Toshiba 4200FA Series User manual

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TOSHIBA
1
4200FA SERIES
THREE PHASE- 15 & 25kVA
BATTERY SYSTEM
OPERATION MANUAL
FOR MODELS
T42-BC-FA
TOSHIBA INTERNATIONAL CORPORATION
INDUSTRIAL DIVISION
13131 West Little York Rd., Houston Texas, U.S.A. 77041

TOSHIBA
2
IMPORTANT NOTICE
UNINTERUPTIBLE POWER SUPPLY
If additional information or technical assistance is required call Toshiba’s marketing department toll free at
1-800-231-1412 or write to: Toshiba International Corporation, 13131 W. Little York Rd., 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:
These Instructions are not intended to cover all of the details or variations in
equipment, or to provide for every possible contingency to be met in connection
with installation, operation, 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 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 contents of this instruction manual shall not become a part of or modify any
prior or existing equipment, 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/CUL listing. Unauthorized modifications also can result in
personal injury, death, or destruction of the equipment.

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GENERAL SAFETY INSTRUCTIONS
Warnings in this manual appear in the following three ways:
1) Danger warnings - The danger symbol is an exclamation mark enclosed in a triangle, which
precedes the 3/16’ high letters spelling the word “DANGER”. The danger symbol is used to
indicate situations, locations, and conditions that exist and WILL serious injury or death.
DANGER
2) Caution warnings - The caution warning symbol is an exclamation mark in a triangle, which
precedes the 3/16” high letters spelling the word “CAUTION”. The warning symbol is used to
indicate situations and conditions that can cause operator injury and/or equipment damage.
CAUTION
3) Attention warning - 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 can cause operator injury
and/or equipment damage.
ATTENTION
Other warning symbols may appear along with the Danger and Caution symbol and 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
may 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 may cause serious injury or death if the proper precautions are not
observed:

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CONTENTS
SECTION PAGE
IMPORTANT NOTICE .................................................................................................................................... 2
GENERAL SAFETY INSTRUCTIONS ........................................................................................................... 3
CONTENTS..................................................................................................................................................... 4
IMPORTANT SAFETY INSTRUCTIONS........................................................................................................ 5
2.0 Uncrating/Inspection/Storage/Disposal ........................................................................................... 8
2.1 Uncrating the Battery System ........................................................................................................... 8
2.2 Inspection of the new Battery System .............................................................................................. 9
2.3 Storage of the Battery System.......................................................................................................... 9
2.4 Disposal ............................................................................................................................................ 9
3.0 Installation......................................................................................................................................... 10
3.1 Installation Precautions................................................................................................................... 10
3.2 Conductor Routing and Grounding ................................................................................................. 10
4.0 Precautions ....................................................................................................................................... 11
4.1 Prestart Precautions ....................................................................................................................... 11
4.2 Operating Precautions .................................................................................................................... 11
5.0 Battery System Connections .......................................................................................................... 12
5.1 Power Connections......................................................................................................................... 12
5.2 Terminal Block Details .................................................................................................................... 12
5.3 Wire Size and tightening torque...................................................................................................... 13
6.0 Specifications ................................................................................................................................... 13
7.0 Preventive Maintenance and Scheduled Maintenance/Parts Replacement ............................... 14
7.1 Preventive Maintenance ................................................................................................................. 14
8.0 External Layouts/Dimensions/Weights.......................................................................................... 15
8.1 External Layouts: T42-BC-FA......................................................................................................... 15
8.2 External Dimensions....................................................................................................................... 16

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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS This manual contains important that
should be followed during the
installation and maintenance of the Battery System. Turn off, lockout and tagout all power sources
before proceeding to connect the power wiring to the equipment or when performing maintenance.
The maximum ambient temperature that the Battery Systems should be operated in is 40oC (104oF).
The nominal battery voltages for these models are as follows:
15kVA: 288VDC
25kVA: 288VDC
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. To arrange for battery replacement, contact your nearest Toshiba authorized service center.
Qualified Personnel ONLY
A Qualified Person is one that has the skills and knowledge relating the construction, installation, operation
and maintenance of the electrical equipment and has received safety training on the hazards involved
(Refer to the latest edition of NFPA 70E for additional safety requirements).
Qualified Personnel shall:
1) Have carefully read the entire operation manual.
2) Be trained and authorized to safely energize, de-energize, ground, lockout and tag circuits and
equipment, and clear faults in accordance with established safety practices.
3) Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves,
hard hats, safety glasses, face shields, flash clothing, etc., in accordance with established safety
practices.
4) Be trained in rendering first aid.
5) Be knowledgeable of batteries and required precautions.
For further information of workplace safety visit www.osha.gov.
When replacing batteries, use the same number and type-form of the following sealed, lead-acid battery:
Model Number Manufacturer Type Quantity
T42-BC-FA Enersys NPX-150R 24
DANGER 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.

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IMPORTANT SAFETY INSTRUCTIONS
CAUTION 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.
CAUTION Failure to replace a battery before it becomes exhausted may cause
the case to crack, possibly releasing electrolytes from inside the
battery, and
resulting in secondary faults such as odor, smoke, and fire.
CAUTION Installation and servicing of batteries should be performed by personnel
knowledgeable of batteries and the required precautions. Keep
unauthorized personnel away from the batteries.
CAUTION 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 service manual.
A battery can present a risk of electrical shock and high
short
DANGER circuit current. Observe the following when working with
Batteries.
QUALIFIED PERSONNEL ONLY!
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, cause 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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INSTRUCTIONS IMPORTANTES CONCERNANT
LA SÉCURITÉ
CONSERVER CES INSTRUCTIONS Cette notice contient des
instructions importantes
concernant la sécurté
ATTENTION Un battery puet présenter un risque de choc électrique, de brûlure
par transfert d’ énergie.
ATTENTION Por le replacement, utiliser le même nombre de batteries du
modéle suivant.
Model Number Manufacturer Type Quantity
T42-BC-FA Enersys NPX-150R 24
ATTENTION L’élimination des batteries est règlementèe. Consultar les codes
locaux à cet effet.

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2.0 Uncrating/Inspection/Storage/Disposal
2.1 Uncrating the Battery System
Upon receipt of the Battery System, a careful inspection for shipping damage should be
made.
1) On International models only, remove the screws
that attach the shipping crate to the pallet.
Remove the crate and packing material.
Figure 2.1.1
2) Unbolt the rails from the shipping pallet.
Place the rails on the front of the pallet
as shown in figure 2.2 and figure 2.3.
Use the four 1/2x3” bolts used to secure
the rails to the shipping pallet to attach
the rails as shown to the front of the
pallet.
Figure 2.2
3) Place the tie brackets as shown in figure 2.3 in the
slots at the lower end of the ramps. SLOWLY roll
the unit down the ramp.
1/2x3” Bolts
Tie Brackets
Figure 2.1.3
Rails

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2.0 Uncrating/Inspection/Storage/Disposal (cont.)
2.2 Inspection of the new Battery System
Upon receipt of the Battery System, a careful inspection for shipping damage should be
made. Use caution when removing the unit from pallet. Refer to labels or documentation
attached to packing material.
After Uncrating:
1) Check the unit for loose, broken, bent, or otherwise damaged parts. If damage has
occurred during shipment, keep all original crating and packing materials for return
to the shipping agent. Warranty will not apply to units that are damaged during
shipment.
2) Check to see that the rated capacity and the model number specified on the
nameplate conform to the order specifications.
2.3 Storage of the Battery System
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 temperature or high humidity.
2) Storage in sites subject to exposures of high levels of dust or metal particles.
3) Storage on inclined floor surfaces or in sites subject to excessive vibrations.
Before Storing:
1) Charge the systems batteries. (See connection diagram on page 5-1)
2) Place the Battery Systems input switch (MCCB-B) in the OFF position.
Storing:
1) Store within a temperature range of –20°to 40°C (-4°to 107°F)
2) For best results store the Battery System in the original shipping container and
place on a wood pallet.
3) The optimum storage temperature is 21°C (70°F). Higher ambient temperatures
cause the batteries to need recharging more frequently.
After Storing:
Batteries need to be recharged to maintain life during storage. Please follow the
recommended recharges for your condition. (FAILURE TO MAINTAIN BATTERY
CONDITION WILL VOID BATTERY WARRANTY)
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), Please consult
the factory (adjustment to the system charger will be needed or over charge
could occur).
2.4 Disposal
Please contact your state environmental agency for details on disposal of electrical
components and packaging in your particular area.
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 manufacture, or call Toshiba toll free at 1-800-231-1412 for more information about
recycling.

TOSHIBA
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3.0 Installation
3.1 Installation Precautions
1) Install the system in a well-ventilated location; allow at least 10cm (4 inches) on all
sides for air ventilation and maintenance.
2) Install the unit in a stable, level, and upright position that is free of vibration.
3) Install the unit where the ambient temperature is within the correct operating range
(see Specifications in Section 6.0).
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 system.
6) Do not install the Battery System in areas that are subject to contamination such as
high levels of airborne dust, metal particles, or flammable gasses.
7) Avoid installation near sources of electrical noise and always make sure that the unit
ground is intact to prevent electrical shock and to help reduce electrical noise.
8) Do not install where water, any foreign object, or substances may get inside the
Battery System.
9) Note: Contact the factory when paralleling Battery Systems, to ensure
compatibility of mating different batteries.
3.2 Conductor Routing and Grounding
1) Use separate metal conduits for routing the power and control circuits.
2) A separate ground cable should be run inside the conduit with the power and control
circuits.
3) Always ground the unit to prevent electrical shock and to help reduce electrical noise.
4) Follow wire size and tightening torque in manual.
CAUTION THE METAL GROUND OF CONDUIT
IS NOT AN ACCEPTABLE GROUND.
CAUTION

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4.0 Precautions
4.1 Prestart Precautions
1) Before connecting the Battery System to the UPS, verify that both DC links are of the
same polarity and voltage.
2) Before connecting the Battery System to the UPS, move the MCCB-B switch
(ON/OFF) on the front panel (See Section 5.2) to the OFF position.
UPS MODEL NUMBER DC VOLTS BATTERY CABINET MODEL DC VOLTS
T42#3#150##### 288 T42-BC-FA 288
T42#3#250##### 288 T42-BC-FA 288
3) The Battery System should not be used with an UPS other than those listed above.
DO NOT attempt 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
representative if you should have any questions.
4) When installing a Battery System, do not connect different size (AMP/HR) battery
systems to the UPS. If necessary, contact Toshiba so an authorized service technician
can be scheduled to disconnect the smaller batteries to ensure proper operation.
4.2 Operating Precautions
1) The Battery System should not be energized until the entire operation manual has
been reviewed.
2) Do not insert metal objects or combustible materials in the unit’s ventilation slots.
3) Do not place, hang, or paste any objects on the top or on the exterior surfaces of the
Battery System.
4) Do not attempt to disassemble, modify or repair the Battery System. Call your Toshiba
sales representative for repair information.
5) Move the MCCB-B switch to the ON position only after attaching ALL the covers. Do
not remove any covers when the MCCB-B is in the ON position.
6) If the Battery System should emit smoke or an unusual odor or sound, turn the power
off immediately.
7) Additional warnings and notifications shall be posted at the equipment installation
location as deemed required by Qualified Personnel.
CAUTION
When the UPS is in inverter mode, turning the breaker to the “OFF”
position will cause the unit to go into the battery backup mode. The
UPS will continue to provide power to the load. The unit must be in
bypass mode and then the breaker turned to the “OFF” position for the
UPS to shutdown power to the load.
CAUTION

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5.0 Battery System Connections
5.1 Power Connections
The following shows the wiring connections from the UPS System to the terminals of the
Battery System models T42-BC-FA.
5.2 Terminal Block Details
The following illustration is a detail view of the terminal block and wiring connections
necessary for proper operation. (See section 8.0 for terminal block locations)
DANGER
To prevent the risk of Electrical Shock, Fire, and or
Explosion: Observe Proper Polarity
UPS 4200FA SERIES
TB3-(+)
TB3-(-)
TB3-3
TB3-4
TB3-5
TB3-6
(+)
(-)
BATTERY CABINET 4200FA SERIES
TB1-1 (SHUNT TRIP)
TB3-4 (AUX. CONTACT)
TB3-5 (COMMON)
TB1-2 (SHUNT TRIP)
12 VOLT
24 IN SERIES
MCCB-B
TB1-6 N/A
TB1-5 Common
TB1-4 (Aux. N.O.) TB1-3 N/A
TB1-2 Shunt
TB1-1 Shunt
ON
OFF
+ -
Battery Control Circuit Connections
Battery Power Circuit Connections
MCCB-B
Control Circuit
Terminal Block

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5.0 Battery System Connections
5.3 Wire Size and tightening torque
Wire Size and Tightening Torque
for Battery System Terminals (15 & 25kVA)
15 & 25kVA
Terminal
(Terminal Number) Wire Size Tightening Torque
Battery Control Circuit
(1-6) 14-16 16 in-lbs.
Battery
(+ -) 3 AWG min. 350MCM max. 150 in-lbs.
Ground
(GND) 8 AWG min. 75 in-lbs.
6.0 Specifications
Power Circuit Battery Voltage 288Vdc nominal
Discharge Cut-off Voltage 216Vdc min. (1.50Vdc/cell)
Discharge Current 100Adc max.
Nominal Run Time 15minutes min., 25kVA UPS at 100% load
30minutes min., 15kVA UPS at 100% load
Charging Voltage 328Vdc max.
Charging Current 5.5Adc max.
Control Circuit Shunt Trip Coil Voltage 24Vdc nominal, 18Vdc min., 26.4Vdc max.
Shunt Trip Coil Current 1.5A nominal
Auxiliary Contact Ratings 5Adc max. at 30Vdc
10Aac max. at 120Vac to 250Vac
Environmental Operating Temperature 0°C to 40°C; optimal temperature is 25 °C
Operating Humidity Less than 90% RH (non-condensing)
Altitude Less than 1000 meters
Mechanical Dimensions 23.5 inch W, 33.7 inch D, 59.2 inch H

TOSHIBA
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7.0 Preventive Maintenance and Scheduled Maintenance/Parts Replacement
7.1 Preventive Maintenance
Toshiba’s 4200FA Series UPS battery cabinets have been design to provide years of
trouble free operation requiring a minimum of preventive maintenance.
The best preventive measure that the UPS Battery System user can take is to keep the
area around the unit, particularly the air inlet vents, clean and free of moisture and dust
accumulations. If the atmosphere of the installation site is very dusty, use a vacuum
cleaner to periodically remove the dust accumulations from the system. Schedule
authorized service centers to perform internal parts inspections annually.
CAUTION Before performing any maintenance the technician
should be familiar with and follow the Important
Safety Instructions on Pages 3 and 4.
CAUTION Proper maintenance of the Battery System by a
qualified service technician is essential to the safety
and reliability of your UPS System. Refer to the
Service Manual.
The following list shows intervals for periodic maintenance and replacement of certain
battery cabinet parts:
1) Batteries: SVRLA batteries are maintenance free with respect to electrolyte only. The
charging voltage, temperature, performance, and connection resistance must be
monitored periodically. Necessary corrective actions must be made in order to assure
safe reliable power is supplied by the UPS System. The aforementioned items affect
the life of the batteries, so replacement should be once every 5 years as a minimum.
All of the batteries must be replaced at the same time.
Quarterly Maintenance
a) Visual Checks
1) Leakage
2) Corrosion on Positive terminal
b) Check the battery temperature at the negative terminal.
c) Measure and record the system float charging voltage.
d) Measure and record the individual unit’s float charging voltage.
Semi-Annual Maintenance
a) Repeat the quarterly checks.
b) Perform a 10-second high rate (e.g. 100 amp) load test on the
individual batteries.
c) Optionally test for the purpose of trending the battery over time.
d) Re-torque all inter-battery connector hardware.
e) Perform inter-battery connector resistance checks.

TOSHIBA
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MCCB-B
Control Circuit
Terminal Block
Side Conduit Bracket Side Conduit Bracket
Bottom Conduit Bracket
TB1-6 N/A TB1-5 Common
TB1-4 (Aux. N.O.)
TB1-3 N/A TB1-2 Shunt
TB1-1 Shunt
8.0 External Layouts/Dimensions/Weights
8.1 External Layouts: T42-BC-FA
The following shows the location of the Battery Systems Control Terminal Block, DC
Disconnect (MCCB-B) and the Conduit Brackets. The Conduit Brackets may be removed
in order to drill the holes necessary to accommodate the conduit fittings used in the
installation.

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8.0 External Layouts/Dimensions/Weights
8.2 External Dimensions
The following shows the external dimensions of the T42-BC-FA

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TOSHIBA INTERNATIONAL CORPORATION
INDUSTRIAL DIVISION
13131 West Little York Road, Houston, Texas 77041
Tel: [phone] Fax: [phone] Telex: 762078
Printed in the U.S.A.