Toshiba G2020 Series User manual

TOSHIBA SYNC KIT
INSTALLATION MANUAL
480/480 V 500/750 kVA
Document: 200153-001
Ref: 4GBH0112 Rev. B
March 2020

G2020 TOSHIBA SYNC KIT Installation Manual - 200153-001i
UNINTERRUPTIBLE POWER SYSTEM
If additional information or technical assistance is required call TOSHIBA Customer Support Center at 877-867-8773, or
write to: Toshiba International Corporation, 13131 West Little York Road, Houston, TX 77041-9990 Attn: UPS Product
Manager.
Please complete the following information for your records.
Keep this manual with the UPS equipment.
Job Number:
Model Number:
Serial Number:
Application:
Shipping Date:
Date of Installation:
Inspected By:
IMPORTANT NOTICE
Never attempt to install, operate, maintain or dispose of this equipment until you have first read and understood all
of the relevant product warnings and user directions that are contained in this Installation manual.
The installation of this equipment must only be performed by qualified personnel.
The Instructions contained in this manual 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. Should
further information be required or should particular problems arise which are not covered sufficiently the matter
should be referred to the local TOSHIBA sales office.
Nothing in this manual shall alter Toshiba International Corporation’s standard terms and conditions or the
conditions of any written sales contract.
Any Electrical or mechanical modifications to this equipment without prior written consent of
TOSHIBA will void all warranties and may void UL/CUL listing. Unauthorized modifications may
also result in personal injury, death, or equipment damage.

ii G2020 TOSHIBA SYNC KIT Installation Manual - 200153-001
Purpose and Scope of Manual
This manual provides information on how to safely install, operate, and maintain your TOSHIBA power electronics product.
This manual includes a section on General Safety Instructions that describes the warning labels and symbols that are used
throughout the manual. Read the manual completely before installing, operating, or performing maintenance on this
equipment.
This manual and the accompanying drawings should be considered a permanent part of the equipment and should be
readily available for reference and review. Dimensions shown in the manual are in metric and/or the English equivalent.
TOSHIBA reserves the right, without prior notice, to update information, make product changes, or to discontinue any
product or service identified in this publication.
TOSHIBA is a registered trademark of TOSHIBA INTERNATIONAL CORPORATION. All other product or trade references
appearing in this manual are registered trademarks of their respective owners.
TOSHIBA shall not be liable for technical or editorial omissions or mistakes in this manual. Nor shall it be liable for
incidental or consequential damages resulting from the use of information contained in this manual.
This manual is copyrighted. No part of this manual may be photocopied or reproduced in any form without the prior written
consent of TOSHIBA INTERNATIONAL CORPORATION.
© Copyright 2020 TOSHIBA INTERNATIONAL CORPORATION.
All rights reserved.
Printed in Japan
Contacting TOSHIBA Customer Support Center
The TOSHIBA Customer Support Center can be contacted to obtain help in resolving any Uninterruptible Power System
problem that you may experience or to provide after sales service support.
Toshiba Customer Support Center
8 a.m. to 5 p.m. (CST) –Monday through Friday
Tel [phone]
Fax [phone]
E-mail –[email protected]
You may contact TOSHIBA by writing to:
TOSHIBA INTERNATIONAL CORPORATION.
SOCIAL INFRASTRUCTURE SYSTEMS GROUP
POWER ELECTRONICS DIVISION
13131 West Little York Rd.
Houston, TX 77041-9990
Attn: UPS Product Manager
For further information on Toshiba products and services, please visit our website at:
http://www.toshibaups.com/

G2020 TOSHIBA SYNC KIT Installation Manual - 200153-001iii
Table of Contents
Table of Contents................................................................................................................................................................iii
List of Tables.......................................................................................................................................................................iii
List of Figures......................................................................................................................................................................iii
1How to use this Manual...............................................................................................................................................1
1.1 Notice Icons.........................................................................................................................................................1
1.2 Qualified Personnel.............................................................................................................................................2
2OVERVIEW.................................................................................................................................................................3
3Toshiba Sync KIT parts list .........................................................................................................................................4
4Toshiba Sync KIT Parts Location................................................................................................................................6
5MASTER UPS Installation procedure .........................................................................................................................8
6SLAVE UPS Installation Procedure............................................................................................................................9
7SLAVE UPS Setting Procedure ................................................................................................................................12
8Verify Proper Setup...................................................................................................................................................14
List of Tables
Table 3-1: Parts List of TOSHIBA SYNC KIT...................................................................................................................4
List of Figures
Figure 2-1: Synchronous Operation Configuration...........................................................................................................3
Figure 3-1: TOSHIBA SYNC KIT Parts Identification.......................................................................................................5
Figure 4-1: Toshiba Sync KIT Parts Location (MASTER UPS)........................................................................................6
Figure 4-2: Toshiba Sync KIT Parts Location (SLAVE UPS) ...........................................................................................7
Figure 5-1: Installation Procedure for MASTER UPS.......................................................................................................8
Figure 6-1: Installation procedure for SLAVE UPS (1)...................................................................................................10
Figure 6-2: Installation procedure for SLAVE UPS (2)...................................................................................................10
Figure 6-3: Installation procedure for SLAVE UPS (3)...................................................................................................11
Figure 6-4: Installation procedure for SLAVE UPS (4)...................................................................................................11
Figure 7-1: SLAVE UPS Setting Procedure ...................................................................................................................13
Figure 8-1: Example of TOSHIBA SYNC operation display...........................................................................................14

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G2020 TOSHIBA SYNC KIT Installation Manual - 200153-0011
1 How to use this Manual
This manual is designed for ease of use, giving the user easy and quick reference to information.
This manual uses notice icons to draw attention to the user important information regarding the safe operation and
installation of the UPS.
1.1 Notice Icons
The notice icons used in this manual are explained below, and should be taken into account and adhered to whenever
they appear in the text of this manual.
Warning: A warning symbol shows potentially hazardous situation or condition which could result in
personal injury or death, if not avoided.
Caution: A caution symbol shows potentially hazardous situation or condition which could result in
personal injury or equipment damage, if not avoided.
Note: A Note symbol shows the information the user or the service personnel should observe during
the UPS operation or service work.
Prohibit: A prohibit symbol shows the act the user or the service personnel should NEVER perform
during the UPS installation, operation or service work.
Safety Recommendations: If any problems are encountered while following this manual, contact the Toshiba Customer
Support Center.
WARNING
CAUTION
!
NOTE
PROHIBIT

2 G2020 TOSHIBA SYNC KIT Installation Manual - 200153-001
1.2 Qualified Personnel
Only qualified persons are to install, operate or service this equipment according to all applicable codes and established safety
practices.
A qualified person must:
1) Read this entire instruction manual carefully.
2) Be skilled in the installation, construction or operation of the equipment and aware of the hazards involved.
3) Be trained and authorized to safely energize, de-energize, clear, ground, lockout and tag circuits in accordance with
established safety practices
4) Be trained and authorized to perform the service, maintenance or repair of this equipment
5) Be trained in the proper care and use of protective equipment such as rubber gloves, hard hat, safety glasses, face shield,
flash clothing, etc. in accordance with established practices
6) Be trained in rendering first aid.

G2020 TOSHIBA SYNC KIT Installation Manual - 200153-0013
2 OVERVIEW
TOSHIBA G2020 Uninterruptible Power Supply Systems (UPS) need a TOSHIBA SYNC KIT whenever two SMS UPSs
are installed in a synchronous operation configuration.
Each TOSHIBA SYNC KIT contains all hardware necessary for one pair of master and slave UPS to operate in a
synchronous configuration. Each additional UPS unit will require another sync kit, if applicable. This manual contains kit
installation and startup information specifically for the G2020 Series UPS.
The UPSs must be de-energized when the TOSHIBA SYNC KITs are installed and the
synchronous operation configuration is established between the UPSs.
Figure 2-1: Synchronous Operation Configuration
CAUTION
TOSHIBA Sync circuit
Slave
BYPASS Input
AC Input
UPS #A: MASTER G2020
INV
CONV
INV
CONV
UPS #B: SLAVE G2020
BYPASS Input
STS
PDU
VSAU-16
To Load
AC Input
IOAU-09*
TN1
13 14
Jumper
Input Contact
TOSHIBA Sync circuit
Master
Qty. 3 #16AWG, 600V insulation,
multi-strand, twisted trio wire, with ring
lugs for #12 screws.
Field installed by Others

4 G2020 TOSHIBA SYNC KIT Installation Manual - 200153-001
3 Toshiba Sync KIT parts list
Table 3-1: Parts List of TOSHIBA SYNC KIT
Parts
No.
Part name
Qty
Remarks
Master
Slave
1
VS1 PCB: Sensor Board (VSAU-16*)
-
1
2
Fuse holder
1
1
3
Fuses
3
3
4
Flat Cable (UPGR-X* - VSAU-16*)
-
1
L=2000mm
5
Wire (VSAU-16* - Fuses) 3-twisted
-
1
L=600mm
6
Wire (Output Bus bars –Fuse holder) 3-twisted
1
-
L=1500mm
7
Wire (Terminal Jumper for VSAU-16*, UN-V)
-
1
L=150mm
8
Wire (Terminal Jumper for VSAU-16*, VN-W)
-
1
L=150mm
9
Wire (Terminal Jumper for VSAU-16*, WN-U)
-
1
L=150mm
10
Wire (E –FG for VSAU-16*)
-
1
L=850mm
11
Wire (Terminal Jumper for IOAU-09*)
-
1
L=40mm
12
Spacers
-
4
13
Screws (M3) with spring washer and flat washer
-
4
For spacers
14
Screws (M4) with spring washer and flat washer
5
3
15
Screws (M5) with spring washer and flat washer
2
4
16
Spring washers (M3)
-
4
For spacers
17
Flat washers (M3)
-
4
For spacers
18
Fuse label
1
1
19
Cable Tie
10
Use as necessary
20
Cover Plate
1
1
Note –Part number followed by “*” denotes any letter A to Z.

G2020 TOSHIBA SYNC KIT Installation Manual - 200153-0015
Part No. 1: VSAU-16*: Sensor Board
Part No. 2: Fuses holder
Part No. 3: Fuses
Part No. 4: Flat Cable
Part No. 5: Wire
(3-twisted, Yellow/Blue/White)
Part No. 6: Wire
(3-twisted)
Part No. 7,8,9: Wires
Part No. 10: Wire
Part No. 11: Wire (Jumper)
Part No. 12: Spacer
Part No. 18: Fuse label
Part No. 20: Cover plate
Figure 3-1: TOSHIBA SYNC KIT Parts Identification

6 G2020 TOSHIBA SYNC KIT Installation Manual - 200153-001
4 Toshiba Sync KIT Parts Location
Figure 4-1: Toshiba Sync KIT Parts Location (MASTER UPS)
6) Wire
(Output Bus bars –Fuse holder)
To SLAVE UPS
(Field Installed)
AC Output
Bus bars
2) Fuses holder
3) 3 x Fuses
20) Cover Plate
(Attach after fuses and
cables installed)
Color of wirings
A-phase: Yellow
B-phase: Blue
C-phase: White

G2020 TOSHIBA SYNC KIT Installation Manual - 200153-0017
Figure 4-2: Toshiba Sync KIT Parts Location (SLAVE UPS)
2) Fuses holder
3) 3x Fuses
From MASTER UPS
(Field Installed)
1) VSAU-16*
Sensor Board
To UP1 board on rear of door
(from the window on upper right)
Grounding Bar
20) Cover Plate
(Attach after fuses, PCB and
cables installed)
4) Flat Cable

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5 MASTER UPS Installation procedure
1. Prior to the installation of the parts, confirm that the AC input breaker, AC output breaker,
Bypass input breaker and DC breaker are turned off. (De-energize the interior of the UPS.)
2. Then remove the metal cover plates from UPS.
1. Install the Fuse holder using (2) screws (M4) on the Metallic Plate inside Cable entry section.
2. Insert three (3) Fuses into the Fuse holder.
3. Affix the Fuse label to the Metallic Plate.
4. Connect the wiring between the Output Bus-bars and the Fuse holder.
5. Connect the field-installed wirings (between MASTER and SLAVE UPS) to the Fuse holder.
Note: wires (qty. 3) should have 600V insulation and be #16AWG, multi-strand, twisted trio with ring lungs sized
for #12 screws.
6. Attach the cover plate using (2) screws (M5) on the Metallic Plate.
Figure 5-1: Installation Procedure for MASTER UPS
CAUTION
From Output Bus-bars
Part No. 2
Fuse holder
Part No. 3
Three (3) Fuses
Part No. 16
Fuse label
* Use part No.14
Two (2) screws (M4)
with spring washer and
flat washer for the Fuse holder.
A
B
C
A
B
C
Part No. 6
Wire
To SLAVE UPS
Field-installed wirings
From Bus-bars
To SLAVE UPS
Attach Part No. 20 cover plate.
* Use part No.15
Two (2) screws (M5) with
spring washer and flat washer
for the cover plate.
Color of wirings
A-phase: Yellow
B-phase: Blue
C-phase: White
* Use part No.14
Two (3) screws (M4) with
spring washer and
flat washer for connection

G2020 TOSHIBA SYNC KIT Installation Manual - 200153-0019
6 SLAVE UPS Installation Procedure
1. Prior to the installation of the parts, confirm that the AC input breaker, AC output breaker,
Bypass input breaker and DC breaker are turned off. (De-energize the interior of the UPS.)
2. Then remove the metal cover plates from UPS.
1. Install the Fuse holder using (2) screws (M4) on the Metallic Plate.
2. Insert three (3) Fuses into the Fuse holder.
3. Stick the Fuse label on the Metallic Plate.
4. Screw four (4) spacers with spring washers (M3) and flat washers (M3) on the Metallic Plate.
5. Install the VS1 PCB, Sensor Board (VSAU-16*), onto the spacers using (4) screws (M3).
6. Connect the wirings between the Fuse holder and the VS1 PCB.
7. Connect the wirings between the terminals (UN and V, VN and W, WN and U) on the VS1 PCB.
8. Connect the Flat cable between the CN1 of VS1 PCB and the CN50 of UP1 PCB (Main Control board).
9. Connect the green wire between the E on VS1 PCB and Ground bus bar.
10. Connect the field-installed wirings (from MASTER UPS) to the Fuse holder.
11. Attach the cover plate using (2) screws (M5) on the Metallic Plate.
12. Connect the Jumper wiring between the terminal 13 and 14 of TN1 on IO1 PCB (IOAU-09*).
CAUTION

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Figure 6-1: Installation procedure for SLAVE UPS (1)
Figure 6-2: Installation procedure for SLAVE UPS (2)
Part No. 2
Fuse holder
Part No. 3
Three (3) Fuses
* Use part No.14
Two (2) screws (M4) with
spring washer and flat washer
for the Fuse holder
Part No. 12
Four (4) Spacers
* Use part No.16, No.17
Four (4) spring washers
Four (4) flat washers
Part No. 18
Fuse label
Part No. 10
Wire
Part No. 1
VS1 PCB (VSAU-16*)
Part No. 8,9,10
Wires
UN - V
VN - W
WN - U
Part No. 5
Wire (3-twisted)
U - U
V - V
W - W
A
B
C
* Use part No.14
One (1) screw (M4) with
spring washer and flat washer
for grounding.
* Use part No.13
Four (4) screws (M3)
with spring washer
and flat washer
for VS1 PCB.
From
MASTER UPS
To UP1 PCB
(Main control board)
CN1
U
V
W

G2020 TOSHIBA SYNC KIT Installation Manual - 200153-00111
Figure 6-3: Installation procedure for SLAVE UPS (3)
Figure 6-4: Installation procedure for SLAVE UPS (4)
CN50
UP1 PCB (Main Control board)
* Use part No.15
Two (2) screws (M5) with
spring washer and flat washer
for the cover plate.
TN1
13
14
Part No. 11
Wire (Jumper)
The terminal of TN1
on IO1 PCB (IOAU-09*)

12 G2020 TOSHIBA SYNC KIT Installation Manual - 200153-001
7 SLAVE UPS Setting Procedure
The setting for MASTER UPS is unnecessary.
1. Before the UPS setting, install the metal cover plates for the UPS.
2. Keep door closed except when the "MAINT" button located on the SW1
PCB (DPAU-81*) is pressed.
1. Supply the AC input and the Bypass input voltage to the UPS.
Initialization will start. Under initializing, the UPS will automatically:
-Turn on contactor CB1;
-Initialize converter operation;
-Initialize inverter operation;
After initialization, LCD screen should appear.
(Refer to the G2020 series service manual, 5-1 Start-up Procedure for details.)
2. Press the "MAINT" button located on the SW1 PCB (DPAU-81*).
Maintenance screen will appear.
3. Press the "SETUP" tab on the Maintenance screen, and then press the "INPUT PORT" button.
4. Press the "IN4" button, and select item "9: ANOTHER BUS. SYNC." by pressing
" " key then press "OK" button.
1. As the “IN4”default setting, it may be “POWER DEMAND”.
2. Before making a change of the “IN4”setting, make sure that the POWER DEMAND
function is defunct.
(Contact Toshiba International Corporation, if POWER DEMAND function is under service.)
5. Press the "CLOSE" button, and confirm that "9: ANOTHER BUS. SYNC." is lay out.
6. Press the "MAINTENANCE" tab, and then press the "MAIN MENU" button for completion of SLAVE UPS
SETTING.
CAUTION
ATTENTION
!
NOTE

G2020 TOSHIBA SYNC KIT Installation Manual - 200153-00113
Press the "MAINT" button Return to "MAIN" screen
Press the "SETUP" tab Return to "MAINTENANCE" screen
Press the "INPUT PORT" button Confirm "9: ANOTHER BUS. SYNC."
Press the "IN4" button Select item "9: ANOTHER BUS. SYNC."
Figure 7-1: SLAVE UPS Setting Procedure
MAINT

14 G2020 TOSHIBA SYNC KIT Installation Manual - 200153-001
8 Verify Proper Setup
To confirm that the TOSHIBA SYNC circuit is functioning properly, during TOSHIBA SYNC operation, “Ath Bus Sync.”
is displayed at the bottom of LCD screen as shown in Figure 8-1.
Figure 8-1: Example of TOSHIBA SYNC operation display