Toshiba G9000 SERIES User manual

UNINTERRUPTIBLE POWER SYSTEM (UPS)
G9000 SERIES
INSTALLATION AND
OPERATION MANUAL
480/480 V 1000kVA
Document No.: 91649-0041
Reference: 4GBA0051 Rev. A
September. 2014

G9000 1000kVA Installation and Operation Manual 91469-004

G9000 SERIES
INSTALLATION AND OPERATION MANUAL
480/480 V 1000 kVA
Document No. 91469-004
Reference: 4GBA0051 Rev. A
September. 2014
G9000 1000kVA Installation and Operation Manual 91469-004

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:
G9000 1000kVA Installation and Operation Manual 91469-004

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
www.toshiba.com/tic/industrial/uninterruptible-power-systems
.
G9000 1000kVA Installation and Operation Manual 91469-004

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G9000 1000kVA Installation and Operation Manual 91469-004

Table of Contents
List of Figures ...............................................................................................................ii
List of Tables................................................................................................................iii
1HOW TO USE THIS MANUAL..................................................................................1
2INTRODUCTION.......................................................................................................2
2.1 SAFETY PRECAUTIONS.............................................................................................................3
2.2 GENERAL.....................................................................................................................................5
2.3 DEFINITIONS................................................................................................................................6
2.4 OPERATION OVERVIEW.............................................................................................................7
3SPECIFICATIONS..................................................................................................14
4OPERATOR CONTROLS AND INDICATORS.......................................................18
4.1 LED DISPLAY.............................................................................................................................18
4.2 EPO BUTTON (Emergency Power Off Button) (7).....................................................................19
4.3 LIQUID CRYSTAL DISPLAY (8).................................................................................................19
4.3.1 Test Mode Options..................................................................................................................19
4.3.2 Menu .......................................................................................................................................20
4.3.3 Input Power Failure.................................................................................................................23
4.3.4 Fault Indication........................................................................................................................24
4.4 EXTERNAL SIGNAL TERMINAL BLOCK ..................................................................................24
5INSTALLATION AND OPERATION.......................................................................30
5.1 TRANSPORTATION AND INSTALLATION................................................................................30
5.2 PROCEDURE FOR CABLE CONNECTIONS *..........................................................................31
5.3 OPERATING PROCEDURES.....................................................................................................42
6RESPONSE TO UPS FAILURE..............................................................................46
7MAINTENENACE AND PARTS REPLACEMENT .................................................47
8FAULT CODES.......................................................................................................48
8.1 BYPASS MODULE FAULT CODES...........................................................................................48
8.2 UPS MODULE FAULT CODES..................................................................................................52
9DAILY INSPECTION...............................................................................................55
APPENDIX A – Installation Planning Guide (IPG).....................................................57
G9000 1000kVA Installation and Operation Manual 91469-004 i

List of Figures
Figure 2-1 Single Line Diagram - Normal Operation: Load powered by UPS inverter...........................7
Figure 2-2 Single Line Diagram - Bypass Operation: Load fed through static bypass line....................9
Figure 2-3 Single Line Diagram - Battery Operation ............................................................................10
Figure 2-4 UPS Parts Location.............................................................................................................12
Figure 2-5 UPS Parts Location – Front Inside View.............................................................................13
Figure 4-1 Operation/Display Panel (Front panel)................................................................................18
Figure 4-2 Main Screen ........................................................................................................................20
Figure 4-3 Startup/Shutdown Guidance ...............................................................................................21
Figure 4-4 Startup Guidance ................................................................................................................21
Figure 4-5 Shutdown Guidance............................................................................................................21
Figure 4-6 Input Values ........................................................................................................................22
Figure 4-7 Output values ......................................................................................................................22
Figure 4-8 Remote/Local operation and Date & Time adjustment select.............................................22
Figure 4-9 Log menu.............................................................................................................................23
Figure 4-10 Event Log ..........................................................................................................................23
Figure 4-11 Battery log .........................................................................................................................23
Figure 4-12 Main Screen (Battery Operation)....................................................................................23
Figure 4-13 Measurement screen (Battery Operation).........................................................................23
Figure 4-14 Main screen (Fault indication)...........................................................................................24
Figure 4-15 Message Screen ...............................................................................................................24
Figure 4-16 External Signal Terminal Block TN21-25 (NEC Class2 ....................................................25
Figure 4-17 External Signal Terminal Block TN11-14 (NEC Class2)...................................................26
Figure 4-18 Control Wiring for External Contacts.................................................................................27
Figure 4-19 Remote "Start" Contact Connections................................................................................28
Figure 5-1 UPS Terminal Designation..................................................................................................36
Figure 5-2 Diagram of input/output bus bars and terminal blocks........................................................37
Figure 5-3 Diagram of Power Wire & Control Wire Interconnections between UPS and Battery ........37
Figure 5-4 Diagram of power wire connections (Parallel Operation system connection).....................39
Figure 5-5 Diagram of Power Wire & Control Wire Connect ( Parallel Operation system connection 2x
to 8x)........................................................................................................................................................40
Figure 5-6 Outline Drawing of IFAU-16 and the Parallel System Operation Connection.....................41
Figure 5-7 LCD Screen (MMS Operation)............................................................................................45
ii G9000 1000kVA Installation and Operation Manual 91469-004

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............................................................................................................14
Table 3-2 UPS Cabinet Information......................................................................................................14
Table 3-3 UPS Shipping Dimensions ...................................................................................................14
Table 3-4 Specifications .......................................................................................................................14
Table 3-5 Typical UPS Efficiencies at Various Load............................................................................16
Table 3-6 MTBF of 1000kVA ................................................................................................................16
Table 3-7 Rating of Contactors, Breaker and Fuses ............................................................................16
Table 5-1 How to transport and install the system ...............................................................................30
Table 5-2 List of UPS weights ..............................................................................................................30
Table 5-3 Maximum Permitted Fault Current .......................................................................................31
Table 5-4 Recommended Cable Sizes.................................................................................................34
Table 5-5 Recommended Hardware.....................................................................................................34
Table 5-6 Crimp Type Compression Lug..............................................................................................35
Table 7-1 Standard Replacement Parts List.........................................................................................47
Table 7-2 Ait Filters...............................................................................................................................48
Table 8-1 Bypass Module Fault Code List............................................................................................48
Table 8-2 UPS Module Faults Code List ..............................................................................................52
Table 9-1 How to Perform Daily Inspection..........................................................................................55
G9000 1000kVA Installation and Operation Manual 91469-004 iii

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iv G9000 1000kVA Installation and Operation Manual 91469-004

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
G9000 1000kVA Installation and Operation Manual – 91469-004 1

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
System 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.
In no event will TOSHIBA be responsible or liable for either indirect or
consequential damage or injury that may come from the use of this equipment.
Any modifications without authorization by TOSHIBA could result in personal
injuries, death or destruction of the UPS.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
WARNING 1
WARNING 2
2 G9000 1000kVA Installation and Operation Manual – 91469-004

2.1 SAFETY PRECAUTIONS
APPLICATION
This UPS shall NOT be applied to support equipment (*) that could affect human
lives. * •Life support equipment in medical operation 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.
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:
WARNING 3
!
NOTE
PROHIBIT
!
NOTE
G9000 1000kVA Installation and Operation Manual – 91469-004 3

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
1980m(6500ft) above seal level.
5 Dust Dust in the room where the UPS is installed mu
st not exceed normal
atmospheric dust levels. In particular, that dust shoud
not include iron
particles, 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
4 G9000 1000kVA Installation and Operation Manual – 91469-004

This UPS does not include a Bypass input circuit breaker (MCCB) to protect
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)
1000 480 1203 1600
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 1.6.
2.2 GENERAL
The TOSHIBA G9000 SERIES 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, back up 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 100, 160, 225, 300, 500, 750, and 1000 kVA. This manual
covers the 1000 kVA mode onlyl. Specifications are shown in Section 1.5.
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.
WARNING 4
G9000 1000kVA Installation and Operation Manual – 91469-004 5

2.3 DEFINITIONS
UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS 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 CABINET – The metal enclosure which is the main part of UPS and composed of the Bypass
module, the 3 UPS modules, and the Cable Entry Section.
UPS MODULE - The metal enclosure which contains the Converter / Inverter, Charger, and
internal control systems required to provide specified AC power to a load.
CONVERTER / INVERTER - The UPS components which contain the equipment and controls
necessary to convert input AC power to output AC power required by the critical load.
CHARGER - The UPS components which contain the equipment and controls necessary to
regulate DC power required for battery charging and for supplying power to the Inverter.
BYPASS MODULE - The metal enclosure which contains the Bypass line, the Static transfer switch,
UPS operator controls, and internal control systems.
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.
STATIC TRANSFER SWITCH - The device which connects the critical load to the bypass line
when the Inverter cannot supply continuous power.
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.
6 G9000 1000kVA Installation and Operation Manual – 91469-004

2.4 OPERATION OVERVIEW
The UPS provides two power paths between the utility source and the critical load.
Figure 1.1 shows the path for normal operation, with the load powered from the inverter. Figure 1.2
shows the path for bypass operation, with the load supplied through the static bypass line.
A) Normal operation: Load power supplied by each system UPS inverter.
During normal operation, the path through the UPS inverters is used to power the load.
Referring to Figure 2-1: 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
Bypass Module
CB
3
CONVERTER / INVERTER
CHARGER
52
C
Static Transfer
Switch
52
S
CB
1
CB2
UPS Module
CONVERTER / INVERTER
CHARGER
52
C
CB
1
CB2
UPS Module
CONVERTER / INVERTER
CHARGER
52
C
CB
1
CB2
UPS Module
UPS
CABINET
AC
input
Battery
Cabinet
Bypass
Input
CB
Output
supplied
MCCB
User
supplied
MCCB
CB
External
BATTERY
Power Flow
Not in Use
Output
CB
Figure 2-1 Single Line Diagram - Normal Operation: Load powered by UPS inverter
G9000 1000kVA Installation and Operation Manual – 91469-004 7

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 whenever the system is in
the Parallel Operation. (Refer to Figure 3.4 that shows a sample of Parallel Operation System
Configuration.)
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 circuit breaker (MCCB) for protection of the UPS and cables are field
supplied and field installed. (See WARNING 4 on page 1-4).
8 G9000 1000kVA Installation and Operation Manual – 91469-004

B) Bypass Operation: Load Power supplied through UPS internal static bypass line.
Referring to Figure 1.2: 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.
Bypass Module
CB
3
CONVERTER / INVERTER
CHARGER
52
C
Static Transfer
Switch
52
S
CB
1
CB2
UPS Module
CONVERTER / INVERTER
CHARGER
52
C
CB
1
CB2
UPS Module
CONVERTER / INVERTER
CHARGER
52
C
CB
1
CB2
UPS Module
UPS
CABINET
AC
input
Bypass
Input
CB
User
supplied
MCCB
User
supplied
MCCB
CB
Power Flow
Not in Use
Output
Battery
Cabinet
External
BATTERY
CB
Figure 2-2 Single Line Diagram - Bypass Operation: Load fed through static bypass line
G9000 1000kVA Installation and Operation Manual – 91469-004 9

Each UPS internal static bypass line will equally share the power supplied to the critical load
whenever the system is in the Parallel Operation.
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.
C) Battery operation: Load Power supplied by UPS battery.
Bypass Module
CB
3
CONVERTER / INVERTER
CHARGER
52
C
Static Transfer
Switch
52
S
CB
1
CB2
UPS Module
CONVERTER / INVERTER
CHARGER
52
C
CB
1
CB2
UPS Module
CONVERTER / INVERTER
CHARGER
52
C
CB
1
CB2
UPS Module
UPS
CABINET
AC
input
Bypass
Input
CB
supplied
MCCB
User
supplied
MCCB
CB
Power Flow
Not in Use
Output
Battery
Cabinet
External
BATTERY
CB
Figure 2-3 Single Line Diagram - Battery Operation
10 G9000 1000kVA Installation and Operation Manual – 91469-004