Toshiba 4200 series Operation Manual

Uninterruptible power system three phase- 75/100kva ups
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TOSHIBA
UNINTERRUPTIBLE POWER SYSTEM
THREE PHASE- 75/100kVA UPS
4200 SERIES
MANUFACTURED IN THE U.S.A.
OPERATION MANUAL
Part Number: 51751-001
Date: March, 2003

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  • Page 1 TOSHIBA UNINTERRUPTIBLE POWER SYSTEM THREE PHASE- 75/100kVA UPS 4200 SERIES MANUFACTURED IN THE U.S.A. OPERATION MANUAL Part Number: 51751-001 Date: March, 2003...
  • Page 2 TOSHIBA 4200 SERIES THREE PHASE- 75/100 kVA UNINTERUPTIBLE POWER SYSTEM OPERATION MANUAL FOR MODELS U42B3F750C6CB U42B3F10KC6CB TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Rd., Houston, Texas 77041...
  • Page 3 UNINTERUPTIBLE POWER SUPPLY If additional information or technical assistance is required call Toshiba’s marketing department toll free at 1-800-231-1412, or write to: Toshiba International Corporation, 13131 W. Little York Rd., Houston, TX 77041-9990. Please complete the following information for your records; however, please keep this manual with the UPS equipment.
  • Page 4: General Safety Instructions

    TOSHIBA GENERAL SAFETY INSTRUCTIONS Warnings in this manual appear in any of four ways: Danger- The danger symbol is a lightning bolt mark enclosed in a triangle which precedes 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 severe property damage.
  • Page 5: Table Of Contents

    RS-232C ............................18 4.3.3 UPS Shutdown (via RS-232C) ...................... 18 Specifications ......................19 4200 Series Specifications 75 and 100kVA @ Standard 208Vac Output.......... 19 Operating the UPS....................20 Operating the UPS ..........................20 6.1.1 AC Input Mode (normal operation) ....................20 6.1.2...
  • Page 6 TOSHIBA 6.14.3 OUT ............................... 32 6.14.4 BATT Key ............................33 6.14.5 MENU, F1, ENTER, UP, & DOWN Keys..................33 6.14.6 BATT TEST Key ..........................33 6.14.7 BUZZ STOP Key ........................... 34 6.14.8 RESET Key............................ 34 6.15 Menu Data Screens ..........................35 6.15.1 Settings for Calendar and Clock....................
  • Page 7: Important Safety Instructions

    40°C. (25°C max. if battery cabinet is subject to same ambient) The nominal battery voltage for 75kVA is 240VDC; 100kVA is 324VDC A qualified Toshiba Representative who is knowledgeable of batteries and the required precautions should only perform servicing of the batteries. Keep unauthorized personnel away from batteries.
  • Page 8: Instructions Importantes Concernant

    TOSHIBA WARNING Personnel knowledgeable of batteries and the required precautions should perform installation and servicing of batteries. Keep Unauthorized personnel away from the batteries. Proper maintenance to the battery system of this unit must be done by a WARNING qualified service technician, this is essential to the safety and reliability of your UPS system.
  • Page 9: Product Description

    Application and use Toshiba's 4200 Series of on-line, Uninterruptible power systems (UPS) provide continuous computer grade 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 10: Uncrating/Inspection/Storage/Disposal

    TOSHIBA 2.0 Uncrating/Inspection/Storage/Disposal Uncrating the new UPS equipment: Upon receipt of the UPS, a careful inspection for shipping damage should be made. 1) Remove the screws that attach the shipping crate to the pallet; remove the crate and foam packing material.
  • Page 11: 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.
  • Page 12: Precautions

    TOSHIBA 3.0 Precautions Based on the 4200 Series UPS unit's external dimensions and the way the outer panels are removed; minimum amounts of unobstructed space around the unit is necessary for ventilation and maintenance access. Figure 3.1 shows the minimum clearances required for proper UPS site installation.
  • Page 13: Pre-Start Precautions

    TOSHIBA Pre-start Precautions Before connecting the UPS to a power source; move the MCCB switch (ON/OFF), on the side panel, to the OFF position and move the operation STOP/RUN key switch, on the front panel (See Section 9 for location), to the STOP position.
  • Page 14: Ups Connections

    TOSHIBA 4.0 UPS Connections Power Connections 75 and 100kVA The following illustrates the wiring connections to the Input and Output Terminations points for the 75 and 100kVA UPS Models 4.1.1 Input (N)
  • Page 15: Recommended Wire Size And Tightening Torque For Ups Input And Output Terminals

    TOSHIBA Recommended Wire Size and Tightening Torque For UPS Input and Output Terminals Minimum Wire Size and Tightening Torque of UPS Input and Output Terminals 75 & 100kVA (USE MINIMUM 90° C INSULATED COPPER WIRING) 75kVA 100kVA Phase: (A) (B) (C)
  • Page 16: Power Connection Cable Routing

    TOSHIBA 4.1.2 Power Connection Cable Routing The following illustrates the proper cable routing that should be followed during the power connection process of the 75 and 100kVA. Top Conduit Entry Main Input Main MCCB Main Input (N) Output Ground Bottom Conduit Entry...
  • Page 17: Control Circuit And External Battery Interface Connections 75 And 100Kva

    TOSHIBA Control Circuit and External Battery Interface Connections 75 and 100kVA The following illustrates the wiring connections of the Control Circuits, and Battery Interface Circuits. 4.2.1 Recommended Wire Size and Tightening Torque UPS Control and Battery Interface Minimum Wire Size and Tightening Torque for UPS Control and Battery Interface Circuits USE MINIMUM 75°...
  • Page 18: Communication Interface

    TOSHIBA Communication Interface 4.3.1 Remote Contact (IBM AS/400) The AS/400 interface is a standard feature and is available as dry switch contacts through a DB9 male connector located on the back side of the UPS (see Section 9 for DB9 connector location). The following schematic shows the contact state and pin assignment for each signal and the associated DB9 connector pin-out.
  • Page 19: Rs-232C

    UPS (see Section 9 for DB9 connector 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...
  • Page 20: Specifications

    TOSHIBA 5.0 Specifications 4200 Series Specifications 75 and 100kVA @ Standard 208Vac Output Model Number U42B3F750C6CB U42B3F10KC6CB Rated Output Capacity 75kVA 100kVA External Dimensions Input Rated Voltage 208V/120V Voltage Variation +10% to –15% ; (-15% to –30%) **** Rated Frequency...
  • Page 21: Operating The Ups

    TOSHIBA 6.0 Operating the UPS Operating the UPS 6.1.1 AC Input Mode (normal operation) The following illustration shows circuit power flow when the UPS is operating normally in the AC input mode. The UPS unit's rectifier, including a boost chopper circuit, converts AC input power to DC power.
  • Page 22: Battery Backup Mode

    Power flow in battery backup mode for the 75 and 100 kVA models 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 75, 100 kVA models (Refer to the Battery System Manual for back-up times).
  • Page 23: Battery Low Voltage Tolerances

    TOSHIBA The following illustration graphically shows the battery discharge process at full load conditions. Battery Low Voltage Tolerances Excessive discharge will cause the UPS system's battery voltage to drop bellow tolerable levels. 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.
  • Page 24: Front Panel Layout (All Units)

    TOSHIBA The recharge process usually consists of three periods. During the first period, the charging current is maintained at approximately 38.0 amperes. This current is the maximum value that can be used to charge the batteries (for minimal recharge time) while assuring safety and long battery life.
  • Page 25: Epo (Emergency Power Off) Function

    TOSHIBA EPO (Emergency Power Off) Function These units are equipped with terminals for receiving an emergency power-off (EPO) "closed contact" switch command from two locations: (1) a remote location (see Section 4.3 Terminal Block Details) and (2) from a front panel mounted EPO switch (see Section 6.5 "Front Panel Layout).
  • Page 26: Light Emitting Diode (Led) Functions

    TOSHIBA Light Emitting Diode (LED) Functions The following list describes the conditions necessary for each LED lamp to be "on". This green LED lamp is "on" when the UPS is not in an input over-voltage condition, input under-voltage condition, or power failure state. If there is an input power failure, this lamp is "off".
  • Page 27: Liquid Crystal Display (Lcd) Functions

    TOSHIBA Liquid Crystal Display (LCD) Functions The liquid crystal display (LCD) screen is a 4-line by 20-character wide display. The LCD display contains information about the operation of the UPS. It should be used in conjunction with the LED display (see Section 6.8) and the audible alarms (see Section 6.7) for total system monitoring.
  • Page 28: 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 chart shows the allowable Line-4 messages. Line-4 Messages Displayed Message Meaning Displayed when input Phase rotation is not wired for PHEI clockwise rotation.
  • Page 29: Initial Battery Charge

    TOSHIBA 6.10 Initial Battery Charge The UPS System's battery must be charged before it is used for the first time or when the unit has not been used (AC power source removed) for more than 10 days. Use the following procedure to recharge the UPS System's battery: 1) Switch on power at the UPS input distribution panel.
  • Page 30: 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). If the batteries are charged then use the following start-up procedure: 1) Verify that all power switches are off, and that the "RUN / STOP Switch on the UPS is in...
  • Page 31: Shutdown Procedure

    TOSHIBA 6.12 Shutdown Procedure When turning off the UPS, the following shutdown procedure should be used: 1) Move the unit's STOP/RUN key switch, located on the front panel, to STOP. Operation of the UPS unit's inverter stops. Output power is now provided to the load through the unit's bypass circuit.
  • Page 32: 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 MONI Press to display system-monitoring screens (see Section 6.14.1).
  • Page 33: Key Functions

    TOSHIBA 6.14 Key Functions 6.14.1 MONI After the UPS has been successfully started, the system will be in the normal 'AC input mode' of operation. The LCD screen will automatically display the main MONI (monitor) function. If the MONI key is pressed at this time the screen output will not change.
  • Page 34: Batt Key

    TOSHIBA 6.14.4 BATT Key When the BATT key is pressed during normal 'ac input mode' of operation, the LCD screen displays details about the unit's battery capacity. 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 35: Buzz Stop Key

    - DISPLAY ERROR - Note: If this error message persist MAIN COMM. ERROR contact Toshiba Service Center. PRESS & HOLD RESET KEY If the 'reset' function is successful then the display will begin from the 'start-up screen' and then change to the 'main monitor' screen.
  • Page 36: Menu Data Screens

    TOSHIBA 6.15 Menu Data Screens 6.15.1 Settings for Calendar and Clock Press the MENU key to access the menu data screens and press the 'down' arrow key to scroll to the present date and time adjustment screen: CALENDER / CLOCK DATE (DAY) TIME >*F1: DATA SET MODE...
  • Page 37: Run Switch Select

    TOSHIBA DISPLAY DURATION SET <3 MIN> 30 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 38: Output Voltage Adjustment

    TOSHIBA 6.15.6 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 Note: ### indicate an actual OUTPUT VOLTAGE.=###%...
  • Page 39: Reset To Default Settings

    TOSHIBA 6.15.8 Reset to Default Settings Press the MENU key to access the menu data screens and press the 'down' arrow key to scroll to the original factory 'default settings' adjustment screen display: MENU DATA RESET DATA INITIALIZATION >F1: TO ACCESS RESET >∆/∇:PRV/NEXT SCREEN...
  • Page 40 TOSHIBA - BYPASS OPERATION - OUTPUT VOLTAGE=208V CURRENT= 100/100/100 >PLEASE WAIT Or if the UPS is waiting and the RUN/STOP key switch is switched to the STOP position while the UPS is waiting, the following screen will be displayed: - BYPASS OPERATION -...
  • Page 41: Ups Protection System

    TOSHIBA 7.0 UPS Protection System System Protection Features The preceding one-line schematic illustrates the electrical locations of the protection devices on the 75, and 100kVA UPS models. System Protection Functions The following charts shows the built-in UPS’s fault protection functions on the 75 and 100kVA models.
  • Page 42: Preventive And Scheduled Maintenance / Part Replacement

    8.0 Preventive and Scheduled Maintenance / Part Replacement Preventive Maintenance Toshiba's 4200 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.
  • Page 43: External Layouts / Dimensions / Shipping Weights

    TOSHIBA 9.0 External Layouts / Dimensions / Shipping Weights External Dimensions 75 and 100kVA 62.797 (1595mm)
  • Page 44: Shipping Dimensions 75, And 100Kva

    TOSHIBA Shipping Dimensions 75, and 100kVA Shipping Dimensions 75Kva 100kVA Width- Inches 64.0 64.0 (cm) (162.6) (162.6) Depth- Inches 42.5 42.5 (cm) (108.0) (108.0) Height- Inches 72.438 72.438 (cm) (184.0) (184.0) Model Shipping Weights U42B3F10KC6CB 2600 Pounds 1180 Kilograms U42B3F750C6CB...
  • Page 45 TOSHIBA TOSHIBA TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Road, Houston, Texas 77041 Tel: (713) 466-0277 Fax: (713) 466-8773 Printed in the U.S.A.

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