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© Copyright 2012 T oshiba International Corporation All rights reserved. Document: 61001-001 July 2012 UNINTERRUPTIBLE POWER SYSTEM (UPS) G8000 SERIES INST ALLA TION and OPERA TION MANUAL 480/480 V 1.
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G8000 Series Installation and Operation Manual UNINTERRUPTIBLE POWER SYSTEM (UPS) © Copyright 2012 T oshiba International Corporation All rights reserved.
G8000 Series Installation and Operation Manual The T oshiba products listed in this document are intended for usage in general electronics applications (computer , personal equipment, ofce equipment, measuring equipment, industrial robotics, domestic appliances, etc.
G8000 Series Installation and Operation Manual UNINTERRUPTIBLE POWER SYSTEM (UPS) Please complete the following information and retain for your records. Unless otherwise specied, the warranty period for the UPS or UPS part is 12 months from the shipment date (see T oshiba International Corporation bill of lading).
G8000 Series Installation and Operation Manual Purpose This manual provides information on how to safely install and operate your T oshiba International Corporation power electronics product. This manual includes a section of general safety instructions that describes the warning labels and symbols that are used throughout the manual.
i G8000 Series Installation and Operation Manual T able of Contents 1 Introduction ..........................................................................................................................1 2 General Safety Instructions ..............
ii G8000 Series Installation and Operation Manual 1 1.4 External Breakers .......................................................................................................36 1 1.5 Grounding Wire ..................................................
1 G8000 Series Installation and Operation Manual 1 Introduction This manual provides information on how to safely operate your G8000 Series Uninterruptible Power System (UPS). This manual includes a section of general safety instructions that describes the warning labels and symbols that are used throughout the manual.
2 G8000 Series Installation and Operation Manual 2 General Safety Instructions DO NOT attempt to transport, install, operate, maintain or dispose of this equipment until you have read and understood all of the product safety information provided in this manual.
3 G8000 Series Installation and Operation Manual 2.2 Signal Words The signal words listed below are used throughout this manual. When the words DANGER, W ARNING, CAUTION and A TTENTION are used in this manual they will include important safety information that must be carefully followed.
4 G8000 Series Installation and Operation Manual • Be trained in rendering rst aid. For further information on workplace safety visit www .osha.gov . 2.4 Factory Authorized Personnel Factory authorized personnel have been factory trained and certied to install, service, and repair the UPS.
5 G8000 Series Installation and Operation Manual 4 Safety Precautions The T oshiba products listed in this document are intended for usage in general electronics applications (computer , personal equipment, ofce equipment, measuring equipment, industrial robotics, domestic appliances, etc.
6 G8000 Series Installation and Operation Manual 4.3 T ransporting/Unpacking W ARNING When transporting the UPS by crane, follow the SPECIFIED WORK PROCEDURE. The suspension wire angle should be less than 60°. The UPS falling or overturning may cause crushing, trapping or other personal injuries.
7 G8000 Series Installation and Operation Manual CAUTION DO NOT transport, move, store, or place the UPS on its side. Forces due to heavy components inside may damage the UPS. A void vibration or shock exceeding 0.5G. Failing to observe this precaution may cause damage to the UPS.
8 G8000 Series Installation and Operation Manual 4.4 Inspection/Storage Inspection Upon receipt of the UPS, an inspection for shipping damage should be performed. Use caution when removing the unit from the pallet. Refer to labels or documentation attached to packing material.
9 G8000 Series Installation and Operation Manual CAUTION Install the UPS in a controlled environment. Improper storage and installation environment may deteriorate insulation, shorten component life and cause malfunctions. See T able 5.1 - UPS Installation Environment Standards DO NOT tilt the UPS more than 10° from upright position.
10 G8000 Series Installation and Operation Manual DO NOT block air vents. Blocking the vents will increase the internal temperatures and may result in UPS failure or re. DO NOT install the UPS where water may fall on it. W ater may cause electrical shock, personal injury or UPS failure.
11 G8000 Series Installation and Operation Manual T ABLE 5.1 - UPS INST ALLA TION ENVIRONMENT ST ANDARDS Item Environment standard Installation Location Indoors Ambient T emperature Minimum operating temperature: 32 °F ( 0 ° C). Maximum operating temperature: 86 °F (30 ° C) at 1.
12 G8000 Series Installation and Operation Manual 7) The UPS generates and can radiate radio-frequency energy during operation. Although RFI noise lters are installed inside of the unit, there is no guarantee that the UPS will not inuence some sensitive devices that are operating near by .
13 G8000 Series Installation and Operation Manual 5.1 Wiring/Connection W ARNING Perform wiring and connections with correct polarity . Be careful when connecting the UPS to the battery system. A wrong connection may cause damage to the UPS, battery , or charger .
14 G8000 Series Installation and Operation Manual 6 W arning Labels Below are representative warning labels and their location on the UPS. Exterior Handling labels shown in section 4.3, T ransporting/Unpacking, are in the manual packet, and attached to the UPS shipping covering and shipping pallet.
15 G8000 Series Installation and Operation Manual 6.1 W arning Label Locations FIGURE 6.2 – 100 KV A UPS WARNING LABELS DA NGE R Hazardous vo lt ag es are used in the ope rat ion of this e quipment and could c ause severe pers onal inj ury or los s of l i fe.
16 G8000 Series Installation and Operation Manual FIGURE 6.3 – 150/225 KV A UPS WARNING LABELS FIGURE 6.4 - 300 KV A UPS WARNING LABELS.
17 G8000 Series Installation and Operation Manual 7 W eight and Dimensions T able 7.1 lists the unit and shipping weights for G8000 UPS models illustrated in Figures 7.1 – 7.3. T ABLE 7.1 G8000 UPS UNIT AND SHIPPING WEIGHTS Model Unit Shipping 100 kV A 1740 lb.
18 G8000 Series Installation and Operation Manual FIGURE 7.2 - 150/225 KV A UPS EXTERIOR DIMENSIONS (INCHES) FIGURE 7.3 – 300 KV A UPS EXTERIOR DIMENSIONS (INCHES) “8A” SWITCH TERMINAL BLOCKS “8A” SWITCH GROUND BUS 79.2 TERMINAL BLOCKS GROUND BUS 82.
19 G8000 Series Installation and Operation Manual 8 T ransporting The UPS may be packed in a crate for extra protection during transportation. Avoid impact or vibration against the UPS during transportation. DO NOT expose the UPS directly to water . W ARNING When transporting the UPS by crane, follow the SPECIFIED WORK PROCEDURE.
20 G8000 Series Installation and Operation Manual 8.1 T ransporting By Crane Cables should have sufcient ratings and be of the same length. Make sure the suspension cables are hooked at eyebolts. See Figure 8.1. Keep the angle less than 60° between cables.
21 G8000 Series Installation and Operation Manual 8.2 T ransporting By Forklift Refer to Chapter 7 - Weight and Dimensions. V erify forklift maximum load capacity and ensure that the forks are long enough to properly support the UPS. Insert the forks into the space shown in Figure 8.
22 G8000 Series Installation and Operation Manual 9 Storage/Operating Environment Observe the following when storing the UPS. • Store UPS indoors.
23 G8000 Series Installation and Operation Manual W ARNING While operating in the inverter mode, placing the input breaker in the “OFF” position will switch the UPS to the battery backup mode. The output of the UPS will continue uninterrupted to the load.
24 G8000 Series Installation and Operation Manual 9.2 Maintenance Precautions All internal maintenance sould be performed by factory authorized personnel. 1) T urn off, lockout, and tagout ALL power sources before connecting the power wiring to the equipment or when performing maintenance.
25 G8000 Series Installation and Operation Manual CAUTION DO NOT dispose of the batteries in a re. The batteries may explode. DO NOT open or mutilate the batteries. Released electrolyte is harmful to the eyes and skin and could also be toxic. DANGER A battery can present a risk of electrical shock and high short circuit current.
26 G8000 Series Installation and Operation Manual 10 Installation W ARNING Keep the SPECIFIED CLEARANCE around the UPS. Inadequate space around the UPS makes it difcult to perform maintenance/inspections, lead to insufcient ventilation, and/or will cause malfunctions.
27 G8000 Series Installation and Operation Manual 10.1 Unpacking Unpack the UPS indoors on a paved oor . The UPS should be as close as possible to its nal storage location. Overhead traveling cranes should be used to unpack any G8000 Series UPS.
28 G8000 Series Installation and Operation Manual G8000 Series Installation Manual 26 10.3 Anchor Bolts Install the anchor bolts to secure the UPS on the floor. See Figu re 10.2 for anchor bolt installation detail. Use 12mm (1/2”) diameter anchor bolts.
29 G8000 Series Installation and Operation Manual 1 1 UPS Wiring Note: Always consult your local and NEC electrical codes for wiring, cabling, and circuit protection device requirements. Figure 1 1.1 illustrates the external wiring of the G8000 UPS. See corresponding section to each wiring term.
30 G8000 Series Installation and Operation Manual 1 1.1 100 kV A T erminal Blocks and Power Cables Note: Always consult your site specic, local, state, and NEC electrical codes for wiring, cabling, and circuit protection device requirements. The terminal blocks for the 100 kV A UPS are shown in Figure 1 1.
31 G8000 Series Installation and Operation Manual 1 1.2 150, 225, and 300 kV A Buss Strip T erminals and Power Cables Note: Always consult your site specic, local, state, and NEC electrical codes for wiring, cabling, and circuit protection device requirements.
32 G8000 Series Installation and Operation Manual For UPS’ equipped with buss strip terminals for the A/C INPUT , BYP ASS INPUT , A/C OUTPUT and BA TTERY connections, T oshiba recommends using the compression lugs listed in T able 1 1.2, or their equivalent, for cable terminations to be mounted on the bus strips.
33 G8000 Series Installation and Operation Manual T ABLE 1 1.4 RECOMMENDED CABLE SIZE AND F ASTENER TORQUE FOR 225 KV A UNIT Block Number Cable Size Recommended Fastener T orque ** 1 T wo A WG 2/0 or larger 540 in.-lb. (6.2 kg-m) 2 T wo A WG 2/0 or larger 540 in.
34 G8000 Series Installation and Operation Manual 1 1.3 UPS Power Cable Knockout Plates Cable knockout plates are provided at the bottom of the 100 kV A UPS, and at the top and bottom of the 150/225 kV A UPS. (Older models of the G8000 150/225 kV A UPS do not come equipped with an upper knockout plate.
35 G8000 Series Installation and Operation Manual Figure 1 1.9 shows the four (4) cable knockout plates provided at the top of the 300 kV A UPS. Seven (7) holes must be punched during installation. The dashed rectangle indicates the UPS opening behind the knockout plates.
36 G8000 Series Installation and Operation Manual 1 1.4 External Breakers The G8000 UPS units are not equipped with circuit breakers. Qualied personnel should provide the external breakers for the AC input/output, bypass input and DC input. See Figure 1 1.
37 G8000 Series Installation and Operation Manual FIGURE 1 1.10 - EARTH GROUND WIRE G8000 - 100 kV A 12 mm or 1/2 in. T erminal 10 mm or 7/16 in. Bolt Feed-through opening A WG 2 (38 mm) ground wire T.
38 G8000 Series Installation and Operation Manual 1 1.6 Control Wires The control wires terminal layouts at TB1 (terminal bus 1) are shown below in T able 1 1.
39 G8000 Series Installation and Operation Manual The UPS battery cabinet and bypass breaker should be wired as shown below in Figure 1 1.1 1. FIGURE 1 1.1 1 - CONNECTION BETWEEN UPS, BA TTERY CABINET & BYP ASS BREAKER 10 11 12 13 14 15 16 17 18 19 20 21 22 TC TB1 Battery Cabinet Overheat B-Contact Bypass Breaker Ext.
40 G8000 Series Installation and Operation Manual 1 1.7 Grounding Conguration This section describes the grounding conguration to be used with various AC service entrance congurations.
41 G8000 Series Installation and Operation Manual 1 1.7.2 Grounding Conguration (without input neutral) When the input source is wye-connected, the neutral line out to the bypass input should be left open. The UPS is grounded by connecting the neutral terminal to the ground bus with the internal jumper cable.
42 G8000 Series Installation and Operation Manual 1 1.7.4 Grounding Conguration (with corner-grounded delta-input) If one phase of delta-input source is grounded (B-phase for example), the ground bus in the UPS cabinet should NOT be connected to the neutral terminal of UPS output.
43 G8000 Series Installation and Operation Manual 12 UPS Specications 12.1 General Specication T erms Specication Remarks Conforming Standard UL1778-2001 UL, cUL Ambient T emperature PF = 1.0: 32 – 86 ° F (0 – 30 ° C) PF = 0.8: 86 – 104 ° F (30 – 40 ° C) Relative Humidity 30% – 90% Non-condensing Altitude < 3280 ft.
44 G8000 Series Installation and Operation Manual 12.2 Mechanical Specication (cont.) Nominal Capacity 150 kW 225 kW 300 kW Cabinet Protection Conformity IEC298 IP20* Exterior Paint Sherwin Williams, HHT2-7055, 079 Beige T exture Panel Thickness FRONT : 1/16 in.
45 G8000 Series Installation and Operation Manual 12.3 Electrical Specication Nominal Capacity 100 kW 150 kW 225 kW 300 kW AC Input Rated Capacity* 1 10 kW (120 kW) 165 kW (180 kW) 245 kW (270 kW) 320 kW (320 kW) Input V oltage 480 V ( +10% to -15% ), 3-Phase 3-Wire Input Frequency 60 Hz ±5% Input Power Factor 0.
46 G8000 Series Installation and Operation Manual 13 Operator Interface T able 13.1 shows the functions of the operating buttons on the graphic display panel. A TTENTION Press an operating button for at least 0.5 seconds to change UPS modes. Press the reset button for at least 5 seconds to reset the UPS.
47 G8000 Series Installation and Operation Manual 13.1 Key-Switch and Buttons The key-switch and operating buttons on the graphic display panel are shown in Figure 13.1. See the sections titled “Key-switch” and “Operating buttons” for each function.
48 G8000 Series Installation and Operation Manual 13.2 LCD/LED Indicators FIGURE 13.2 – GRAPHIC DISPLA Y P ANEL LCD/LED INDICA TORS 23 11 21 20 19 18 17 16 15 14 13 22 24 25 12.
49 G8000 Series Installation and Operation Manual 13.3 LCD Indicators The operator can scroll through the following LCD display screens using the scroll buttons. T ABLE 13.1 - LCD DISPLA Y SCREENS Name Description Normal Display Displays operational status, operational guidance, and measured data.
50 G8000 Series Installation and Operation Manual 13.4 Normal Display The Normal Display screen indicates the UPS operational status and provides various screens: an operation guidance screens, mode screens and measured data screens. T able 13.2 shows these screens page by page and illustrates the UPS Normal Display operational status screens.
51 G8000 Series Installation and Operation Manual T ABLE 13.2 - CONTINUED MEASUREMENT SCREENS O/P CURRENT (PEAK) Shows the peak output current peak (%) for each phase. U 50[%] V 50[%] W 50[%] Peak value of output current x 100 [%] RMS value for rated current x 1.
52 G8000 Series Installation and Operation Manual 13.5 Fault Display The Fault Display screen displays the fault records until they are reset. The W arning Display screen displays the warning records until they are reset.
53 G8000 Series Installation and Operation Manual 13.6 LCD Scroll Scroll through the LCD display screens (see Figure 13.4), in sequence, using the “SCROLL UP” and “SCROLL DOWN” buttons on the graphic display panel. • SCROLL UP - Moves back to the previous screen • SCROLL DOWN - Moves forward to the next screen T ABLE 13.
54 G8000 Series Installation and Operation Manual 14 Operating the UPS This section describes the basic procedures to operate the UPS. Figure 14.1 shows the location and functions of the operating switches to operate the UPS.
55 G8000 Series Installation and Operation Manual 14.1 Operation T ypes The operation types are summarized below . T ABLE 14.1 OPERA TION TYPES Operation Description Complete Shutdown T urn off the control power supply . Shut down the UPS completely .
56 G8000 Series Installation and Operation Manual 14.3 Startup Procedures The procedure to start the UPS is shown in Steps 1-5. STEP 1 T urn on the control power supply switch. (Figure 14.1) and ensure the operation lock is set to OPERA TION. (Figure 13.
57 G8000 Series Installation and Operation Manual Step 4-5 continues the procedure to start the UPS. STEP 4 T urn on the DC Input Breaker (72B) on the external battery cabinet. BA TTERIES LED is “ON”. STEP 5 *Press the “UPS” button for at least 0.
58 G8000 Series Installation and Operation Manual CONVERTER INVERTER UPS AC OUTPUT BA TTERIES BYP ASS INPUT DISCHARGE EQUAL CHARGE FLOA T CHARGE BYP ASS AC INPUT AC SWITCH UPS SUPPL Y AC - V o 480 v AC - Io 50% 14.
59 G8000 Series Installation and Operation Manual 14.5 Stop The procedure to stop the UPS is shown in Steps 1-3. STEP 1 T ransfer to Bypass supply as described in Switch Power Supply .
60 G8000 Series Installation and Operation Manual 14.6 Complete Shutdown The procedure to turn off the control power and shut down the UPS completely is shown in Steps 1-6. STEP 1 T ransfer to Bypass supply as described in Switch Power Supply . UPS LED is “OFF”.
61 G8000 Series Installation and Operation Manual 14.7 Changing Between Float Charge and Equalize Charge The procedure to change the recharge mode between oat charge and equalize charge is shown in Steps 1-3. See the Note below for an explanation of Float and Equalize charge modes.
62 G8000 Series Installation and Operation Manual 14.8 Changing to Float Charge from Protection Charge (If applicable) The manual procedure to change from protection charge to oat charge is shown in Step 1-3.This operation applies to batteries after they have experienced over temperature condition.
63 G8000 Series Installation and Operation Manual 14.9 Emergency Power Off (EPO) Press the EPO switch for immediate shutdown of all power through the UPS. The signal from the EPO is processed as a “hard fault” by the UPS and results in gate-blocks on the transistors and opens all the internal contactors.
64 G8000 Series Installation and Operation Manual 15.2 Faults and W arnings Data Screen This screen appears when a trip error is detected. Up to 10 screens of fault data can be displayed. Figure 15.1 and T able 15.2 show a sample screen and describe the data shown in the screen.
65 G8000 Series Installation and Operation Manual 15.3 LCD Fault & W arning Displays When a fault occurs, a screen is shown as in Figure 15.2. When a warning occurs, a screen is shown as in Figure 15.3. Select the desired fault or warning data to be displayed using the scroll buttons.
66 G8000 Series Installation and Operation Manual 15.4 Fault Messages Figure 15.4 show the locations for fault detection. T ables 15.3 through 15.7 gives details for the fault and warning messages referred to in section “Fault Data Screen.
67 G8000 Series Installation and Operation Manual T ABLE 15.5 - W ARNING - 2 (STOP AND REST ART) Item LCD Message Indication Description 27 I AC O/P UV AC output voltage is low . 30U UNIT F AUL T IGBT Stack Failure. 45 DC OV Over-voltage in DC circuit.
68 G8000 Series Installation and Operation Manual 15.5 LCD Scroll (w/ faults or warnings) This section describes how to scroll through the LCD screens when a fault has occurred (when Fault Data screens exist). Figure 15.5 shows the locations of the buttons to scroll the LCD screens.
69 G8000 Series Installation and Operation Manual 15.6 Restoring UPS Operation The procedure to restore UPS operation is shown in Steps 1-2. The example shows the UPS restored after a trip fault occurred on inverter over current with the message “INV .
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INDUSTRIAL DIVISION 13131 West Little Y our road, Houston, T exas 77041 T el (713) 466-0277 Fax (713) 466-8773 U.S. (877) 867-8773 Canada (800) 872-2192 Mexico 01/800/527-1204 www .
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