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Toshiba 4200FA User Manual

Uninterruptible power system three-phase 75 / 80 kva ups
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TOSHIBA
4200FA
U N I N T E R R U P T I B L E P O W E R S Y S T E M
THREE-PHASE 75 / 80 kVA UPS
M A N U F A C T U R E D I N T H E U . S . A .
U S E R S M A N U A L
D o c u m e n t N u m b e r : 5 6 4 1 8 - 0 0 2
D a t e : D e c e m b e r , 2 0 0 4

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  Summary of Contents for Toshiba 4200FA

  • Page 1 TOSHIBA 4200FA U N I N T E R R U P T I B L E P O W E R S Y S T E M THREE-PHASE 75 / 80 kVA UPS M A N U F A C T U R E D I N T H E U . S . A .
  • Page 3 T O S H I B A 4200FA THREE-PHASE 75/80 kVA UNINTERRUPTIBLE POWER SYSTEM OPERATION MANUAL FOR MODELS T42#3F750XAXXN, T42#3F750FAXXN, T42#3F800XAXXN, T42#3F800FAXXN. INTERNATIONAL CORPORATION T O S H I B A INDUSTRIAL DIVISION 13131 West Little York Rd., Houston, Texas 77041...
  • Page 4: Important Notice

    UNINTERRUPTIBLE POWER SYSTEM If additional information or technical assistance is required call Toshiba’s Customer Service 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. Unless otherwise specified on the warranty card, the warranty period for the UPS or UPS part is 36 months from the shipment date (see TIC bill of lading).
  • Page 5: Table Of Contents

    4.3.2 ...RS-232C ..........................31 4.3.3 ...UPS Shutdown (via RS-232C) ....................31 Specifications ....................... 32 Specifications – 4200FA 75kVA with Internal Transformer ............32 Specifications – 4200FA 75kVA without Internal Transformer .............33 Specifications – 4200FA 80kVA with Internal Transformer ............34 Specifications – 4200FA 80kVA without Internal Transformer .............35 Operating the UPS....................
  • Page 6 T O S H I B A 6.9.1... Line-1 System Messages ...................... 43 6.9.2... Line-2 System Fault Messages ..................... 43 6.9.3... Line-3 System Messages ...................... 43 6.9.4... Line-4 System Messages ...................... 44 6.10 Initial Battery Charge ......................... 45 6.11 Start-up Procedure........................46 6.12 Shutdown Procedure........................
  • Page 7: Purpose And Scope Of Manual

    Toshiba International Corporation reserves the right, without prior notice, to update information, make product changes, or to discontinue any product or service identified in this publication. 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 8: General Safety Instructions

    T O S H I B A GENERAL SAFETY INSTRUCTIONS DO NOT attempt to install, operate, maintain or dispose of this equipment until you have read and understood all of the product safety information and directions that are contained in this manual. Safety Alert Symbol The Safety Alert Symbol indicates that a potential personal injury hazard exists.
  • Page 9 T O S H I B A molten exploding parts that may cause serious injury or death if the proper precautions are not observed.
  • 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 T O S H I B A...
  • Page 12: 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 your nearest Toshiba authorized service center.
  • Page 13 T O S H I B A This unit contains sealed lead acid batteries. Lack of preventative CAUTION maintenance could result in batteries exploding and emitting gasses and/or flame. An authorized technician must perform annual preventative maintenance. Failure to replace a battery before it becomes exhausted may cause CAUTION the case to crack;...
  • Page 14: Instructions Importantes Concernant

    T O S H I B A INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITÉ Cette notice contient des CONSERVER CES INSTRUCTIONS instructions importantes concernant la sécurté Un battery puet présenter un risque de choc électrique, de brûlure ATTENTION par transfert d’ énergie. L’élimination des batteries est règlementèe.
  • Page 15: Product Description

    UPS battery-charge cycle resumes. Application and use Toshiba's 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 16: Unpacking/Inspection/Storage/Disposal

    T O S H I B A 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 units shipped in a crate, remove the screws that attach the shipping crate panels to each other and to the pallet.
  • Page 17: Inspection Of The New Ups Equipment

    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.
  • Page 18: Precautions

    T O S H I B A 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.
  • Page 19: Pre-Start Precautions

    CHARGE LED has gone out before removing the front panel of the UPS once the UPS power has been turned off. 8) Do not attempt to disassemble, modify, or repair the UPS. Call your Toshiba sales representative for repair information.
  • Page 20: Ups Connections

    T O S H I B A 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 75/80 kVA UPS.
  • Page 21: Recommended Wire Size And Tightening Torque For Ups Input And Output Terminals

    T O S H I B A 4.1.1 Recommended Wire Size and Tightening Torque for UPS Input/Output Terminals Minimum/Maximum Wire Size and Tightening Torque of UPS Input and Output Terminals Main Input & Tightening Torque (H1 – H3, Bypass Input (N, BYPN) (in-lbs.) BYP1, BYP2, BYP3)
  • Page 22: Power Connection Cable Routing

    T O S H I B A 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 23 T O S H I B A Dual Input UPS with input transformer. Shown with bottom cable entry configuration.
  • Page 24 T O S H I B A Single Input UPS with no transformers. Shown with bottom cable entry configuration.
  • Page 25 T O S H I B A Dual Input UPS with no transformers. Shown with bottom cable entry configuration.
  • Page 26 T O S H I B A Single Input UPS with input transformer. Shown with top cable entry configuration.
  • Page 27 T O S H I B A Dual Input UPS with input transformer. Shown with top cable entry configuration.
  • Page 28 T O S H I B A Single Input UPS with no transformers. Shown with top cable entry configuration.
  • Page 29 T O S H I B A Dual Input UPS with no transformers. Shown with top cable entry configuration.
  • Page 30: Dual Input Configuration

    T O S H I B A 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. Bypass jumpers are factory installed on bypass bus bars.
  • Page 31: Control Circuit And External Battery Interface Connections

    T O S H I B A Control Circuit and External Battery Interface Connections 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 32: Communication Interface

    T O S H I B A Communication Interface 4.3.1 Remote Contact The remote contact 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).
  • Page 33: 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 communication link is shown below.
  • Page 34: Specifications

    T O S H I B A 5.0 Specifications Specifications – 4200FA 75kVA with Internal Transformer Model Number T42#3F750@AXXN Rated Output Capacity 75kVA External Dimensions 44 inch W x 31 inch D x 74 inch H Weight 2150 pounds Rated Voltage...
  • Page 35: Specifications - 4200Fa 75Kva Without Internal Transformer

    T O S H I B A Specifications – 4200FA 75kVA without Internal Transformer Model Number T42F3F750@AXXN Rated Output Capacity 75kVA External Dimensions 44 inch W x 31 inch D x 74 inch H Weight 1560 pounds Rated Voltage 208 Vac Voltage Variation +10% to –15% ;...
  • Page 36: Specifications - 4200Fa 80Kva With Internal Transformer

    T O S H I B A Specifications – 4200FA 80kVA with Internal Transformer Model Number T42#3F800@AXXN Rated Output Capacity 80kVA External Dimensions 44 inch W x 31 inch D x 74 inch H Weight 2150 pounds Rated Voltage # = (B-208, H- 220, C-240, N-380,T-400/415, D-480, M-600 )Vac Voltage Variation +10% to –15% ;...
  • Page 37: Specifications - 4200Fa 80Kva Without Internal Transformer

    T O S H I B A Specifications – 4200FA 80kVA without Internal Transformer Model Number T42F3F750@AXXN Rated Output Capacity 80kVA External Dimensions 44 inch W x 31 inch D x 74 inch H Weight 1560 pounds Rated Voltage 208 Vac Voltage Variation +10% to –15% ;...
  • Page 38: Operating The Ups

    Charger/ Chopper External Batteries Power flow in AC input mode for the 4200FA 75/80 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 39: Battery Backup Mode

    33 shows (V min). The battery backup time and discharge process is explained in Section 6.2. Static Power Flow Bypass MCCB Output Isolating Converter Inverter XFMR Power Input Power Charger/ Chopper External Batteries Power flow in battery backup mode for the 4200FA 75/80 kVA UPS...
  • Page 40: 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 41: Battery Recharging

    T O S H I B A Battery Recharging The illustration below shows the battery recharge process after a full discharge. The recharge process typically consists of three periods. During the first period, the charging current is maintained at approximately 20.0 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 42: Front Panel Layout (All Units)

    T O S H I B A Front Panel Layout (All Units) 4-line liquid crystal Emergency RUN/STOP display screen Power Off switch key switch (see Section 6.9) (see Section 6.6) Line-1 Line-2 MONI BATT STOP Line-3 BATT INPUT OUTPUT TEST Line-4 BUZZ MENU ENTER...
  • Page 43: Epo (Emergency Power Off) Function

    T O S H I B A 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 44: Light Emitting Diode (Led) Functions

    T O S H I B A User Notification LEDs The following is a list of the user-notification LEDs and their function. 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 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 45: Liquid Crystal Display (Lcd) Functions

    T O S H I B A LCD Functions The LCD display is a 4-line by 20-character display. The LCD display conveys system operational information. 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. Listed below are the types of user-notification messages that are available for each line of the LCD display screen and a description of each.
  • Page 46: Line-4 System Messages

    T O S H I B A 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 is not wired for PHEI...
  • Page 47: Initial Battery Charge

    T O S H I B A 6.10 Initial Battery Charge The battery of the UPS must be charged before it is used for the first time or if the unit has not been used (AC power source removed) for more than 10 days. Use the following procedure to recharge the battery of the UPS.
  • Page 48: Start-Up Procedure

    T O S H I B A 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 perform the start-up procedure as follows: 1) Verify that all power switches are off, and that the RUN / STOP Switch is in the STOP position.
  • Page 49: Shutdown Procedure

    T O S H I B A 6.12 Shutdown Procedure When turning off the UPS, the following shutdown procedure should be used. 1) Move the RUN/STOP key switch of the UPS to STOP. Operation of the inverter halts. Output power is now provided to the load via the bypass circuit. If a power failure occurs in the commercial power source while in this state, the UPS will lose power and power to the load will be interrupted.
  • Page 50: Keypad Overview

    T O S H I B A 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). BATT Press to display UPS battery conditions (see Section 6.14.4).
  • Page 51: Key Functions

    T O S H I B A 6.14 Key Functions 6.14.1 MONI Upon completion of a successful UPS startup, the system will be in the AC Input mode of operation. The LCD display will show the main MONI (monitor) function. If the MONI key is pressed at this time the display output will not change.
  • Page 52: Batt Key

    T O S H I B A 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 53: 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 54: Menu Data Screens

    T O S H I B A 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 55: Settings For Display Duration

    T O S H I B A 6.15.3 Settings for Display Duration The LCD display is designed to switch off after a user-set period of inactivity. To set the duration of inactivity allowed, press the MENU key to access the menu data screens.
  • Page 56: Serial Com Station Address

    T O S H I B A 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 >...
  • Page 57: Charge Mode Select

    T O S H I B A 6.15.7 Charge Mode Select Press the MENU key to access the menu data screens. Press the Down arrow key to access the Charge Mode Select screen. CHARGE MODE SELECT EQUAL CHARGE>OFF ON >F1:DATA SET MODE >∆/∇:PRV/NEXT SCREEN Press the F1 key to display the following adjustment screen: CHARGE MODE SELECT...
  • Page 58: Overload Operation

    T O S H I B A 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...
  • Page 59: Backup History & Fault History

    T O S H I B A If the RUN/STOP key switch remains in the RUN position when the wait period of the UPS is complete the following screen will be displayed: - UPS ON-LINE - OUTPUT VOLTAGE= 208V CURRENT=100/100/99% DATE (DAY) TIME 6.17 Backup History &...
  • Page 60 T O S H I B A Press the F1 key to display the record relating to the first fault. FAULT HISTORY ( 1) Date Time fault code >∆/∇: EXIT F1: NEXT Press the F1 key again to display the record relating to each subsequent fault. FAULT HISTORY ( #) Date Time fault code...
  • Page 61: Ups Protection System

    T O S H I B A 7.0 UPS Protection System System Protection Features The following one-line schematic illustrates the electrical locations of the protection devices on the 75/80 kVA UPS models. Over-Voltage / Current-Limit Input Abnormal Overheat Under-Voltage Overload Overcurrent Static Power Flow...
  • Page 62: Preventive And Scheduled Maintenance / Part Replacement

    8.0 Preventive and Scheduled Maintenance / Part Replacement 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 63: External Dimensions / Shipping Weights

    T O S H I B A 9.0 External Dimensions / Shipping Weights External Dimensions...
  • Page 64: Shipping Dimensions

    T O S H I B A Shipping Dimensions Shipping Dimensions, Shipping Dimensions, All models Standard with crate Inches (cm) Inches (cm) Width 56 (142) 56 (142) Depth 43 (109) 43 (109) Height 79 (201) 82 (208) Height with packing material 82 (208) 82 (208) Shipping Weights...
  • Page 65 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.