Toshiba Black Gold TB Series User manual

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TOSHIBA
1
NOTE
The instructions contained in this manual are not intended to cover all of the details
or variations in equipment, nor to provide for every possible contingency to be met
in connection with installation, operation, or maintenance. Should further
information be desired or should particular problems arise which are not covered
sufficiently for the purchaser’s purposes, the matter should be referred to the local
Toshiba sales office.
The context of this instruction manual shall not become a part of or modify any
prior or existing agreement, commitment, or relationship. The sales contract
contains the entire obligation of Toshiba International Corporation’s UPS Division.
The warranty contained in the contract between the parties is the sole warranty of
Toshiba International Corporation’s UPS Division and any statements contained
herein do not create new warranties or modify the existing warranty.
Any electrical or mechanical modifications to this equipment,
without prior written consent of Toshiba International
Corporation, will void all warranties and may void UL listing
and/or CSA certification. Unauthorized modifications also can
result in personal injury, death, or destruction of the
equipment.
UNINTERRUPTIBLE POWER SUPPLY
Please complete the Extended Warranty Card Supplied with this UPS and return it
by prepaid mail to Toshiba. This activates the extended warranty. If additional
information or technical assistance is required call Toshiba’s marketing department
toll free at [phone] or write to: Toshiba International Corporation, 13131
W. Little York Road, Houston, TX 77041-9990
Please complete the following information for your records and to remain within this
equipment manual.
Model Number:
Serial Number:
Date of installation:
Inspected By:

TOSHIBA
2
CONTENTS
SECTION PAGE
NOTE...................................................................................................................................................................................1
CONTENTS ........................................................................................................................................................................2
INTRODUCTION ..............................................................................................................................................................4
GENERAL SAFETY INSTRUCTIONS...........................................................................................................................5
IMPORTANT SAFETY INSTRUCTIONS......................................................................................................................6
IMPORTANT SAFETY INSTRUCTIONS (CONT.)......................................................................................................7
1.0 PRODUCT DESCRIPTION..................................................................................................................................8
1.1 THEORY OF OPERATION.........................................................................................................................................8
1.2 APPLICATION AND USE...........................................................................................................................................8
1.3 POWER BACKUP.....................................................................................................................................................8
1.4 POWER CONDITIONING ..........................................................................................................................................8
2.0 INSPECTION/STORAGE/DISPOSAL................................................................................................................9
2.1 INSPECTION OF THE NEW UPS EQUIPMENT:...........................................................................................................9
2.2 STORAGE OF UPS EQUIPMENT...............................................................................................................................9
2.3 DISPOSAL...............................................................................................................................................................9
3.0 PRECAUTIONS ...................................................................................................................................................10
3.1 INSTALLATION PRECAUTIONS (GENERAL)...........................................................................................................10
3.2 INSTALLATION PRECAUTIONS (RACK MOUNTED) ................................................................................................10
3.3 PRESTART PRECAUTIONS.....................................................................................................................................11
3.4 OPERATING PRECAUTIONS...................................................................................................................................11
4.0 SPECIFICATIONS...............................................................................................................................................12
4.1 BLACK GOLD TB SERIES SPECIFICATIONS ......................................................................................................12
5.0 OPERATING THE UPS ......................................................................................................................................13
5.1 OPERATION MODES .............................................................................................................................................13
5.1.1 AC Input Mode (normal operation) ............................................................................................................13
5.1.2 Battery Backup Mode..................................................................................................................................14
5.1.3 Circuit-bypass Mode...................................................................................................................................15
5.2 SYSTEM PROTECTION FEATURES.........................................................................................................................16
5.3 OPERATION MONITORING....................................................................................................................................17
5.3.1 Visual Indicator Functions..........................................................................................................................17
5.3.2 Audible Alarm Functions............................................................................................................................17
5.3.3 Visual and Audible Indicator Function Chart.............................................................................................17
5.4 FRONT PANEL LAYOUT........................................................................................................................................18
5.5 UPS INVERTER MODE DISPLAY...........................................................................................................................18
5.6 BATTERY RECHARGING.......................................................................................................................................19
5.7 BATTERY BACKUP TIME......................................................................................................................................20
5.8 BATTERY LOW VOLTAGE TOLERANCES ..............................................................................................................20
5.9 BATTERY CHECK FUNCTION................................................................................................................................20
5.10 SYSTEM RESET ....................................................................................................................................................20

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6.0 UPS CONTROL INTERFACE ...........................................................................................................................21
6.1 REMOTE CONTACT AND IBM AS/400 .................................................................................................................21
6.2 RS-232C COMMUNICATION INTERFACE..............................................................................................................22
6.2.1 UPS Shutdown (via RS-232C).....................................................................................................................22
7.0 TROUBLESHOOTING PROCEDURES...........................................................................................................23
7.1 NON-FATAL FAULT MODE...................................................................................................................................23
7.2 FATAL FAULT MODE ...........................................................................................................................................24
8.0 PREVENTIVE AND SCHEDULED MAINTENANCE/PARTS .....................................................................25
8.1 PREVENTIVE MAINTENANCE................................................................................................................................25
8.2 PARTS REPLACEMENT..........................................................................................................................................25
9.0 EXTERNAL DIMENSIONS/SHIPPING WEIGHTS/PANEL LAYOUT.......................................................26
9.1 EXTERNAL DIMENSIONS FOR THE 2000 VA (120V AND 230V) BLACK GOLD TB MODEL. ............................26
9.2 PANEL LAYOUT/SHIPPING WEIGHT .....................................................................................................................27
CONTENTS
SECTION PAGE

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INTRODUCTION
Thank you for purchasing the BLACK GOLD TB SERIES UPS. This Series features the very
latest state of the art microprocessor technology and also uses IGBT transistors for fast, high
power and low noise PWM (pulse with modulation) switching. Also, the Series features a low
impedance output transformer to provide isolation even during bypass operation.
It is the intent of this manual to provide a guide for
safely installing, operating, and maintaining
the UPS. This operation manual contains a section of general safety instructions and is marked
throughout with warning symbols.
Read this operation manual thoroughly before installation
and operation of this electrical equipment.
All safety warnings must be followed to ensure personal safety.
General safety instructions are found on page 5 and important safety instructions are found
on pages 6 and 7. Read and save these instructions for future reference.
This manual is divided into major sections of interest. Section 1 contains the product description
with the theory of operation and applications. All of the initial inspection, storage, installation,
operating, and pre-start precautions can be found in Section 2 and 3.
Section 4 contains the equipment standard specifications.
Section 5 outlines the operating modes, protective features, battery recharging, battery low voltage
tolerances, and alarm-panel indicator functions.
Section 6 shows the control interface pin configurations.
Sections 7 and 8 are devoted to troubleshooting procedures, preventative maintenance
techniques and periodic parts replacement. A fuse-rating chart is also shown.
Section 9 shows the front, rear, and side panel layout views with dimensional data. Labels,
connectors and switch placement, and shipping weights are also shown.
We hope that you find this operation manual informative and easy to use. If additional information
or technical assistance is needed, please call toll free [phone] or write to Toshiba
International Corporation, 13131 W. Little York, Houston TX 77041-9990.
Again, thank you for the purchase of this product.
TOSHIBA INTERNATIONAL CORPORATION

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GENERAL SAFETY INSTRUCTIONS
Warnings in this manual appear in any of four ways:
1)
Danger - The danger symbol is a lightning bolt mark enclosed in a triangle, which precedes
the 3/16” high letters spelling the word “DANGER”. The danger symbol is used to indicate
imminently hazardous situations, locations, and conditions which, if not avoided, WILL result
in death, serious injury, and/or severe property damage.
DANGER
2) Warning -The warning symbol is an exclamation mark enclosed in a triangle, which precedes
the 3/16” high letters spelling the word “WARNING”. The warning symbol is used to indicate
potentially hazardous situations and conditions which, if not avoided COULD result in serious
injury or death. Severe property damage COULD also occur.
WARNING
3) Caution -The caution symbol is an exclamation mark enclosed in a triangle, which precedes
the 3/16” high letters spelling the word “CAUTION”. The caution symbol is used to indicate
potentially hazardous situations and conditions which, if not avoided COULD result in injury.
Equipment damage may also occur.
CAUTION
4) Attention warnings -The attention warning symbol is an exclamation mark enclosed in a
triangle, which precedes the 3/16” high letters spelling the word “ATTENTION”. The Attention
warning symbol is used to indicate situations and conditions that COULD cause operator
injury and/or equipment damage.
ATTENTION
Other warning symbols may appear along with the Danger and Caution symbol. The additional symbols
are used to specify special hazards. These warnings describe particular areas where special care and/or
procedures are required in order to prevent serious injury and possible death:
1)
Electrical warnings - The electrical warning symbol is a lighting bolt mark enclosed in a
triangle. The Electrical warning symbol is used to indicate high voltage locations and
conditions that COULD cause serious injury or death if the proper precautions are not
observed:
2)
Explosion warnings - The explosion warning symbol is an explosion mark enclosed in a
triangle. The Explosion warning symbol is used to indicate locations and conditions where
molten, exploding parts that COULD cause serious injury or death if the proper precautions
are not observed:

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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS This manual contains important
instructions for the BLACK GOLD TB
Series that should be followed during
the installation, operation, and maintenance of the UPS Systems.
The maximum ambient temperatures in which the UPS should be operated or stored is 40°C (104°F).
The nominal battery voltage for these models is 72VDC.
Servicing of the batteries should only be performed by a qualified Toshiba Representative who is
knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from
batteries.
When replacing batteries, use the same number and type of sealed, lead acid batteries (do not mix types
of batteries).
Model Capacity BLACK GOLD
TB 2.0kVA
Manufacture Yuasa
Type NPH5-12FR
Quantity 6
CAUTION Misuse of this equipment could result in human injury and equipment
damage. In no event will Toshiba Corporation be responsible or liable for
either indirect or consequential damage or injury that may result from the use of this equipment.
CAUTION Do not dispose of the batteries in a fire. The batteries may explode.
CAUTION Do not open or mutilate the batteries. Released electrolyte is harmful to
the eyes and skin and could also be toxic.
WARNING This unit contains sealed lead acid batteries. Lack of preventative
maintenance could result in batteries exploding and emitting gasses and/or
flame. An authorized, trained technician must perform annual preventative maintenance.
WARNING Failure to replace a battery before it becomes exhausted may cause the
case to crack, possibl
y
releasin
g
electrol
y
tes from inside the batter
y
, and
resulting in secondary faults such as odor, smoke, and fire.

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IMPORTANT SAFETY INSTRUCTIONS (CONT.)
WARNING Personnel knowledgeable of batteries and the required precautions
should perform installation and servicing of batteries. Keep
unauthorized personnel away from the batteries.
WARNING Proper maintenance to the battery system of this unit must be done by a
qualified service technician, this is essential to the safety and reliability of
your UPS system. Refer to the service manual.
A battery can present a risk of electrical shock and high short
DANGER circuit current. The following precautions should be observed when
working with batteries:
1) Verify that the UPS is off and that the power cord is disconnected from the power source.
2) Remove watches, rings or other metal objects.
3) Use tools with insulated handles to prevent inadvertent shorts.
4) Wear rubber gloves and boots.
5) Do not lay tools or metal parts on top of batteries.
6) Determine if the battery is inadvertently grounded. If inadvertently grounded, remove
source of ground. Contact with any part of a grounded battery can result in electrical
shock. The likelihood of such shock will be reduced if such grounds are removed during
installation and maintenance.
7) Verify circuit polarities prior to making connections.
8) Disconnect charging source and load prior to connecting or disconnecting terminals.
9) VRLA batteries contain an explosive mixture of hydrogen gas. Do not smoke, or create a flame
or spark in the immediate area of the batteries. This includes static electricity from the body.
10) Do not attempt to open the batteries in order to add water or sample the specific gravity of the
electrolyte. The batteries are valve regulated lead acid type and such servicing is not possible
without damaging the battery.
11) Use proper lifting means when moving batteries and wear all appropriate safety clothing and
equipment.
12) Do not dispose of lead acid batteries except through channels in accordance with local, state
and federal regulations.

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1.0 Product Description
1.1 Theory of Operation
An Uninterruptible Power Supply (UPS) is a system that is installed between the utility
power and the load equipment. The UPS provides steady AC output power during utility
power fluctuations and interruptions.
During normal operation, the UPS utilizes utility AC power and removes high voltage
spikes and transients caused by switching and faults on the main utility. The result of this
process is maximum power conditioning and regulation.
If the AC power supplied to the UPS drops below a specified voltage level, the unit’s
batteries automatically begin supplying power instead of receiving it. This insures that the
loads connected to the UPS continue to receive power with no interruption. This power is
provided for a long enough time so that the load can be shut down in an orderly fashion.
This prevents loss of data and possible damage to both hardware and software.
When AC input power becomes available again, operation returns to normal. The UPS
batteries begin to recharge, so they will be ready for the next power interruption.
1.2 Application and use
Toshiba’s BLACK GOLD TB on-line Uninterruptible Power Supply (UPS) system provides
continuous computer-grade isolated AC power in a compact, efficient, high performance
unit. The UPS assures safe, reliable operation of critical equipment, ranging from
personal computers to mini-computers to local area networks (LAN). All units feature an
audible alarm that sounds if the battery voltage drops below standard during use. This is
an additional aid to help in retaining the valuable data storage, and all units allow for
computer interfacing.
1.3 Power Backup
During an electrical power failure, the UPS unit's batteries automatically supply DC power
to the inverter that supports the load equipment without interruption. For example, when
used to support a computer, the UPS backup assures additional time to complete your
activity and store data after a power failure occurs.
1.4 Power Conditioning
While utility power is present, the UPS supplies conditioned power to the load while
maintaining its batteries in a charged condition. The UPS protects the connected load
against the normal, everyday problems associated with heavy use of raw utility power,
including power sags, surges, signal interference, and spikes. This protection keeps
power-line problems from reaching your load, where it can cause equipment to operate
erratically, or damage software and hardware.

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2.0 Inspection/Storage/Disposal
2.1 Inspection of the new UPS equipment:
Upon receipt of the UPS, a careful inspection for shipping damage should be made.
After Uncrating:
1) Check the unit for loose, broken, bent or other damaged parts. If damage has
occurred during shipment, keep all original crating and packing materials for
return to the shipping agent. The equipment warranty will not apply to units that
are damaged during shipment.
2) Check to see that the model number specified on the nameplate conforms to the
order specifications.
2.2 Storage of UPS equipment
If the UPS equipment is to be subject to long or short-term storage, the following
guidelines should be used.
Avoid:
1) Storage in sites subject to extreme changes in temperature or high humidity.
2) Storage in sites subject to exposure of high levels of dust or metal particles.
Before storing:
1) Charge the unit’s batteries.
2) Place the STOP/RUN switch in the STOP position.
Storing:
1) Store within a temperature range of -20° to 40° C (-4° to 104° F).
2) For best results, store the UPS in the original shipping container and place on a
wood or metal pallet.
3) The optimum storage temperature is 21° C (70° F). Higher ambient temperatures
cause UPS batteries to need recharging more frequently.
After Storing:
1) If stored in an ambient temperature under 20° C (68° F); recharge the batteries
every 9 months.
2) If stored in an ambient temperature of 20° to 30° C (68° to 86° F), recharge the
batteries every 6 months.
3) If stored in an ambient temperature of 30° to 40° C (86° to 104° F), recharge the
batteries every 3 months.
2.3 Disposal
Please contact your state environmental agency for details on proper disposal of
electrical components and packaging in your particular area.
ATTENTION
It is illegal to dump lead-acid batteries in landfills or dispose of
improperly.
Please help our Earth by contacting the environmental
protection agencies in your area, the battery manufacturer, or call Toshiba
International Corporation toll-free at [phone] for more information
about recycling batteries.

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3.0 Precautions
3.1 Installation Precautions (General)
1) Install the unit in a well-ventilated location; allow at least 10 cm (4
inches) on all sides for air ventilation and for maintenance.
2) Install the unit where the ambient is within the correct operation range
(see Specifications Section 4.0).
3) Do not allow liquids or foreign objects to get inside the UPS.
4) Do not install the UPS in a location that is subject to high humidity. Also,
do not install the unit in areas that are exposed to direct sunlight, or
contaminated areas subject to high levels of airborne dust, metal particles,
or flammable gas.
Ambient temperature range for operating the UPS is 0° to 40°C (32° ~ 104°F);
25°C (77°F) is the recommended operating temperature for maximum
battery life.
5) Avoid installation near sources of electrical noise. Always make sure that
the unit’s ground is intact to prevent electrical shock and help prevent
electrical noise.
6) This UPS generates and radiates radio-frequency energy during operation.
Although RFI noise filters are installed inside the unit, there is no guarantee
that the UPS will not influence some sensitive devices, which are operating
in near proximity. If such interference occurs, the UPS should either be
installed farther away from the affected equipment and/or powered from a
different source than the affected equipment.
3.2 Installation Precautions (Rack mounted) CAUTION
1) Install the UPS in a conventional rack-style structure. The recommended
rack slide for the BLACK GOLD TB series UPS is General Devices, CTS-
124 (Call Toshiba for further information on rack slides). The rack must
be bolted to the floor, secured permanently to a wall, or otherwise
secured to prevent toppling.
2) Allow at least 4 inches of open space in the front and rear of the unit for
proper ventilation. Allow at least 6 inches of open space at the rear of
the unit for operation and disconnect devices.
3) Two people handling is required when moving this unit into and out of the
rack structure.
Front Panel Cutout
Use both handles when lifting entire
weight of the unit, unit weight
119.00lbs. (53.98 kg.) for the 120Vac
111.00lbs. (50.35 kg.) for the 230Vac

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3.0 Precautions (Cont.)
3.3 Prestart Precautions
1) Before connecting the UPS to a power source move all the breakers (MCCB1, 2,
3, and 4), on the front panel, to the OFF position and move the operation
STOP/RUN, on the front panel (See Section 9 for location), to the STOP position.
3.4 Operating Precautions CAUTION
1) The UPS should not be powered up until the entire operation manual has been
reviewed and understood.
2) The input power source voltage must be within +10% to -30% of the rated input
voltage. The input frequency must be within the rated input frequency range.
Voltages and frequencies outside of the permissible range may cause internal
protection devices to activate.
3) The UPS should not be used with a load whose rated input is greater than the
rated UPS output.
4) Do not use the UPS to provide power to motors that require high starting current
or a long starting time such as vacuum cleaners and machine tools.
5) Do not insert metal objects or combustible materials in the unit’s ventilation slots.
6) Do not place, hang, or paste any objects on the top or on the exterior surfaces of
the UPS.
7) Always use caution when connecting or disconnecting load equipment.
The UPS may be supplying power to the output load receptacles
through the bypass circuit. This can occur when the RUN/STOP
switch is in the STOP position, the output breakers are on (MCCB2-4),
and the unit is connected to a source of supply power (See Circuit-
bypass Mode Section 5.1.3).

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4.0 Specifications
4.1 BLACK GOLD TB Series Specifications
Model Number UC1A1A020C6RKBIG UC1E1E020C5RKBIG
Rated Output Capacity 2000 VA (1.4 kW)
General
Information
External Dimensions 16.75W X 24D X 5.25H in.
(425W x 610D x 133H mm)
Rated Voltage 120Vac, Single Phase (*) 230Vac, Single Phase (*)
Voltage Variation +10% to –30% (*)
Rated Frequency 50/60 Hz 50 Hz
Power Factor Greater than .98 when in inverter mode
Input
Harmonic Currents Less than 10% THD
DC Nominal (Voltage Range) 72Vdc (57.6 to 82.8 Vdc)
Float Charge (Regulation) 82.8Vdc (±2%)
Ripple Voltage 2% R.M.S.
Rated Back-up Time when fully
charged with .7pF at 77°F (25°C) 6 min. at full load (**)
18 min. at half load (**)
Recharge Time Maximum 24hrs. to 100% (90% recharge after 8Hrs.) (***)
Rated Charge Current 0.40 Amps
Battery
Type of Batteries Sealed lead-acid
Rated Voltage (Single phase) 120 Vac 230Vac
Output Voltage Regulation Within than +/- 3%, steady state
Output Frequency 50/60Hz +/- 0.5% in free
running mode (Line sync
range +/- 1Hz)
50Hz +/- 0.5% in free
running mode (Line sync
range +/- 1Hz)
Output Voltage Waveform Computer-grade sinewave with less than 3.0% THD with
linear load.
Rated Current (RMS) 16.6 Amps 8.6 Amps
Rated Power Factor .7 lagging
Maximum overload capacity 150% for 90 seconds
Voltage Transient Characteristic +/-5% under 100% load step change
Output
Crest Factor 3.0
Operating Temperature 32 to 104°F (0 to 40°C), optimal at 77°F (25°C)
Storage Temperature -4 to 104°F (-20 to 40°C)
Operating Humidity 30% to 90% (no condensation)
Altitude (****) Less than 3000 ft (1000 m) above sea level
Net. Weight 119.00 lbs. (53.98 kg) 111.00 lbs. (50.35 kg.)
Acoustical Noise <45 dB at max. output, measured 3.3 ft (1 m) from front
panel
Environment
Efficiency (AC-DC-AC) 82%
Bypass An automatic transfer of load to bypass switch (with 4mS-transfer time) may be caused by an
overload of the inverter output, or by an internal fault condition. Also, the load can be manually
transferred to bypass by putting the rocker switch in the STOP position.
IBM ™ AS/400 Pins 5 through 9
LAN Manager Pins 2 and 3
Fault detect and input power loss Pins 1 and 4 DB9 male connector
Interface
RS232 ASCII Pins 1 through 8 DB9 female
connector
(Pin 9 not used)
Options Software for unattended computer
shutdown. Contact Toshiba for details on this option
(*) Output capacity reduced when input voltage is between –15% and –30% of nominal.
(**) Battery backup time may vary depending on the operating conditions and ambient temperature at the
installation site.
(***) An initial charge time of 24 hrs is necessary to obtain proper battery performance level before
unit is used for battery backup.
(****) At 6000-ft (2000 m) above sea level, output capacity should be de-rated by 3%.

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Input
Power
MCCB1 MCCB
2
3
4
CHP INV
Batteries
B
yp
ass circuit
Power
Flow
Input
Power
MCCB1 MCCB
2
3
4
CHP INV
Batteries
Power
Flow
+
-
+
-
B
yp
ass circuit
5.0 Operating the UPS
5.1 Operation Modes
5.1.1 AC Input Mode (normal operation)
Input
Xfmr
Power flow in AC input mode for the 2000VA 230V BLACK GOLD TB Model
Both of the above illustrations show circuit power flow in the ac-input mode.
The UPS unit’s rectifier, included in a boost chopper circuit, converts ac input
power to dc power. This dc power runs the unit’s transistor inverter and charges
the batteries. The boost chopper circuit maintains a constant voltage, with
current limiting, for charging the batteries and assures proper sine waveform
generation for the output current. The unit’s batteries are maintained in a
constantly charged state when the UPS is in the normal operation mode.
On the front panel, LED’s labeled “AC LINE” and “INVERTER” should be on and
the “FAULT” LED should be off (See Section 5.4 Front Panel Layout).
Input
Xfmr
(230V)
Output
Xfmr
(230V)
Power flow in AC input mode for the 2000VA 120V BLACK GOLD TB Model

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Input
Power
MCCB1 MCCB
2
3
4
CHP INV
Batteries
Power
Flow
Input
Power
MCCB1 MCCB
2
3
4
CHP INV
Batteries
Power
Flow
+
-
+
-
B
yp
ass circuit
B
yp
ass circuit
5.0 Operating the UPS
5.1 Operation Modes (Contd.)
5.1.2 Battery Backup Mode
Input
Xfmr
Power flow in battery backup mode for the 2000VA 230V BLACK GOLD TB
Model
The above illustrations show power flow during the battery backup mode.
When commercial ac power failures occur, the UPS’s batteries instantly begin
supplying dc voltage to the UPS’s main inverter circuit. This circuit will change
(invert) the dc power into ac power. The ac power is available at the unit’s
output receptacles. This back-up process will continue until the UPS battery
voltage drops below a specific minimum level. When this occurs, the batteries
will stop supplying power to the load. This minimum level is the rated minimum
voltage (Vmin). The rated battery voltage chart on pages 5-6 (See Section 5.7
for battery backup time) shows (Vmin). On the front panel, LED’s labeled
“AC LINE” and “FAULT” should be off. The “INVERTER” LED should be on
(See Section 5.4 Front Panel Layout).
Input
Xfmr
(230V)
Output
Xfmr
(230V)
Power flow in battery backup mode for the 2000VA 120V BLACK GOLD TB
Model

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Input
Power
MCCB1 MCCB
2
3
4
CHP INV
Batteries
Power
Flow
Input
Power
MCCB1 MCCB
2
3
4
CHP INV
Batteries
Power
Flow
+
-
+
-
B
yp
ass circuit
B
yp
ass circuit
5.0 Operating the UPS
5.1 Operation Modes (Contd.)
5.1.3 Circuit-bypass Mode
Input
Xfmr
Power flow in circuit-bypass mode for the 2000VA 230V BLACK GOLD TB
Model
If the UPS unit is overloaded or develops an internal fault, the power flow is
automatically switched from the unit’s main circuit to the bypass circuit mode.
Power flow through the bypass is shown in the above illustrations. This change-
over occurs automatically in approximately 4 milliseconds. The switching period
is not long enough to cause interruptions to occur in most UPS equipment loads.
The energy flow must be transferred manually from the UPS bypass
circuit back to the inverter circuit after first correcting the fault.
Toggle the
STOP/RUN switch (on the unit’s front panel) first to STOP and then back to RUN.
This procedure resets the UPS and transfers back to inverter. On the front panel,
the LED labeled “FAULT” should be off. The “INVERTER” LED and “AC LINE”
LED should be on (See Section 5.4 Front Panel Layout).
Input
Xfmr
(230V)
Output
Xfmr
(230V)
Power flow in circuit-bypass mode for the 2000VA 120V BLACK GOLD TB
Model

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5.0 Operating the UPS
5.2 System Protection Features
The schematic shown below depicts the electrical locations of the protection devices
on the 2000 VA 120V UPS model.
Input
Bypass
Rectifier/
Charger/
Chopper Inverter
Input
Xfmr
Batteries
Output 2
Output 3
Output 4
MCCB
2
3
4
MCCB1
Overcurrent
Input
Abnormal
Overvoltage/
Undervolta
g
e
Current Limit
Overload
Overheating
Low Battery
Level
The schematic shown below depicts the electrical locations of the protection
devices on the 2000VA 230V UPS model.
Input
Bypass
Rectifier/
Charger/
Chopper Inverter
Input
Xfmr
230V
Batteries
Output 2
Output 3
Output 4
MCCB
2
3
4
MCCB1
Overcurrent
Input
Abnormal
Overvoltage/
Undervolta
g
e
Current Limit
Overload
Overheating
Low Battery
Level
Note: The three UPS rear panel output receptacles are supplied from the UPS inverter
section through separate 20A breakers (10A for the 230V model). Thus, an
overload on one of the receptacle sets can cause a loss of power to it while the
other receptacle sets remain active. If all of the UPS indicator lights appear
normal and power is not available at one of the receptacle sets, check the
associated output breaker.
Output
Xfmr
230V
Power flow
Power flow
+
-
+
-

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5.0 Operating the UPS
5.3 Operation Monitoring
5.3.1 Visual Indicator Functions
The following LED (light emitting diode) indicators are located on the front panel
(See Section 5.4 Front Panel Layout). Refer to these lamps for visual information
about the operating condition of the UPS (See Section 5.3.3 “Visual and Audible
Indicator Function Chart”).
1) AC LINE: This green LED lights when normal ac input power is being
supplied to the UPS unit.
2) INVERTER: This green LED lights when the inverter output voltage is normal.
3) FAULT: This red LED lights when an abnormal operating condition is
detected. Operation of the unit’s inverter is inhibited until the fault has been
corrected and the system reset (See Section 5.10 System Reset).
5.3.2 Audible Alarm Functions
The UPS is equipped with an audible alarm system, which activates under
various operating conditions. Sound patterns are used to indicate these
conditions (See Section 5.3.3 Visual and Audible Indicator Function Chart).
Alarms for the battery backup mode or low battery voltage will stop automatically
when AC input voltage is restored. Alarms for a fault condition will continue to
sound until the UPS has been reset (See Section 5.10 System Reset).
5.3.3 Visual and Audible Indicator Function Chart
Condition Cause Audible
Alarm
Pattern
Visual
Indicators UPS Operation
Overcurrent (OC) Problem in chopper or
inverter circuit.
DC Bus Overvoltage (DCOV) Vout > 115% of rated.
Output Overvoltage (OV) Vout > 110% of rated.
Undervoltage (UV) Vout < 85% of rated.
Overheat (OH) Heatsink exceeds 90º C.
Overload (OL) Output current and over-
load specifications have
been exceeded.
Battery problem Problem in battery
circuit.
1) “Fault” LED
is ON
2) “Inverter
LED is OFF
3) “AC Line”
LED is ON
1) Auto
transfer
to
bypass
2) Chopper
stopped
3) Inverter
stopped
Normal battery backup
operation Loss of AC power
Low battery voltage
(voltage less than 90%) Battery voltage too low.
1) “Fault” LED
is OFF
2) “Inverter”
LED is ON
3) “AC Line”
LED is OFF
1) Chopper
running
2) Inverter
running
ON
OFF
2s 1.5s
ON
OFF
.5s .5s
ON
OFF
1s 2s
ON
OFF
1s .5s
ON
OFF
70s 5s

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5.0 Operating the UPS
5.4 Front Panel Layout AC LINE (green lamp)
Lights green when normal ac input is being
supplied to the UPS Unit.
INVERTER (green lamp)
Lights green when the UPS unit is operating in
the run mode and the output is normal.
Fault (red lamp)
Lights red when the UPS unit has tripped in the
fault mode.
OUTPUT/BATTERY (green/red lamp level
meter) The UPS unit’s level meter consists of six
green and two red LED lamps.
INPUT/RECPT1/RECPT2/RECPT3
Directs to the unit’s input breaker and its
respective set of receptacles.
5.5 UPS Inverter Mode Display
The following chart shows normal operating conditions when the UPS INVERTER lamp is
green UPS Run Mode Display Chart
Output Display Status Explanation
Normal
When output current is between 30% and 100%, the
green lamps light in 15% increments (from bottom to
top) to indicate relative output value (This sample
display shows a value level of approximately 45% to
60% of available output current).
Overload
All green lamps light and one or two red lamps flash
once per second. Remove overload as quickly as
possible to prevent fault (fault timeouts vary
depending on overload condition).
Battery backup
During battery backup all green and all red lamps flash
once per second. As the batteries discharge, the green
lamps extinguish from bottom to top to indicate
remaining battery capacity (This sample display shows
a value level of approximately 55% to 70% of available
battery capacity).
Low battery
during battery
backup
All green lamps are off and one or two red lamps
continue to flash.
=Steady lit
LED
=Flashing
LED
=Steady lit
LED
=Flashing
LED
=Steady lit
LED
=Flashing
LED
=Steady lit
LED
=Flashing
LED

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5.0 Operating the UPS
5.6 Battery Recharging
The graph below shows the typical voltage requirements for recharging the UPS unit’s
batteries.
The recharge process usually consists of three periods. During the first period, the
current is maintained at approximately 0.4 amperes. In the second period, the constant
voltage control starts and the current gradually decreases as the batteries continue to
charge. In the third period, a slight current gradually decreases as the batteries continue
to charge. In the third period, slight current flows into the batteries to keep them fully
charged. After a complete discharge, a full recharge asually requires 24 hours (90%
recharge in 8 hours).
The chart depicted below shows the rated maximum and minimum battery voltages, and
the charge current.
Rated battery voltages
Model Vmax. Vmin. Charge
2000 VA 82.8Vdc 57.6Vdc 0.4 (A)