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/toshiba02/User2/UPSMKT/GENERAL/UPS/3 Phase Systems/White Papers/G9000 White Paper - multi-level converter.doc

UPSG 9000WP081201

G9000 Uninterruptible Power Supply

Multi-level PWM IGBT Technology

White Paper

Summary of Contents for T90S3S08KS6XSN

Page 1: ...Footprint and Highest Power Density in Industry Electronic Battery Isolation for Battery Longevity Generator Friendly Design and Compatibility Complete Front Access for Installation Operation and Service Handles Leading Power Factor Loads Without Derating SNMP Web Based Monitoring Three Year Warranty for Lower Cost of Ownership UNINTERRUPTIBLE POWER SYSTEMS 80 100 160 225 KVA UPS G9000 Series 96 5...

Page 2: ...00 x 832 x 2047 mm 35 4 x 32 8 x 80 6 in 900 x 832 x 2047 mm Weight 855 lbs 388 kg 855 lbs 388 kg 1160 lbs 526 kg 1230 lbs 558 kg Features Digital Signal Processor DSP Control Fully Digital IGBT Converter Inverter High Efficiency Over Wide Load Range Transformer Less Design N 1 and N N Up to Four in Parallel Capability Dual Input Feed Electronic Battery Isolation RS232 and Dry Contact Interface Sm...

Page 3: ... 13131 WEST LITTLE YORK ROAD HOUSTON TX 77041 PHONE 713 466 0277 800 231 1412 FACSIMILE 713 896 5226 1 TOSHIBA G9000 80 100 160 225 kVA GUIDE SPECIFICATION THREE PHASE UNINTERRUPTIBLE POWER SUPPLY 61963 000 March 2009 ...

Page 4: ...Guide Specification 3 Phase Static Uninterruptible Power Supply 2 March 2009 This Page Intentionally Left Blank ...

Page 5: ... 6 3 2 3 Clearances for installation 7 3 2 4 Cable Access 7 4 SYSTEM PARAMETERS 7 4 1 UPS REQUIREMENTS 7 4 1 1 General Requirements 7 5 FUNCTIONAL DESCRIPTION 9 5 1 IGBT RECTIFIER 9 5 2 IGBT DC DC CONVERTER 9 5 3 IGBT INVERTER 10 5 4 STATIC BYPASS CIRCUIT 11 5 5 METERING MONITORING ALARMS AND CONTROLS 12 6 MECHANICAL DESIGN 14 6 1 UPS ENCLOSURE 14 6 2 CABLE ACCESS 14 7 WARRANTY 14 7 1 UPS WARRANTY...

Page 6: ...9 11 MAINTENANCE BYPASS PANEL OPTION 16 11 1 SITE INSTALLATION 16 11 2 ELECTRICAL CONFIGURATION 16 11 3 MECHANICAL INTERLOCK 16 11 4 EXTERNAL MAINTENANCE BYPASS 16 12 AUXILIARY TRANSFORMER CABINETS OPTION 17 13 POWER DISTRIBUTION UNITS OPTION 17 14 EXTENDED SERVICES OPTION 17 ...

Page 7: ...UPS shall be designed in accordance with and be compliant with the following sections of the current revisions of the following standards UL 1778 cUL Listed FCC Class A Article 47 Part 15 B ISO 9001 ISO 14001 ANSI C62 41 2 2 Components The UPS shall consist of the following components 1 Multi level IGBT AC DC Rectifier 2 IGBT DC DC Battery Converter Charger 3 Multi level IGBT DC AC Inverter 4 Hybr...

Page 8: ...S controls shall automatically transfer the critical load from the inverter output to the bypass AC source without interruption When the overload condition is removed after a preset hold period the UPS will automatically re transfer the critical load from the bypass to the inverter output without interruption of power to the critical load 2 3 5Maintenance Bypass An optional manual make before brea...

Page 9: ...se with Optional Side Car 4 SYSTEM PARAMETERS 4 1 UPS Requirements 4 1 1General Requirements Rated Output Capacity 80 100 160 225 kVA 72 90 144 202 5 kW AC DC Rectifier Type AC DC multi level IGBT Rectifier DC AC Inverter Type DC AC multi level IGBT Inverter Inverter External Dimensions W D H 80 kVA 27 6 in x 32 8 in x 78 7 80 6 in 100 kVA 27 6 in x 32 8 in x 78 7 80 6 in 160 kVA 35 4 in x 32 8 in...

Page 10: ...1 4 Bypass Input Configuration 3 Phase 3 Wire Ground Rated Voltage 480 V Input Voltage Synchronous Range 10 Rated Frequency 60 Hz Frequency Variation 5 Frequency Synchronous Range 1 5 0 6 3 0 Hz Selectable Bypass Overload Capacity 1000 for one cycle 4 1 5 AC Output Configuration 3 Phase 3 Wire Ground Rated Capacity 80 100 160 225 kVA 72 90 144 202 5 kW Rated Voltage 480 V Efficiency at Full Load 2...

Page 11: ...able types of malfunctions The load shall be automatically transferred to the bypass line without interruption in the event of an internal UPS malfunction The status of protective devices shall be indicated on a LCD graphic display screen on the front of the UPS 5 1 IGBT Rectifier 5 1 1 General A solid state multi level IGBT Rectifier shall convert the incoming AC power into DC power to supply the...

Page 12: ...ontinuously convert DC power from the IGBT Rectifier to AC power for the critical loads When the utility voltage or frequency exceeds the specified UPS input tolerances the inverter shall continuously convert DC power from the battery source to AC power for the critical load The inverter shall be capable of providing rated output while operating at any battery voltage within the battery operating ...

Page 13: ...l shall be composed of a thyristor switch with a wrap around contactor The thyristor switch shall be a high speed transfer device The wrap around contactor shall be electrically connected in parallel to the thyristor switch and shall at the same time as the thyristor switch be energized and upon closure maintain the bypass source to the load to improve the efficiency and reliability of the system ...

Page 14: ...the UPS rated output frequency 5 4 2 Overload Capacity in Bypass Continuous duty 125 of the system rated capacity Overload duty 1000 of ampere rating for 1 cycle 5 4 3 Retry function When an internal warning failure has been detected power flow shall automatically switch from the main circuit inverter to the bypass circuit without interruption to the load If the internal warning is cleared UPS sha...

Page 15: ...to provide a visual status of contactors within UPS The panel shall display the followings AC Input DC Input Rectifier in Operation Inverter in Operation UPS Bypass supply Battery Operating Condition float charge discharge Fault Warning Operation Guidance LCD Display Fault Guidance LCD Display 5 5 5 Isolated Control Signals Ten 10 Normally Open isolated annunciation signal outputs for remote use w...

Page 16: ... UPS shall be Bottom entry Side entry when using optional side cabinet Top entry when using optional side cabinet 7 WARRANTY 7 1 UPS Warranty The UPS shall come with a 36 month warranty on all mechanical electrical electronic components Parts labor and travel are included during warranty period Optional extended warranties shall be available 7 2 UPS Battery Warranty The back up batteries shall com...

Page 17: ...workstation or management station shall be able to open a RemotEye II website RemotEye II website shall enable the UPS system information to be configured and monitored remotely RemotEye II shall provide access to 3 java applets for monitoring event logging and trend analysis 9 1 3Shutdown Capability The RemotEye II application software shall allow RemotEye II to remotely notify and shutdown selec...

Page 18: ... provide a MBS Maintenance Bypass Panel for the UPS 11 1Site Installation The MBS can be available in either a wall mount or floor mount configuration 11 2Electrical Configuration The MBS can be available in two three or four breaker configurations 11 3Mechanical Interlock The MBS can have the option for a two kirk key interlock system 11 4External Maintenance Bypass A manually operated maintenanc...

Page 19: ...nal PDUs Power Distribution Units for stepping the UPS output voltage down to service load voltages The PDUs can be provided in either front access cabinet or Rack mount style 14 EXTENDED SERVICES OPTION The UPS manufacturer can offer Startup Service Maintenance Contracts Silver Gold Platinum Preventive Maintenance Contracts Spare parts kits A B and C level Extended warranty coverage for up to an ...

Page 20: ...ly and is subject to change without notice TIC is not responsible for any errors or omissions 480 VDC Nominal Battery Cabinet with Main Breaker 72B ST TITLE DRAWING NO REV NOTES A B C D E F G H I J 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 INTERNATIONAL CORPORATION Houston Texas USA THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF TOSHIBA INTERNATIONAL CORPORTION AND SHALL NOT BE REPRODUCED USED OR DISC...

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Page 22: ...nly and is subject to change without notice TIC is not responsible for any errors or omissions 480 VDC Nominal Battery Cabinet with Main Breaker 72B ST TITLE DRAWING NO REV NOTES A B C D E F G H I J 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 INTERNATIONAL CORPORATION Houston Texas USA THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF TOSHIBA INTERNATIONAL CORPORTION AND SHALL NOT BE REPRODUCED USED OR DIS...

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Page 24: ...nly and is subject to change without notice TIC is not responsible for any errors or omissions 480 VDC Nominal Battery Cabinet with Main Breaker 72B ST TITLE DRAWING NO REV NOTES A B C D E F G H I J 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 INTERNATIONAL CORPORATION Houston Texas USA THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF TOSHIBA INTERNATIONAL CORPORTION AND SHALL NOT BE REPRODUCED USED OR DIS...

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Page 26: ...nly and is subject to change without notice TIC is not responsible for any errors or omissions 480 VDC Nominal Battery Cabinet with Main Breaker 72B ST TITLE DRAWING NO REV NOTES A B C D E F G H I J 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 INTERNATIONAL CORPORATION Houston Texas USA THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF TOSHIBA INTERNATIONAL CORPORTION AND SHALL NOT BE REPRODUCED USED OR DIS...

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Page 28: ...UNINTERRUPTIBLE POWER SYSTEM UPS G9000 SERIES INSTALLATION AND OPERATION MANUAL 480 480 V 80 100 160 225 kVA Document GBH0016 Rev 0 21 P N 61480 000 April 2009 ...

Page 29: ...G9000 Installation and Operation Manual ...

Page 30: ...G9000 Installation and Operation Manual G9000 SERIES INSTALLATION AND OPERATION MANUAL 480 480 V 80 100 160 225 kVA Document No GBH0016 Rev 0 21 P N 61480 000 April 2009 ...

Page 31: ...G9000 Installation and Operation Manual ...

Page 32: ... or mechanical modifications to this equipment without prior written consent of TOSHIBA will void all warranties and may void UL CUL listing Unauthorized modifications may also result in equipment damage personal injury or loss of life IMPORTANT NOTICE UNINTERRUPTIBLE POWER SYSTEM If additional information or technical assistance is required call TOSHIBA Customer Support Center toll free at 1 800 ...

Page 33: ...ther product or trade references appearing in this manual are registered trademarks of their respective owners 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 This manual is copyrighted No part of this manual may be photocopied or...

Page 34: ...TTON Emergency Power Off button 7 21 2 3 LIQUID CRYSTAL DISPLAY 8 22 2 3 1 Menu 22 2 3 2 Input Power Failure 26 2 3 3 Fault Indication 26 2 4 EXTERNAL SIGNAL TERMINAL BLOCK 28 2 5 RemotEyeII INTRODUCTION 33 3 INSTALLATION AND OPERATION 37 3 1 TRANSPORTATION AND INSTALLATION 37 3 2 INSTALLATION PROCEDURE 37 3 3 PROCEDURE FOR CABLE CONNECTIONS 38 3 4 OPERATING PROCEDURES 47 4 RESPONSE TO UPS FAILURE...

Page 35: ... of Specifications 16 Table 1 5 b Efficiency at Various Loads 18 Table 1 6 Rating of Contactors Breakers and Fuses 20 Table 2 1 Parts list for UPS monitoring 35 Table 3 1 How to Transport and Install the System 37 Table 3 2 List of UPS Weights lb 37 Table 3 3 Maximum Permitted Fault Current 38 Table 3 4 Recommended Cable Sizes 41 Table 3 5 Crimp Type Compression Lug 42 Table 6 1 Fault Code 54 Tabl...

Page 36: ...nt 24 Figure 2 6 1 Log menu 25 Figure 2 6 2 Event log 25 Figure 2 6 3 Battery log 25 Figure 2 7 1 Main Screen Battery Operation 26 Figure 2 7 2 Measurement Screen Battery Operation 26 Figure 2 8 Main Screen Fault Indication 26 Figure 2 9 Message Screen 27 Figure 2 10 1 External Signal Terminal Block TN2 28 Figure 2 10 2 External Signal Terminal Block TN1 29 Figure 2 11 Control Wiring for External ...

Page 37: ... 3 3 Diag of Power wire Control wire Inter connect between UPS and Battery 44 Figure 3 4 Diag of Power wire Connect Parallel Connection 45 Figure 3 5 Diag of Power and Control wire Connect Parallel Connection 46 Figure 3 6 LCD Screen MMS Operation 50 ...

Page 38: ...ous situation or condition which could result in personal injury or death if not avoided Caution A caution symbol shows potentially hazardous situation or condition which could result in personal injury or equipment damage if not avoided Note A Note symbol shows the information the user or the service personnel should observe during the UPS operation or service work Prohibit A prohibit symbol show...

Page 39: ...PS Please read this manual carefully and retain it for future reference 1 1 1 1 1 1 1 1 This manual contains important instructions for the G9000 SERIES Uninterruptible Power Supply Systems that should be followed during installation and maintenance of the UPS and batteries Lethal voltages exist within the equipment during operation Observe all warning and cautions in this manual Failure to comply...

Page 40: ...ffect human lives Medical operation room equipment Life support equipment artificial dialysis incubators etc Toxic gas or smoke eliminators Equipment that must be provided under fire laws construction standards or other ordinances Equipment equivalent to the above Special considerations are required when applying this UPS to the equipment that affect human safety and or maintain public services Eq...

Page 41: ... humidity The relative humidity must be held between 5 and 95 There must be no condensation due to temperature changes 4 Altitude This equipment must not be applied at altitude that exceeds 2250m 7400ft above seal level 5 Dust Dust in the room where the UPS is installed must not exceed normal atmospheric dust levels In particular that dust should not include iron particles oils or fats or organic ...

Page 42: ...city kVA Bypass Voltage Vac Bypass Rating Aac Breaker A 80 480 96 125 100 480 120 150 160 480 192 250 225 480 271 350 AC input and AC output overcurrent protection and disconnect devices shall be field supplied and installed The DC circuit breaker MCCB shall be field supplied and installed The overcurrent protection device should be installed in the Battery cabinet and rated as indicated in TABLE ...

Page 43: ... up power from the UPS battery permits the orderly shutdown of equipment supported by the UPS The UPS is simple to start up operate and maintain The G9000 SERIES UPS is available in Four kVA sizes 80 100 160 and 225 kVA Specifications for each kVA model appear in Section 1 5 The principles of operation described herein are applicable to all models This manual provides an overview of the G9000 SERI...

Page 44: ...controls necessary to convert DC power from the Converter Charger or the battery to AC power required by the critical load CONVERTER CHARGER The UPS components which contain the equipment and controls necessary to convert input AC power to regulated DC power required for battery charging and for supplying power to the Inverter STATIC TRANSFER SWITCH The device which connects the critical load to t...

Page 45: ...nput AC power is converted to DC by the Converter DC power is utilized to charge the UPS battery and to provide power to the Inverter The Inverter converts the DC power to clean AC power to supply the critical load The conversion inversion process eliminates any voltage transients or fluctuations existing in the input power before it reaches the critical load The power drawn by the critical load i...

Page 46: ...ternal Bypass line the Static Transfer Switch line through CB3 herein after STS contactor CB3 supplies the power immediately and then the Internal Bypass line through 52S supplies the power In the event of a switching to the Bypass line the power to the critical load will be uninterrupted The purpose of this Internal Bypass line is to route power to the critical load while the UPS module is de ene...

Page 47: ...on the UPS Converter s will de energize and the UPS battery s will immediately discharge and supply DC power to the Inverter to maintain continuous AC power to the load This operation will continue until a The battery capacity expires and the inverter turns off or b Input power is restored When input power is restored the converter will simultaneously power the inverter and critical load and recha...

Page 48: ...d the Inverter s is automatically restarted without operator intervention Load is automatically assumed by the inverter without operator intervention s In the case of the Parallel Operation The power drawn by the load is equally shared between all UPS regardless of the presence or absence of the UPS that is are in battery operation or not whenever the system is in the Parallel Operation ...

Page 49: ...r 8 Parallel I F PCB IFAU 08 Item 9 AC input AC output DC input terminal is not shown in Figure 1 4 1 Refer to Figure 3 2 FIGURE 1 4 2 UPS Parts Location 160 225kVA UPS module Front View CPMC CPMS EMB 88F Inverter Converter Charger Unit 5 Relay PCB RYAU 09 4 Main PCB UPGR M 7 Parallel control PCB TLCR C Ground Fault Sensor FDAU 04 CB3 10 Grounding Bar E 52C 52S CB1 3 External I F PCB IOAU 09 2 Dis...

Page 50: ...rnal I F PCB IOAU 09 FIGURE 1 7 Parallel I F PCB IFAU 08 OFF ON OFF ON IOAU 0 9 TN1 TN2 External contact signal terminal block IFAU 0 8A TLIN CN96 TLOUT CN95 CBIN CBOU T CAIN CAOU T CN94 13 SW6 MAINTENANCE button 12 SW5 TEST switch START button STOP button CNV SW switch 11 SW1 RESET switch ...

Page 51: ...to FIGURE 2 1 for details 2 Display PCB DPAU 81 Figure 1 5 Switches on DPAU 81 board FOR SERVICE PERSONNEL ONLY 11 SW1 RESET switch 12 SW5 TEST switch 13 SW6 MAINTENANCE switch 3 External I F PCB IOAU 09 Figure 1 6 Signal I F on IOAU 09 board 17 External contact signal terminal block Refer to FIGURE 2 10 for details 4 Main PCB UPGR M Figure 1 8 Switches on UPGR M board FOR SERVICE PERSONNEL ONLY 1...

Page 52: ...ch FOR SERVICE PERSONNEL ONLY This switch sets the UPS menu parameters 14 BOOT switch FOR SERVICE PERSONNEL ONLY This switch enables firmware to be loaded on the control board 15 52L S W switch FOR SERVICE PERSONNEL ONLY This switch prohibits turning on the AC output contactor 52C during test maintenance in Parallel Operation system application 16 External contact signal terminal block Terminal bl...

Page 53: ...88 6 2 250 990 450 160 43 3 1 100 41 3 1 050 88 6 2 250 1 320 600 225 43 3 1 100 41 3 1 050 88 6 2 250 1 430 650 TABLE 1 5 a Detail of Specifications Rated Output kVA 80 100 160 225 Rated Output kW 72 90 144 202 5 AC INPUT Configuration 3 phase 3 wire Voltage 480 V 15 to 20 Frequency 60 Hz 10 Power Factor 99 Lagging at 25 115 Load Input kVA Charging kVA 76 kVA 85 kVA chg 95 kVA 106 kVA chg 151 kVA...

Page 54: ...480 V Voltage Regulation 1 0 100 balanced load 2 0 100 unbalanced load Voltage Adj Range 5 0 in 0 5 V increments Voltage Unbalance 2 maximum at 100 unbalanced load Crest Factor 2 3 Transient Response 2 maximum at 100 load step 1 maximum at loss return of AC power 5 maximum at load transfer to from static bypass Transient Recovery Time Less than 20ms Frequency 60 Hz Frequency Synch Range 1 to 5 sel...

Page 55: ...access Enclosure NEMA 1 Audible Noise 70 dB 1 m Listings Standards UL cUL FCC Class A Article 47 Part 15 B ISO 9001 ISO14001 ANSI C62 41 IEEE 587 Cat B Warranty 3 Years Parts and Labor Emergency Power Off Included MONITORING Dry Contacts Included Yes for Input and Output Signals RS232 Port Included Intelligent Monitoring Optional SNMP MODBus RTU MODBus TCP BACNET METASYS Display LCD Touch Panel fo...

Page 56: ...eaker Recommended 125A 150A 250A 350A User supply OPTION AC bypass breaker Recommended 125A 150A 250A 350A User supply OPTION AC output breaker Recommended 125A 150A 250A 350A Fuses FCU FCV FCW FCR FCS FCT DC fuse 315A 690V 315A 690V 200A 690V 200A 690V FPU FPV FNU FNV DC fuse 200A 690V 200A 690V 350A 690V 350A 690V FUA FUB FUC Control power fuse 30A 600V 30A 600V 30A 600V 30A 600V FSU FSV FSW OPT...

Page 57: ...allation and Operation Manual 2 OPERATOR CONTROLS AND INDICATORS The G9000 Series operator controls and indicators are located as follows Door exterior FIGURE 2 1 Operation Display Panel Front panel 8 3 2 1 7 4 5 6 ...

Page 58: ...vices by static bypass Indicates the state of bypass transfer switch 52S 4 Overload OVERLOAD orange Illuminates in overload condition 5 LCD fault LCD FAULT red Illuminates when LCD is not responding 6 UPS fault UPS FAULT red Annunciator intermittent or constant tones Illuminates when an error occurs in the system In this case the details of the error are indicated on the display panel 2 2 EPO BUTT...

Page 59: ...s the user to verify the status and operation of the UPS Module FIGURE 2 2 Main screen The following will be displayed when the START STOP key on the MAIN MENU is pressed Jump into OPERATION MENU 1 Startup Shutdown Guidance FIGURE 2 3 The display indicates the Startup and Shutdown guidance for the UPS system If this operation is PIN protected the user is required to enter the security PIN before t...

Page 60: ...guidance FIGURE 2 3 3 Shutdown guidance Follow Startup Shutdown guidance accordingly B MEASUREMENT MENU FIGURE 2 4 This screen shows details of measured values Input and Output values are displayed During Battery operation Remaining battery power and Run time are also displayed FIGURE 2 4 1 Input values ...

Page 61: ...s the user to select a whether the start stop operation will be performed by local or remote operation b date time adjustment c battery equalizing charge The battery equalizing charge operation key will appear when battery equalizing charge is set up Setup is based on battery type FIGURE 2 5 1 Remote Local operation select FIGURE 2 5 2 Date Time adjustment ...

Page 62: ... LOG and BATTERY LOG Pressing the EVENT LOG icon up to 50 condition operation records will be displayed Press or button for page turning Pressing the BATTERY LOG icon Number of battery operations and Summed battery operation time are displayed FIGURE 2 6 1 Log menu FIGURE 2 6 2 Event log FIGURE 2 6 3 Battery log ...

Page 63: ...attery Discharge announcement is displayed when the battery end voltage is reached At this time the inverter will perform an electronic shutdown to prevent battery loss of life typical from extreme deep discharge conditions When the input power is restored the inverter will automatically restart to power the load and the batteries will be simultaneously recharged The End of Battery announcement is...

Page 64: ...ximum of 10 faults are displayed at one time If an input power failure occurs during a fault condition the fault indication and input power failure announcement are alternatively displayed at 5 second intervals FIGURE 2 9 Message screen 2 SILENCE ALARM This icon will appear when a failure occurs The audible alarm announcing the failure can be silenced by pressing this icon ...

Page 65: ...rt presented OUT1 to OUT8 are user programmable but factory default settings are shown in Figure 2 10 1 Adding same external I F PCB IOAU 09 doubling signal outputs is applicable for OUT1 to OUT8 FIGURE 2 10 1 External Signal Terminal Block NEC Class2 TN2 SUMMARY ALARM OUT2 LOAD ON INVERTER OUT3 BATTERY OPERATION OUT4 CONVERTEN OPERATION OUT5 BATTERY LOW VOLTAGE OUT6 OVERLOAD OUT1 LOAD ON BYPASS U...

Page 66: ...Terminal Block NEC Class2 TN1 User supplied dry contact IN3 BATTERY TEMP HIGH IN1 REMOTE INVERTER START IN2 REMOTE INVERTER STOP REMOTE EPO IN4 POWER DEMAND UPS CB2 UVT CB2 AX 52L AX 1 3 5 7 9 19 17 15 13 11 2 4 6 8 10 20 18 16 14 12 Battery Breaker Panel Load Circuit Switch ...

Page 67: ... Activated when the power is supplied from the static bypass input Terminals 5 to 6 Load on Inverter contact OUT2 Activated when the power is supplied by the inverter Terminals 7 to 8 Battery Operation contact OUT3 Activated when the battery is operating following an AC power failure Terminals 9 to 10 Converter Operation contact OUT4 Activated when the converter is operating Terminals 11 to 12 Bat...

Page 68: ...vide external dry contact accordingly Do not apply voltages to remote access input terminals Damage to UPS may result Refer to Figure 2 12 for a typical wiring configuration Although this figure applies to the remote start stop terminals the same wiring arrangement is used for emergency stop power demand and battery temperature high FIGURE 2 12 Remote Start Contact Connections Start Relay Coil cur...

Page 69: ... temperature The converter float voltage level is reduced for battery over temperature conditions External thermocouple is user supplied Terminals 13 to 14 Power Demand Command contact input IN4 This contact is used to control the input power Power demand is turned ON when the contact is closed and power demand is turned OFF when the contact is open Terminals 15 to 16 Remote EPO contact input Used...

Page 70: ...pertext Transfer Protocol HTTP methods The RemotEyeII module is installed at the rear of the front door in G9000 UPS units The configuration of the RemotEyeII is shown in FIGURE 2 13 below FIGURE 2 13 configuration of the RemotEyeII overview Consult Toshiba International Corporation for details on RemotEyeII monitoring software and its capabilities DPAU 81 SW1 PSAU 60 PS1 RemotEyeII Back of the fr...

Page 71: ...en the Display Control PCB DPAU 81 designated as SW1 and the RemotEyeII module in G9000 UPS units The RemotEye II communicates with the UPS via a Cable2 The connection is described in FIGURE 2 14 below The UPS has to be de energized when the RemotEyeII module is installed for safety reason FIGURE 2 14 Connection between Display Control PCB SW1 and RemotEyeII module CAUTION P S1 PSAU 60 RemotEyeII ...

Page 72: ...ble3 1 PCB revision suffix may be applied Connected with 3BBA0083P001 Cable1 Shown in FIGURE 2 17 D sub connector CN1 to be connected with RemotEyeII Terminal block TN to feed 12VDC power to RemotEyeII 12V across P to N Optional interface CN2 to give 12VDC power 12V Pin 1 to 2 Note 12VDC exposed FIGURE 2 15 PSAU 60 PCB PS1 FIGURE 2 17 3BBA0083P001 Cable1 Connector CN44 to be connected with CN27 of...

Page 73: ...l ground Pin 4 24VS 24VDC Pin 5 GND S 24VDC ground D3200 5Pin contact D5 Description Pin 1 RXD Receive data Pin 2 TXD Transmit data Pin 3 GND Signal ground Pin 4 24VS 24VDC Pin 5 GND S 24VDC ground D3200 5Pin contact TB2 Description Pin 1 12VS 12VDC Pin 2 GND S 12VDC ground Terminal Block 2Pin D SUB 9Pin male DB9 Description Pin 1 Not used Pin 2 RXD Receive data Pin 3 TXD Transmit data Pin 4 Not u...

Page 74: ...thin 15 of the vertical during handling 3 2 INSTALLATION PROCEDURE A Note the load tolerance of the floor Refer to Table 3 2 for list of UPS weights TABLE 3 2 List of UPS weights UPS Capacity kVA 80 100 160 225 Weight lbs 855 855 1160 1230 B Minimum clearance required for ventilation Right side 25 mm 1 inch not required when sidecars are used Left side 25 mm 1 inch not required when sidecars are u...

Page 75: ...mitted A 80 480 25 000 100 480 25 000 160 480 25 000 225 480 25 000 3 3 PROCEDURE FOR CABLE CONNECTIONS 1 Confirm the capacity of the UPS being installed Identify the input output power terminal blocks as shown in the appropriate Figures 3 1 through 3 3 2 Connect the internal control wire and power wire 1 Control wire Inter connect 1 CB2 UVT to terminal TN1 1 2 of external I F PCB IOAU 09 2 CB2 ON...

Page 76: ...er terminals identified as A40 B40 and C40 in Figures 3 1 to 3 3 Bypass input cables must be sized for an ampere rating larger than the maximum output current capacity of the UPS Refer to Table 3 4 for recommended cable sizes 2 Connect the external signal terminal block as desired Refer to section 2 4 and Figure 2 10 for functional description 2mm 2 or less shielded conductor is recommended 5 One ...

Page 77: ...ions for Parallel Operation System 1 Confirm the number of units to be connected in parallel Identify the input output power terminal blocks and control wire connections for parallel operation systems as shown in the appropriate Figures 3 4 and 3 5 2 Connect the external control wire and power wire a Control wire connection Parallel configuration wiring Refer to Figure 3 4 and 3 5 52L control sign...

Page 78: ...0 AWG 100 135 in lbs 350 MCM 400 MCM 100 135 in lbs 160kVA 480V 480V 250 MCM 300 MCM 100 135 in lbs 250 AWG 300 MCM 100 135 in lbs 250 MCM 300 MCM 100 135 in lbs 2x350 MCM 2x400 MCM 100 135 in lbs 225kVA 480V 480V 500 MCM 2x250 MCM 100 135 in lbs 500 MCM 2x250 MCM 100 135 in lbs 500 MCM 2x250 MCM 100 135 in lbs 3x300 MCM 3x350 MCM 100 135 in lbs 1 The cables must be selected to be equal to the siz...

Page 79: ...0 MCM B I BURNDY ILSCO BURNDY YA29 CRA 250L YA30 LB YELLOW YELLOW 16 16 1024 300 MCM B I BURNDY ILSCO BURNDY YA30 CRA 300L YA32 LB WHITE WHITE 17 298 17 298 1026 350 MCM B I BURNDY ILSCO BURNDY YA31 CRA 350L YA34 LB RED RED 18 324 18 324 1027 400 MCM B I BURNDY ILSCO BURNDY YA32 CRA 400L YA36 LB BLUE BLUE 19 470 19 470 1027 500 MCM B I BURNDY ILSCO BURNDY YA34 CRA 500L YA38 LB BROWN BROWN 20 299 2...

Page 80: ...ed Power Terminals H 80 6 2047mm D 32 8 832mm For power terminals use 1 2 12mm Diameter bolts UPS module 160kVA to 225kVA 35 4 900mm 80kVA to 100kVA 27 6 700mm AC Input A DC Input AC Output Bypass Input C B A40 C40 B40 A50 C50 B50 BN BP Bypass Input A40 B40 C40 UPS module Battery Input BN BP AC Output A50 B50 C50 AC Input A B C Grounding Bar E External Block IOAU 09 ...

Page 81: ...44 G9000 Installation and Operation Manual FIGURE 3 3 Diagram of Power Wire Control Wire Inter Connect between UPS and Battery 2 ...

Page 82: ...ttery 52L2 UPS Breaker 52C Tie Cabinet UPS Breaker 52Ln 1 SMB Maintenance Bypass Breaker Output Breaker 52L 52S Bypass input AC input Bypass input AC input Bypass input AC input AC output AC output AC output Converter Charger UPS 2 UPS n 1 Bypas s CB 2 Inverter CB1 Battery 52C 52S Converter Charger Bypass CB 2 Inverter CB1 Battery 52C 52S Converter Charger 1 n Maximum 4 ...

Page 83: ...CN94 CAIN UPS 3 CN94 CBIN UPS n 1 CN96 TLOUT UPS n 1 CN94 CAOUT UPS n 1 CN94 CBOUT A B C UPS 1 A B C UPS 2 A B C UPS n AC OUTPUT 35 36 37 38 49 50 1 8 ON 1 8 OFF 1 8 ON 52L1 AX 52L2 AX 52Ln AX Critical Load Cabinet CBIN CAIN CBOUT CAOUT CBIN CAIN CBOUT CAOUT 1 n Maximum 4 2 Return from the last UPS module to the first UPS module continuous loop 3 DIP switch position UPS 1 and UPS n ON Otherwise OF...

Page 84: ...er supplied b Verify that Battery Disconnect Circuit Breaker CB2 is opened or in tripping position c If a dual source is feeding the UPS close the External AC Input Circuit Breaker manually user supplied d The LCD panel boots up automatically and the screen will show that the Load is powered by bypass line e On the LCD panel select OPERATION tab and then press the STARTUP GUIDANCE button to contin...

Page 85: ...e OPERATION MENU e If stopping both the Inverter and Converter is required open the Battery Disconnect circuit breaker CB2 manually in accordance with guidance Verify the load is OFF if the next step is to be performed Power to the load has been supplied through the bypass line Power to load will be lost after execution of the next step The load will drop f If a dual source is feeding the UPS open...

Page 86: ...ss the STOP icon on the LCD Transfer from bypass to inverter UPS 1 Press the START STOP icon on the LCD 2 Follow the STARTUP GUIDANCE and Press the START icon on the LCD When REMOTE OPERATION MODE is displayed on the LCD panel the inverter start operation can only be performed remotely If local inverter start or stop operation is required at the UPS select LOCAL ONLY or REMOTE LOCAL in the OPERATI...

Page 87: ...the bypass input The Maintenance Bypass Switch is synchronized with the Static Transfer Switch Transfer from Maintenance Bypass to MMS Bypass Operation 1 Close Tie cabinet breaker 52L 2 Open Tie cabinet Breaker SMB When REMOTE OPERATION MODE is displayed on the LCD panel the inverter start operation can only be performed remotely If local inverter start operation is required at the UPS select LOCA...

Page 88: ...t the Authorized Toshiba Service Representatives or call Toshiba International Corporation at 1 800 231 1412 UPS FAULT Annunciator Silence Recording of Fault Primary Action Note The error code indicated on the LCD display panel when an UPS alarms is very important In order to reduce repair time please include this information along with the operation and load status for all correspondence to Toshi...

Page 89: ...inal capacity Replace battery if its capacity is within this percentage B UPS Component Parts UPS components have a defined life expectancy Fans Capacitors Filters etc Contact Toshiba International Corporation or its authorized service representatives for a complete parts replacement schedule Recommended replacement time interval varies with operating environment Contact Toshiba International Corp...

Page 90: ...d required action At time of error A Verify and record the occurrence of the alarm Note details of alarm message displayed on the LCD display panel Contact Toshiba International Corporation at 1 800 231 1412 B If a circuit breaker MCCB has tripped depress the toggle to reset the breaker before closing it again ...

Page 91: ...NG DECREASE LOAD Intermittent sound Alarm Overload UA808 INVERTER OVERLOAD The output load current has exceeded 150 of the rated current WARNING DECREASE LOAD Intermittent sound Alarm Overload UA810 INVERTER OVERLOAD Short time over current has been detected during the inverter operation WARNING DECREASE LOAD Intermittent sound Alarm Overload UA812 BYPASS VOLTAGE OUT OF RANGE Bypass line voltage i...

Page 92: ...AL ALARM External Alarm relay turned on Intermittent sound Alarm UF001 INPUT CIRCUIT ABNORMAL The MMS input reference error signal exceeds specifications CALL SERVICE ENGINEER Continuous sound Major Lit on UF002 CONVERTER OVERCURRENT Detection of MMS converter overcurrent CALL SERVICE ENGINEER Continuous sound Major Lit on UF003 CONVERTER ABNORMAL Pre charging circuit is not working properly CALL ...

Page 93: ...LL SERVICE ENGINEER Intermittent sound Minor Flicker UF154 CB2 ABNORMAL During UVT status signal from CB2 is ON CALL SERVICE ENGINEER Intermittent sound Minor Flicker UF156 CHG STOPPED B ATTERY OVERTEMP UF157 failure persisted for over 2 hours CHECK BATTERY Intermittent sound Minor Battery abnormal Flicker UF157 BATTERY OVERTEMPERAT URE Detection of overtemperature at the batteries CHECK BATTERY I...

Page 94: ...e contactor 52C CALL SERVICE ENGINEER Continuous sound Major Lit on UF211 52C ABNORMAL No answer from contactor 52C during inverter operation CALL SERVICE ENGINEER Continuous sound Major Lit on UF213 OVERTEMP Heatsinks temperature exceeds thermal settings CALL SERVICE ENGINEER Continuous sound Major Lit on UF214 COOLING FAN ABNORMAL Thermal relay activated protection CALL SERVICE ENGINEER Continuo...

Page 95: ...ration CALL SERVICE ENGINEER Continuous sound Major Lit on UF352 CONTROL POWER SUPPLY ABNORMAL SMS backup control power supplies exhibit abnormal CALL SERVICE ENGINEER Intermittent sound Minor Flicker UF363 UPS CONTROL CIRCUIT ERROR Synchronization error signal is being received for a considerable time CALL SERVICE ENGINEER Intermittent sound Minor Flicker UF371 UPS CONTROL CIRCUIT ERROR Minor com...

Page 96: ... CALL SERVICE ENGINEER Intermittent sound Minor Flicker UF452 CB3 ABNORMAL Contactor CB3 is not working properly CALL SERVICE ENGINEER Intermittent sound Minor Flicker Note 1 1 Major is defined as major failure Inverter transferred to the static bypass line 2 Minor is defined as a minor failure UPS continues to operate normally but cause of alarm must be identified Note 2 Indicates one of two poss...

Page 97: ...on or Audible noise Daily Touch and hearing Check if fans have irregular sound Contact service representative in case of abnormalities Overheating When needed Touching exterior Contact service representative in case of abnormalities Air filter clog When needed Visual check Clean wipe if clogged or dusty 3 Operation LCD sharpness Brightness Left bottom LED Daily Visual check No characters faded ill...

Page 98: ...G9000 Installation and Operation Manual 61 APPENDIX A Installation Planning Guides IPG ...

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Page 103: ...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 Japan ...

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Page 132: ...abinet SKR K TITLE DRAWING NO REV NOTES A B C D E F G H I J 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 INTERNATIONAL CORPORATION Houston Texas USA THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF TOSHIBA INTERNATIONAL CORPORTION AND SHALL NOT BE REPRODUCED USED OR DISCLOSED TO OTHERS UNLESS PRIOR WRITTEN AUTHORIZATION IS OBTAINED Drawn by EKM Date 2 24 09 Approved by CB1 ST 42 pole panelboard 42 pole pan...

Page 133: ...poses only and is subject to change without notice TIC is not responsible for any errors or omissions TOSHIBA INTERNATIONAL CORPORATION Houston Texas USA THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF TOSHIBA INTERNATIONAL CORPORATION AND SHALL NOT BE REPRODUCED USED OR DISCLOSED TO OTHERS UNLESS PRIOR WRITTEN AUTHORIZATION IS OBTAINED Date 3 3 09 36 00 78 7 32 01 FRONT VIEW INNER DOORS FRONT VIEW OUT...

Page 134: ...nly and is subject to change without notice TIC is not responsible for any errors or omissions TOSHIBA INTERNATIONAL CORPORATION Houston Texas USA THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF TOSHIBA INTERNATIONAL CORPORATION AND SHALL NOT BE REPRODUCED USED OR DISCLOSED TO OTHERS UNLESS PRIOR WRITTEN AUTHORIZATION IS OBTAINED Date 3 3 09 42 00 78 7 32 01 FRONT VIEW INNER DOORS FRONT VIEW OUTER DOOR...

Page 135: ...Hybrid Transfer Switch needs no cooling fans because the SCR device only conducts the load for the short time needed for the magnetic contactor to change contact states The SCR has ample short time current and heating rating for this duty With much less heat produced and no requirement for forced cooling the risk of failure due to excessive heat is drastically reduced In addition the contactor is ...

Page 136: ...perates the Gate Switch closing the SCR Power instantly flows through the SCR from the Bypass supply to the output Route 2 The Inverter supply is automatically synchronized to the Bypass supply 3 R2 also energizes coil 83MC2 causing the contactor to change state switching the output power flow from the Inverter to the Bypass supply Route 3 4 Switch contact Bypass is opened and R2 is de energized T...

Page 137: ...the Switch Gate closing the SCR Power instantly flows through the SCR from the Bypass supply to the output Route 2 The Inverter supply is automatically synchronized to the Bypass supply 7 R1 also energizes coil C1 causing the contactor to change state switching the output power flow from the Bypass to the Inverter supply Route 1 8 Switch contact UPS is opened and R1 is de energized This turns off ...

Page 138: ...41 PHONE 713 466 0277 800 231 1412 FACSIMILE 713 896 5226 toshiba02 User2 UPSMKT GENERAL UPS 3Phase Systems White Papers G9000 White Paper multi level converter doc UPSG9000WP081201 G9000 Uninterruptible Power Supply Multi level PWM IGBT Technology White Paper ...

Page 139: ... 2008 TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION toshiba02 User2 UPSMKT GENERAL UPS 3Phase Systems White Papers G9000 White Paper multi level converter doc UPSG9000WP081201 ...

Page 140: ...ilding design and management of mission critical applications have become even more challenging To meet current and future demands in terms of efficiency greenhouse emissions reliability layout reconfiguration and power availability adoption of state of the art UPS Uninterruptible Power Supply power electronics technology is a good practice to avoid obsolescence reduce waste and enhance flexibilit...

Page 141: ...ntal concerns building design and management of mission critical applications have become even more challenging High level performance site infrastructure features redundant power capacity fault tolerance constant cooling and enough space for maintenance and future reconfiguration 2 Therefore high efficiency and size effective uninterruptible power supplies play a key role in powering these critic...

Page 142: ... converter is basically an array of semiconductors switches These switches are arranged in such way that their commutation enables the synthesis of the required output voltage waveform Conventional inverters have a configuration as shown in Figure 2 In this configuration note that n the voltage stress on each power switch can be as high as the DC link voltage E n the output voltage at each termina...

Page 143: ...as three voltage levels E 0 E Volts as a result of four possible combinations Table 1 Figure 4 shows a train of variable width pulses line to line voltage using a conventional inverter To obtain a sinusoidal signal filtering using bulky reactors is required to suppress high frequency components E E 2 2 E E 2 2 E E 2 2 E E 2 2 E E 0 Terminal U Terminal V Line to Line Voltage U V 0 E 0 E FIGURE 3 Eq...

Page 144: ...the voltage stress on each power switch is equal to E 2 Volts n the output voltage at each terminal assumes one out of three levels E 2 0 and E 2 Volts This observation shows that n voltage stresses on power switches are half of those in the conventional circuit n the voltage variation dv dt at each terminal is equal to E 2 Volts These findings imply that n voltage ratings of power semiconductors ...

Page 145: ...hows nine possible combinations and five resulting voltage levels E E 2 0 E 2 and E Volts A train of variable width pulses for a 3 level power processor is shown in Figure 7 The resulting output waveform tracks the sinusoidal much better than in the case of the conventional inverter E E 2 2 E E 2 2 E E 2 2 E E 2 2 E E 2 2 E E 2 2 E E 2 2 E E 2 2 0 0 E 0 0 0 0 0 E 0 Terminal U Terminal V Line to Li...

Page 146: ...r n a multilevel inverter with a 0 05 p u filter reactor n a conventional inverter with a 0 10 p u filter reactor Note that to match the current ripple and harmonic spectrum performance seen in a three level converter a two level topology requires a larger reactor Therefore three level based structures have a competitive advantage in terms of size weight reduction Inverter Current Inverter Current...

Page 147: ...ty in design allows the selection of power semiconductors with better conduction and switching characteristics As an example refer to the Figure 9 that shows the switching losses and saturation voltage for a typical 1200V and a 600V class IGBT of same generation from the same manufacturer Although the saturation voltage is almost the same a 600V class IGBT exhibits better switching characteristics...

Page 148: ...tter characteristics of using an IGBT with lower voltage ratings Considering both types of losses in an UPS the three level concept realizes an overall improvement of power conversion efficiency Figure 10 shows a typical scenario of power loss distribution in an UPS system for both circuit topologies Despite of the fact that conduction losses almost doubles switching losses are dramatically reduce...

Page 149: ... this package features the latest significant advances in the power semiconductor industry and the proven reliable record of an extremely mature technology As a result this combination offers great reduction of power losses better thermal characteristics and higher reliability To further enhance the features of the chosen IGBT chip internal circuit layout and component placement play a leading rol...

Page 150: ...e final result is an exclusive IGBT power module for an innovative circuit concept Its tailored design boosts the benefits of three level power converters by n increasing efficiency by reduction of semiconductor power losses n improving reliability through lower electrical and thermal stresses n reducing electromagnetic noise due to its intelligent circuit design FIGURE 12 Schematic circuit of the...

Page 151: ... to the conventional two level topology The exclusive power module has become a key component to make the multilevel concept even more attractive In terms of advances in systems DSP 4 based fully digital control ensures superior performance to meet modern industry demands and standards In addition The G9000 UPS introduces a cross current sensor less control for parallelism of multiple modules This...

Page 152: ...f the future n Better utilization of available space Its transformerless all transistorized three level circuit design results in a high power density UPS with small footprint and low weight The 225kVA G9000 UPS occupies an area of 8 11 square feet 7 542 square centimeters and weights only 1230 lbs 558 kg These characteristics promote a considerable reduction of shipment costs when compared with c...

Page 153: ...on in critical mission facilities Its industry leading power electronics technology delivers unmatched double conversion efficiency and competitive size weight reduction to meet current and future demands in terms of greenhouse emissions redundancy and layout reconfiguration With a wide range of benefits the G9000 UPS avoids technological obsolescence reduces waste and enhances flexibility The G90...

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