Toshiba 300 - Manuals
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Manual Toshiba 300
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G8000 Series Installation and Operation Manual UNINTERRUPTIBLE POWER SYSTEM (UPS) © Copyright 2013 Toshiba International Corporation All rights reserved. G8000 SERIES INSTALLATION and OPERATION MANUAL 480/480 V 80/100/125/150/225/300/500 kW Document: 61001-002 April 2013
G8000 Series Installation and Operation Manual The Toshiba products listed in this document are intended for usage in general electronics applications (computer, personal equipment, office equipment, measuring equipment, industrial robotics, domestic appliances, etc.). These Toshiba products are nei...
G8000 Series Installation and Operation Manual Purpose This manual provides information on how to safely install and operate your Toshiba International Corporation power electronics product. This manual includes a section of general safety instructions that describes the warning labels and symbols t...
i G8000 Series Installation and Operation Manual Table of Contents 1 Introduction ..........................................................................................................................1 2 General Safety Instructions ...................................................................
ii G8000 Series Installation and Operation Manual 11.2 150, 225, 300, and 500 kVA Buss Strip Terminals and Power Cables .......................3411.3 UPS Power Cable Conduit Landing Plates ................................................................3911.4 External Breakers .........................
iii G8000 Series Installation and Operation Manual 16 Periodic Maintenance/Parts Replacement ......................................................................77 16.1 Scheduled Maintenance ............................................................................................7716.2 Parts Re...
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 th...
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. 2.1 Symbols The symbols listed below a...
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, WARNING, CAUTION and ATTENTION are used in this manual they will include important safety information that must be carefully followed. 2.3 Qualified...
4 G8000 Series Installation and Operation Manual • Be trained in rendering first aid. For further information on workplace safety visit www.osha.gov. 2.4 Factory Authorized Personnel Factory authorized personnel have been factory trained and certified to install, service, and repair the UPS. Contact...
5 G8000 Series Installation and Operation Manual TABLE 3.2 UPS NOMINAL BATTERY VOLTAGE C apaCity n Ominal V Oltage F lOat V Oltage 80 kVA 360 Vdc 405 V 100 kVA 360 Vdc 405 V 125 kVA 360 Vdc 405 V 150 kVA 360 Vdc 405 V 225 kVA 360 Vdc 405 V 300 kVA 360 Vdc 405 V 500 kVA 480 Vdc 540 V 4 Safety Precaut...
6 G8000 Series Installation and Operation Manual 4.2 General Maintenance WARNING DO NOT remove the rear/side panels, or any sheet metla not designed to be removed. Removing rear/side panels may result in electric shock, burns, personal injuries or UPS failure. Keep the area arround the UPS clean. Us...
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. Avoid vibration or shock exceeding 0.5G. Failing to observe this precaution may cause damage to the UPS. DO NOT allow the UP...
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. Unpacking Check the un...
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 Table 5.1 - UPS Installation Environment Standards DO NOT tilt the UPS mo...
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 fire. DO NOT install the UPS where water may fall on it. Water may cause electrical shock, personal injury or UPS failure. DO NOT use ...
11 G8000 Series Installation and Operation Manual TABLE 5.1 - UPS INSTALLATION ENVIRONMENT STANDARDS Item Environment standard Installation Location Indoors Ambient Temperature Minimum operating temperature: 32 °F ( 0 ° C). Maximum operating temperature: 86 °F (30 ° C) at 1.0 PF (UPS with/without ba...
12 G8000 Series Installation and Operation Manual 7) The UPS generates and can radiate radio-frequency energy during operation. Although RFI noise filters are installed inside of the unit, there is no guarantee that the UPS will not influence some sensitive devices that are operating near by. If suc...
13 G8000 Series Installation and Operation Manual 5.1 Wiring/Connection WARNING 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. Connect ONLY one (1) ground wire to the...
14 G8000 Series Installation and Operation Manual 6 Warning Labels Below are representative warning labels and their location on the UPS. Exterior Handling labels shown in section 4.3, Transporting/Unpacking, are in the manual packet, and attached to the UPS shipping cover- ing and shipping pallet. ...
15 G8000 Series Installation and Operation Manual 6.1 Warning Label Locations FIGURE 6.2 – 80/100/125 KVA UPS WARNING LABELS DANGER Hazardous v oltages are used in t he operationof this equipment and could cause s evere personalinjury or loss of lif e.T he following prec aut ions should be observed ...
18 G8000 Series Installation and Operation Manual 7 Weight and Dimensions Table 7.1 lists the unit and shipping weights for G8000 UPS models. See Appendix B for detailed outline and dimensioins of all models. TABLE 7.1 G8000 UPS UNIT AND SHIPPING WEIGHTS Model Unit Shipping 80 kVA 1390 lb. (630 kg) ...
19 G8000 Series Installation and Operation Manual 8 Transporting 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. WARNING When transporting the UPS by crane, follow t...
20 G8000 Series Installation and Operation Manual 8.1 Transporting By Crane Cables should have sufficient 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. Refer to Chapter 7 - Weight and Dimension ...
21 G8000 Series Installation and Operation Manual 8.2 Transporting By Forklift Refer to Chapter 7 - Weight and Dimensions. Verify 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 8.6. Spaces for the ...
23 G8000 Series Installation and Operation Manual 9 Storage/Operating Environment Observe the following when storing the UPS. • Store UPS indoors. • Maximum storage time for the UPS between powered operation cycles is three years. If the UPS has been stored for a period exceeding 36 months, contact ...
24 G8000 Series Installation and Operation Manual WARNING 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. The unit must be in the bypass mode at the ti...
25 G8000 Series Installation and Operation Manual 9.2 Maintenance Precautions All internal maintenance sould be performed by factory authorized personnel. 1) Turn off, lockout, and tagout ALL power sources before connecting the power wiring to the equipment or when performing maintenance. 2) Hardwir...
26 G8000 Series Installation and Operation Manual 9.3 Disposal Please contact your local or state environmental agency for details on disposal of electrical components and packaging in your particular area. It is illegal to dump lead-acid batteries in landfills or dispose of them improperly. Please ...
27 G8000 Series Installation and Operation Manual 10 Installation WARNING Keep the SPECIFIED CLEARANCE around the UPS. Inadequate space around the UPS makes it difficult to perform maintenance/inspections, lead to insufficient ventilation, and/or will cause malfunctions. See Figure 10.1 - UPS Cleara...
28 G8000 Series Installation and Operation Manual 10.1 Unpacking Unpack the UPS indoors on a paved floor. The UPS should be as close as possible to its final storage location. Overhead traveling cranes should be used to unpack any G8000 Series UPS. If an overhead traveling crane is not available, al...
30 G8000 Series Installation and Operation Manual 11 UPS Wiring Note: Always consult your local and NEC electrical codes for wiring, cabling, and circuit protection device requirements. Figure 11.1 illustrates the external wiring of the single-input G8000 UPS. See corresponding section to each wirin...
32 G8000 Series Installation and Operation Manual 11.1 80/100/125 kVA Terminal Blocks and Power Cables Note: Always consult your site specific, local, state, and NEC electrical codes for wiring, cabling, and circuit protection device requirements. The terminal blocks for the 80/100/125 kVA UPS are s...
35 G8000 Series Installation and Operation Manual Figure 11.7 shows the terminal mounting hole arrangement for the terminal buss strips for the 500 kVA UPS units. Figure 11.8 shows the arrangement of the terminal buss strips for the 500 kVA UPS. The buss strips are located inside at the top of the u...
37 G8000 Series Installation and Operation Manual TABLE 11.4 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 150 KVA UNIT (USE 75 °C Copper Wire) Block Number Cable Size (Min-Max) Tightening Torque 2 75 °C Copper Wire 90 °C Copper Wire 1 300 kcmil – (2) #1 AWG 250 kcmil – (2) #1 AWG 540 in.-lb. (61 N...
39 G8000 Series Installation and Operation Manual 11.3 UPS Power Cable Conduit Landing Plates Cable conduit landing plates are provided at the bottom of the 80 kVA and100 kVA UPS, at the top and bottom of the 150/225 kVA UPS (Older models of the G8000 150/225 kVA UPS do not come equipped with an upp...
41 G8000 Series Installation and Operation Manual Figure 11.12 shows the four (4) cable landing plates provided at the top of the 300 kVA UPS. Seven (7) holes must be punched during installation. The dashed rectangle indicates the UPS opening behind the conduit landing plates. Figure 11.13 shows the...
42 G8000 Series Installation and Operation Manual 11.4 External Breakers The G8000 UPS units are not equipped with circuit breakers. Qualified personnel should provide the external breakers for the AC input/output, bypass input and DC input.See Figure 11.1 – External Wiring Diagram, for the circuit ...
44 G8000 Series Installation and Operation Manual 11.6 Control Wires The control wires terminal layouts at TB1 (terminal bus 1) are shown below in Table 11.8. TABLE 11.8 EXTERNAL CONNECTIONS No. I/O Signal Name Operation 1 Output Low Battery Closed at Low Battery 2 Output Backup Operation Closed dur...
46 G8000 Series Installation and Operation Manual FIGURE 11.16 - GROUNDING CONFIGURATION WITH INPUT NEUTRAL GROUNDED A 2 AWG (or 38 mm 2 ) jumper cable is provided between the neutral terminal and ground bus in the UPS cabinet. The qualified personnel should remove the jumper cable in this configura...
48 G8000 Series Installation and Operation Manual 11.7.4 Grounding Configuration (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. The jumper cable ...
49 G8000 Series Installation and Operation Manual 12 UPS Specifications 12.1 Specification Table G8000 Specifications Model Number T80S3K08 KK6XSxx T80S3K10 KK6XSxx T80S3K12 KK6XSxx T80S3K15 KK6Xxx T80S3K22 KK6XSxx T80S3K30 KK6XSxx T80S3K50 KK6XSxx Input Rated Output Capacity 80 kVA / 80 kW 100 kVA ...
50 G8000 Series Installation and Operation Manual G8000 Specifications Model Number T80S3K08 KK6XSxx T80S3K10 KK6XSxx T80S3K12 KK6XSxx T80S3K15 KK6Xxx T80S3K22 KK6XSxx T80S3K30 KK6XSxx T80S3K50 KK6XSxx Output Voltage 480Y/277V Configuration 3-Phase; 4-Wire + Gnd Voltage Regulation ±1% for 0-100%Bala...
51 G8000 Series Installation and Operation Manual G8000 Specifications Model Number T80S3K08 KK6XSxx T80S3K10 KK6XSxx T80S3K12 KK6XSxx T80S3K15 KK6Xxx T80S3K22 KK6XSxx T80S3K30 KK6XSxx T80S3K50 KK6XSxx Environ- ment (cont.) Dimension - Width 36.8 in. (935 mm) 55.1 in. (1400 mm) 76.8 in. 1951 mm) 101...
53 G8000 Series Installation and Operation Manual 13 Operator Interface Table 13.1 shows the functions of the operating buttons on the graphic display panel. 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. The UP...
54 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. FIGURE 13.1 – GRAPHIC DISPLAY PANEL KEY-SWITCH/OPE...
56 G8000 Series Installation and Operation Manual 13.3 LCD Indicators The operator can scroll through the following LCD display screens using the scroll buttons. TABLE 13.2 - LCD DISPLAY SCREENS Name Description Normal Display Displays operational status, operational guidance, and measured data. Fau...
57 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. Table 13.3 shows these screens page by page and illustrates the UP...
59 G8000 Series Installation and Operation Manual 13.5 Fault Display The Fault Display screen displays the fault records until they are reset. The Warning Display screen displays the warning records until they are reset. The fault records will remain in the memory until the reset button is pressed f...
60 G8000 Series Installation and Operation Manual 13.6 LCD Scroll Scroll through the LCD display screens (see Figure 13.5), 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 ...
61 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. FIGURE 14.1 - EPO AND CONTROL POWER SUPPLY OPERATING SWITCHES WARNING If t...
62 G8000 Series Installation and Operation Manual 14.1 Operation Types The operation types are summarized below. TABLE 14.1 OPERATION TYPES Operation Description Complete Shutdown Turn off the control power supply. Shut down the UPS completely. Float / Equalize Charge Changing the battery recharge m...
63 G8000 Series Installation and Operation Manual 14.3 Startup Procedures The procedure to start the UPS is shown in Steps 1-5. STEP 1 Turn on the control power supply switch. (Figure 14.1) and ensure the operation lock is set to OPERATION. (Figure 13.1 - 1) STEP 2 Wait for a few seconds. STEP 3 Pre...
64 G8000 Series Installation and Operation Manual Step 4-5 continues the procedure to start the UPS. STEP 4 Turn on the DC Input Breaker (72B) on the external battery cabinet.BATTERIES LED is “ON”. STEP 5 *Press the “UPS” button for at least 0.5 seconds. This completes UPS startup procedureBYPASS LE...
65 G8000 Series Installation and Operation Manual CONVERTER INVERTER UPS AC OUTPUT BATTERIES BYPASS INPUT DISCHARGE EQUAL CHARGE FLOAT CHARGE BYPASS AC INPUT AC SWITCH UPS SUPPLY AC - Vo 480 v AC - Io 50% 14.4 Switch Power Supply (UPS to Bypass) The procedure to transfer between the UPS supply and t...
66 G8000 Series Installation and Operation Manual 14.5 Stop The procedure to stop the UPS is shown in Steps 1-3. STEP 1 Transfer to Bypass supply as described in Switch Power Supply . UPS LED is “OFF”.BYPASS LED is “ON”. STEP 2 Turn off the DC Input Breaker (72B) on the external battery cabinet, and...
67 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 Transfer to Bypass supply as described in Switch Power Supply . UPS LED is “OFF”.BYPASS LED is “ON”. STEP 2 Turn off the...
68 G8000 Series Installation and Operation Manual 14.7 Changing Between Float Charge and Equalize Charge The procedure to change the recharge mode between float charge and equalize charge is shown in Steps 1-3.See the Note below for an explanation of Float and Equalize charge modes. STEP 1 Make sure...
69 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 float charge is shown in Step 1-3.This operation applies to batteries after they have experienced over temperature condition...
70 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 contac...
71 G8000 Series Installation and Operation Manual 15.2 Faults and Warnings 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 Table 15.2 show a sample screen and describe the data shown in the screen. FAULTS & WARNINGS ...
73 G8000 Series Installation and Operation Manual 15.4 Fault Messages Figure 15.4 show the locations for fault detection. Tables 15.3 through 15.7 gives details for the fault and warning messages referred to in section “Fault Data Screen.” The “item” code associated with each fault or warning messag...
75 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. See Table 15.8 fo...
76 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. OC.” STEP 1 Check the LCD screen.Also check othe...
77 G8000 Series Installation and Operation Manual 16 Periodic Maintenance/Parts Replacement The G8000 is designed to provide long-term trouble-free power conditioning and backup. Optimum performance can be best maintained by regular, periodic, preventive maintenance. 16.1 Scheduled Maintenance The G...
79 G8000 Series Installation and Operation Manual Appendix A - Installation Planning Guides TOSHIBA G8000 Series UPS Installation Planning Guide for 80kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx) Rev. 2.2 Page 1 of 3 G8000-IPG-80kVA General Mechanical Information Dimen...
80 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 80kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx) Rev. 2.2 Page 2 of 3 G8000-IPG-80kVA G8000 80kVA UPS Cabling Connection Dimensions To p Fr ont Rig ht S id e B ot t...
81 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 80kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx) Rev. 2.2 Page 3 of 3 G8000-IPG-80kVA Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/...
82 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 100kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx) Rev. 2.2 Page 1 of 3 G8000-IPG-100kVA General Mechanical Information Dimensions (W x D x H) Weight Floor Loading A...
85 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 125kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx) Rev. 0 Page 1 of 3 G8000-IPG-125kVA 0.8PF General Mechanical Information Dimensions (W x D x H) Weight Floor Load...
88 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 150kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx) Rev. 2.2 Page 1 of 3 G8000-IPG-150kVA General Mechanical Information Dimensions (W x D x H) Weight Floor Loading A...
89 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 150kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx) Rev. 2.2 Page 2 of 3 G8000-IPG-150kVA G8000 150kVA UPS Cabling Connection Dimensions To p Fr ont Rig ht S ide Top/...
91 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 225kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K22KK6XSxx) Rev. 2.3 Page 1 of 3 G8000-IPG-225kVA General Mechanical Information Dimensions (W x D x H) Weight Floor Loading A...
94 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 300kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K30KK6XSxx) Rev. 2.3 Page 1 of 3 G8000-IPG-300kVA General Mechanical Information Dimensions (W x D x H) Weight Floor Loading A...
95 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 300kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K30KK6XSxx) Rev. 2.3 Page 2 of 3 G8000-IPG-300kVA G8000 300kVA UPS Cabling Connection Dimensions To p Fr ont Rig ht S ide C ab...
97 G8000 Series Installation and Operation Manual TOSHIBA G8000 Series UPS Installation Planning Guide for 500kVA UPS Standard System: 480V Input, 480Y/277V Output (P/N T80S3K50KK6XSxx) Rev. 0.0 Page 1 of 3 G8000-IPG-500kVA General Mechanical Information Dimensions (W x D x H) Weight Floor Loading A...
101 G8000 Series Installation and Operation Manual Appendix B - Outline Drawings FIGURE B.1 - G8000 80/100/125 KV A OUTLINE DRA WING
105 G8000 Series Installation and Operation Manual Appendix C - 500kVA Input- and Output- Cabinet Joining Instructions Joining the G8000 500kVA Sections1. Remove Shipping Material (Retain Connection Kit Box and Manual).2. On a leveled floor bring the two cabinets together. Input cabinet on the left ...
106 G8000 Series Installation and Operation Manual 5. On Output cabinet: Open the door. Insert Neutral bus between the cabinets as shown in FIG. 5 & FIG. 6 and connect on corresponding output and input cabinet neutral bus using 3/8-16X1.25” bolt, flat, belleville washer and nut (supplied). Inser...
108 G8000 Series Installation and Operation Manual NEUT RAL BUS AC BU S DC BU S FIG . 6
INDUSTRIAL DIVISION 13131 West Little Your road, Houston, Texas 77041 Tel (713) 466-0277 Fax (713) 466-8773 U.S. (877) 867-8773 Canada (800) 872-2192 Mexico 01/800/527-1204 www.toshiba.com/ind Printed in the U.S.A.
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