Page 3 - InSTAllATIon and operATIon MAnUAl
G8000 Series Installation and operation Manual UnInTerrUpTIble power SySTeM (UpS) © Copyright 2008 Toshiba International Corporation All rights reserved. G8000 SERIES InSTAllATIon and operATIon MAnUAl 480/480 V 100/150/225/300 kw Document: 57056-004 May 2008
Page 4 - NOTICE; PLEASE INFORM TOSHIBA INTERNATIONAL CORPORATION OR AUTHORIZED; Toshiba sales office.; QUALIFIED PERSONNEL ONLY
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...
Page 6 - Purpose; the prior written consent of Toshiba International Corporation.; Toshiba’s Customer Support Center; Toshiba Customer Support Center; you may also contact Toshiba by writing to:; Toshiba International Corporation; Attn: UpS product Manager
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...
Page 7 - Table of Contents; Qualified Personnel
i G8000 Series Installation and operation Manual Table of Contents 1 Introduction ..........................................................................................................................1 2 General Safety Instructions ...................................................................
Page 8 - ii; Grounding Configuration; 2 UPS Specifications; General Specification
ii G8000 Series Installation and operation Manual 11.4 external breakers .......................................................................................................3611.5 Grounding wire .........................................................................................................
Page 9 - Introduction; operating, or performing maintenance on this equipment.; SAVE THESE INSTRUCTIONS
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...
Page 10 - General Safety Instructions
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...
Page 11 - Qualified Personnel shall:; DANGER
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...
Page 12 - Be trained in rendering first aid.; Factory Authorized Personnel; personnel nearest you.; Important Safety Instructions; and maintenance of the G8000 Series UpS.; output disconnection at the AC output.; The user should provide circuit breakers between the UpS AC; CAUTION
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 t...
Page 13 - Safety Precautions; or maintain public services may cause serious accidents.
5 G8000 Series Installation and operation Manual 4 Safety Precautions 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 T...
Page 14 - See Installation Manual: Chapter 8 - Transporting; General Maintenance; WARNING; removing rear/side panels may result in electric shock, burns,
6 G8000 Series Installation and operation Manual 4.3 Transporting/Unpacking WARNING 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. See ...
Page 15 - Forces due to heavy components inside may damage the UpS.; DO NOT allow the UPS to suffer shock or impact when; Tools used to remove packaging materials may cause damage to the; DO NOT push or pull on the sides of the packaging.or the; BA
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...
Page 16 - Inspection; require recharging more frequently during storage; Avoid the following storage locations:; • Inclined floor surfaces
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...
Page 17 - Install the UPS in a controlled environment.; See Table 5.1 - UPS Installation Environment Standards; DO NOT tilt the UPS more than 10° from upright position.; Keep the SPECIFIED CLEARANCE around the UPS.; Inadequate space around the UPS makes it difficult to perform; Install anchor bolts to secure the UPS to the installation floor.; or make modifications to the UPS; Installation Precautions
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...
Page 18 - DO NOT block air vents.; 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 floor wax that contains silicon in the UPS storage; Floor wax that contains silicon may cause static electricity.; by qualified personnel.; When an external maintenance bypass is installed for the UPS,; Switching to the external bypass while the unit is in UpS mode may
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 ...
Page 19 - Item; Installation Precautions
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...
Page 20 - the UpS output and the load input.; METAL CONDUIT IS NOT AN ACCEPTABLE GROUND.; ) Follow the wire size and tightening torque specifications.
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...
Page 21 - Perform wiring and connections with correct polarity.; be careful when connecting the UpS to the battery system. A wrong; Connect ONLY one (1) ground wire to the earth ground terminal.; A missing ground wire may cause an electrical shock hazard.; DO NOT damage wire insulation.; observe the above precautions when making wire connections or; ATTENTION; Follow the torque criteria for tightening screws.; Loose connections may cause fire due to heating.
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...
Page 22 - Warning Labels; covering and shipping pallet.; authorized representative.; AC VOLTAGE; W A R N I N G; GND; C A U T I O N
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 covering and shipping pallet. AT...
Page 23 - Warning Label Locations
15 G8000 Series Installation and operation Manual 6.1 Warning Label Locations 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 t oreduce t he risk of injury or death. HAZARDO...
Page 25 - Weight and Dimensions; Model
17 G8000 Series Installation and operation Manual 7 Weight and Dimensions Table 7.1 lists the unit and shipping weights for G8000 UpS models illustrated in Figures 7.1 – 7.3. TABLE 7.1 G8000 UPS UNIT AND SHIPPING WEIGHTS Model Unit Shipping 100 kVA 1740 lb. (789 kg) 1790 lb. (812 kg) 150 kVA 2467 lb...
Page 27 - Transporting; Tilting the UpS more than 10° may cause crushing, trapping or other; excessive force applied from heavy components inside may damage
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...
Page 28 - refer to Chapter 7 - weight and Dimension for UpS cabinet weight.; Transporting By Crane
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 ...
Page 29 - Transporting By Forklift; refer to Chapter 7 - weight and Dimensions.
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 ...
Page 30 - Storage/Operating Environment; Temperature fluctuations should be minimized.; Operating Precautions
22 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 your...
Page 31 - While operating in the inverter mode, placing the input breaker; must be in the bypass mode at the time that the breaker is placed in; After an Emergency Power Off (EPO), DO NOT reset the breaker; The UpS could be damaged if the unit is not fully discharged before; CHARGE LED
23 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...
Page 32 - Maintenance Precautions; the equipment or when performing maintenance.; with established safety practices.; Misuse of equipment could result in injury and equipment damage.; misuse of this equipment.
24 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...
Page 33 - DO NOT dispose of the batteries in a fire.; The batteries may explode.; DO NOT open or mutilate the batteries.; A battery can present a risk of electrical shock and high short; and packaging in your particular area.
25 G8000 Series Installation and operation Manual CAUTION DO NOT dispose of the batteries in a fire. 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...
Page 34 - 0 Installation; Inadequate space around the UPS makes it difficult to perform; The UpS may fall during an earthquake if the anchor bolts are not
26 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...
Page 35 - UPS Clearance
27 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...
Page 37 - • earth ground wire at grounding terminal.; 1 UPS Wiring
29 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 G8000 UpS. See corresponding section to each wiring term. • pow...
Page 38 - 00 kVA Terminal Blocks and Power Cables; circuit protection device requirements.; block number; Terminal Blocks and Power Cables; located inside, at the bottom of the UpS.; Use only copper wires for external cables.; AC INPUT
30 G8000 Series Installation and operation Manual 11.1 100 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 100 kVA UpS are shown in Figure...
Page 39 - located inside at the top of the unit.
31 G8000 Series Installation and operation Manual 11.2 150, 225, and 300 kVA Buss Strip Terminals and Power Cables Note: Always consult your site specific, local, state, and NEC electrical codes for wiring, cabling, and circuit protection device requirements. The 150, 225, and 300 kVA UpS units have...
Page 42 - UPS Power Cable Knockout Plates; behind the knockout plates.; FIGURE 11.5 - TERMINAL BUSSES OF THE 300kVA UPS; FIGURE 11.5 - TERMINAL BUSSES OF THE 300kVA UPS
34 G8000 Series Installation and operation Manual 11.3 UPS Power Cable Knockout Plates Cable knockout plates are provided at the bottom of the 100 kVA UpS, and 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 upper knockout plate.)...
Page 44 - External Breakers; Capacity; Grounding Wire; Be sure to ground the UPS as specified.; should be less than or equal to 10 ohms.
36 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 ...
Page 46 - Control Wires; Signal name
38 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...
Page 48 - location is illustrated below.
40 G8000 Series Installation and operation Manual 11.7 Grounding Configuration This section describes the grounding configuration to be used with various AC service entrance configurations. Inadequate grounding will cause problems at start-up. Connections for the ground line and the neutral line mus...
Page 50 - recommended at output distribution as shown in Figure 11.16.
42 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 ...
Page 51 - Terms; Mechanical Specification; nominal Capacity; kW
43 G8000 Series Installation and operation Manual 12 UPS Specifications 12.1 General Specification Terms Specification remarks Conforming Standard Ul1778-2001 Ul, cUl Ambient Temperature pF = 1.0: 32 – 86 ° F (0 – 30 ° C) pF = 0.8: 86 – 104 ° F (30 – 40 ° C) relative Humidity 30% – 90% non-condensin...
Page 53 - Electrical Specification; Nominal Capacity; DO NOT open the front cover.
45 G8000 Series Installation and operation Manual 12.3 Electrical Specification Nominal Capacity 100 kW 150 kW 225 kW 300 kW AC Input rated Capacity* 110 kw (120 kw) 165 kw (180 kw) 245 kw (270 kw) 320 kw (320 kw) Input Voltage 480 V ( +10% to -15% ), 3-phase 3-wire Input Frequency 60 Hz ±5% Input p...
Page 54 - 3 Operator Interface; the reset button for at least 5 seconds to reset the UPS.; The UpS may not respond if the button press is too short.
46 G8000 Series Installation and operation Manual 13 Operator Interface Table 13.1 shows the functions of the operating buttons on the graphic display panel. ATTENTION 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 U...
Page 55 - epo
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. FIGURE 13.1 – GRAPHIC DISPLAY PANEL KEY-SWITCH/OPE...
Page 57 - LCD Indicators
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. TABLE 13.1 - LCD DISPLAY SCREENS name Description normal Display Displays operational status, operational guidance, and measured data. Fau...
Page 58 - Normal Display; OPERATIONAL STATUS SCREENS; BYPASS; MEASUREMENT SCREENS
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. Table 13.2 shows these screens page by page and illustrates the Up...
Page 60 - Fault Display; FUSE BLOWN; displayed by pressing the up/down buttons.; UPS OVERLOAD; This screen is displayed if there are no; NO ALARM
52 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...
Page 61 - “SCroll Down” buttons on the graphic display panel.; SCROLL UP; - Moves back to the previous screen; SCROLL DOWN; - Moves forward to the next screen; Abbreveations
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 ...
Page 62 - 4 Operating the UPS; functions of the operating switches to operate the UpS.; If the UPS produces smoke or smells strange, immediately turn; This may result in UpS faults.
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. FIGURE 14.1 - EPO AND CONTROL POWER SUPPLY OPERATING SWITCHES WARNING If t...
Page 63 - Operation Types; Operation; Changing the battery recharge mode between float charge and; Perform the pre-operational check before operating the UPS.
55 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...
Page 64 - Startup Procedures; The procedure to start the UpS is shown in Steps 1-5.; SYSTEM INITIALIZE
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 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...
Page 65 - specification, this operation will be inhibited.; UPS SUPPLY
57 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...
Page 66 - NOTE; Startup Procedures - STEP 5
58 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→Bypass) The procedure to transfer between the UpS supply and the ...
Page 67 - Switch Power Supply; INVERTER LED flashes then “OFF”.
59 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...
Page 68 - Complete Shutdown; STEP 5 - This operation is different from
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 Transfer to bypass supply as described in Switch Power Supply . UpS leD is “oFF”.bypASS leD is “on”. STEP 2 Turn off the...
Page 69 - Changing Between Float Charge and Equalize Charge; a specified voltage (depending on the
61 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...
Page 70 - The battery is normally being charged at float
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 float charge is shown in Step 1-3.This operation applies to batteries after they have experienced over temperature condition...
Page 71 - 5 Troubleshooting; Types of Errors
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 contac...
Page 72 - Faults and Warnings Data Screen; UpS oVerloAD; Description
64 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 ...
Page 73 - bypASS
65 G8000 Series Installation and operation Manual 15.3 LCD Fault & Warning 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. bypASS FAUl...
Page 74 - Fault Messages; line diagram for each UpS.; Inverter
66 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...
Page 76 - scroll buttons and how they are used for screen scrolling.
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. See Table 15.8 fo...
Page 77 - Restoring UPS Operation; Contact Toshiba in the event of malfunction or fault.
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. oC.” STEP 1 Check the lCD screen.Also check othe...
Page 79 - INDUSTRIAL DIVISION
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.