Toshiba G9400 Series User manual

G9400 SERIES
INSTALLATION AND
OPERATION MANUAL
480/480V 1200/1600/2000kVA
Document No.: 203078-001
Reference: 4GBH0170 Rev. C
January 2022

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 i
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.
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 G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001
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 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 2022 TOSHIBA INTERNATIONAL CORPORATION
All rights reserved.
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 –[e-mail]
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

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 iii
Table of Contents
List of Tables......................................................................................................................................................................... v
List of Figures.......................................................................................................................................................................vi
1How to use this Manual ................................................................................................................................................ 1
1.1 Notice Icons.........................................................................................................................................................1
1.2 Qualified Personnel.............................................................................................................................................2
2Introduction....................................................................................................................................................................3
2.1 Safety Precautions ..............................................................................................................................................4
3General...........................................................................................................................................................................7
3.1 Definitions............................................................................................................................................................8
3.2 Operation Overview.............................................................................................................................................9
3.2.1 Normal Operation: Load Power Supplied By Each System UPS Inverter ..........................................................9
3.2.2 Bypass Operation: Load Power Supplied Through UPS Internal Static Bypass Line. .....................................11
3.2.3 Backup Operation: Load Power Supplied by UPS battery................................................................................12
3.2.4 VRLA Battery Charging Operation....................................................................................................................14
3.2.5 SCiB Lithium Ion Battery Charging Operation ..................................................................................................14
3.2.6UPS Parts Location...........................................................................................................................................15
3.3 Specifications ....................................................................................................................................................18
4Operator Controls and Indicators..............................................................................................................................22
4.1 LED Display.......................................................................................................................................................23
4.2 EPO Button (Emergency Power Off Button).....................................................................................................23
4.3 Liquid Crystal Display........................................................................................................................................24
4.3.1 Menu..................................................................................................................................................................24
4.3.2 Input Power Failure...........................................................................................................................................27
4.3.3 Fault Indication..................................................................................................................................................28
4.4 External Aux Contact Input and Output Terminal Blocks..................................................................................29
4.4.1 Aux Contacts - Input..........................................................................................................................................29
4.4.2 Aux Contacts - Output.......................................................................................................................................32
4.5 RemotEye®4 Introduction.................................................................................................................................34
5Installation and Operation.......................................................................................................................................... 37
5.1 Transportation and Installation..........................................................................................................................37
5.2 Installation Procedure........................................................................................................................................37
5.3 Procedure for Cable Connections.....................................................................................................................38
5.4 Operating Procedures.......................................................................................................................................50
6Response to UPS Fault...............................................................................................................................................54
7Parts Replacement......................................................................................................................................................55
7.1 Recommended Maintenance ............................................................................................................................55
7.2 Battery...............................................................................................................................................................55
7.3 UPS Component Parts......................................................................................................................................55

iv G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001
7.4 Air Filters ...........................................................................................................................................................56
8Fault Codes..................................................................................................................................................................56
8.1 Bypass Module Fault Codes .............................................................................................................................57
8.2 Power module Fault Codes...............................................................................................................................58
9Daily Inspection...........................................................................................................................................................60
Appendix A Installation Planning Guides (IPG) & Outline Drawings........................................................................61
Appendix B Index.........................................................................................................................................................70

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 v
List of Tables
Table 2–1 UPS Installation Environment..............................................................................................................................5
Table 2–2 Rating of Bypass Input Circuit Breaker (100% Rated)........................................................................................6
Table 3–1 Power Specifications.........................................................................................................................................18
Table 3–2 UPS Cabinet Information...................................................................................................................................18
Table 3–3 1200kVA Shipping Information..........................................................................................................................19
Table 3–4 1600kVA Shipping Information..........................................................................................................................19
Table 3–5 2000kVA Shipping Information..........................................................................................................................19
Table 3–6 Specifications ....................................................................................................................................................20
Table 3–7 Rating of Contactors, Breakers, and Fuses ......................................................................................................21
Table 3–8 AC-AC Efficiency Specifications........................................................................................................................21
Table 4–1 External Input Functions....................................................................................................................................31
Table 4–2 External Output Functions.................................................................................................................................33
Table 5–1 How to Transport and Install the G9400 System ..............................................................................................37
Table 5–2 List of UPS Weights...........................................................................................................................................37
Table 5–3 Maximum Permitted Fault Current ....................................................................................................................38
Table 5–4 Recommended Cable Quantities at 500kcmil...................................................................................................41
Table 5–5 Hardware Sizing................................................................................................................................................41
Table 5–6 Crimp Type Compression Lug...........................................................................................................................42
Table 5–7 Status of Jumpers on Parallel Interface Board (IFAU-16A) ..............................................................................49
Table 7–1 Standard Replacement Parts List......................................................................................................................55
Table 7–2 Replacement Air Filters.....................................................................................................................................56
Table 8–1 Bypass Module Warning Alarm List ..................................................................................................................57
Table 8–2 UPS Module Fault Code List.............................................................................................................................58
Table 9–1 How to Perform Daily Inspection.......................................................................................................................60

vi G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001
List of Figures
Figure 3-1 Single Line Diagram - Normal Operation: Load fed by UPS inverter .................................................................9
Figure 3-2 Single Line Diagram - Bypass Operation: Load Fed Through Static Bypass Line...........................................11
Figure 3-3 Single Line Diagram - Backup Operation: Load Fed by Energy Storage.........................................................12
Figure 3-4 Typical Battery Charging Curve........................................................................................................................14
Figure 3-5 UPS Parts Location (1200kVA).........................................................................................................................15
Figure 3-6 UPS Parts Location (1600-2000kVA) ...............................................................................................................16
Figure 4-1 Operation/Display Panel (Front Panel).............................................................................................................22
Figure 4-2 Main Screen......................................................................................................................................................24
Figure 4-3 Start/Stop Operation .........................................................................................................................................25
Figure 4-4 Start Operation..................................................................................................................................................25
Figure 4-5 Stop Operation..................................................................................................................................................25
Figure 4-6 Input Values ......................................................................................................................................................25
Figure 4-7 Output Values ...................................................................................................................................................25
Figure 4-8 Remote/Local Operation or Date & Time Adjustment Select ...........................................................................26
Figure 4-9 Log Menu..........................................................................................................................................................26
Figure 4-10 Event Log........................................................................................................................................................26
Figure 4-11 Battery Log......................................................................................................................................................26
Figure 4-12 Main Screen (On Battery)...............................................................................................................................27
Figure 4-13 Measurement Screen (On Battery).................................................................................................................27
Figure 4-14 Main Screen (Fault Indication)........................................................................................................................28
Figure 4-15 Message Screen (Alarm, Major Fault, Minor Fault)........................................................................................28
Figure 4-16 Control Wiring for Aux Input Contacts.............................................................................................................29
Figure 4-17 External Signal Input Terminal Block (with default settings)...........................................................................30
Figure 4-18 Control Wiring for Aux Output Contacts..........................................................................................................32
Figure 4-19 External Signal Output Terminal Block (with default settings)........................................................................32
Figure 4-20 RemotEye® 4 Installation (Overview).............................................................................................................34
Figure 4-21 Detailed Configuration of RemotEye® Installation..........................................................................................35
Figure 4-22 Connection Between IOAU-19* PCB (IO1) and RemotEye® Module .............................................................36
Figure 4-23 Communication Connector (CN2, Dsub-9) on N0031 ....................................................................................36
Figure 4-24 VH Connector (CN85) on IOAU-19* PCB (IO1)..............................................................................................36
Figure 5-1 UPS Terminal Designation................................................................................................................................43
Figure 5-2 Diagram of Input/Output Bus Bars and Terminal Blocks (1200kVA)................................................................44
Figure 5-3 Diagram of Input/Output Bus Bars and Terminal Blocks (1600-2000kVA).......................................................45
Figure 5-4 Diagram of Power Wire & Control Wire Inter-Connect between UPS and Battery...........................................46
Figure 5-5 Diagram of Power Wire Connections (Parallel System Configuration).............................................................47
Figure 5-6 Diagram of Power Wire & Control Wire Connection (Parallel system connection 2x to 6x).............................48
Figure 5-7 Detail of IFAU-16A Control Wire Connections for N units in MMS Configuration ............................................49
Figure 5-8 LCD Screen (MMS Operation)..........................................................................................................................53

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 vii

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 1
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 G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001
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.

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 3
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 instructions required to operate the UPS. Please read this
manual carefully and retain it for future reference.
This manual contains important instructions for the G9400 Series Uninterruptible Power Supply System that should be
followed during installation, operation, 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.
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
WARNING 1
CAUTION
WARNING

4 G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001
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.
Do not 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
UNINTENDED USAGE
This UPS shall NOT be used in the following applications. Use of this UPS in any
of the below applications will result in serious injury or death:
Medical operation room equipment
Life support equipment
Fire Prevention or Suppression Equipment
Always read all applicable regulations and standards for the application of this
UPS. Special considerations are required when using this UPS in the following
applications:
Nuclear Power Plants.
Control Equipment.
Transportation Equipment
WARNING 2
WARNING
PROHIBIT
PROHIBIT
!
NOTE

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 5
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 2–1UPS 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)
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 is designed to operate without derating at 1980m (6500ft) 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 particles, oils or fats, or conductive
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
4
WARNING

6 G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001
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 2–2Rating of Bypass Input Circuit Breaker (100% Rated)
Capacity
(kVA)
Bypass Voltage
(V)
Bypass Rating
(A)
Breaker
(A)
1200
480
1443
1500
1600
480
1925
2000
2000
480
2406
2500
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 rated as indicated in Appendix A Installation Planning Guides (IPG) & Outline Drawings.
Cover to prevent foreign objects from entering sensitive electronic equipment.
Keep this cover in place during shipping and installation.
To be removed by Authorized Service Personnel at time of startup.
WARNING 4
WARNING
WARNING 5
WARNING

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 7
3 General
The TOSHIBA G9400 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 backup time.
If the input power is not restored promptly, back up power from the UPS DC Energy Storage System permits the
orderly shutdown of equipment supported by the UPS. The UPS is simple to start-up, operate and maintain.
The G9400 SERIES UPS is available in 1200, 1600, and 2000kVA capacity models. Specifications are shown in
Section 3.3.
This manual provides an overview of the G9400 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.

8 G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001
3.1 Definitions
UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS Cabinet, ancillary cabinets,
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 3～5
power modules, and the Cable Entry Section.
LINK CABINET –The metal enclosure in which buses between separately shipped power modules are connected.
POWER 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 operating in double conversion mode.
STATIC TRANSFER SWITCH - The device which connects the critical load to the bypass line when the Inverter
cannot or should not supply continuous power to the load.
AC INPUT POWER - Power provided by the electrical utility company, or auxiliary generator, which is connected to
the UPS Converter & Bypass for supplying the critical load.
ENERGY STORAGE SYSTEM - The rechargeable energy storage device (Lithium Ion/VRLA/Wet Cell batteries)
which supplies DC power to the inverter to maintain continuous AC power to the load during AC input power failure
conditions.

G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001 9
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. Figure 3-3
shows the path for backup operation, with the load powered by the inverter.
3.2.1 Normal Operation: Load Power Supplied By Each System UPS Inverter
Figure 3-1 Single Line Diagram - Normal Operation: Load fed 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 regulated AC power to supply the
critical load.
Bypass Module
CB
3
CONVERTER / INVERTER
CHARGER
52
C
Static Transfer
Switch
52
S
CB
1
CB2
Power module
CONVERTER / INVERTER
CHARGER
52
C
CB
1
CB2
Power module
CONVERTER / INVERTER
CHARGER
52
C
CB
1
CB2
Power module
UPS
CABINET
AC
input
Energy
Storage
System
Bypass
Input
CB
Output
supplied
MCCB
User
supplied
MCCB
CB
Power Flow
Not in Use
Output
CB
3 ~ 5 UPS
modules
Input
Jumper

10 G9400 480V 1200-2000kVA Installation and Operation Manual 203078-001
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. (Refer to
Figure 5-5 that shows a sample of Parallel Operation System Configuration.)
When in Parallel Operation, the rectifier inputs to all G9400 UPS Systems in the
Multi-Module System (MMS)-must be fed from a single source at all times including any
operation of Automatic Transfer Switches. All G9400 bypass inputs must also be fed from a
single source at all times (not necessarily the same source as the rectifier inputs).
In the event of a power module failure during Parallel Operation, the critical load power will be continually
supplied and shared by all other UPS.
For Dual Input applications, remove the supplied input jumpers between Bypass and
Inverter Input Bus bars.
The Bypass Input breaker and cables are to be supplied and installed by the user or
contractor. (See WARNING 4 on page 6)
!
NOTE
CAUTION