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Toshiba 4200FA User Manual

Uninterruptible power system three-phase 15/ 25/ 30/ 33/ 50 kva ups
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U
P
S
NINTERRUPTIBLE
OWER
YSTEM
THREE-PHASE 15/ 25/ 30/ 33/ 50 kVA UPS
FA
4200
USER'S MANUAL
MANUFACTURED IN THE U.S.A.
Document Number: 53878-004
Date: April 2005
0

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  Summary of Contents for Toshiba 4200FA

  • Page 1 NINTERRUPTIBLE OWER YSTEM THREE-PHASE 15/ 25/ 30/ 33/ 50 kVA UPS 4200 USER'S MANUAL MANUFACTURED IN THE U.S.A. Document Number: 53878-004 Date: April 2005...
  • Page 2 4200FA THREE PHASE- 15/25/30/33/50 kVA UNINTERRUPTIBLE POWER SYSTEM OPERATION MANUAL FOR MODELS T42F3F150X#MBN T42F3F150F#MBN T42#3#150##MXN T42F3F250X#MBN T42F3F250F#MBN T42#3#250##MXN T42F3F300X#MBN T42F3F300F#MBN T42#3#300##MXN T42F3F330X#MBN T42F3F330F#MBN T42#3#330##MXN T42F3F500XAMBN T42F3F500F#MBN T42#3#500##MXN TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Rd., Houston, Texas 77041...
  • Page 3 Should further information be desired or should particular problems arise which are not covered sufficiently, the matter should be referred to your local Toshiba sales office. The contents of this instruction manual shall not become a part of or modify any prior or existing equipment, commitment, or relationship.
  • Page 4 TOSHIBA is a registered trademark of the Toshiba Corporation. All other product or trade references appearing in this manual are registered trademarks of their respective owners.
  • Page 5: General Safety Instructions

    CAUTION The word CAUTION or ATTENTION in capital letters without the safety alert symbol indicates a potentially hazardous situation exists which, if not avoided, may result in equipment and property damage. CAUTION/ATTENTION TOSHIBA...
  • Page 6: Special Symbols

    It is comprised of an equilateral triangle enclosing a lightning bolt. Explosion Hazard Symbol A symbol which indicates a hazard of injury from exploding parts. It is comprised of an equilateral triangle enclosing an explosion image. TOSHIBA...
  • Page 7: Equipment Warning Labels

    If the labels are damaged or if additional labels are required, contact your Toshiba representative for additional labels. Labels attached to the equipment are there to provide useful information or to indicate an imminently hazardous situation that may result in serious injury, severe property and equipment damage, or death if the instructions are not followed.
  • Page 8 TOSHIBA...
  • Page 9: Table Of Contents

    UPS Shutdown (via RS-232C) ... 29 Technical Data ... 30 4200FA 15 / 25kVA @ 208 VAC Input/ 208 VAC Output w/Internal Batteries... 30 4200FA 15/ 25kVA w/Internal Transformer... 31 4200FA 30 / 33kVA @ 208 VAC Input/ 208 VAC Output w/Internal Batteries... 32 4200FA 30/ 33kVA w/Internal Transformer...
  • Page 10 System Protection Features ... 59 System Protection Functions... 59 Authorized Factory Service ... 60 Start-up... 60 Preventive Maintenance... 60 Parts Replacement ... 61 External Layouts / Dimensions / Weights... 62 External Dimensions 15/25/30/33kVA... 62 External Dimensions 50kVA... 63 Shipping Dimensions and Weights... 64 TOSHIBA...
  • Page 11: Important Safety Instructions

    Therefore, a user-installed circuit breaker should be provided between the UPS output and the load input. 3. Battery servicing should be performed by a qualified Toshiba Representative only. 4. Unauthorized personnel should not service batteries.
  • Page 12 The nominal battery voltage for all internal battery models is 288VDC. The nominal battery voltage for all external battery models is 288VDC. An Authorized Toshiba Service Representative who is knowledgeable of batteries and the required precautions should perform service on the batteries. Keep unauthorized personnel away from batteries.
  • Page 13 INSTRUCTIONS IMPORTANTES CONCERNANT CONSERVER CES INSTRUCTIONS ATTENTION ATTENTION ATTENTION TOSHIBA LA SÉCURITÉ Un battery puet présenter un risque de choc électrique, de brûlure par transfert d’ énergie. Por le replacement, utiliser le même nombre de batteries du modéle suivant.
  • Page 14: Product Description

    Application and Use Toshiba's 4200FA On-Line, Uninterruptible Power Systems (UPS) provide continuous computer grade isolated AC power in a compact, efficient, high performance unit. The UPS assures safe, reliable operation of critical office equipment, ranging from personal computers to mini-computers to local area networks (LAN).
  • Page 15: Uncrating/Inspection/Storage/Disposal

    ½x3” bolts to secure the rails to the shipping pallet. Attach the rails as shown to the front of the pallet. DANGER TOSHIBA Remove packing material. the screws that attach the shipping crate to the pallet. Remove the crate and foam packing material.
  • Page 16: Uncrating The New Ups Equipment 50Kva

    TOP HEAVY EQUIPMENT. IMPROPER LIFTING CAN RESULT IN INJURY OR DEATH. LIFT AND MOVE CAREFULLY AND ONLY WITH ADEQUATE EQUIPMENT AND TRAINED DANGER PERSONNEL. THIS EQUIPMENT WILL TIP OVER EASILY UNTIL FIXED IN PLACE. TOSHIBA...
  • Page 17: Inspection Of The New Ups Equipment

    It is ILLEGAL to dump lead-acid batteries in landfills or dispose of ATTENTION improperly. Please help our Earth by contacting the environmental protection agencies in your area, the battery manufacturer, or call Toshiba toll-free at (800) 231-1412 for more information about recycling batteries. TOSHIBA 5.18...
  • Page 18: Installation Precautions

    3.0 Installation Precautions Based on the 4200FA UPS external dimensions and the way the outer panels are removed; minimum amounts of unobstructed space around the unit are necessary for ventilation and maintenance access. Figure 3.1 shows the minimum clearances required for proper UPS site installation.
  • Page 19: System Preparation (Pre-Power)

    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. TOSHIBA...
  • Page 20: Ups Connections

    The following illustrates the wiring connections from the power distribution panel (not part of the UPS) to the terminal block of the 15/25/30/33 kVA UPS Models 4.1.1 CUSTOMER-PROVIDED AC DISTRIBUTION PANEL Optional Bypass Input: 3-phase, 3-Wire *208V requires 3-phase, 4-Wire Wye TOSHIBA INPUT GROUND RESISTANCE LESS THAN 10 OHMS...
  • Page 21: Power Connections 15/25/30/33Kva With Internal Transformer

    The following illustrates the wiring connections from the power distribution panel (not part of the UPS) to the terminal block of the 15/25/30/33 kVA UPS Models TO BATTERY SYSTEM GND Optional Bypass Input: 3-Phase, 3-Wire *208V requires 3-Phase, 4-Wire Wye TOSHIBA CUSTOMER-PROVIDED AC DISTRIBUTION PANEL INPUT GROUND RESISTANCE LESS THAN 10 OHMS...
  • Page 22: Recommended Wire Size And Torque Requirements

    UPS Optional Separate Bypass Input “TB4” 15 / 25kVA (USE MINIMUM 75° C INSULATED COPPER WIRING) Phase: (A) (B) (C) 15 kVA Input: (H1) (H2) (H3) Maximum Wire Size is 2 AWG. TOSHIBA 25 kVA Torque Torque 51 in-lbs. 51 in-lbs.
  • Page 23: Power Connection Cable Routing And Conduit Placement

    1) Input and Output conductors shall be installed in separate conduits, and installed in accordance with the latest edition of NEC and the Local Authority having jurisdiction. 2) Battery conductors shall be installed in a separate conduit and be of low resistance type. TOSHIBA OUTPUT CONDUIT BATTERY CONDUIT...
  • Page 24: Control Circuit And External Battery Interface Connections 15/25/30/33 Kva

    BATTERY CONTROL CIRCUITS (3-6)* BATTERY (+/-) *Indicates Class 1 wiring methods is to be used. Maximum Wire Size for Control Circuits is 12 AWG. Maximum for Battery is 2 AWG. TOSHIBA Battery Connection (+) Positive (-) Negative 15/25/30/33 kVA TIGHTENING...
  • Page 25: Power Connections 50 Kva

    The following illustrates the wiring connections from the power distribution panel (not part of the UPS) to the terminal block of the 50 kVA UPS Model (H1) (H2) (H3) (N) INPUT: 3-phase, 3-wire 208V requires 3-phase, 4-wire TOSHIBA (L1) (L2) (L3) OUTPUT: 3-phase (4-wire) (H1)
  • Page 26: Recommended Wire Size And Torque Requirements For Ups Input And Output Terminals

    Phase: (A) (B) (C) Input: (H1) (H2) (H3) 208/120 Maximum Wire Size for Input is 1/0 AWG. Maximum Wire Size for Neutral is 250MCM. TOSHIBA Minimum Wire Size and Torque Requirements UPS Input and Output Terminals 50 kVA OUTPUT: NEUTRAL...
  • Page 27: Power Connection Cable Routing

    4.3.2 Power Connection Cable Routing The following illustrates the proper cable routing that should be followed during the power connection process for the 50kVA. Removable cover for conduit access TOSHIBA Bottom Conduit Entry...
  • Page 28: Control Circuit And External Interface Connections

    UPS CONTROL CIRCUITS (1-24)* BATTERY CONTROL CIRCUITS (3-6)* *Indicates Class 1 wiring methods is to be used. Maximum Wire Size is 12 AWG. TOSHIBA (3) Battery Shunt Trip (4) Battery Shunt Trip (5) Battery Aux. (6) Battery Aux. 50 kVA...
  • Page 29: Communication Interface

    1) Pin “switches” are shown in their inactive states. Example: (if battery voltage is low, pin 7 will be connected to System Common). 2) Contacts are rated at 30 VDC, 0.1 amps; 125 VAC, 3 amps. 3) Pin number “3” is not used. TOSHIBA DB9 Male Connector Outline (Facing Connector) Battery Discharge...
  • Page 30: Rs-232C

    UPS. This interface allows control of the UPS from a computer network running Toshiba RemotEyeII™ software. The computer and the UPS are connected through a serial RS-232C communication port. The available data from the UPS, via the RS-...
  • Page 31: Technical Data

    5.0 Technical Data 4200FA 15 / 25kVA @ 208 VAC Input/ 208 VAC Output w/Internal Batteries Model Number Rated Output Capacity External Dimensions W x D x H (mm) Input Rated Voltage Voltage Variation Rated Frequency Input Cables required Dual Input Option Cables required...
  • Page 32: 4200Fa 15/ 25Kva W/Internal Transformer

    4200FA 15/ 25kVA w/Internal Transformer Model Number Rated Output Capacity External Dimensions W x D x H (mm) Input Rated Voltage Voltage Variation Rated Frequency Input Cables Required Dual Input Option Cables required * Power Factor Required Input kVA Walk-in Function...
  • Page 33: 4200Fa 30 / 33Kva @ 208 Vac Input/ 208 Vac Output W/Internal Batteries

    4200FA 30 / 33kVA @ 208 VAC Input/ 208 VAC Output w/Internal Batteries Model Number Rated Output Capacity External Dimensions W x D x H (mm) Input Rated Voltage Voltage Variation Rated Frequency Input Cables required Dual Input Option Cables required...
  • Page 34: 4200Fa 30/ 33Kva W/Internal Transformer

    4200FA 30/ 33kVA w/Internal Transformer Model Number Rated Output Capacity External Dimensions W x D x H (mm) Input Rated Voltage Voltage Variation Rated Frequency Input Cables Required Dual Input Option Cables required * Power Factor Required Input kVA Walk-in Function...
  • Page 35: 4200Fa 50Kva @ 208 Vac Input/ 208 Vac Output W/Internal Batteries

    4200FA 50kVA @ 208 VAC Input/ 208 VAC Output w/Internal Batteries Model Number Rated Output Capacity External Dimensions W x D x H (mm) Input Rated Voltage Voltage Variation Rated Frequency Input Cables Required Dual Input Option Cables required * Power Factor...
  • Page 36: 4200Fa 50Kva W/Internal Transformer

    4200FA 50kVA w/Internal Transformer Model Number Rated Output Capacity External Dimensions W x D x H (mm) Rated Voltage Voltage Variation Rated Frequency Input Cables Required Dual Input Option Cables required Input * Power Factor Required Input kVA Walk-in Function...
  • Page 37: Operating The Ups

    UPS's Bypass circuit back to the Inverter circuit after removing the overload (see "Overload Operation"). Isolation Transformer Model Input Power 5.7.2.1 Bypass Mode for Optional Alternate Input Models TOSHIBA Bypass Converter Inverter MCCB Chopper Batteries Power flow in AC Input Mode...
  • Page 38: Battery Backup Mode

    When this occurs, the batteries will stop supplying power to the load. This minimum level is the rated minimum voltage (V min). Isolation Transformer Model MCCB Input Power TOSHIBA Bypass Converter Inverter Chopper Batteries Bypass Converter Inverter...
  • Page 39: Battery Backup Time And Discharge Process

    Battery Backup Time and Discharge Process The UPS system, when used in conjunction with a Toshiba designed Battery System, is designed to provide several minutes of back-up time (Refer to the Battery System Manual for back-up times). These times are valid when the unit is operating under full load. When these models are operating at half load, the batteries can provide approximately 2 times the specified value.
  • Page 40: Battery Recharging

    75°F (24° C) ambient. Rated Battery Voltages 15/25/30/33 Model Internal Battery V float 324.0 VDC V min 252 VDC I charge 4.0 A TOSHIBA 50kVA Internal Internal Transformer Battery 324.0 VDC 324.0 VDC 252 VDC 252 VDC 10.0 A 11.5 Amps...
  • Page 41: Front Panel Layout (All Units)

    Audible alarms will sound when the UPS is in the Battery Backup Mode, has a fault, is at the low battery voltage, or is in an overload condition. The following chart shows the audible alarm TOSHIBA Emergency power off switch STOP/RUN key (see Section 6.6)
  • Page 42 TOSHIBA pattern duration for each condition. Time intervals are shown in seconds. The audible alarm can be silenced, by pressing “BUZZ STOP” on the keypad. Condition Audible pattern UPS in Battery Backup Mode (Battery Voltage 100-92%) UPS Low Battery (Battery Voltage < 92%) Overload .5 S...
  • Page 43: Led (Light Emitting Diode) Functions

    Bypass Operation; UPS Fault AC IN BATT FAULT Battery Back-up; (Battery Voltage Low) AC IN BATT ON (Blinking) FAULT TOSHIBA Output Shutdown (After EPO received (Emergency Power Off )) AC IN BATT FAULT Fatal Communication Error (Display to Control Interface) AC IN...
  • Page 44: Lcd (Liquid Crystal Display) Functions

    DCOV VOUV VOOV 5.15.3 Line-3 System Messages Line–3 messages show load current information, and user selected instructions. TOSHIBA LINE-1 MESSAGES Translation Displayed when UPS is in the start-up condition or display board is resetting. Displayed when the UPS is in Bypass Operation.
  • Page 45: Line-4 System Messages

    Line-4 will be blank when the BATT key is pressed during Battery Backup Mode with normal battery voltage. The # symbol signifies numerical values or other information supplied by the UPS. TOSHIBA Line-4 Messages Translation Displayed when Input Phase rotation has been wired in a counter-clockwise rotation.
  • Page 46: Initial Battery Charge

    2) Allow 24-72 hours for the batteries to charge and then move the Circuit Breaker to "off." 3) Repeat Initial Battery Charge procedure. (A failure indicates battery replacement may be necessary). TOSHIBA - UPS START UP - > PLEASE WAIT (DATE) DAY (TIME)
  • Page 47: Start-Up Procedure

    FAULT(s) DETECTED at start-up message such as the following: UPS FAULT (BYPASS ON) PRESS DOWN TO DETAIL > ENTER FOR DETAILS Refer to the "Line-2 System Fault Messages" section for details. TOSHIBA - UPS START UP - > PLEASE WAIT DATE (DAY) TIME - UPS ON-LINE -...
  • Page 48: Shutdown Procedure

    EPO switch) is pushed, the Circuit Breaker is tripped and power is removed from the UPS and to any attached loads. All LED lamps are "off" and the LCD screen will display the following message: - OUTPUT SHUT DOWN - CURRENT=LOW/LOW/LOW% TOSHIBA BYPASS OPERATION OUTPUT VOLTAGE=207V DATE (DAY) TIME OUTPUT VOLTAGE= 0V...
  • Page 49: Maintenance Bypass Procedure

    Cam Switch counter-clockwise until “UPS MODE” Position is reached. 5) Rotate the “STOP/RUN” switch to the “RUN” position. 6) Verify that the Inverter indicator light on the front panel is lit. The unit is now back On-Line and supplying conditioned power to the load. TOSHIBA...
  • Page 50: Keypad Overview

    Press to confirm user-selected command or action. RESET Press to reset UPS panel’s message-display area. Press to forward through display data values or to forward through menus. Press to reverse through display data values or to reverse through menus. TOSHIBA BATT BATT TEST MENU...
  • Page 51: Key Functions

    The Output Line Voltages (phase-neutral, and phase to phase), Frequencies / Sync Mode, Inverter Output Power, and Power factor can be monitored by pressing the "up/down" keys. TOSHIBA - UPS ON-LINE - DATE (DAY) TIME - BATTERY BACKUP –...
  • Page 52: Batt Key

    TOSHIBA 5.21.4 BATT Key When the BATT key is pressed during normal 'AC Input Mode' of operation, the LCD screen displays details about the battery capacity. The following system message is displayed: - UPS ON-LINE - BATTERY VOLTAGE=324V CHARGE CURR.=0% If an AC input power failure occurs, and no abnormal operating conditions are present, the UPS will switch to standard 'Battery Backup Mode'.
  • Page 53: Buzz Stop Key

    TOSHIBA When the battery test is completed, the previous operation will be resumed and the main system MONI screen will be displayed. If the battery test detects a low DC battery voltage, then the message screen will display: - UPS ON-LINE -...
  • Page 54: Menu Data Screens

    'down' arrow key to scroll to the LCD-Idle Mode Select screen display: DISPLAY DURATION SET <3 MIN> >F1: DATA SET MODE >∆/∇:PRV/NEXT SCREEN TOSHIBA CALENDER / CLOCK DATE (DAY) TIME CALENDER / CLOCK DATE (DAY) TIME 30 MIN...
  • Page 55: Run Switch Select

    TOSHIBA Press the F1 key to display the LCD-Idle mode setting adjustment screen: DISPLAY DURATION SET <3 MIN> >∆/∇: CHANGE DATA >ENTER:ACCEPT CHANGE Press the 'up' or 'down' arrow key to move the marker between the two available idle mode times. Press the ENTER key to save the change or press the MENU key to exit to the main menu and discard the change.
  • Page 56: Output Voltage Adjustment

    TOSHIBA 5.22.6 Output Voltage Adjustment When the MENU key is pressed and held 3-4 seconds during normal 'AC Input Mode' of operation, the LCD screen displays the output voltage on the present output voltage adjust screen: OUTPUT VOLT. ADJUST OUTPUT VOLTAGE.=###% >F1:DATA SET MODE...
  • Page 57: Reset To Default Settings

    If the STOP/RUN key switch is in the STOP position; the UPS is in the Bypass Mode and, if the overload condition is still present, the following screen will be displayed: - BYPASS OPERATION - CURRENT= 114/116/114% * UPS OL: REDUCE LOAD * TOSHIBA MENU DATA RESET MENU DATA RESET - UPS ON-LINE - OUTPUT VOLTAGE=208...
  • Page 58: Backup History And Fault History

    Pressing the MONI and F1 keys simultaneously, for a few seconds will cause the Battery Discharge Count screen to be displayed. Press the F1 key to display the record relating to the first discharge event. TOSHIBA - BYPASS OPERATION - OUTPUT VOLTAGE=208V CURRENT= 100/100/100 >PLEASE WAIT...
  • Page 59 TOSHIBA Press the F1 key again to display the record relating to each subsequent discharge event. BACKUP HISTORY ( #) #MIN##SEC VB=324V BT *PF OL >∆/∇: EXIT Press the ‘up’ or ‘down’ arrow keys to return to the Battery Discharge Count screen.
  • Page 60: Ups Protection System

    Battery Discharge Operation Mode Battery Discharge after Fault Audible Alarm Visible Alarm Battery Lamp Flickers Relay Contact Low Battery Relay Alarm closed Auto-Retransfer TOSHIBA Bypass Converter Inverter Chopper Batteries Low Battery Built-in UPS Fault Protection Functions Inverter Under-voltage (IVUV) INVERTER UNDERVOLTAGE Overload or short circuit at the load.
  • Page 61: Authorized Factory Service

    10. Internal Maintenance Bypass: This verifies the operation of the Maintenance Bypass. Preventive Maintenance Toshiba's 4200FA 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.
  • Page 62: Parts Replacement

    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. 4) Cooling fan: Replace once every 3 years. TOSHIBA Necessary corrective...
  • Page 63: External Layouts / Dimensions / Weights

    TOSHIBA 8.0 External Layouts / Dimensions / Weights External Dimensions 15/25/30/33kVA...
  • Page 64: External Dimensions 50Kva

    TOSHIBA External Dimensions 50kVA...
  • Page 65: Shipping Dimensions And Weights

    15 kVA (927mm x 1092mm x 1765mm) 36.5” x 43.0” x 69.5” 25/30/33 kVA (927mm x 1092mm x 1765mm) 55.0” x 44.5” x 69.5” 50 kVA (1397mm x 1130mm x 1765mm) TOSHIBA Internal Model Battery Transformer Battery Transformer Battery Transformer Shipping Weights Lbs.
  • Page 66 TOSHIBA TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Road, Houston, Texas 77041 Tel: (713) 466-0277 Fax: (713) 896-5212 Telex: 762078 E-mail: Toshibaups@tic.toshiba.com Printed in the U.S.A.