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:

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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.