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G8000 Series Installation and Operation Manual

16    Periodic Maintenance/Parts Replacement ......................................................................77

16.1    Scheduled Maintenance ............................................................................................77
16.2    Parts Replacement ....................................................................................................77

Appendix A - Installation Planning Guides .............................................................................79

80kVA IPG .............................................................................................................................79
100kVA IPG ...........................................................................................................................82
125kVA IPG ...........................................................................................................................85
150kVA IPG ...........................................................................................................................88
225kVA IPG ...........................................................................................................................91
300kVA IPG ...........................................................................................................................94
500kVA IPG ...........................................................................................................................97

Appendix B - Outline Drawings ................................................................................................101

Appendix C - 500kVA Input- and Output- Cabinet Joining Instructions ...............................105

Summary of Contents for G8000 Series

Page 1: ...t 2013 Toshiba International Corporation All rights reserved Document 61001 002 April 2013 G8000 SERIES INSTALLATION and OPERATION MANUAL 480 480 V 80 100 125 150 225 300 500 kW UNINTERRUPTIBLE POWER SYSTEM UPS ...

Page 2: ......

Page 3: ...eration Manual UNINTERRUPTIBLE POWER SYSTEM UPS Copyright 2013 Toshiba International Corporation All rights reserved G8000 SERIES INSTALLATION and OPERATION MANUAL 480 480 V 80 100 125 150 225 300 500 kW Document 61001 002 April 2013 ...

Page 4: ...f the details or variations in equipment nor to provide for every possible contingency concerning installation operation or maintenance Should further information be required or if problems arise which are not covered sufficiently contact your Toshiba sales office The contents of this instruction manual shall not become a part of or modify any prior or existing agreement commitment or relationship...

Page 5: ...ty period for the UPS or UPS part is 12 months from the shipment date see Toshiba International Corporation bill of lading Unless otherwise specified the warranty period for a UPS battery is 36 months from the shipment date see Toshiba International Corporation Bill of Lading for shipping date JOB NUMBER MODEL NUMBER SERIAL NUMBER APPLICATION SHIPMENT DATE INSTALLATION DATE INSPECTED BY ...

Page 6: ... or trade references appearing in this manual are registered trademarks of their respective owners Toshiba International Corporation shall not be liable for direct indirect special or consequential damages resulting from the use of the information contained within this manual This manual is copyrighted No part of this manual may be photocopied or reproduced in any form without the prior written co...

Page 7: ...sporting Unpacking 6 4 4 Inspection Storage 8 5 Installation Precautions 9 5 1 Wiring Connection 13 6 Warning Labels 14 6 1 Warning Label Locations 15 7 Weight and Dimensions 18 8 Transporting 19 8 1 Transporting By Crane 20 8 2 Transporting By Forklift 21 9 Storage Operating Environment 23 9 1 Operating Precautions 23 9 2 Maintenance Precautions 25 9 3 Disposal 26 10 Installation 27 10 1 Unpackin...

Page 8: ...3 LCD Indicators 56 13 4 Normal Display 57 13 5 Fault Display 59 13 6 LCD Scroll 60 14 Operating the UPS 61 14 1 Operation Types 62 14 2 Pre operational Check 62 14 3 Startup Procedures 63 14 4 Switch Power Supply UPS to Bypass 65 14 5 Stop 66 14 6 Complete Shutdown 67 14 7 Changing Between Float Charge and Equalize Charge 68 14 8 Changing to Float Charge from Protection Charge If applicable 69 14...

Page 9: ... 16 1 Scheduled Maintenance 77 16 2 Parts Replacement 77 Appendix A Installation Planning Guides 79 80kVA IPG 79 100kVA IPG 82 125kVA IPG 85 150kVA IPG 88 225kVA IPG 91 300kVA IPG 94 500kVA IPG 97 Appendix B Outline Drawings 101 Appendix C 500kVA Input and Output Cabinet Joining Instructions 105 ...

Page 10: ...iv G8000 Series Installation and Operation Manual ...

Page 11: ...nsporting installing and wiring the UPS In addition have a thorough understanding of the information provided in the chapters titled General Safety Instructions Important Safety Instructions Safety Precautions Installation Precautions Please read the G8000 Series Operation Manual for important instructions on operating the UPS This manual and the accompanying drawings should be considered a perman...

Page 12: ...al When symbols are used in this manual they will include important safety information that must be carefully followed Safety Alert Symbol indicates that a potential personal injury hazard exists Prohibited Symbol indicates DO NOT take action Mandatory Symbol indicates that the following instruction is required Ground Symbol indicates the location of the equipment grounding conductor Electrical Vo...

Page 13: ...ound lockout tagout circuits and equipment and clear faults in accordance with established safety practices Be trained in the proper care and use of protective equipment such as safety shoes rubber gloves hard hats safety glasses face shields flash clothing etc in accordance with established safety practices The word DANGER in capital letters preceded by the safety alert symbol indicates that an i...

Page 14: ...should provide circuit breakers between the UPS AC input or Bypass input and the power sources and between the UPS output and the critical load input The minimum device ratings are listed in Table 3 1 TABLE 3 1 UPS MINIMUM DEVICE RATINGS Capacity Rated Output Input Breaker Rating Output Breaker Rating 80 kVA 480 V 277 V 480 V 150 A 480 V 125 A 100 kVA 480 V 277 V 480 V 200 A 480 V 150 A 125 kVA 48...

Page 15: ... instruments traffic signal instruments combustion control instruments medical operating room or life support equipment all types of safety devices etc Unintended Usage of Toshiba products listed in this document shall be made at the customer s own risk The application of the UPS without special consideration for equipment that supports human safety and or maintain public services may cause seriou...

Page 16: ...omer Support Center or an authorized Toshiba representative for informaton on proper disposal of UPS components It is illegal to dispose of certain components without conforming to environmental regulations for indusrial commercial waste 4 3 Transporting Unpacking WARNING WhentransportingtheUPSbycrane followtheSPECIFIEDWORKPROCEDURE The suspension wire angle should be less than 60 The UPS falling ...

Page 17: ...ransporting and positioning the UPS Pushing pulling on the sides of the unit to move it may result in damage to the UPS See Figure 4 1 Exterior Handling label Fig 4 1 Exterior Handling label FORKS 4 Ft Minimum length WARNING Risk of tipping For safe handling lift from back and sides only as shown above UPS Do not push or pull from sides BACK SIDE Do not push or pull from sides BY CRANE BY FORKLIFT...

Page 18: ...ecifications Storage During periods of non use the following guidelines are recommended for storage Storage Preparation 1 Power up the UPS and allow it to operate with no load for 24 hours to fully charge the batteries 2 Stop the unit 3 Place the Main Circuit Breaker switch in the OFF position Storage Conditions For best results store the UPS in the original shipping container and place on a wood ...

Page 19: ...ED CLEARANCE around the UPS Inadequate space around the UPS makes it difficult to perform maintenance inspections will lead to insufficient ventilation and or cause malfunctions Install anchor bolts to secure the UPS to the installation floor The UPS may fall during an earthquake if the anchor bolts are not installed and secured Only factory authorized personnel should relocate modify or replace p...

Page 20: ...d or nearby rooms Floor wax that contains silicon may cause static electricity WARNING The UPS should be installed per local and or national electric codes by qualified personnel Faults or improper operation may occur if the UPS is not installed properly When an external maintenance bypass is installed for the UPS before switching to external bypass ensure that the UPS unit is switched to AC Bypas...

Page 21: ... due to vibrations 50 Hz 100 Hz must not exceed 0 1 mm Dust Dust must not exceed normal atmospheric levels and must not include conductive particles silicone or oils Flammable Gas No flammable and or explosive gas Hydrogen sulfide H2 S Less than or equal to 0 0001 PPM Sulfurous acid gas SO2 Less than or equal to 0 05 PPM Chlorine gas Cl2 Less than or equal to 0 002 PPM Ammonia gas NH3 Less than or...

Page 22: ... of the correct voltage to the input terminals of the UPS NOTE Ensure the input phasing is connected in clockwise rotation CW UPS internal circuitry is designed to disable further UPS operation if the input phasing is installed in counter clockwise rotation CCW 10 Connect the output terminals of the UPS to the load refer to NEC Article 300 Wiring Methods and Article 310 Conductors For General Wiri...

Page 23: ... an electrical shock hazard Connecting to more than one ground may cause a ground loop See Chapter 8 UPS Wiring DO NOT force bend or pull wires DO NOT damage wire insulation DO NOT place heavy objects on top of UPS Observe the above precautions when making wire connections or handling the wires Failing to observe these precautions may damage the insulation of the wires or may cause a fire or an el...

Page 24: ...ements with the power on do not touch any electrical connection points Remove all jewelry from wrists and fingers Make sure test equipment is in good safe operating condition While servicing stand on some type of insulation and be sure not to be grounded Follow the safety instructions given in the equipment manual carefully and observe all danger warning and caution notices 40308 The UPS and Batte...

Page 25: ...TICAL FUSE SIZING WARNI NG D 40830 E 39561 DANGER Turn off and lock out all power sources Wait at least five 5 minutes for power to dissipate then check voltage before servicing Capacitors stay charged after power has been shut off Accidental contact with live parts can cause personal injury and death RISK OF ELECTRIC SHOCK 39561 F 58705 SERIAL LABEL LISTED 27E5 MFD IN U S A FROM FOREIGNAND DOMEST...

Page 26: ...16 G8000 Series Installation and Operation Manual FIGURE 6 3 150 225 KVA UPS WARNING LABELS FIGURE 6 4 300 KVA UPS WARNING LABELS ...

Page 27: ...17 G8000 Series Installation and Operation Manual FIGURE 6 3 500 KVA UPS WARNING LABELS FINAL LAYOUT NOT AVAILABLE AT THIS TIME CONTACT THE FACTORY FOR ADDITIONAL INFORMATION ...

Page 28: ... UPS UNIT AND SHIPPING WEIGHTS Model Unit Shipping 80 kVA 1390 lb 630 kg 1440 lb 652 kg 100 kVA 1740 lb 789 kg 1790 lb 812 kg 125 kVA 1740 lb 789 kg 1790 lb 812 kg 150 kVA 2467 lb 1119 kg 2556 lb 1159 kg 225 kVA 2980 lb 1352 kg 3069 lb 1392 kg 300 kVA 4575 lb 2075 kg 4725 lb 2143 kg 500 kVA Input Cabinet 1570 lb 712 kg 1 1620 lb 735 kg 1 500 kVA Output Cabinet 4950 lb 2245 kg 1 5100 lb 2313 kg 1 1...

Page 29: ...onal injuries CAUTION DO NOT transport move store or place the UPS on its side Excessive force applied from heavy components inside may damage the UPS Avoid vibration or shock exceeding 0 5G Failing to observe this precaution may cause damage to the UPS DO NOT allow the UPS to suffer shock or impact when unpacking Tools used to remove packaging materials may cause damage to the UPS DO NOT install ...

Page 30: ...URE 8 3 UNEVEN CABLES FIGURE 8 4 ACCEPTABLE OPERATION FIGURE 8 5 UNACCEPTABLE OPERATION G8000 Series Installation Manual 21 8 1 Transporting By Crane Cables should have sufficient ratings and be of the same length Make sure the suspension cables are hooked at eyebolts See Figure 8 1 Keep the angle less than 60 between cables Refer to Chapter 7 Weight and Dimension for UPS cabinet weight Keep UPS l...

Page 31: ...Insert the forks into the space shown in Figure 8 6 Spaces for the forks are provided underneath the UPS DO NOT swing or tilt UPS when lifting and or transporting Minimize the impact when lowering the UPS to the floor FIGURE 8 6 TRANSPORTING 80 300 KVA UPS BY FORKLIFT 80 225 kVA 300 kVA Secure the forks against the base then lift Insert the forks here Insert the forks here Secure the forks against...

Page 32: ...KVA UPS BY FORKLIFT See Appendix C for cabinet mating insturctions Input Cabinet Insert the forks here Secure forks against the base and then lift 500 kVA Ships in two parts Input and Output Cabinets Output Cabinet Insert the forks here Secure forks against the base and then lift ...

Page 33: ...Humidity The relative humidity must be between 30 and 90 and without condensation due to temperature changes Altitude This equipment is rated for installations up to 3240 ft 1000m above sea level Consult with the factory to determine the derating factor for installations above 3240 ft 1000m Dust Dust must not exceed normal atmospheric levels and must not include conductive particles silicone or oi...

Page 34: ...er sizing the UPS for lock rotor current 5 DO NOT insert metal objects or combustible materials in the ventilation slots of the UPS 6 DO NOT place hang or paste any objects on the exterior surfaces of the UPS 7 The capacitors in the UPS maintain a residual charge for a while after turning the UPS off The required discharge time for each UPS typeform is provided via a cabinet label and a CHARGE LED...

Page 35: ...onnel have the skills and knowledge relating to the construction installation operation and maintenance of the electrical equipment and has received safety training on the hazards involved Refer to the latest edition of NFPA 70E for additional safety requirements Qualified Personnel shall 1 Have read the entire operation manual 2 Be trained and authorized to safely energize de energize ground lock...

Page 36: ...ly Please help protect the Earth by contacting the environmental protection agencies in your area the battery manufacturer or call Toshiba toll free at 877 867 8773 for more information about recycling batteries CAUTION DO NOT dispose of the batteries in a fire The batteries may explode DO NOT open or mutilate the batteries Released electrolyte is harmful to the eyes and skin and could also be tox...

Page 37: ...s to secure the UPS to the installation floor The UPS may fall during an earthquake if the anchor bolts are not installed and secured DO NOT transport move store or place the UPS on its side Forces due to heavy components inside may damage the UPS DO NOT allow the UPS to suffer shock or impact when unpacking Tools used to remove packaging materials may cause damage to the UPS DO NOT push or pull o...

Page 38: ...ratched and that the UPS cabinet is not damaged DO NOT damage the UPS when using tools to remove packaging materials If provided DO NOT remove the plastic sheet cover until installation Do not remove the fan covers until UPS start up The fan covers should be removed by factory authorized personnel Packing materials should be disposed by the appropriate means Immediately report any abnormalities to...

Page 39: ...ew holes Side View Anchor Bolt FIGURE 10 2 ANCHOR BOLT INSTALLATION DETAIL FIGURE 10 3 HOLE LOCATIONS DIMENSIONS ON BOTTOM OF UPS Back Front 4 x 0 5 in Dia 12 mm 29 7 in 755 mm 21 7 in 551 mm 80 100 125 kVA See Appendix B 21 7 in 551 mm Back Front 4 x 0 5 in Dia 12 mm 46 1 in 1171 mm 150 225 kVA See Appendix B 25 6 in 650 mm Back Front 8 x 0 5 in Dia 12 mm 22 5 in 571 mm 300 kVA See Appendix B 22 ...

Page 40: ...in parallel with the UPS to allow servicing of the G8000 while maintaining power to the UPS load Contact the Toshiba Customer Service for further information G8000 Series Installation Manual 27 11 UPS Wiring Figure 11 1 illustrates the external wiring of the G8000 UPS See corresponding section to each wiring term Power cable connection at terminal blocks buses and external breaker provision for th...

Page 41: ...aining power to the UPS load Contact the Toshiba Customer Service for further information G8000 Series Installation Manual 27 11 UPS Wiring Figure 11 1 illustrates the external wiring of the G8000 UPS See corresponding section to each wiring term Power cable connection at terminal blocks buses and external breaker provision for the AC input output Bypass Input and DC input Earth ground wire at gro...

Page 42: ...N m 3 1 0 2 2 0 AWG 1 2 2 0 AWG 50 in lb 5 6 N m 4 1 0 2 2 0 AWG 1 2 2 0 AWG 50 in lb 5 6 N m 5 1 0 2 2 0 AWG 1 2 2 0 AWG 50 in lb 5 6 N m 6 1 0 2 2 0 AWG 1 2 2 0 AWG 50 in lb 5 6 N m 73 2 1 0 2 2 0 AWG 2 1 2 2 0 AWG 50 in lb 5 6 N m 8 1 0 2 2 0 AWG 1 2 2 0 AWG 50 in lb 5 6 N m 9 1 0 2 2 0 AWG 1 2 2 0 AWG 50 in lb 5 6 N m 10 1 0 2 2 0 AWG 1 2 2 0 AWG 50 in lb 5 6 N m 113 2 1 0 2 2 0 AWG 2 1 2 2 0 ...

Page 43: ...3 Cable sized for neutral current 1 7Xphase current Size cable appropriate to actual load type balanced unbalanced non linear TABLE 11 2 RECOMMENDED CABLE SIZE TIGHTENING TORQUE FOR 125 KVA UPS Block Number Cable Size Min Max 2 Tightening Torque 75 C Copper Wire 90 C Copper Wire 1 2 3 2 2 0 AWG 2 0 2 2 0 AWG 50 in lb 5 6 N m 2 2 3 2 2 0 AWG 2 0 2 2 0 AWG 50 in lb 5 6 N m 3 2 3 2 2 0 AWG 2 0 2 2 0 ...

Page 44: ...l buss strips for the 300 kVA UPS The buss strips are located inside at the top of the unit 5 3 in 135 mm 1 97 in 50 mm 1 77 in 45 mm 1 75 in 45 mm 3 in 77 mm 0 5 in Dia 1 27 mm FIGURE 11 4 TERMINAL BUS DETAIL 13 11 N 1 U 2 V 10 W 12 9 V 8 U 7 N 6 W 5 V 4 U 3 W AC INPUT AC OUTPUT BYPASS INPUT BATTERY Optional Flywheel Input fuse Flywheel connects to Battery Flywheel Input Note Contact the factory ...

Page 45: ...nections Toshiba recommends using the compression lugs listed in Table 11 3 or their equivalent for cable terminations to be mounted on the bus strips 3 Phase AC Power Lugs 4 in 102 mm 1 75 in 44 5 mm 0 875 in 22 mm 1 75 in 44 5 mm 6 x 0 5625 in Dia 14 3 mm 0 875 in 22 mm 0 75 in 19 mm 5 5 in 140 mm 1 75 in 44 5 mm 1 75 in 44 5 mm 0 875 in 22 mm 1 75 in 44 5 mm 6 x 0 5625 in Dia 14 3 mm 0 875 in 2...

Page 46: ... YA 27 CRB 3 OL YA28 LB Orange Orange Purple 14 101 14 101 15 4 0 B I B Burndy Ilsco Burndy YA28 CRB 4 OL YA29 LB Purple Purple Yellow 15 15 16 300 MCM B I B Burndy Ilsco Burndy YA30 CRA 30OL YA32 LB White White Red 17 298 17 298 18 324 350 MCM B I Burndy Ilsco YA31L CRA 350 Red Red 18 18 600 MCM B I Burndy Ilsco YA36L CRA 600 Green Green 22 22 TABLE 11 4 RECOMMENDED CABLE SIZE AND FASTENER TORQUE...

Page 47: ...tring 2 Fastener torque specified for 1 2 in diameter grade 5 steel bolt 3 Per flywheel unit 4 Cable sized for neutral current 1 7Xphase current Size cable appropriate to actual load type balanced unbalanced non linear TABLE 11 5 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 225 KVA UNIT USE 75 C Copper Wire Block Number Cable Size Min Max Tightening Torque2 75 C Copper Wire 90 C Copper Wire 1 2 ...

Page 48: ... bolt 3 Per flywheel unit 4 Cable sized for neutral current 1 7Xphase current Size cable appropriate to actual load type balanced unbalanced non linear TABLE 11 7 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 500 KVA UPS Bus Number Cable Size Min Max Tightening Torque1 75 C Copper Wire 90 C Copper Wire 1 3 250 kcmil 3 400 kcmil 3 4 0 kcmil 3 250 kcmil 540 in lb 61 N m 2 3 250 kcmil 3 400 kcmil 3 ...

Page 49: ...kVA The recommended conduit landing arrangements are illustrated in Figure 11 9 thru 11 13 The five 5 holes must be punched during installation The dashed rectangle indicates the UPS opening behind the conduit landing plates BASE PLATES DIMENSIONS 0 78 in 0 78 in 23 74 in 4 74 in CONTROL WIRES AC INPUT BYPASS AC OUT PUT BATTERY Recommended Conduit Placement Order in Top Conduit Landing Plate 21 85...

Page 50: ...ATE 150 AND 225 KVA ONLY 4 36 in 21 5 in 31 5 in 4 27 in TOP ENTRY DIMENSIONS FRONT OF UPS BASE PLATES DIMENSIONS 0 7 in 0 7 in 42 126 in 4 74 in CONTROL WIRES AC INPUT BYPASS AC OUT PUT BATTERY Recommended Conduit Placement Order in Top Conduit Landing Plate 21 85 in 17 72 in 3 35 in 7 48 in FIGURE 11 10 BOTTOM CONDUIT LANDING PLATES 100 KVA T80S3K10KK6XSNH 150 225 KVA 4 36 in 23 11 in 5 9 in 21 ...

Page 51: ... Ensure that your installation adheres to local and NEC electrical codes FIGURE 11 13 TOP CONDUIT LANDING PLATES FOR THE 500 KVA UPS CABLE ENTRY PLATE AC INPUT BYPASS INPUT 28 0 X 6 3 711 MM X 161 MM CABLE ENTRY PLATE AC OUTPUT DC INPUT 28 0 X 6 3 711 MM X 161 MM CABLE ENTRY PLATE CONTROL 28 0 X 6 3 711 MM X 161 MM Recommended Conduit Placement Order in Top Conduit Landing Plates CONDUIT LANDING P...

Page 52: ... V 600 A 480 V 500 A 500 VDC 1200A 500 kVA 480 V 277 V 480 V 800 A 480 V 800 A 600 VDC 1200A 11 5 Grounding Wire WARNING Be sure to ground the UPS as specified Using the UPS without a proper ground will deteriorate the insulation cause leakage of currents and electric shock The resistance to ground should be less than or equal to 10 ohms The 80 100 150 225kVA earth grounding bus are located inside...

Page 53: ... so may degrade the performance of the unit 10 mm or 7 16 in Bolt Facility earth ground Ground wire routing through top conduit landing plate Ground bus G8000 150 225 kVA Ground bus 12 mm or 1 2 in Terminal 10 mm or 7 16 in Bolt Feed through opening AWG 2 38 mm2 ground wire To facility earth ground Facility earth ground Alternate ground wire routing through top conduit landing plate Note Use eithe...

Page 54: ...7 Input Remote Run Close to run UPS 8 Input P24 9 Input Remote Stop Close to stop UPS 10 Output Bypass Supply Close during Bypass Operation 11 Output Output Signal Ground Ground for pin 1 5 10 12 Input P24 Battery s 13 Input Battery Overheat Overheat B contact 14 Output Bypass Breaker 15 Output 52C Trip Signal Shunt Trip Signal by EPO 16 Output Battery Breaker shunt trip 17 Output 72B Trip Signal ...

Page 55: ... according to the system configuration 11 7 1 Recommended configuration for 4 wire input with Input Neutral grounded Figure 11 16 shows recommended grounding configuration when the input neutral is grounded The neutral line at the input source is usually grounded The neutral terminal in the UPS cabinet should be disconnected from the ground bus The neutral connection for the UPS bypass input shoul...

Page 56: ... GROUND BUS N G 3φ 3φ 3φ N G UPS Cabinet N 3φ 3φ G Input Source Remove Jumper Cable G N 3φ To the Load N G 3φ 3φ 3φ N G UPS Cabinet N 3φ 3φ G Input Source Jumper Cable Remains in Place G N 3φ To the Load N G 3φ 3φ 3φ N G UPS Cabinet 3φ 3φ G Input Source Jumper Cable Remains in Place G N 3φ To the Load N G 3φ 3φ 3φ N G UPS Cabinet G N 3φ 3φ To the Load Output Distribution 3φ 3φ G Input Source Bφ Re...

Page 57: ...erminal in the UPS cabinet must be connected to the ground bus with the internal jumper cable as shown in Figure 11 19 The jumper cable should stay in place See Figure 11 17 for the jumper cable location FIGURE 11 19 GROUNDING CONFIGURATION FOR NON GROUNDED DELTA INPUT N G 3φ 3φ 3φ N G UPS Cabinet N 3φ 3φ G Input Source Remove Jumper Cable G N 3φ To the Load N G 3φ 3φ 3φ N G UPS Cabinet N 3φ 3φ G ...

Page 58: ...d see Figure 11 17 for the jumper cable location During normal operation the UPS output is floating relative to the ground An isolation transformer is recommended at output distribution as shown in Figure 11 20 FIGURE 11 20 GROUNDING CONFIGURATION WITH CORNER GROUNDED DELTA INPUT Remains in Place N G 3φ 3φ 3φ N G UPS Cabinet 3φ 3φ G Input Source Jumper Cable Remains in Place G N 3φ To the Load N G...

Page 59: ... PF Lagging Walk in Function EEPROM Upgrade Maximum Input Current Normal Charging 107 A 120 A 134 A 147 A 135 A 148 A 196 A 209 A 297 A 311 A 396 A 409 A 582 A 608 A Reflected THD 5 100 Load 6 25 Load Bypass Configuration 3 Phase 4 Wire Gnd Voltage 480 277V 10 Frequency 60 Hz 5 Bypass Overload Capacity 1000 for 1 Cycle 500 for 2 Cycle Battery Number of Cells 180 240 Type Lead Acid Contact factory ...

Page 60: ...u lation 0 01 in free running mode Current 96 A 120 A 150 A 180 A 271 A 361 A 601 A Power Factor 1 0 PF Lag 32 86 F 0 30 C 0 8 PF Lag 86 104 F 30 40 C 0 8 PF Lag 32 104 F 0 40 C 1 0 PF Lag 32 86 F 0 30 C 0 8 PF Lag 86 104 F 30 40 C 0 9 PF Lag 32 104 F 0 40 C Overload Capacity 125 for 10 Minutes 150 for 60 Seconds 110 for 5 Minutes 120 for 60 Seconds 125 for 10 Minutes 150 for 60 Seconds Voltage TH...

Page 61: ... hr 37 281 BTUs hr 38 524 BTUs hr 67 667 BTUs hr 89 011 BTUs hr 110 262 BTUs hr Audible Noise 65 dBA 1m Typical 68 dBA 1m Typical 72 dBA 1m Typical 78 dBA 1m Typical Operating Tem perature 32 F to 86 F 0 C to 30 C for 1 0PF 32 F to 104 F 0 C to 40 C for 0 8 PF Operating Humid ity 30 to 90 Non Condensing Operating Altitude 3200 ft 1000 m Listings Standards UL 1778 UL 17025 cUL 22 2 No 107 1 ANSI C6...

Page 62: ...ent Full Load 25 50 75 100 80 kVA 83 9 85 3 90 0 90 6 100 kVA 86 4 90 1 91 2 91 0 125 kVA 88 5 90 9 90 9 90 2 150 kVA 86 9 91 7 92 3 93 3 225 kVA 87 9 91 9 92 3 91 9 300 kVA 88 8 91 6 92 2 92 8 500 kVA 91 6 91 1 90 2 93 3 Actual efficiency may differ due to manufacturing variations and input power quality ...

Page 63: ...Transfers from normal operation to bypass operation 10 EPO BUTTON ON during Bypass Supply 11 LCD DISPLAY Displays the operational status and warning fault messages 12 UPS SUPPLY LED FLASHES during START or STOP sequence ON when operating in inverter mode 13 CONVERTER LED ON after DC bus capacitors are fully charged through the converter 14 AC INPUT LED ON with nominal AC input FLASHES with AC inpu...

Page 64: ... and Buttons The key switch and operating buttons on the graphic display panel are shown in Figure 13 1 See the sections titled Key switch and Operating buttons for each function FIGURE 13 1 GRAPHIC DISPLAY PANEL KEY SWITCH OPERATING BUTTONS EPO 5 6 10 7 8 4 3 2 1 9 ...

Page 65: ...55 G8000 Series Installation and Operation Manual 13 2 LCD LED Indicators FIGURE 13 2 GRAPHIC DISPLAY PANEL LCD LED INDICATORS 23 11 21 20 19 18 17 16 15 14 13 22 24 25 12 ...

Page 66: ...TABLE 13 2 LCD DISPLAY SCREENS Name Description Normal Display Displays operational status operational guidance and measured data Fault Display Displays detailed data when a fault occurs Warning Display Displays detailed data when a warning occurs FIGURE 13 3 CHANGING SCREENS WITH SCROLL BUTTONS SCROLL UP SCROLL DOWN NORMAL DISPLAY WARNIG DISPLAY FAULT DISPLAY ...

Page 67: ...L DISPLAY SCREEN EXAMPLES OPERATIONAL STATUS SCREENS BYPASS Shows the UPS status at the top and guidance message or measured data underneath Shows a guidance message at start up PRESS RUN SWITCH UPS SUPPLY Shows the output voltage and current after start up AC VO 480 V AC I O 50 OPERATION MODE Shows the UPS Operation mode NORMAL OPERATION MODE SYNC MEASUREMENT SCREENS O P VOLTAGE Output Voltage Sh...

Page 68: ...C INPUT Shows the internal DC bus voltage battery voltage and battery current The battery current value displayed is negative during recharge and positive during discharge DC V 632 V BATT V 400 V BATT I 0 A MODE COUNT Shows the cumulative UPS operation time the cumulative battery backup time and the number of battery backup operations UPS 35 H BATTERY 56 MIN 32 TIM CLOCK The current time is displa...

Page 69: ...e fault history is cleared and operation continues If the UPS is RESET while the system is on backup mode the system will power down re initialize and restart TABLE 13 4 FAULT WARNING DISPLAY SCREEN EXAMPLES FAULTS WARNINGS A fault record is shown with time stamp An arrow indicates that another record can be displayed by pressing the up down buttons 1 FUSE BLOWN 09 09 06 08 05 30 ANOTHER ITEM FAUL...

Page 70: ...ARNINGS AC VO 480 V AC I O 50 NO FAULT NO WARNING OPERATION MODE CLOCK NORMAL OPERATION MODE SYNC TIME 03 24 06 13 58 The LCD displays a diagram of the electrical power flow MODE COUNT UPS 35 H BATTERY 56 MIN 32 TIM O P VOLTAGE DC INPUT VOLT 480 V FREQ 60 0 HZ DC V 632 V BATT V 400 V BATT I 0 A O P CURRENT R M S BATTERY U 50 V 50 W 50 BACK UP RATING 10 MIN DISCHARGING 15 MIN O P CURRENT PEAK AC IN...

Page 71: ...14 1 EPO AND CONTROL POWER SUPPLY OPERATING SWITCHES WARNING If the UPS produces smoke or smells strange immediately turn off all AC and DC input circuit breakers Continued operation may result in fire Contact Toshiba or Authorized representatives DO NOT turn off the control power supply switch 8A during UPS operation This may result in UPS faults EPO Switch Emergency Power Off Switch See Section ...

Page 72: ...on charge to float charge Startup Starting up and operating the UPS Stop Stop the inverter and chopper charger Switch Power Supply Switching power supply source between UPS and Bypass 14 2 Pre operational Check Before operating the UPS 1 Make sure all covers panels are in place and secured 2 Make sure the temperature in the UPS Battery room is within specified limits 3 Before starting the UPS chec...

Page 73: ...0 5 seconds CONVERTER LED is ON and INVERTER LED flashes CONVERTER INVERTER UPS AC OUTPUT BATTERIES BYPASS INPUT DISCHARGE EQUAL CHARGE FLOAT CHARGE BYPASS AC INPUT AC SWITCH SYSTEM INITIALIZE CONVERTER INVERTER UPS AC OUTPUT BATTERIES BYPASS INPUT DISCHARGE EQUAL CHARGE FLOAT CHARGE BYPASS AC INPUT AC SWITCH BYPASS PRESS RUN SWITCH CONVERTER INVERTER UPS AC OUTPUT BATTERIES BYPASS INPUT DISCHARGE...

Page 74: ...ot function contact Toshiba or authorized representatives If the bypass power source is out of specification this operation will be inhibited In order to switch manually press the UPS button for 5 seconds or more CONVERTER INVERTER UPS AC OUTPUT BATTERIES BYPASS INPUT DISCHARGE EQUAL CHARGE FLOAT CHARGE BYPASS AC INPUT AC SWITCH BYPASS MOVE 72B TO ON POSITION CONVERTER INVERTER UPS AC OUTPUT BATTE...

Page 75: ...the UPS STEP 2 Press the BYPASS button for at least 0 5 seconds UPS LED is OFF BYPASS LED is ON STEP 3 Please wait until procedure is completed NOTE To change from Bypass to UPS supply follow the Startup Procedures STEP 5 If the AC switch does not function contact Toshiba or authorized representatives CONVERTER INVERTER UPS AC OUTPUT BATTERIES BYPASS INPUT DISCHARGE EQUAL CHARGE FLOAT CHARGE BYPAS...

Page 76: ...es then OFF FLOAT CHARGE LED and CONVERTER LED are OFF STEP 3 Wait until procedure is completed CONVERTER INVERTER UPS AC OUTPUT BATTERIES BYPASS INPUT DISCHARGE EQUAL CHARGE FLOAT CHARGE BYPASS AC INPUT AC SWITCH BYPASS AC Vo 480 V AC Io 50 PRESS UPS SWITCH CONVERTER INVERTER UPS AC OUTPUT BATTERIES BYPASS INPUT DISCHARGE EQUAL CHARGE FLOAT CHARGE BYPASS AC INPUT AC SWITCH BYPASS MOVE 72B TO OFF ...

Page 77: ...D flashes then OFF FLOAT CHARGE LED and CONVERTER LED are OFF STEP 3 Please wait until procedure is completed STEP 4 Scroll the LCD screen to see the DC INPUT and make sure DC bus voltage is 0V STEP 5 Turn off the control power supply switch 8A Nothing is displayed on the LCD All LED s are OFF STEP 6 Turn off all breakers at AC Input Bypass Input and AC Output Shutdown is completed and UPS is isol...

Page 78: ... NOTE In equalize charge mode the battery is charged for a programmed period at a specified voltage depending on the battery spec rather than the float charge in order to prevent voltage deviations among battery cells This should be done once every six months if possible The G8000 UPS will automatically perform the equalize recharge after battery backup operation CONVERTER INVERTER UPS AC OUTPUT B...

Page 79: ...al runaway of the battery this mode will automatically be changed to protection charge when a BATT FAULT1 Battery over temperature warning occurs In protection charge mode the battery is automatically charged at a voltage about 5 lower than float charge If the BATT FAULT1 warning message goes away and a programmed duration is elapsed about 24 hours this mode will automatically be changed back to f...

Page 80: ...e procedures to correct the errors 15 1 Types of Errors The following types of errors may occur in the UPS TABLE 15 1 OPERATION TYPES Name Description Fault Fault Trip The UPS has been tripped and has stopped operating The UPS is in Bypass mode Warning Warning 1 Input Power Failure Power is supplied from the battery When the warning is corrected power will automatically be supplied from the AC inp...

Page 81: ...5 2 FAULT AND WARNING DATA SCREEN DESCRIPTIONS Name Description 1 Number The number of the message in the order that it was detected 1 10 Up to 10 screens of fault data can be displayed 2 Message Shows the type of the fault or warning message 3 Time The date mm dd yy and time in 24 hour format the fault was detected 4 Scroll Indicator Indicates whether there is a fault screen before or after this ...

Page 82: ...When a warning occurs a screen is shown as in Figure 15 3 Select the desired fault or warning data to be displayed using the scroll buttons BYPASS FAULT STOP FAULTS WARNINGS 1 FUSE BLOWN 09 09 06 08 05 30 FIGURE 15 2 FAULT DISPLAY UPS SUPPLY AC VO 480 V AC I O 50 FAULTS WARNINGS 1 UPS OVERLOAD 09 09 06 08 05 30 FIGURE 15 3 WARNING DISPLAY ...

Page 83: ...HEAT HIGH TEMP IN THE CABINET 30ST NO INDICATION AN ERROR OCCURRED IN THE MAIN CONTROL MICROPROCESSOR CPU 48 STARTUP ERR STARTUP WAS NOT COMPLETED WITHIN THE NORMAL TIME FRAME 5E EMG STOP AN EMERGENCY STOP WAS ACTIVATED VIA THE EXTERNAL CONTACT 71F FUSE BLOWN RECTIFIER DC OR INVERTER MAIN CIRCUIT FUSE BLOWN 76 DC OC DC OVER CURRENT EXCESSIVE CURRENT IN DC CIRCUIT 80B2 BATT UV BATTERY VOLTAGE IS BE...

Page 84: ... O P OV AC output voltage is high 76C BATT OC Over current in Battery section TABLE 15 6 WARNING OPERATION CONTROL Item LCD Message Indication Description 27C BYPASS UV Bypass input voltage is low 47C BYPASS ERR Bypass input phase rotation error 59C BYPASS OV Bypass input voltage is high 95C BYPASS ASY Bypass input frequency error TABLE 15 7 WARNING GUIDANCE Item LCD Message Indication Description...

Page 85: ...tions of the buttons to scroll the LCD screens See Table 15 8 for details of the scroll buttons and how they are used for screen scrolling FIGURE 15 5 POSITION OF SCROLL AND RESET BUTTONS TABLE 15 8 BUTTON FUNCTIONS Name Function 5 SCROLL UP Scrolls to the previous screen 6 SCROLL DOWN Scrolls to the following screen 7 RESET Resets the UPS faults and warnings shown on the LCD and deletes fault his...

Page 86: ...be repaired only by factory authorized personnel Servicing by untrained personnel may extend the fault or result in electric shock or personal injury Do NOT attempt to modify or relocate the UPS Electric shock personal injury or fault may result if unauthorized personnel attempt to modify or relocate the UPS Be sure to contact toshiba customer service if you need to modify or relocate the UPS Do n...

Page 87: ...ider The preventive maintenance should include at minimum Clean UPS exterior Clean UPS interior Verify power supply voltages Check for loose overheated connections Scan error log and correct potential UPS related issues 16 2 Parts Replacement The following list shows the recommended intervals for periodic replacement of certain UPS parts Aluminum electrolytic capacitors Replace once every 7 10 yea...

Page 88: ...78 G8000 Series Installation and Operation Manual ...

Page 89: ... 2 0 Important Notes 1 CABLE ACCESS Bottom only 2 Maximum Current required at Primary AC Input based on full load output and maximum battery charging current 3 Output load conductors are to be installed in separate conduit from input conductors 4 Control wires and power wires are to be installed in separate conduits 5 Recommended AC input and output overcurrent protection based on continuous full ...

Page 90: ... Planning Guide for 80kVA UPS Standard System 480V Input 480Y 277V Output P N T80S3K08KK6XSxx Rev 2 2 Page 2 of 3 G8000 IPG 80kVA G8000 80kVA UPS Cabling Connection Dimensions Top Front Right Side Bottom Access Only Power Terminals Two 2 0 AWG max per terminal G8000 80KVA OUTLINE DRAWING ...

Page 91: ...480V Input 480Y 277V Output P N T80S3K08KK6XSxx Rev 2 2 Page 3 of 3 G8000 IPG 80kVA Anchorage pattern Install anchor bolts to secure the UPS to the floor Use 1 2 12mm diameter anchor bolts The UPS base has four pre drilled 5 8 16 mm holes provided See the figure below for dimensions and locations Anchorage Pattern for G8000 80kVA UPS ...

Page 92: ...Maximum Current required at Primary AC Input based on full load output and maximum battery charging current 3 Output load conductors are to be installed in separate conduit from input conductors 4 Control wires and power wires are to be installed in separate conduits 5 Recommended AC input and output overcurrent protection based on continuous full load current per NEC 6 Wiring shall comply with al...

Page 93: ...lanning Guide for 100kVA UPS Standard System 480V Input 480Y 277V Output P N T80S3K10KK6XSxx Rev 2 2 Page 2 of 3 G8000 IPG 100kVA G8000 100kVA UPS Cabling Connection Dimensions Top Front Right Side Bottom Access Only Power Terminals Two 2 0 AWG max per terminal G8000 100KVA OUTLINE DRAWING ...

Page 94: ...80V Input 480Y 277V Output P N T80S3K10KK6XSxx Rev 2 2 Page 3 of 3 G8000 IPG 100kVA Anchorage pattern Install anchor bolts to secure the UPS to the floor Use 1 2 12mm diameter anchor bolts The UPS base has four pre drilled 5 8 16 mm holes provided See the figure below for dimensions and locations Anchorage Pattern for G8000 100kVA UPS ...

Page 95: ... 2 Maximum Current required at Primary AC Input based on full load output and maximum battery charging current 3 Output load conductors are to be installed in separate conduit from input conductors 4 Control wires and power wires are to be installed in separate conduits 5 Recommended AC input and output overcurrent protection based on continuous full load current per NEC 6 Wiring shall comply with...

Page 96: ...nning Guide for 125kVA UPS Standard System 480V Input 480Y 277V Output P N T80S3K12KK6XS2xx Rev 0 Page 2 of 3 G8000 IPG 125kVA 0 8PF G8000 100kVA UPS Cabling Connection Dimensions Top Front Right Side Bottom Access Only Power Terminals Two 2 0 AWG max per terminal G8000 125KVA OUTLINE DRAWING ...

Page 97: ...V Input 480Y 277V Output P N T80S3K12KK6XS2xx Rev 0 Page 3 of 3 G8000 IPG 125kVA 0 8PF Anchorage pattern Install anchor bolts to secure the UPS to the floor Use 1 2 12mm diameter anchor bolts The UPS base has four pre drilled 5 8 16 mm holes provided See the figure below for dimensions and locations Anchorage Pattern for G8000 100kVA UPS ...

Page 98: ... Notes 1 CABLE ACCESS Top and Bottom 2 Maximum Current required at Primary AC Input based on full load output and maximum battery charging current 3 Output load conductors are to be installed in separate conduit from input conductors 4 Control wires and power wires are to be installed in separate conduits 5 Recommended AC input and output overcurrent protection based on continuous full load curren...

Page 99: ...ries UPS Installation Planning Guide for 150kVA UPS Standard System 480V Input 480Y 277V Output P N T80S3K15KK6XSxx Rev 2 2 Page 2 of 3 G8000 IPG 150kVA G8000 150kVA UPS Cabling Connection Dimensions Top Front Right Side Top Bottom Access G8000 150KVA OUTLINE DRAWING ...

Page 100: ...80V Input 480Y 277V Output P N T80S3K15KK6XSxx Rev 2 2 Page 3 of 3 G8000 IPG 150kVA Anchorage pattern Install anchor bolts to secure the UPS to the floor Use 1 2 12mm diameter anchor bolts The UPS base has four pre drilled 5 8 16 mm holes provided See the figure below for dimensions and locations Anchorage Pattern for G8000 150kVA UPS ...

Page 101: ...rtant Notes 1 CABLE ACCESS Top and Bottom 2 Maximum Current required at Primary AC Input based on full load output and maximum battery charging current 3 Output load conductors are to be installed in separate conduit from input conductors 4 Control wires and power wires are to be installed in separate conduits 5 Recommended AC input and output overcurrent protection based on continuous full load c...

Page 102: ...ries UPS Installation Planning Guide for 225kVA UPS Standard System 480V Input 480Y 277V Output P N T80S3K22KK6XSxx Rev 2 3 Page 2 of 3 G8000 IPG 225kVA G8000 225kVA UPS Cabling Connection Dimensions Top Front Right Side Top Bottom Access G8000 225 KVA OUTLINE DRAWING ...

Page 103: ...80V Input 480Y 277V Output P N T80S3K22KK6XSxx Rev 2 3 Page 3 of 3 G8000 IPG 225kVA Anchorage pattern Install anchor bolts to secure the UPS to the floor Use 1 2 12mm diameter anchor bolts The UPS base has four pre drilled 5 8 16 mm holes provided See the figure below for dimensions and locations Anchorage Pattern for G8000 225kVA UPS ...

Page 104: ...mportant Notes 1 CABLE ACCESS Top only 2 Maximum Current required at Primary AC Input based on full load output and maximum battery charging current 3 Output load conductors are to be installed in separate conduit from input conductors 4 Control wires and power wires are to be installed in separate conduits 5 Recommended AC input and output overcurrent protection based on continuous full load curr...

Page 105: ...peration Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 300kVA UPS Standard System 480V Input 480Y 277V Output P N T80S3K30KK6XSxx G8000 300kVA UPS Cabling Connection Dimensions Top Front Right Side Cable Entry Top Only ...

Page 106: ...S Standard System 480V Input 480Y 277V Output P N T80S3K30KK6XSxx Anchorage pattern Install anchor bolts to secure the UPS to the floor Use 1 2 12mm diameter anchor bolts TheUPS base has eight pre drilled 5 8 16 mm holes provided See the figure below for dimensions and locations Anchorage Pattern for G8000 300kVA UPS ...

Page 107: ...x 500 kcmil Important Notes 1 CABLE ACCESS Top only 2 Maximum Current required at Primary AC Input based on full load output and maximum battery charging current 3 Output load conductors are to be installed in separate conduit from input conductors 4 Control wires and power wires are to be installed in separate conduits 5 Recommended AC input and output overcurrent protection based on continuous f...

Page 108: ...and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 500kVA UPS Standard System 480V Input 480Y 277V Output P N T80S3K50KK6XSxx G8000 300kVA UPS Cabling Connection Dimensions Top Front Cable Entry Top Only ...

Page 109: ...80V Input 480Y 277V Output P N T80S3K50KK6XSxx Rev 0 0 Page 3 of 3 G8000 IPG 500kVA Anchorage pattern Install anchor bolts to secure the UPS to the floor Use 1 2 12mm diameter anchor bolts The UPS base has eight pre drilled 5 8 16 mm holes provided See the figure below for dimensions and locations Anchorage Pattern for G8000 500kVA UPS ...

Page 110: ...100 G8000 Series Installation and Operation Manual ...

Page 111: ...101 G8000 Series Installation and Operation Manual Appendix B Outline Drawings FIGURE B 1 G8000 80 100 125 KVA OUTLINE DRAWING ...

Page 112: ...102 G8000 Series Installation and Operation Manual FIGURE B 2 G8000 150 225 KVA OUTLINE DRAWING ...

Page 113: ...103 G8000 Series Installation and Operation Manual FIGURE B 3 G8000 300 KVA OUTLINE DRAWING ...

Page 114: ...104 G8000 Series Installation and Operation Manual FIGURE B 4 G8000 500 KVA OUTLINE DRAWING ...

Page 115: ... a leveled floor bring the two cabinets together Input cabinet on the left side See FIG 1 Leave a gap of 0 25 0 30 between the cabinets See FIG 2 3 4 On Input cabinet Open the door remove back panel retain hardware See FIG 3 Insert 1 2 13X1 75 bolt flat lock washer assembly supplied two in the front and two in the back See FIG 4 FIG 5 INPUT CABINET OUTPUT CABINET LEAVE A GAP OF 0 25 0 30 BETWEEN C...

Page 116: ...y 3 between the cabinets as shown in FIG 5 FIG 6 and connect on corresponding output and input cabinet AC bus using 1 2 13X1 25 bolt flat bel leville washer and nut supplied Insert Belleville washer between flat washer and nut 7 Insert DC Bus qty 2 between the cabinets as shown in FIG 5 FIG 6 and con nect on corresponding output and input cabinet DC bus using 1 2 13X1 25 bolt flat belleville washe...

Page 117: ...located in input cabinet to the Ground Bus located in the output cabinet thru the grommet hole in the side panels NOTE SEE MANUAL PAGE 38 FOR CONNECTING POWER CABLES ANCHOR ING THE CABINETS TO THE FLOOR AFTER CONNECTING THE CABLES ENSURE NO LOOSE HARDWARE METAL SHAVINGS TOOLS ETC ARE LEFT BE HIND INSIDE THE CABINET CLOSE THE CABINETS FRONT AND BACK RECOMMENDED TORQUE VALUES OF 3 8 STEEL BOLT IS 22...

Page 118: ...108 G8000 Series Installation and Operation Manual N E U T R A L B U S A C B U S D C B U S FIG 6 ...

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Page 120: ...INDUSTRIAL DIVISION 13131 West Little Your road Houston Texas 77041 Tel 713 466 0277 Fax 713 466 8773 U S 877 867 8773 Canada 800 872 2192 Mexico 01 800 527 1204 www toshiba com ind Printed in the U S A ...

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