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Toshiba 4200FA User Manual

Uninterruptible power system three-phase 80 kva ups
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TOSHIBA
U
P
S
NINTERRUPTIBLE
OWER
YSTEM
THREE-PHASE 80 kVA UPS
4200FA
User's Manual
Document Number: 56418-004
Date: November 2007

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  Summary of Contents for Toshiba 4200FA

  • Page 1 TOSHIBA NINTERRUPTIBLE OWER YSTEM THREE-PHASE 80 kVA UPS 4200FA User’s Manual Document Number: 56418-004 Date: November 2007...
  • Page 2 TOSHIBA 4200FA User’s Manual...
  • Page 3 TOSHIBA 4200FA THREE-PHASE 80 kVA UNINTERRUPTIBLE POWER SYSTEM USER’S MANUAL FOR MODELS T42F3F800FAXXN T42F3#800FAXXN T42#3F800FAXXN TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Road Houston, TX 77041-9990 4200FA User’s Manual...
  • Page 4 TOSHIBA 4200FA User’s Manual...
  • Page 5: Important Notice

    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 6: 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.
  • Page 7: Table Of Contents

    4.2.2 RS-232C ............................ 26 4.2.3 UPS Shutdown (via RS-232C)....................26 Specifications....................... 27 Specifications – 4200FA 80kVA without Internal Transformer ............27 ..Specifications – 4200FA 80kVA with Internal Transformer ............28 ..Operating the UPS ....................29 Operating the UPS.......................... 29 ..
  • Page 8 Preventive and Scheduled Maintenance / Part Replacement ......53 Preventive Maintenance ......................... 53 ..Parts Replacement ......................... 53 ..External Dimensions / Shipping Weights ............54 External Dimensions........................54 ..Shipping Dimensions ........................55 ..Shipping Weights..........................55 ..4200FA User’s Manual...
  • Page 9: General Safety Instructions

    Explosion warning ─ The explosion warning symbol is an explosion image enclosed in a triangle. The Explosion warning symbol is used to indicate locations and conditions where molten exploding parts that may cause serious injury or death if the proper precautions are not observed. 4200FA User’s Manual...
  • Page 10: Equipment Warning Labels

    If the labels are damaged or if additional labels are required, contact your TOSHIBA representative for additional labels. The following are examples of the warning labels that may be found on the equipment. The labels 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 11 TOSHIBA DANGER HAZARDOUS VOLTAGES Hazardous voltages are used in the operation of this equipment and could cause severe personal injury or loss of life. The following precautions should be observed to reduce the risk of injury or death. Only qualified technicians familiar with this equipment and the information supplied with it should be permitted to install and operate this equipment.
  • Page 12 Accidental contact with live parts can cause personal injury and death. Turn off and lock out all power sources. Wait at least five (5) minutes for power to dissipate then check voltage before servicing. 39561 (For Battery Units Only) 4200FA User’s Manual...
  • Page 13: Important Safety Instructions

    The maximum ambient temperature in which the UPS unit should be operated is 40°C (104°F). The nominal battery voltage is 288VDC. Only a qualified TOSHIBA Representative who is knowledgeable in batteries and the required precautions should only perform battery servicing. Keep unauthorized personnel away from batteries. To arrange for battery replacement, contact TOSHIBA for service.
  • Page 14 Use proper lifting means when moving batteries and wear all appropriate safety clothing and equipment. Do not dispose of lead acid batteries except through channels in accordance with local, state and federal regulations. 4200FA User’s Manual...
  • Page 15: Instructions Importantes Concernant

    TOSHIBA INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITÉ Cette notice contient des CONSERVER CES INSTRUCTIONS instructions importantes concernant la sécurté Un batterie puet présenter un risque de choc électrique, de brûlure ATTENTION par transfert d’ énergie. L’élimination des batteries est règlementèe. Consultar les codes ATTENTION locaux à...
  • Page 16: Product Description

    UPS battery-charge cycle resumes. Application and use The TOSHIBA 4200FA Uninterruptible Power Systems (UPS) provide continuous computer grade AC power in a compact and 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 17: Unpacking/Inspection/Storage/Disposal

    TOSHIBA 2.0 Unpacking/Inspection/Storage/Disposal Unpacking the UPS Equipment 1) Upon receipt of the UPS, a careful inspection for shipping damage should be made. 2) For international units, remove the screws that attach the shipping crate panels to each other and to the pallet. Remove the crate and foam packing material.
  • Page 18: Ups Equipment Inspection

    It is illegal to dump lead-acid batteries in landfills or dispose ATTENTION of 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. 4200FA User’s Manual...
  • Page 19: Precautions

    TOSHIBA 3.0 Precautions Because of the external dimensions of the 4200FA UPS and the way the outer panels are to be removed; only a minimum amount of space around the unit is required for ventilation and maintenance access. Figure 3.1 shows the minimum clearances required for proper UPS installation.
  • Page 20: Pre-Start Precautions

    UPS once the UPS power has been turned off 8) Do not attempt to disassemble, modify, or repair the UPS. Call TOSHIBA Service for repair information. 9) Turn the power on only after attaching ALL the covers and DO NOT remove any covers of the UPS when the power is on.
  • Page 21: Ups Connections

    4.0 UPS Connections UPS Power and Control Connections The following illustration shows the wiring connections to the input and output termination points and the Control Circuit Terminal Blocks for the 4200FA 80 kVA UPS. 4200 FA User’s Manual...
  • Page 22: Recommended Wire Size And Tightening Torque For Ups Input/Output Terminals

    Neutral Conductors are rated @ 1.73 or 200% of phase conductors, per NEC Note 1: Use a UL listed lug suitable for the wire size used. Note 2: Use tightening torque recommended by manufacturer of lug used. 4200FA User’s Manual...
  • Page 23: Power Connection Cable Routing

    TOSHIBA 4.1.2 Power Connection Cable Routing 1) Use separate metal conduits for routing the input power, output power, battery, and control circuits. 2) A separate ground cable should be run inside of the conduit with the input power, output power, and control circuits.
  • Page 24 TOSHIBA Dual Input UPS with input transformer. Shown with bottom cable entry configuration. 4200FA User’s Manual...
  • Page 25 TOSHIBA Single Input UPS with no transformers. Shown with bottom cable entry configuration. 4200 FA User’s Manual...
  • Page 26 TOSHIBA Dual Input UPS with no transformers. Shown with bottom cable entry configuration. 4200FA User’s Manual...
  • Page 27 TOSHIBA Single Input UPS with input transformer. Shown with top cable entry configuration. 4200 FA User’s Manual...
  • Page 28 TOSHIBA Dual Input UPS with input transformer. Shown with top cable entry configuration. 4200FA User’s Manual...
  • Page 29 TOSHIBA Single Input UPS with no transformers. Shown with top cable entry configuration. 4200 FA User’s Manual...
  • Page 30 TOSHIBA Dual Input UPS with no transformers. Shown with top cable entry configuration. 4200FA User’s Manual...
  • Page 31: Dual Input Configuration

    TOSHIBA 4.1.3 Dual Input Configuration Units are shipped from the factory wired for single input configuration. For those requiring a dual input configuration see below. This change should only be performed by factory trained service personnel and not by the end user.
  • Page 32: Control Circuit And External Battery Interface Connections

    Minimum Wire Size and Tightening Torque for UPS Control and Battery Interface Circuits USE MINIMUM 75° C COPPER WIRING TERMINAL (TERMINAL #) TIGHTENING TORQUE *UPS CONTROL CIRCUITS (1-18) 14-16 8 in-lbs. *BATTERY CONTROL CIRCUITS (3-6) 14-16 8 in-lbs. *Indicates Class 1 wiring method is to be used. 4200FA User’s Manual...
  • Page 33: Communication Interface

    TOSHIBA Communication Interface 4.2.1 Remote Contact The remote contact interface is a standard feature and is available as dry switch contacts through a DB9 male connector located under the Remote Eye Cover on the front of the UPS (see Section 4 for location). The following schematic shows the contact state and pin assignment for each signal and the associated DB9 connector pin-out.
  • Page 34: Rs-232C

    Remote Eye Cover on the front of the UPS (see Section 4 for location). This interface allows control of the UPS from a personal computer running special TOSHIBA software. The computer and the UPS are connected through a serial RS-232C communication port. The available data from the UPS, via the RS-232C communication link is shown below.
  • Page 35: Specifications

    TOSHIBA 5.0 Specifications Specifications – 4200FA 80kVA without Internal Transformer Model Number T42F3F800FAXXN Rated Output Capacity 80 kVA 41 in. x 31 in. x 74 in. External Dimen. (WxDxH) (1041 mm x 787 mm x 1880 mm) Weight 2000 lbs (907 kg)
  • Page 36: Specifications - 4200Fa 80Kva With Internal Transformer

    TOSHIBA Specifications – 4200FA 80kVA with Internal Transformer Model Number T42#3F800FAXXN Rated Output Capacity 80 kVA External Dimensions 41 in. x 31 in. x 74 in. (W x D x H) (1041 mm x 787 mm x 1880 mm) Weight...
  • Page 37: Operating The Ups

    Charger/ Chopper External Batteries Power flow in AC input mode for the 4200FA 80 kVA UPS 6.1.2 Bypass Mode If the UPS detects an overload or develops an internal fault, power flow is automatically switched from the main circuit of the UPS to the Bypass circuit. Power flow through the Bypass is shown in the following illustration.
  • Page 38: Battery Backup Mode

    Charger/ Chopper External Batteries Power flow in battery backup mode for the 4200FA 80 kVA UPS 6.1.4 External Maintenance Bypass (Customer Supplied) An external maintenance bypass may be installed in parallel with the UPS to allow servicing of the UPS while maintaining power to the load. Contact an authorized service representative for further information.
  • Page 39: 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 for the 4200FA UPS (Refer to the Battery System Manual for back-up times). These times are valid for full-load operation. At half-load operation the batteries can provide approximately 2 times the specified value.
  • Page 40: Battery Recharging

    The following table shows the rated maximum and minimum battery voltages, and the charge current for each of the sizes for 75 °F (24 °C) operation. Rated Battery Voltages 324 VDC V float 216 VDC V min 20.0 Amps I charge 4200FA User’s Manual...
  • Page 41: Front Panel Layout (All Units)

    Line-3 BATT INPUT OUTPUT Line-4 TEST BUZZ MENU ENTER STOP AC IN BATT FAULT 4200FA RESET ON LINE UNINTERUPTIBLE POWER SYSTEM Green light-emitting Red light-emitting 12-key Data entry keypad diodes (LED) diode (LED) (see Section 6.13) (see Section 6.8) (see Section 6.8)
  • Page 42: Epo (Emergency Power Off) Function

    TOSHIBA EPO (Emergency Power Off) Function The 4200FA UPS system is equipped with terminals for receiving an emergency power-off (EPO) closed contact switch command from two locations: (1) a remote location (see Section 4.2 Terminal Block Details) and (2) from a front panel mounted EPO switch (see Section 6.5 Front Panel Layout).
  • Page 43: User Notification Leds

    TOSHIBA User Notification LEDs The following is a list of the user-notification LEDs and their function. On when the UPS has normal AC input power that is within tolerance. If there is an input power failure this LED is off. If there is no power failure and the input voltage is in an over- voltage condition, the AC IN LED will flicker on and off rapidly (0.4 sec on and 0.4 sec off).
  • Page 44: Lcd Functions

    DCOC DC Over-current DCUB DC Unbalanced DCOV DC Over-voltage EERR Main EEPROM error Overheat (internal) Output Overload IVUV Inverter Under-voltage IVOV Inverter Over-voltage 6.9.3 Line-3 System Messages Line–3 messages show load current information, and user selected instructions. 4200FA User’s Manual...
  • Page 45: Line-4 System Messages

    TOSHIBA 6.9.4 Line-4 System Messages Line-4 messages reflect the UPS operating conditions. Warning messages will be displayed when an abnormal operating condition occurs. The following table shows the allowable Line-4 messages. LINE-4 MESSAGES Displayed Message Meaning Displayed when input Phase rotation has been wired PHEI in a counter clockwise rotation.
  • Page 46: Initial Battery Charge

    1) Turn the key switch to STOP. 2) Allow 24 hours for the batteries to charge and, upon completion, move the MCCB switch (see Section 4 for location) to off. 3) Repeat Initial Battery Charge procedure (a failure indicates battery replacement required). 4200FA User’s Manual...
  • Page 47: Start-Up Procedure

    TOSHIBA 6.11 Start-up Procedure The UPS batteries must be charged before the UPS is used for the first time or if the unit has not been used (ac power source removed) for more than 10 days (Refer to Section 6.10).
  • Page 48: Shutdown Procedure

    Emergency Power Off activation trips the MCCB and power is removed from the UPS and to any connected loads (see Section 6.6 "EPO Function"). All LEDs are off and the LCD display will show the following message: - OUTPUT SHUT DOWN - OUTPUT VOLTAGE= 0V CURRENT=LOW/LOW/LOW% 4200FA User’s Manual...
  • Page 49: Keypad Overview

    TOSHIBA 6.13 Keypad Overview The following illustrates the 12-key data entry pad with each key functionally labeled (see Section 6.5 ─ Front Panel Layout). MONI BATT BATT TEST BUZZ MENU ENTER STOP RESET Monitor: Press to display system-monitoring screens (see Section 6.14.1).
  • Page 50: Key Functions

    Ia =100% 15% display reads: CURR=LOW. CURRENT Ib= 100% Ic= 100% The Output Line Voltages (phase-neutral, and phase to phase), Frequencies / Sync Mode, Inverter Output Power, and Power Factor may be monitored by pressing the DOWN/UP keys. 4200FA User’s Manual...
  • Page 51: Batt Key

    TOSHIBA 6.14.4 BATT Key Pressing the BATT key during normal AC Input mode of operation displays battery capacity information. The following system message is displayed: Note: Discharge current in Line-3 is 0% - UPS ON-LINE - unless unit is in the battery mode.
  • Page 52: Buzz Stop Key

    - DISPLAY ERROR - Note: If the error message persists MAIN COMM. ERROR contact the TOSHIBA Service Center. PRESS & HOLD RESET KEY Upon a successful Reset the Startup Screen appears followed by the Main Monitor.
  • Page 53: Menu Data Screens

    TOSHIBA 6.15 Menu Data Screens 6.15.1 Settings for Calendar and Clock Press the MENU key to access the system configuration screens. Press the Down arrow key until the time and date screen is shown: CALENDER / CLOCK DATE (DAY) TIME >*F1: DATA SET MODE...
  • Page 54: Settings For Display Duration

    Press the Up/Down arrow keys to toggle from RUN to SWITCH. Press the ENTER key to save the selection or press the MENU key to exit to the main menu and discard the change (Remote S/U option required). This function is available in the Bypass mode only. 4200FA User’s Manual...
  • Page 55: Serial Com Station Address

    TOSHIBA 6.15.5 Serial Com Station Address Press the MENU key to access the menu data screens. Press the Down arrow key to access the Run/Switch select screen. SER COM STATION ADDR STATION ADDRESS: >*F1: DATA SET MODE > Δ/∇: PRV/NEXT SCREEN...
  • Page 56: Equalize Charge Mode Select

    TOSHIBA 6.15.7 Equalize Charge Mode Select Contact Toshiba Customer Support toll free at 1-800-231-1412 before using this option. DAMAGE to the battery system may occur if this option is used improperly. 6.15.8 Reset to Default Settings Press the MENU key to access the menu data screens. Press the Down arrow key to access...
  • Page 57: Overload Operation

    TOSHIBA 6.16 Overload Operation When the UPS is operating and an overload condition is detected the following screen is displayed. - UPS ON-LINE - Note: ### indicates an actual OUTPUT VOLTAGE= ###V numerical value. OUTPUT CURRENT= ###% * UPS OL: REDUCE LOAD * After a period of time, if the overload is still not reduced and the RUN/STOP key switch is in the RUN position, the UPS will transfer to bypass automatically.
  • Page 58: Backup History & Fault History

    Press the Up/Down arrow keys to return to the Battery Discharge Count screen. BATT DISCHARGE COUNT # TIMES > F1: FOR DETAILS >Δ/∇: TO SCROLL Press the Up/Down arrow keys to display the Fault Count screen. TOTAL FAULT COUNT ## TIMES > F1: FOR DETAILS >Δ/∇: TO SCROLL 4200FA User’s Manual...
  • Page 59 TOSHIBA Press the F1 key to display the record relating to the first fault. FAULT HISTORY ( 1) Date Time fault code >Δ/∇: EXIT F1: NEXT Press the F1 key again to display the record relating to each subsequent fault.
  • Page 60: Ups Protection System

    Inverter / chopper fault Operation Mode Start is inhibited Bypass operation; chopper and inverter are stopped after Fault Yes; continuous buzzer Audible Alarm RED fault lamp On Visible Alarm Relay Contact Fault relay closed; bypass relay closed Alarm Auto-Retransfer 4200FA User’s Manual...
  • Page 61: Preventive And Scheduled Maintenance / Part Replacement

    8.0 Preventive and Scheduled Maintenance / Part Replacement Preventive Maintenance TOSHIBA 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: External Dimensions / Shipping Weights

    TOSHIBA 9.0 External Dimensions / Shipping Weights External Dimensions 4200FA User’s Manual...
  • Page 63: Shipping Dimensions

    TOSHIBA Shipping Dimensions Shipping Dimensions, Shipping Dimensions, All models Standard with crate Inches (cm) Inches (cm) Width 56.2 (143) 56.9 (145) Depth 42.8 (109) 45.0 (114) Height 79.0 (201) 81.8 (208) Height with packing material 82.0 (208) 82.0 (208) Shipping Weights...
  • Page 66 INDUSTRIAL 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/ind Printed in the U.S.A.