or b) Input power is restored after which the converter will power the inverter and critical load and...

  • Page 22: Figure 2-4 Ups Parts Location

    1) UPS cabinet – Front View LCD Touch Panel Bypass Module Monitor Display UPS Module Cable Entry Section 2) Backside of Bypass Module door LCD Touch Panel Monitor Display Display PCB DPAU-89A Main PCB UPHR-SA Figure 2-4 UPS Parts Location G9000 1000kVA Installation and Operation Manual –...

  • Page 23: Figure 2-5 Ups Parts Location - Front Inside View

    3) UPS cabinet – Front Inside View External I/F PCB CB1(left), 52C(right) IOAU-19 (Back Side of PCB Unit) Figure 2-5 UPS Parts Location – Front Inside View G9000 1000kVA Installation and Operation Manual – 91469-004...

  • Page 24: Specifications

    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...
  • Page 25 G9000 1000 kVA SPECIFICATIONS STATIC BYPASS INPUT Configuration 3 phase, 3 wire Voltage 480 V +/-10% Frequency 60 Hz +/-5% Bypass Overload 500% for 1 cycle BATTERY Type Lead Acid Ride Through Application Specific Nominal Voltage 480 Vdc Minimum Voltage 400 Vdc Float Voltage Up to 545 Vdc...

  • Page 26: Table 3-5 Typical Ups Efficiencies At Various Load

    G9000 1000 kVA SPECIFICATIONS Relative Humidity 5% ~ 95% Non-Condensing Altitude 0 to 6500 feet (1981 M) No Derating at 40ﾟC Location Indoor (free from corrosive gases and dust) Paint Color Munsell N1.5 (Black) Clearance Required Top: 24 in. (610 mm) Front: 39 in.
  • Page 27 OUTPUT CAPACITY OF EQUIPMENT IDENTIFI- APPLICATION CATION 1000kVA / 1000kW AC input breaker User supply 1600A (Recommended) Bypass input breaker User supply 1600A (Recommended) FP, FC, FN DC fuse 315A / 690V FBP, FBN DC fuse 1000A / 600V FBR1, FBR2, FBR3 FBR, FBS, FBT Control power fuse 30A / 600V...

  • Page 28: Operator Controls And Indicators

    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) LED DISPLAY 1) Load on inverter [ LOAD ON INVERTER ] (green) Illuminates when power is supplied from inverter to the critical load.

  • Page 29: Epo Button (Emergency Power Off Button) (7)

    The UPS "Equalize Charge" parameter is disabled by default unless the unit is sold with a wet cell battery system. The "Equalize Charge" button can be enabled by a Toshiba Service Representative while the UPS is in Test Mode (Battery Run Setup). Once enabled, the "Equalize ON/OFF" button is located under OPERATION / SETUP.

  • Page 30: Menu

    4.3.1.2 Battery Self Check The UPS "Battery Self Check" function provides a periodic battery self-check at preset intervals. The parameter is disabled by default. The adjustable Self Check cycle ships with a default setting of 720hrs. The minimum interval is 5 hrs. When the Self Check is initiated, the converter contributes 5% of the load to the inverter for up to 200ms.

  • Page 31: Figure 4-3 Startup/Shutdown Guidance

    -Start: When the bypass voltage is abnormal, the LCD asks the operator if an interrupted transfer is acceptable (Load may be lost). -Stop: When the bypass voltage is abnormal, the user cannot transfer from inverter to bypass line. Meaning of Icons in SMS (Single Module System) INV START;...

  • Page 32: Figure 4-6 Input Values

    B) MEASUREMENT MENU (Figure 4-6 and Figure 4-7) This screen shows details of measured values. Input and Output values are displayed. During Battery operation, remaining battery power and Run time are also displayed. Figure 4-6 Input Values Figure 4-7 Output values C) OPERATION MENU (Error! Reference source not found.Figure 4-8) This screen prompts the user to select: (a) whether the start &...

  • Page 33: Input Power Failure

    Figure 4-9 Log menu Figure 4-10 Event Log Figure 4-11 Battery log 4.3.3 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).

  • Page 34: Fault Indication

    4.3.4 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. 1) MESSAGE The display shows a fault code, the description of the fault and a guidance of what action is to be taken by the user.

  • Page 35: Figure 4-16 External Signal Terminal Block Tn21-25

    Figure 4-16 External Signal Terminal Block TN21-25 (NEC Class2) G9000 Installation and Operation Manual – 61480-012...

  • Page 36: Figure 4-17 External Signal Terminal Block Tn11-14 (Nec Class2)

    Figure 4-17 External Signal Terminal Block TN11-14 (NEC Class2) G9000 Installation and Operation Manual – 61480-012...

  • Page 37: Figure 4-18 Control Wiring For External Contacts

    A) Output Contacts (for external alarm annunciation) Output contacts consist of form “A” dry type contacts. Rated capacity of all output contacts is NEC Class2 (30Vdc/1Adc). All dry contacts should be operated at their rated values or lower. Figure 4-18 illustrates a typical installation. The external relay can also be a lamp, LED, computer, etc. UPS Cabinet External to UPS Cabinet...

  • Page 38: Figure 4-19 Remote "Start" Contact Connections

    NOTE: The UPS is equipped with a selectable output contact feature. The above alarms are the default settings. Contact TOSHIBA International Corporation for setup information. B) Input Contacts (for remote access to UPS) External contacts are provided by the user of the UPS system. Terminal voltage at the UPS is 12Vdc.
  • Page 39 The load will be dropped. NOTE: The UPS is equipped with a selectable input contact item. The above items are the default settings. Contact TOSHIBA International Corporation for setup information. CAUTION : In all cases, a switch having a protective cover is recommended in order to reduce the possibility of accidental operation.

  • Page 40: Installation And Operation

    INSTALLATION AND OPERATION TRANSPORTATION AND INSTALLATION Table 5-1 How to transport and install the system Transportation Installation Transport unit with forklift. Using the pre-drilled 2 or 4 holes in the each UPS channel base*, anchor the unit using appropriate hardware. (Not provided) * 4x 4-holes bases and 3x 2-holes bases CAUTION : Do not transport in a horizontal position.

  • Page 41: Procedure For Cable Connections

    Back side 0.0 mm (0 inch) Top side 500 mm (20 inches) D) External Battery Supply Please refer to the following when installing and maintaining batteries: The customer shall refer to the battery manufacturer's installation manual for battery installation and maintenance instructions. The maximum permitted fault current from the remote battery supply, and the DC voltage rating of the battery supply over-current protective device are shown in Table 3.3.
  • Page 42 Two (2) sources feeding the UPS: (1) Connect the AC input power cables from the input service entrance to the AC input power terminals, identified as A, B, C in Figure 3.1. Input cables must be sized for an ampere rating larger than the maximum input drawn by the converter.
  • Page 43 - Parallel control signal for TLAIN, TLAOUT, TLBIN, TLBOUT, CA1IN, CA1OUT, DIAIN, DIAOUT, DIBIN, DIBOUT as shown in Fig. 3.5. b.) Power wire connections From UPS AC Output Terminals to Toshiba Tie Cabinet (TTC) (Refer to Figure 3.4 and 3.5.) Straight through, shielded CAT5 cables with metal shrouded RJ-45 heads on both sides are to be used for the parallel control signal cables.

  • Page 44: Table 5-4 Recommended Cable Sizes

    Table 5-4 Recommended Cable Sizes 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 5 x 400MCM or 347 - 469 5 x 400MCM or 347 - 469...

  • Page 45: Table 5-6 Crimp Type Compression Lug

    Table 5-6 Crimp Type Compression Lug WIRE WIRE RECOMMENDATION CRIMP TOOL REQUIRED SIZE STRAND BURNDY TYPE Y35 OR Y46 (CODE) CLASS VENDOR CAT. NO. COLOR KEY DIE INDEX 300 MCM BURNDY YA30 WHITE 17 / 298 ILSCO CRA-300L WHITE 17 / 298 BURNDY YA32-LB 1026...

  • Page 46: Figure 5-1 Ups Terminal Designation

    52 S Terminals Bypass Module Bypass Input CB 3 Static Transfer Switch CONVERTER / INVERTER Terminals CB 1 Terminals 52 C Output input CHARGER Terminals Battery UPS Module Cabinet CONVERTER / INVERTER CB 1 52 C CHARGER UPS Module CONVERTER / INVERTER CB 1 52 C CHARGER...

  • Page 47: Figure 5-2 Diagram Of Input/Output Bus Bars And Terminal Blocks

    Figure 5-2 Diagram of input/output bus bars and terminal blocks Location of bus bars and terminal blocks (Bottom/Top/ Entry) 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” (12mm) diameter bolts.

  • Page 48: Figure 5-3 Diagram Of Power Wire & Control Wire Interconnections Between Ups And Battery

    Figure 5-3 Diagram of Power Wire & Control Wire Interconnections between UPS and Battery DC circuit breaker External signal User supplied terminal IOAU-19 - [TN1] Auxiliary “-” Negative “+” Positive Power terminal User supplied UPS module Wall mounted DC breaker for Battery G9000 Installation and Operation Manual –...

  • Page 49: Figure 5-4 Diagram Of Power Wire Connections (Parallel Operation System Connection)

    Figure 5-4 Diagram of power wire connections (Parallel Operation system connection) TOSHIBA TIE CABINET 52MB UPS-1 Bypass input Bypass Converter / Inverter 52L 1 Charger AC input AC output Battery UPS-2 Bypass input Bypass 52CS Converter / Inverter 52L 2...

  • Page 50: Figure 5-5 Diagram Of Power Wire & Control Wire Connect ( Parallel Operation System Connection 2X To 8X)

    Figure 5-5 Diagram of Power Wire & Control Wire Connect ( Parallel Operation system connection 2x to 8x) UPS - 1 UPS - 2 UPS -N 23 24 23 24 23 24 Toshiba Tie Cabinet IOAU- 19 IOAU- 19 IOAU- 19 TN11-14 TN11-14 TN11-14...

  • Page 51: Figure 5-6 Outline Drawing Of Ifau-16 And The Parallel System Operation Connection

    Figure 5-6 Outline Drawing of IFAU-16 and the Parallel System Operation Connection UPS- N CN95-20P CN94 CN96 J-10P J-16P GNDA GNDB CN95 CN94 CN96 IFAU-16 GNDC GNDD 8　　　　　　　　　　 ...1 TLBIN TLAIN TLBOUT TLAOUT CA1IN CA1OUT DIBIN DIAIN DIBOUT DIAOUT CN952 CN951 CN954 CN953...

  • Page 52: Operating Procedures

    OPERATING PROCEDURES For Parallel Operation system, refer to section “D) MMS Start-up Procedure”. (Parallel Operation system is herein after MMS [Multi Module System]) Start-up Procedure CAUTION : Before the UPS startup, the internal Bypass line starts to supply the unconditioned bypass input power to the critical load if the External input (or Bypass) Circuit Breaker is closed.
  • Page 53 B) Shutdown Procedure If a total UPS shutdown is required, verify that the critical load is OFF. On the LCD panel, select “OPERATION” tab, and then press the “STOP OPERATION” icon to proceed UPS shutdown. (Refer to Figure 2.3) Follow the “STOP OPERATION” guidance accordingly. During the procedure, UPS will transfer the power feeding from the Inverter supply to the Bypass line supply.
  • Page 54 OPERATION MENU. MMS Start-up Procedure External Circuit Check Verify that Toshiba Tie Cabinet (TTC) Circuit Breaker 52-MB is closed. Verify that TTC System Output Circuit Breaker 52L is open. Verify that TTC UPS Circuit Breakers 52L1, 52L2…and 52Ln are closed.

  • Page 55: Figure 5-7 Lcd Screen (Mms Operation)

    Transfer from Maintenance Bypass to MMS Bypass Operation Close the TTC System Output Circuit Breaker 52L. Open the TTC Circuit Breaker 52-MB. NOTE : 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"...

  • Page 56: Response To Ups Failure

    The error code indicated on the LCD display panel when an UPS alarms is very important. In order to reduce repair time, please include this information, along with the operation and load status for all correspondence to TOSHIBA field service group. G9000 Installation and Operation Manual – 61480-012...

  • Page 57: Maintenenace And Parts Replacement

    Toshiba recommends two Major 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.

  • Page 58: Fault Codes

    Air Filters Air filters can be obtained in bulk quantities from Toshiba International Corporation. Use only air filters specified by Toshiba. Table 7-2 Ait Filters UNIT Toshiba Part Number Quantity (per unit) 1000 kVA T90-AF-15x30x1 5 ea. 15”x30”x1” , Arrestance: 60-80%, Eff. <20%, MERV 1-4 FAULT CODES This section covers fault codes, their description and required action.
  • Page 59 BYPASS MODULE FAULT CODE LIST External Code relay Status Audible indication Meaning Guidance contact Message Alarm (Note 2) (Note 1) CHECK Bypass BYPS.VOLT.OUT Bypass line voltage is out of the Intermittent UA812 BYPASS Input RNG. specific range. sound INPUT Abnormal Bypass line power conductors CHECK Bypass...
  • Page 60 BYPASS MODULE FAULT CODE LIST External Code relay Status Audible indication Meaning Guidance contact Message Alarm (Note 2) (Note 1) CALL CONVERTER Intermittent UF055 Mixed operation (20 seconds) SERVICE Minor ABNORMAL sound ENGINEER All power converter modules CALL Intermittent UF151 BAT.VOLTAGE ABNL.
  • Page 61 BYPASS MODULE FAULT CODE LIST External Code relay Status Audible indication Meaning Guidance contact Message Alarm (Note 2) (Note 1) Cable disconnection in the CALL Continuous UF320 CTRL.CIRCUIT ERR. parallel interface board during SERVICE Major sound load supply (SMS). ENGINEER Cable disconnection in the CALL parallel interface board during...

  • Page 62: Ups Module Fault Codes

    BYPASS MODULE FAULT CODE LIST External Code relay Status Audible indication Meaning Guidance contact Message Alarm (Note 2) (Note 1) CALL Logic signal abnormal (Supply Intermittent UF377 CTRL. CIRCUIT ERR. SERVICE Minor OFF). sound ENGINEER CALL No answer for sending Intermittent UF378 CTRL.CIRCUIT ERR.
  • Page 63 UPS MODULE FAULTS CODE LIST Code External relay Status indication contact Meaning message (Note 2) (Note 1) Short time over-current has exceeded 150% of the Alarm MA810 INVERTER OVERLOAD rated current Overload The emergency stop was activated by the EPO switch MA817 EMERG.STOP ACTIV.
  • Page 64 UPS MODULE FAULTS CODE LIST Code External relay Status indication contact Meaning message (Note 2) (Note 1) Discrepancy between output voltage and inverter MF253 CTRL.CIRCUIT ERR. voltage, or between output voltage and bypass Minor voltage. MF254 COOLING FAN ABNL. Thermal relay of cooling fan worked. Minor MF256 O/P VOLTAGE ABNL.

  • Page 65: Daily Inspection

    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 the Authorized Toshiba Service Representatives or call Toshiba International Corporation at 1-877-867-8773. NOTE Table 9-1 How to Perform Daily Inspection No.
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  • Page 67: Appendix A - Installation Planning Guide (Ipg)

    - AC Output: 3φ, 3-wire + ground. - DC Input: 2-wire (Positive/Negative) + ground. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal). TOSHIBA INTERNATIONAL CORPORATION Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC.
  • Page 68 G9000 Installation and Operation Manual – 61480-012...
  • Page 69 G9000 Installation and Operation Manual – 61480-012...
  • Page 70 G9000 Installation and Operation Manual – 61480-012...
  • Page 72 SOCIAL INFRASTRUCTURE SYSTEMS GROUP POWER ELECTRONICS DIVISION 13131 West Little York Rd., Houston, TX 77041 Tel: 713/466-0277 Fax 713/466-8773 US 877/867-8773 Canada 800/872-2192 Mexico 01/800/527-1204 www.toshiba.com/tic/industrial/uninterruptible-power-systems Printed in Japan...

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