Toshiba 1400 XL PLUS Series User manual

TOSHIBA
Battery Cabinet System
SINGLE PHASE - 2.4/3.6/6.0/8.0 VA PLUS
October, 1996
Part # 43241-002
OPERATION MANUAL
MANUFACTURED IN THE U.S.A.

TOSHIBA

TOSHIBA
i
NOTE
These instructions are not intended to cover all of the details or variations in
equi ment, nor to rovide for every ossible contingency to be met in connection
with installation, o eration, or maintenance. This manual may change without
notice. Contact your local Toshiba sales office to verify that this is the latest
revision. Should further information be desired or should articular roblems arise
which are not covered sufficiently for the urchaser's ur oses, the matter should
be referred to the local Toshiba sales office.
The contents of this instruction manual shall not become a art of or modify any
rior or existing agreement, commitment, or relationshi . The sales contract
contains the entire obligation of Toshiba International Cor oration's UPS Division.
The warranty contained in the contract between the arties is the sole warranty of
Toshiba International Cor oration's UPS Division and any statements contained
herein do not create new warranties or modify the existing warranty.
UNINTERRUPTIBLE POWER SUPPLY
Please com lete the enclosed Extended Warranty Card and return it by re aid mail
to Toshiba. This activates the extended warranty. If additional information or technical
assistance is required call Toshiba's marketing de artment toll free at
1-800-231-1412 or write to: Toshiba International Cor oration, 13131 W. Little York
Road, Houston, TX 77041-9990.
Please com lete the following information for your records and to remain within this
equi ment manual:
Model Number:
Serial Number:
Date of Installation:
Ins ected By:

TOSHIBA
ii
GENERAL SAFETY INSTRUCTIONS
Warnings in this manual a ear in any of four ways:
1) Danger- The danger symbol is a lightning bolt mark enclosed in a triangle which recedes
the 3/16" high letters s elling 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 ro erty damage.
2) Warning - The warning symbol is an exclamation mark enclosed in a triangle which
recedes the 3/16" high letters s elling the word "WARNING". The warning symbol is
used to indicate otentially hazardous situations and conditions which, if not avoided
COULD result in serious injury or death. Severe ro erty damage COULD also occur.
3) Caution - The caution symbol is an exclamation mark enclosed in a triangle which
recedes the 3/16" high letters s elling the word "CAUTION". The caution symbol is used
to indicate otentially hazardous situations and conditions which, if not avoided may result
in injury. Equi ment damage may also occur.
4) Attention warnings - The attention warning symbol is an exclamation mark enclosed in a
triangle which recedes the 3/16" high letters s elling the word "ATTENTION". The
Attention warning symbol is used to indicate situations and conditions that can cause
o erator injury and/or equi ment damage:
Other warning symbols may a ear along with the Danger and Caution symbol and are used to s ecify
s ecial hazards. These warnings describe articular areas where s ecial care and/or rocedures are
required in order to revent serious injury and ossible 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 may cause serious injury or death if the ro er recautions are not
observed:
DANGER
WARNING
ATTENTION
2) Explosion warnings - The ex losion warning symbol is an ex losion mark enclosed in
a triangle. The Ex losion warning symbol is used to indicate locations and conditions
where molten, ex loding arts may cause serious injury or death if the ro er
recautions are not observed:
CAUTION

TOSHIBA
CONTENTS
SECTION PAGE
Disclaimer ............................................................................................................. i
General Safety Instructions ................................................................................. ii
Contents ............................................................................................................... iii
1.0 Important Safety Instructions............................................................................ 1-1
.0 Inspection/Storage/Disposal ............................................................................. -1
2.1 Inspection of the new Battery System ...................................................... 2-1
2.2 Storage of the Battery System .................................................................. 2-1
2.3 Disposal .................................................................................................... 2-1
3.0 Precautions ......................................................................................................... 3-1
3.1 Installation Precautions ............................................................................. 3-1
3.2 Prestart Precautions ................................................................................. 3-1
3.3 Operating Precautions .............................................................................. 3-1
4.0 UPS Connections ............................................................................................... 4-1
4.1 Power onnections .................................................................................. 4-1
4.2 Terminal Block Details .............................................................................. 4-1
4.3 Wire Size and Tightening Torque ............................................................. 4-1
5.0 6.0/8.0KVA Connection ...................................................................................... 5-1
5.1 Battery connections .................................................................................. 5-1
5.2 Illustration ................................................................................................. 5-1
5.3 onnection Procedure .............................................................................. 5-1
5.4 harger connection .................................................................................. 5-1
6.0 .4/3.6KVA Connection ...................................................................................... 6-1
6.1 Battery connections .................................................................................. 6-1
6.2 Illustration ................................................................................................. 6-1
6.3 onnection Procedure .............................................................................. 6-1
6.4 harger connection .................................................................................. 6-1
7.0 Preventative Maintenance/Parts Replacement ................................................ 7-1
7.1 Preventative Maintenance ........................................................................ 7-1
7.2 Parts Replacement ................................................................................... 7-1
8.0 External Layouts ................................................................................................ 8-1
8.1 External layouts ........................................................................................ 8-1
8.2 Dimensions ............................................................................................... 8-1
8.3 Shipping Weights ...................................................................................... 8-1
9.0 EPO connection .................................................................................................. 9-1
9.1 Shunt Trip ................................................................................................. 9-1
9.2 onnection diagram ................................................................................. 9-1
iii

TOSHIBA
1-1
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
CAUTION
CAUTION
CAUTION
This manual contains im ortant instructions
for models UC3-BC-0230, 0260, 0330, 0360,
0630, 0660, and 0830 that should be followed during the installation and maintenance of the Battery
System.
The maximum ambient tem erature in which the Battery System should be o erated is 40° C.
The nominal battery voltages for these models are as follows:
2.4 KVA: 96VDC
3.6 KVA: 144VDC
6.0 KVA: 216VDC
8.0 KVA: 252VDC
Servicing of the batteries should only be erformed by a qualified Toshiba Re resentative who is
knowledgeable of batteries and the required recautions. Kee unauthorized ersonnel away from
batteries.
When re lacing batteries, use the same number and ty e of one of the following sealed, lead-acid
batteries:
Misuse of this equi ment could result in human injury and equi ment
damage. In no event will Toshiba Cor oration be res onsible or liable for
either indirect or consequential damage or injury that may result from the use of this equi ment.
Do not dis ose of the batteries in a fire. The batteries may ex lode.
Do not o en or mutilate the batteries. Released electrolyte is harmful to the
eyes and skin and could also be toxic.
This unit contains sealed lead acid batteries. Lack of reventative
maintenance could result in batteries ex loding and emitting gasses
and/or flame. Annual reventative maintenance must be erformed by an authorized, trained
technician.
Failure to re lace a battery before it becomes exhausted may cause the
case to crack, ossibly releasing electrolytes from inside the battery, and
resulting in secondary faults such as odor, smoke, and fire.
Installation and servicing of batteries should be erformed by ersonnel
knowledgeable of batteries and the required recautions. Kee
unauthorized ersonnel away from the batteries.
WARNING
WARNING
WARNING
Model Capacity Manufacturer Type Quantity
UC3-BC-0230
Yuasa NP7-12FR
8
UC3-BC-0260 24
UC3-BC-0330 12
UC3-BC-0360 36
UC3-BC-0630 18
UC3-BC-0660 54
UC3-BC-0830 42

TOSHIBA
CONSERVER CES INSTRUCTIONS
1-2
INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITÉ
Cette notice contient des
instructions im ortantes concernant
la sécurité.
Un battery uet résenter un risque de choc électrique, de brûlure ar
transfert d' énergie.
Por le re lacement, utiliser le même nombre de batteries du modéle
suivant.
L' élimination des batteries est règlementèe. Consultar les codes
locaux à cet effet.
ATTENTION
ATTENTION
© Copyright 1994
ATTENTION
DANGER
IMPORTANT SAFETY INSTRUCTIONS
Pro er maintenance to the battery system of this unit must be done by a
qualified service techincian, this is essential to the safety and reliability of
your UPS system. Refer to service manual.
A battery can present a risk of electrical shock and high short
circuit current. The following recautions should be observed when
working with batteries:
1) Verify that the UPS is off and that the ower cord is disconnected from the ower source.
2) Remove watches, rings or other metal objects.
3) Use tools with insulated handles to revent inadvertent shorts.
4) Wear rubber gloves and boots.
5) Do not lay tools or metal arts on to 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 olarities rior to making connections.
8) Disconnect charging source and load roir to connecting or diconnecting terminals.
9) VRLA batteries contain an ex losive mixture of hydrogen gas. Do not smoke, cause a flame
or s ark in the immediate area of the batteries. This includes static electricity from the body.
10) Do not attem t to o en the batteries in order to add water or sam le the s ecific gravity of the
electrolyte. The batteries are valve regulated lead acid ty e and such servicing is not
ossible without damaging the battery.
11) Use ro er lifting means when moving batteries and wear all a ro riate safety clothing and
equi ment.
12) Do not dis ose of lead acid batteries exce t through channels in accordance with local, state
and federal regulations.
WARNING
Model Capacity Manufacturer Type Quantity
UC3-BC-0230
Yuasa NP7-12FR
8
UC3-BC-0260 24
UC3-BC-0330 12
UC3-BC-0360 36
UC3-BC-0630 18
UC3-BC-0660 54
UC3-BC-0830 42

TOSHIBA
2.0 Inspection Storage Disposal
2.1 Inspection of t e new Battery System
U on recei t of the Battery System, a careful ins ection for shi ing damage should be
made.
After Uncrating:
1) Check the unit for loose, broken, bent or otherwise damaged arts. If damage
has occurred during shi ment, kee all original crating and acking materials
for return to shi ing agent. Warranty will not a ly to units which are damaged
during shi ment.
2) Check to see that the rated ca acity and the model number s ecified on the
name late conform to the order s ecifications.
2.2 Storage of Battery equipment.
If the Battery System is to be subjected to long or short term storage the following
guidelines should be used.
Avoid:
1) Storage in sites subject to extreme changes in tem erature or high humidity.
2) Storage in sites subject to ex osure of high levels of dust or metal articles.
3) Storage on inclined floor surfaces or in sites subject to excessive vibration.
Before storing:
1) Charge the system's batteries.
2) Place the Battery System's in ut switch (MCCB-C) in the OFF osition.
Storing:
1) Store within a tem erature range of -20° to 40° C (-4° to 104° F).
2) For best results, store the UPS in the original shi ing container and lace on a
wood or metal allet.
3) The o timum storage tem erature is 21° C (70° F). Higher ambient
tem eratures cause UPS batteries to need recharging more frequently.
4) Batteries need to be recharged to maintain life during storage. Please follow
recomended recharges for your condition.
A) If stored in an ambient tem erature under 20° C (68° F); recharge the
batteries every 9 months.
B) If stored in an ambient tem erature of 20° to 30° C (68° to 86° F); recharge
the batteries every 6 months.
C) If stored in an ambient tem erature 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 dis osal of electrical
com onents and ackaging in your articular area.
It is illegal to dump lead-acid batteries in landfills or dispose of improperly.
Please hel our Earth by contacting the environmental rotection agencies in your area,
the battery manufacturer, or call Toshiba toll-free at 1-800-231-1412 for more information
about recycling.
2 - 1

TOSHIBA
3.0 Precautions
3.1 Installation Precautions
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 in a stable, level, and u right osition which is free of vibration.
3) Install the unit where the ambient tem erature is within the correct o erating
range.
4) Do not install the Battery System in areas that are subject to high humidity.
5) Do not allow direct sunlight to shine on the unit.
6) Do not install the Battery System in areas which are subject to contamination
such as high levels of airborne dust, metal articles, or inflammable gas.
7) Avoid installation near sources of electrical noise and always make sure that
the unit ground is intact to revent electrical shock and to hel reduce
electrical noise.
8) Do not install where water or any foreign object/substances may get inside the
Battery System.
3.2 Prestart Precautions
1) Before connecting the Battery System to the UPS verify that the two cabinets are
com atible by com aring them to the following chart.
DO NOT attem t to connect if the Model numbers do
not match the above chart. This will result in damage
to the UPS, the Battery System, or both. Call your
Toshiba re resentative if you should have any ques-
tions.
2) Before connecting the Battery System to the UPS; move the (MCCB-C) switch
(ON/OFF), on the rear anel (See Sections 5 & 6), to the OFF position.
3.3 Operating Precautions
1) The Battery Cabinet should not be owered u until the entire o eration manual
has been reviewed.
3 - 1
CAUTION
UPS Model Number Battery Cabinet Model Number
UC3G2L024C6(#)
UC3A2L024C6(#) UC3-BC-0230 UC3-BC-0260
UC3G2L036C6(#) UC3-BC-0330
UC3-BC-0360
UC3G2L060C6(#) UC3-BC-0630
UC3-BC-0660
UC3G2L080C6(#) UC3-BC-0830
CAUTION
CAUTION
WARNING

TOSHIBA
L2
L1
4.0 Power Connections
4.1 Power Connections
The following illustration details the wiring connections from the ower distribution anel
(not art of the UPS) to the UPS unit and the Battery unit. This connection diagram is to
be used with the following Battery units: UC3-BC-0230, 0260, 0330, 0360, 0630, 0660,
and 0830.
4 - 1
Terminal blocks 1 and 2 are used for wiring the EPO of the Battery System
Terminal block 3 is used to connect the battery cabinet to UPS ground.
Terminal block 4 is used to su ly ower to the internal battery charger circuit of the battery
cabinet. The entire terminal block acce ts #6 to #16 Awg. (Tightening torque is 13 inch- ounds
minimum). Use co er 90° C wire only.
4.3 Wire Size and Tig tening Torques
Main UPS Unit
Source Power
Distribution
Panel
Battery Unit
12
13
MCCB
H2
H1
1
3
2
GMCCB-B
+BUS
P
N
P
N
16 4
NOTE: The following model numbers do not require the +Bus connection:
(UC3-BC-0230, UC3-BC-0330, and UC3-BC-0630)
12 4
EPO EPO G +BUS
Battery C arger
3
BATTERY BREAKER SIZING
MODEL BREAKER
UC3-BC-0230
UC3-BC-0260 32A 250VDC
UC3-BC-0330
UC3-BC-0360 32A 250VDC
UC3-BC-0630
UC3-BC-0660 32A 250VDC
UC3-BC-0830 32A 500VDC
83
Recommended Wire Size
Battery Cabinet EPO (Terminal
Blocks 1 & 2) Gnd. (Terminal Block 3) +Bus (Terminal Block 4)
2.4KVA 18 AWG 14 AWG 14 AWG
3.6KVA 18 AWG 14 AWG 14 AWG
6.0KVA 18 AWG 14 AWG 14 AWG
8.0KVA 18 AWG 14 AWG 14 AWG
MCCB-C
Breaker
208VAC
240VAC
11
MCCB-C
4.2 Terminal Block details
The following illustration is a detail of the Battery Cabinets terminal block (see sections
5 & 6 for terminal block location).
Charger
N
L
Customer Supplied
120VAC

TOSHIBA
5 - 1
UPS Cover Removed
Cooling Vent
Terminal
Block
DC Connector
DC Breaker
(MCCB-B)
BATTERY
CABINET
5.3 Connection Procedure
1) Ensure all ower is locked and tagged out.
2) Remove the Battery Connector Housing mounted on the to of the UPS anel box.
3) Remove the DC connector cover located at the to rear of the Battery Cabinet.
4) Plug the DC Connector of the UPS into the DC Connector socket on the Battery Unit.
5) Reinstall all lates before initializing ower.
5.4 C arger connection
Battery Cabinet models UC3-BC-0660 and UC3-BC-0830 require the +Bus connection
between the UPS and Battery Cabinet. This connection is made from the terminal block
labeled "+Bus" on the UPS and Battery Cabinet. Without this connection the battery
cabinet will not be able to charge its batteries thus reventing extended backu time
during a ower outage.
5.0 Connection Instructions and Diagrams
5.1 Battery Connections
The following illustrations detail the wiring connections between the UPS unit and the
Battery Unit.
Contacts are not rated with interru ting ca acity. DO NOT attem t to connect the UPS to
the Battery Cabinet without having the MCCB switch on the rear anel of the UPS and
Battery Unit, in the OFF osition.
5.2 6.0KVA / 8.0KVA illustration
The following diagram shows the rear view of a 6KVA / 8KVA UPS and 6KVA / 8KVA
Battery Cabinet. NOTE: Use only compatible cabinets! UPS ty eform
"UC3G2L060C6(#)" and Battery Cabinet ty eform "UC3-BC-0630" or "UC3-BC-0660".
UPS ty eform "UC3G2L080C6(#)" and Battery Cabinet ty eform "UC3-BC-0830".
DANGER
DC Breaker
(MCCB-C)
Cover Removed
Battery
Connector
Housing
DC Connector
C arger connection

TOSHIBA
6.0 Connection Instructions (continued)
6.1 Battery Connections
DO NOT attem t to connect the UPS to the Battery Unit without having the MCCB switch
(ON/OFF), on the rear anel of the UPS and Battery Unit, to the OFF osition.
NOTE: Use only compatible cabinets! UPS ty eform
"UC3G2L024C6(#)" and battery cabinet ty e form "UC3-BC-0230" or "UC3-BC-0260".
UPS ty eform "UC3G2L036C6(#)" and battery cabinet ty eform "UC3-BC-0330" or
"UC3-BC-0360".
6.2 2.4KVA / 3.6KVA illustration
The following diagram shows the rear view of a 2.4KVA / 3.6KVA UPS and 2.4KVA
3.6KVA Battery Cabinet.
6.3 Connection Procedure
1) Ensure all ower is locked and tagged out.
2) Remove the Battery Connector Housing mounted on the to of the UPS anel box.
3) Remove the DC Breaker Cover located on the anel box of the Battery Unit.
4) Plug the DC connector of th UPS into the DC Connector socket on the Battery Cabinet.
5) Reinstall all lates before initializing ower.
6.4 C arger connection
Battery Cabinet models UC3-BC-0260 and UC3-BC-0360 need to have the +Bus
connection between the UPS and Battery Cabinet. This connection is made from the
terminal block labeled "+Bus" on the UPS and "+Bus" on the battery cabinet. Without
this connection, the battery cabinet will not be able to charge its batteries, thus reventing
extended backu time during a ower outage.
6-1
DC Connector
Cover Removed
Cooling Vent
Battery
Connector
Housing
BATTERY
CABINET
DC Connector
DC Breaker
(MCCB-B)
C arger connection
DANGER
DC Breaker
(MCCB-C)
UPS

TOSHIBA
7 - 1
7.0 Preventive and Sc eduled Maintenance/Parts Replacement
7.1 Preventive Maintenance
Toshiba's 1400XL Plus Series of UPS battery cabinets have been designed to
rovide years of trouble-free o eration requiring a minimum of reventive maintenance.
The best reventive measure that the battery cabinet user can take is to kee the area
around the unit, articularly the air inlet vents, clean and free of moisture and dust
accumulations. If the atmos here of the installation site is very dusty, use a vacuum
cleaner to eriodically remove dust accumulations from the system. Schedule authorized
service centers to erform internal arts ins ections annually.
Before performing any maintenance t e tec nician s ould
be familiar wit and follow t e important safety instructions
located on pages 1-1 and 1-2.
Pro er maintenance of the battery system of this unit by a
qualified service techincian is essential to the safety and
reliability of your UPS system. Refer to service manual.
7.2 Parts Replacement
The following list shows intervals for eriodic maintenance and re lacement of certain
battery cabinet arts.
1) Batteries: VRLA batteries are maintenance free with res ect to electrolyte only.
The charging voltage, tem erature, erformance and connection resistance must
be monitored eriodically. Necessary corrective actions must be made in order to
assure safe reliable ower is su lied by the UPS. The aforementioned items
affect the life of batteries, so re lacement should be once every 3 to 5 years as a
minimum. All of the batteries must be re laced at the same time.
Quarterly maintenance
a) Visual checks
1) Leakage
2) Corrosion on ositive terminal
b) Check battery tem erature at the negative terminal.
c) Measure and record the system float charging voltage.
d) Measure and record the individual units float charging voltage.
Semi-Annual maintenance
a) Re eat the quarterly checks.
b) Perform a 10 second high rate (e.g. 100 am ) load test on the
individual batteries.
c) O tionally test for the ur ose of trending the battery over time.
d) Re-torque all inter-battery connecting hardware (if a licable).
e) Perform inter-battery connector resistance checks.
CAUTION
WARNING

TOSHIBA
7.0 External Layouts/Dimensions/S ipping Weig ts
7.1 External Layouts
Front View Side View
7.2 Dimensions
Model Dimensions
A B C D E F
UC3-BC-0230
UC3-BC-0260 22.2 in. (555 mm) 10 in. (250 mm) 27.2 in. (680 mm) 19.4 in. (486 mm) 2.2 in. (55 mm) 2.76 in. (69 mm)
UC3-BC-0330
UC3-BC-0360 22.2 in. (555 mm) 10 in. (250 mm) 27.2 in. (680 mm) 19.4 in. (486 mm) 2.2 in. (55 mm) 2.76 in. (69 mm)
UC3-BC-0630
UC3-BC-0660 28 in. (700 mm) 10 in. (250 mm) 31.2 in. (780 mm) 24.6 in. (615 mm) 2.2 in. (55 mm) 3.4 in. (85 mm)
UC3-BC-0830 28 in.
(700 mm) 10 in. (250 mm) 31.2 in. (780 mm) 24.6 in. (615 mm) 2.2 in. (55 mm) 3.4 in. (85 mm)
7.3 Shipping Weights Model Shipping Weights
Pounds Kilograms
UC3-BC-0230 148 67
UC3-BC-0260 240 109
UC3-BC-0330 170 77
UC3-BC-0360 316 143
UC3-BC-0630 230 104
UC3-BC-0660 460 209
UC3-BC-0830 430 195
8-1

TOSHIBA
9.0 Emergency Power Off (EPO) Connections
9.1 S unt Trip
A shunt tri for the DC breaker on the battery cabinet is rovided. This device is o erated
with an a lied voltage of 120VAC. When voltage is a lied, the shunt tri will cause the
breaker to switch to the OFF osition disabling the battery cabinet.
NOTE: The shunt tri o erates the DC Breaker of the Battery Cabinet only! The DC
breaker of the UPS remains in the ON osition regardless the status of the Battery
Cabinet.
9.2 Connection diagram
NOTE: Push button not rovided.
DANGER
AC Source
(120VAC)
EPO EPO
12
Pus Button
DC Breaker
9- 1

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TOSHIBA
TOSHIBA INTERNATIONAL CORPORATION
I NDUSTRIAL DIVISION
13131 West Little York Rd., Houston Texas 77041
Tel [713] 466-0277 Fax [713] 466-8773 Telex 762078
Printed in U.S.A.