Toshiba G9000 SERIES User manual

UNINTERRUPTIBLE POWER SYSTEM (UPS)
G9000 SERIES
INSTALLATION AND
OPERATION MANUAL
480/480 V 100/160/225/300/500/750 kVA
Document: 61480-012
Ref: 4GBA0012 Rev. E
August 2014
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G9000 SERIES
INSTALLATION AND OPERATION MANUAL
480/480 V 100/160/225/300/500/750 kVA
Document No. 4GBA0012 Rev. E
P/N 61480-012
August 2014
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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.
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. The warranty contained in the contract between
the parties is the sole warranty of TOSHIBA, 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 will void all warranties and may void UL/CUL listing.
Unauthorized modifications may also result in equipment damage, personal
injury, or loss of life.
IMPORTANT NOTICE
UNINTERRUPTIBLE POWER SYSTEM
If additional information or technical assistance is required call TOSHIBA Customer Support Center toll
free at 1- 800-231-1412, 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. Unless otherwise specified on the warranty
card, the warranty period for the UPS or UPS part is 36 months from the shipment date (see bill of lading).
Unless otherwise specified on the warranty card, the warranty period for a UPS battery is 36 months full
replacement, and an additional 7 years pro-rated from the shipment date (see bill of lading).
Keep this manual with the UPS equipment.
Job Number:
Model Number:
Serial Number:
Application:
Shipping Date:
Date of Installation:
Inspected By:
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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 2014 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 application information.
The center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Support Center’s toll free
number in USA is [phone].
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
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Table of Contents
List of Tables................................................................................................................................................. ii
List of Figures................................................................................................................................................iii
1How to use this Manual..........................................................................................................................1
2INTRODUCTION ...................................................................................................................................2
2.1 SAFETY PRECAUTIONS.............................................................................................................3
3GENERAL..............................................................................................................................................6
3.1 DEFINITIONS................................................................................................................................7
3.2 OPERATION OVERVIEW.............................................................................................................8
3.2.1 Normal operation: Load power supplied by each system UPS inverter....................................8
3.2.2 Bypass Operation: Load Power supplied through UPS internal static bypass line...................9
3.2.3 Battery Operation: Load Power supplied by UPS battery.......................................................10
3.2.4 UPS Parts Location.................................................................................................................11
3.2.5 PCB Layouts. ..........................................................................................................................15
3.3 SPECIFICATIONS ......................................................................................................................19
4OPERATOR CONTROLS AND INDICATORS....................................................................................26
4.1 LED DISPLAY.............................................................................................................................26
4.2 EPO BUTTON (Emergency Power Off button) (7)......................................................................27
4.3 LIQUID CRYSTAL DISPLAY (8).................................................................................................27
4.3.1 Test Mode Options..................................................................................................................27
4.3.2 Menu .......................................................................................................................................28
4.3.3 Input Power Failure.................................................................................................................32
4.3.4 Fault Indication........................................................................................................................33
4.4 EXTERNAL AUX CONTACT INPUT AND OUTPUT TERMINAL BLOCKS...............................34
4.4.1 Aux contacts - Input ................................................................................................................34
4.4.2 Aux Contacts - Output.............................................................................................................37
5INSTALLATION AND OPERATION ....................................................................................................40
5.1 TRANSPORTATION AND INSTALLATION................................................................................40
5.2 INSTALLATION PROCEDURE...................................................................................................40
5.3 PROCEDURE FOR CABLE CONNECTIONS............................................................................41
5.4 OPERATING PROCEDURES.....................................................................................................65
6RESPONSE TO UPS FAILURE..........................................................................................................69
7PARTS REPLACEMENT.....................................................................................................................70
8FAULT CODES....................................................................................................................................71
9DAILY INSPECTION............................................................................................................................78
APPENDIX A – Installation Planning Guides (IPG)....................................................................................79
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List of Tables
Table 2-1 UPS Installation Environment.................................................................................................4
Table 2-2 Rating of Bypass Input Circuit Breaker...............................................................................5
Table 3-1 Power Specifications ............................................................................................................19
Table 3-2 UPS Module Information ......................................................................................................20
Table 3-3 Detail of Specifications .........................................................................................................21
Table 3-4 Typical UPS Efficiencies at Various Loads ..........................................................................23
Table 3-5 MTBF and MTTR..................................................................................................................24
Table 3-6 Rating of Contactors, Breakers and Fuses ..........................................................................25
Table 4-1 External Input Functions.......................................................................................................36
Table 4-2 External Output Functions....................................................................................................38
Table 5-1 How to Transport and Install the System .............................................................................40
Table 5-2 List of UPS Weights..............................................................................................................40
Table 5-3 Maximum Permitted Fault Current .......................................................................................41
Table 5-4 Recommended Cable Sizes.................................................................................................44
Table 5-5 Crimp Type Compression Lug..............................................................................................45
Table 7-1 Standard Replacement Parts List.........................................................................................70
Table 7-2 Air Filters...............................................................................................................................71
Table 8-1 Fault Code............................................................................................................................72
Table 9-1 How to Perform Daily Inspection..........................................................................................78
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List of Figures
Figure 3-1 Single Line Diagram – Normal Operation: Load powered by UPS inverter..........................8
Figure 3-2 Single Line Diagram – Bypass Operation: Load fed through static bypass line. ..................9
Figure 3-3 Single Line Diagram – Battery Operation............................................................................10
Figure 3-4 UPS Parts Location (100kVA)................................................................................................11
Figure 3-5 UPS Parts Location (160, 225kVA).....................................................................................11
Figure 3-6 UPS Parts Location (300kVA).............................................................................................12
Figure 3-7 UPS Parts Location (500kVA).............................................................................................13
Figure 3-8 UPS Parts Location (750kVA).............................................................................................14
Figure 3-9 Display PCB DPAU-81........................................................................................................15
Figure 3-10 External I/F PCB IOAU-09.................................................................................................15
Figure 3-11 Parallel I/F PCB IFAU-08 (100-225kVA)...........................................................................16
Figure 3-12 Parallel I/F PCB IFAU-09 (300-750kVA)...........................................................................16
Figure 3-13 MAIN PCB UPGR-M .........................................................................................................17
Figure 4-1 Operation/Display Panel (Front panel)................................................................................26
Figure 4-2 Main Screen ........................................................................................................................28
Figure 4-3 Startup/Shutdown Guidance ...............................................................................................29
Figure 4-4 Startup Guidance ................................................................................................................29
Figure 4-5 Shutdown Guidance............................................................................................................29
Figure 4-6 Input values.........................................................................................................................30
Figure 4-7 Battery Operation Values....................................................................................................30
Figure 4-8 Output values ......................................................................................................................30
Figure 4-9 Remote/Local operation select............................................................................................31
Figure 4-10 Date & Time adjustment....................................................................................................31
Figure 4-11 Log menu...........................................................................................................................31
Figure 4-12 Event Log ..........................................................................................................................32
Figure 4-13 Battery log .........................................................................................................................32
Figure 4-14 Main Screen (Battery Operation)....................................................................................32
Figure 4-15 Measurement screen (Battery Operation).........................................................................32
Figure 4-16 Main screen (Fault indication)...........................................................................................33
Figure 4-17 Message Screen ...............................................................................................................34
Figure 4-18 Control Wiring for Aux Input Contacts...............................................................................35
Figure 4-19 External Signal Input Terminal Block (with default settings).............................................35
Figure 4-20 Control Wiring for Aux Output Contacts............................................................................37
Figure 4-21 External Signal Output Terminal Block (with default settings) ..........................................38
Figure 5-1 UPS Terminal Designation.....................................................................................................45
Figure 5-2 Diagram of input/output bus bars and terminal blocks (100-225kVA).................................46
Figure 5-3 Diagram of input/output bus bars and terminal blocks (300kVA)........................................47
Figure 5-4 Diagram of input/output bus bars and terminal blocks (500kVA)........................................48
Figure 5-5 Diagram of input/output bus bars and terminal blocks (750kVA)........................................49
Figure 5-6 Detail of the main cabinet bus bars (300kVA......................................................................50
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Figure 5-7 Detail of the main cabinet bus bars (500kVA).....................................................................51
Figure 5-8 Detail of the main cabinet bus bars (750kVA).....................................................................52
Figure 5-9 Bus bar connection between main cabinet and landing cabinet (300kVA).........................53
Figure 5-10 Bus bar connection between main cabinet and landing cabinet (500kVA).......................54
Figure 5-11 Bus bar connection between main cabinet and landing cabinet (750kVA).......................55
Figure 5-12 Diagram of Power Wire & Control Wire Inter-Connect between UPS and Battery...........56
Figure 5-13 Diagram of Power Wire Connections (Parallel System Configuration).............................57
Figure 5-14 Diagram of Comm., Power, & Control Wire Connections for 4 units in MMS
Config .(100-225kVA)..............................................................................................................................58
Figure 5-15 Diagram of Communication, Power & Control Wire Connections for 2 units in MMS
Configuration (300-750kVA)....................................................................................................................59
Figure 5-16 Detail of IFAU-09 Control Wire Connections for 2 units in MMS Configuration
(300-750kVA) ..........................................................................................................................................60
Figure 5-17 Diagram of Power Wire & Control Wire Connections for 3-4 units in MMS Config.
(300-750kVA) ..........................................................................................................................................61
Figure 5-18 Detail of IFAU-09 Control Wire Connections for 3 or 4 units in MMS Configuration.........62
Figure 5-19 Diagram of Power Wire & Control Wire Connections for 5 to 8 units in MMS Configuration
(300-750kVA) ..........................................................................................................................................63
Figure 5-20 Detail of IFAU-09 Control Wire Connections for 5 to 8 units in MMS Configuration
(300-750kVA) ..........................................................................................................................................64
Figure 5-21 Circuit Protectors Location................................................................................................65
Figure 5-22 LCD Screen (MMS Operation)..........................................................................................68
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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. 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, Toshiba field
service group assistance and correspondence is recommended.
WARNING
CAUTION
!
NOTE
PROHIBIT
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2 INTRODUCTION
The Toshiba Uninterruptible Power Supply System (UPS) is designed to provide many years of reliable
protection from power failure, brown-outs, line noise, and voltage transients. To ensure optimum
performance of the equipment, follow the manufacturer's instructions. This manual contains descriptions
required to operate the UPS. Please read this manual carefully and retain it for future reference.
This manual contains important instructions for the G9000 SERIES Uninterruptible Power Supply Systems
that should be followed during installation and maintenance of the UPS and batteries.
Lethal voltages exist within the equipment during operation. Observe all warning
and cautions in this manual. Failure to comply may result in serious injury or death.
Obtain qualified service for this equipment as instructed.
WARNING 1
WARNING
CAUTION
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
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In no event will TOSHIBA be responsible or liable for either indirect or consequential damage or
injury that may come from the misuse of this equipment.
Don’t modify the UPS entirely or partially.
Any modifications without authorization by TOSHIBA could result in
personal injuries, death or destruction of the UPS.
2.1 SAFETY PRECAUTIONS
APPLICATION
This UPS shall NOT be applied to support equipment (*) that could affect human
lives. * •Life support equipment in operating rooms (artificial dialysis,
incubators, etc.)
•Toxic gas or smoke eliminators
•Equipment that must be provided under fire laws, construction
standards or other ordinances
•Equipment equivalent to the above
Special considerations are required when applying this UPS to the equipment
(**) that affect human safety and/or maintain public services.
** •Equipment to supervise or control airways, railways, roads,
sea-lanes or other transportation.
•Equipment in nuclear power plants.
•Equipment to control communications.
•Equipment equivalent/similar to the above mentioned.
WARNING 2
CAUTION
PROHIBIT
PROHIBIT
!
NOTE
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The UPS is to be installed in a controlled environment.
Improper storage and installation environment may deteriorate insulation, shorten component
life and cause malfunctions.
Keep the installation environment per standard described as follows:
Table 2-1 UPS Installation Environment
No. Item Environment standard
1 Installation
location
Indoors
2 Ambient
temperature Minimum temperature: 32 °F(0 °C), Maximum temperature: 104 °F(40 °C)
The
average temperature over any 24-hour period must be in the range 41 °F (5 °C)
to 95 °F(35 °C).
3 Relative humidity The relative humidity must be held between 5
and 95%. There must be no
condensation due to temperature changes.
4 Altitude This equipment must not be applied at altitude that exceeds 2250m (7380ft)
above sea level.
5 Dust
Dust in the room where the UPS is installed must not exceed normal
atmospheric dust levels. In particular, that dust should not include iron particl
es,
oils or fats, or organic materials such as silicone.
6 Inflammable gas
following
IEC654-4
Part 4
There should be no inflammable/explosive gas.
Hydrogen sulfide (H2S) No more than 0.003 PPM
Sulfurous acid gas (SO2) No more than 0.01 PPM
Chlorine gas (Cl2) No more than 0.002 PPM
Ammonia gas (NH3) No more than 1 PPM
Nitrous oxides (NOx) No more than 0.05 PPM
Ozone (O3) No more than 0.002 PPM
WARNING 3
!
NOTE
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This UPS does not include a Bypass input circuit breaker (MCCB) to protect the
bypass circuit. The Bypass input circuit breaker (MCCB) is to be field supplied
and installed. Recommended Breaker (MCCB)'s Specifications are as follows:
Table 2-2 Rating of Bypass Input Circuit Breaker
Capacity (kVA) Bypass Voltage (Vac)
Bypass Rating (Aac)
Breaker (A)
100
480
120
150
160
480
192
250
225
480
271
350
300
480
361
500
500
480
601
800
750
480
902
1200
AC input and AC output overcurrent protection and disconnect devices shall be field supplied
and installed. The DC circuit breaker (MCCB) shall be field supplied and installed. The
overcurrent protection device should be installed in the Battery cabinet and rated as indicated
in Table 3-6.
Note: The DC input overcurrent protection (Battery disconnect breaker) hereinafter will be
referred as “CB2”.
WARNING 4
!
NOTE
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3 GENERAL
The Toshiba G9000 UPS is designed to provide continuous and clean electrical power to a critical
load. Additionally the UPS monitors power conditions affecting the load. In the event of an input
power failure, the UPS will supply power to the critical load for the specified battery time.
If the input power is not restored promptly, backup power from the UPS battery permits the orderly
shutdown of equipment supported by the UPS. The UPS is simple to start-up, operate and maintain.
The G9000 SERIES UPS is available in six kVA sizes - 100, 160, 225, 300, 500, 750 kVA.
Specifications for each kVA model appear in Section 3.3. The principles of operation described
herein are applicable to all models.
This manual provides an overview of the G9000 SERIES components and their functions. The
appearance and purpose of operator controls and indicators is described with procedures for
operation, start-up, shutdown and basic maintenance included.
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3.1 DEFINITIONS
UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) – All components within the UPS Module
Cabinet and associated batteries that function as a system to provide continuous, conditioned AC
power to a load. This is sometimes referred to as the "System".
UPS MODULE CABINET – The metal enclosure which contains the Converter / Charger, Inverter,
Static Transfer Switch, Internal Bypass line, operator controls, and internal control systems required
to provide specified AC power to a load.
UPS MODULE – The Converter / Charger and Inverter assemblies which, under the direction of the
internal control system and operator controls, provide specified AC power to a load.
INVERTER – The UPS components which contain the equipment and controls necessary to convert
DC power from the Converter / Charger, or the battery, to AC power required by the critical load.
CONVERTER / CHARGER – The UPS components which contain the equipment and controls
necessary to convert input AC power to regulated DC power required for battery charging and for
supplying power to the Inverter.
STATIC TRANSFER SWITCH – The device which connects the critical load to the bypass line when
the Inverter cannot supply continuous power.
BYPASS LINE – The line which conducts electricity directly from the input power source to the critical load
during Maintenance or whenever the UPS is not completely operational.
AC INPUT POWER – Power provided by the electrical utility company, or auxiliary generator, which is
connected to the UPS for supplying the critical load.
BATTERY – The rechargeable battery strings which supply DC power to the inverter to maintain
continuous AC power to the load during AC input power failure conditions.
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3.2 OPERATION OVERVIEW
The UPS provides two power paths between the utility source and the critical load.
Figure 3-1 shows the path for normal operation, with the load powered by the inverter.
Figure 3-2 shows the path for bypass operation, with the load supplied through the static bypass line.
3.2.1 Normal operation: Load power supplied by each system UPS inverter.
Bypass
Input
CB
User supplied
MCCB Static Transfer
Switch
52S
AC
Input CB1
CONVERTER INVERTER
52C
Output
Power Flow
Not in Use
UPS Module
Battery
Cabinet
CB
User supplied
MCCB
CB2
External
Battery
CB3
CB
CHARGER
Figure 3-1 Single Line Diagram – Normal Operation: Load powered by UPS inverter
During normal operation, the path through the UPS inverter is used to power the load.
In Figure 3-1 input AC power is converted to DC by the Converter. DC power is utilized to charge the
UPS battery and to provide power to the Inverter. The Inverter converts the DC power to clean AC power
to supply the critical load.
The conversion - inversion process eliminates any voltage transients or fluctuations existing in the
input power before it reaches the critical load.
The power drawn by the critical load is equally shared between all UPS systems when multiple UPSs
are in Parallel Operation. (Figure 5-12 shows a sample of Parallel Operation System Configuration.)
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In the event of a UPS module failure during Parallel Operation, the critical load power will be
continually supplied and shared by all other UPS.
The Bypass Input breaker and cables are to be supplied and installed by the user or the
constructor. (See WARNING 4 on page 5)
3.2.2 Bypass Operation: Load Power supplied through UPS internal static bypass line.
Bypass
Input
CB
User supplied
MCCB
52S
AC
Input CB1
CONVERTER INVERTER
52C
Output
Power Flow
Not in Use
UPS Module
Battery
Cabinet
CB
User supplied
MCCB
CB2
External
Battery
CB3
CB
Static Transfer
Switch
CHARGER
Figure 3-2 Single Line Diagram – Bypass Operation: Load fed through static bypass line.
Figure 3-2 shows the Internal Bypass line is a Hard-wired line through 52S which supplies the critical
load with unconditioned bypass input power. Upon switching to the Internal Bypass line, the Static Transfer
Switch line through CB3 (herein after STS contactor CB3) supplies the power immediately, and then the
Internal Bypass line through 52S supplies the power. In the event of a switching to the Bypass line, the
power to the critical load will be uninterrupted. The purpose of this Internal Bypass line is to route power to
the critical load while the UPS module is de-energized (converter and inverter), and during Start-up before
the system is fully operational.
Each UPS internal static bypass line will equally share the power supplied to the critical load
whenever the system is in the Parallel Operation.
!
NOTE
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In the event of a load overcurrent, the UPS transfers to bypass without interruption to the critical load.
In the case of the Parallel Operation, all UPS will transfer to bypass without interruption to the critical load.
The internal control system determines the operation of the two paths, with the load powered from the
inverter being the normal operation.
3.2.3 Battery Operation: Load Power supplied by UPS battery.
Bypass
Input
CB
User supplied
MCCB Static Transfer
Switch
52S
AC
Input CB1
CONVERTER INVERTER
52C
Output
Power Flow
Not in Use
UPS Module
Battery
Cabinet
CB
User supplied
MCCB
CB2
External
Battery
CB3
CB
CHARGER
Figure 3-3 Single Line Diagram – Battery Operation
Figure 3-3 shows that in the event of AC input source failure or interruption, the UPS Converter(s)*
will de-energize and the UPS battery(s)* will immediately discharge and supply DC power to the Inverter to
maintain continuous AC power to the load. This operation will continue until:
a) The battery capacity expires and the inverter turns off, or
b) Input power is restored.(When input power is restored the converter will simultaneously power
the inverter and critical load, and recharge the batteries.)
A fully charged battery will provide power for the specified time at the rated load, or longer, at a
reduced load. (* (s): In the case of the Parallel Operation.)
When power is restored after a low battery shutdown, the UPS converter(s) automatically restarts
operation, the charger(s) recharges the batteries and the Inverter(s) is automatically restarted without
operator intervention. Load is automatically assumed by the inverter without operator intervention. (*
(s): In the case of the Parallel Operation.)
The power drawn by the load is equally shared between all UPS regardless of the presence or
absence of the UPS that is (are) in battery operation or not whenever the system is in the Parallel
Operation.
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