Toshiba G8000 SERIES Installation And Operation Manual

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480/480 v 80/100/125/150/225/300/500 kw

Manuals Content

UNINTERRUPTIBLE POWER SYSTEM (UPS)

G8000 SERIES INSTALLATION and OPERATION MANUAL

480/480 V 80/100/125/150/225/300/500 kW

Document: 61001-002 April 2013

© Copyright 2013 Toshiba International Corporation All rights reserved.





UNINTERRUPTIBLE POWER SYSTEM (UPS)

G8000 SERIES INSTALLATION and OPERATION MANUAL 480/480 V 80/100/125/150/225/300/500 kW Document: 61001-002 April 2013

© Copyright 2013 Toshiba International Corporation All rights reserved.

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 neither intended nor warranted for usage in equipment that requires extraordinarily high quality and/or reliability; nor are they intended to be used in equipment that, if a malfunction or failure occurs, may result in loss of human life or bodily injury (collectively referred to as “Unintended Usage”). Unintended Usage includes atomic energy control instruments, airplane or spaceship instruments, transportation instruments, traffic signal instruments, combustion control instruments, life support equipment, all types of safety devices, etc. Unintended Usage of Toshiba products listed in this document shall be made at the customer’s own risk.

NOTICE PLEASE INFORM TOSHIBA INTERNATIONAL CORPORATION OR AUTHORIZED REPRESENTATIVE IN CASE OF INCONSISTENCIES, OMISSIONS, OR QUESTIONS.

The instructions contained in this manual are not intended to cover all of the details or variations in equipment, nor to provide for every possible contingency concerning installation, operation, or maintenance. Should further information be required or if problems arise which are not covered sufficiently contact your Toshiba sales office. The contents of this instruction manual shall not become a part of or modify any prior or existing agreement, commitment, or relationship. The sales contract contains the entire obligation of Toshiba International Corporation’s UPS Division. The warranty contained in the contract between the parties is the sole warranty of Toshiba International Corporation’s UPS Division and any statements contained herein DO NOT create new warranties or modify the existing warranty. Any electrical or mechanical modifications to this equipment without prior written consent of Toshiba International Corporation will void all warranties and may void the UL/CUL listing. Unauthorized modifications can also result in personal injury, death, or destruction of the equipment.

QUALIFIED PERSONNEL ONLY Qualified Personnel is one that has the skills and knowledge relating to the construction, installation, operation, and maintenance of the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of NFPA 70E for additional safety requirements).

G8000 Series Installation and Operation Manual



UNINTERRUPTIBLE POWER SYSTEM (UPS) Please complete the following information and retain for your records. Unless otherwise specified, the warranty period for the UPS or UPS part is 12 months from the shipment date (see Toshiba International Corporation bill of lading). Unless otherwise specified, the warranty period for a UPS battery is 36 months from the shipment date (see Toshiba International Corporation Bill of Lading for shipping date).

JOB NUMBER MODEL NUMBER SERIAL NUMBER APPLICATION SHIPMENT DATE INSTALLATION DATE INSPECTED BY

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 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 customary equivalent. Toshiba International Corporation reserves the right, without prior notice, to update information, make product changes, or discontinue any product or service identified in this publication. Toshiba is a registered trademark of the Toshiba Corporation. All other product or trade references appearing in this manual are registered trademarks of their respective owners. Toshiba International Corporation shall not be liable for direct, indirect, special, or consequential damages resulting from the use of the information contained within 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 2013 Toshiba International Corporation All rights reserved. Printed in the U.S.A.

Toshiba’s Customer Support Center Contact the Toshiba Customer Support Center for assistance with application information or for any problems that you may experience with your Uninterruptible Power System (UPS). Toshiba Customer Support Center 8 a.m. to 5 p.m. (CST) - Monday through Friday USA Toll Free (877) 867-8773 Tel (713) 466-0277 Fax (713) 896-5212 You may also contact Toshiba by writing to: Toshiba International Corporation 13131 West Little York Road Houston, Texas 77041-9990 Attn: UPS Product Manager For further information on Toshiba’s products and services, please visit our website at: www.toshiba.com/ind

G8000 Series Installation and Operation Manual



Table of Contents 1

Introduction...........................................................................................................................1

2

General Safety Instructions.................................................................................................2 2.1

Symbols........................................................................................................................2

2.2

Signal Words.................................................................................................................3

2.3

Qualified Personnel.......................................................................................................3

2.4

Factory Authorized Personnel.......................................................................................4

3

Important Safety Instructions..............................................................................................4

4

Safety Precautions...............................................................................................................5

5

4.1

Disclaimer.....................................................................................................................5

4.2

General Maintenance....................................................................................................6

4.3

Transporting/Unpacking................................................................................................6

4.4

Inspection/Storage........................................................................................................8

Installation Precautions.......................................................................................................9 5.1

6

Wiring/Connection.........................................................................................................13

Warning Labels.....................................................................................................................14 6.1

Warning Label Locations...............................................................................................15

7

Weight and Dimensions ......................................................................................................18

8

Transporting..........................................................................................................................19

9

10

11

8.1

Transporting By Crane..................................................................................................20

8.2

Transporting By Forklift.................................................................................................21

Storage/Operating Environment.........................................................................................23 9.1

Operating Precautions..................................................................................................23

9.2

Maintenance Precautions.............................................................................................25

9.3

Disposal........................................................................................................................26

Installation..........................................................................................................................27 10.1

Unpacking...................................................................................................................28

10.2

UPS Clearance...........................................................................................................28

10.3

Anchor Bolts................................................................................................................29

UPS Wiring..........................................................................................................................30 11.1 80/100/125 kVA Terminal Blocks and Power Cables....................................................32

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12

13

14

15

11.2

150, 225, 300, and 500 kVA Buss Strip Terminals and Power Cables........................34

11.3

UPS Power Cable Conduit Landing Plates.................................................................39

11.4

External Breakers........................................................................................................42

11.5

Grounding Wire...........................................................................................................42

11.6

Control Wires..............................................................................................................44

11.7

Grounding Configuration.............................................................................................45

UPS Specifications.............................................................................................................49 12.1

Specification Table......................................................................................................49

12.2

Typical Efficiency vs. Load..........................................................................................52

Operator Interface..............................................................................................................53 13.1

Key-Switch and Buttons..............................................................................................54

13.2

LCD/LED Indicators....................................................................................................55

13.3

LCD Indicators............................................................................................................56

13.4

Normal Display............................................................................................................57

13.5

Fault Display...............................................................................................................59

13.6

LCD Scroll...................................................................................................................60

Operating the UPS..............................................................................................................61 14.1

Operation Types..........................................................................................................62

14.2

Pre-operational Check................................................................................................62

14.3

Startup Procedures.....................................................................................................63

14.4

Switch Power Supply (UPS to Bypass).......................................................................65

14.5

Stop.............................................................................................................................66

14.6

Complete Shutdown....................................................................................................67

14.7

Changing Between Float Charge and Equalize Charge.............................................68

14.8

Changing to Float Charge from Protection Charge (If applicable)..............................69

14.9

Emergency Power Off (EPO)......................................................................................70

Troubleshooting.................................................................................................................70 15.1

Types of Errors............................................................................................................70

15.2

Faults and Warnings Data Screen..............................................................................71

15.3

LCD Fault & Warning Displays....................................................................................72

15.4

Fault Messages...........................................................................................................73

15.5

LCD Scroll (w/ faults or warnings)...............................................................................75

15.6

Restoring UPS Operation...........................................................................................76

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G8000 Series Installation and Operation Manual

16

Periodic Maintenance/Parts Replacement.......................................................................77 16.1

Scheduled Maintenance.............................................................................................77

16.2

Parts Replacement.....................................................................................................77

Appendix A - Installation Planning Guides..............................................................................79 80kVA IPG..............................................................................................................................79 100kVA IPG............................................................................................................................82 125kVA IPG............................................................................................................................85 150kVA IPG............................................................................................................................88 225kVA IPG............................................................................................................................91 300kVA IPG............................................................................................................................94 500kVA IPG............................................................................................................................97 Appendix B - Outline Drawings.................................................................................................101 Appendix C - 500kVA Input- and Output- Cabinet Joining Instructions................................105

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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. Read the manual completely before installing, operating, or performing maintenance on this equipment. Qualified personnel should read this manual carefully before transporting, installing and wiring the UPS. In addition have a thorough understanding of the information provided in the chapters titled: • General Safety Instructions • Important Safety Instructions • Safety Precautions • Installation Precautions Please read the G8000 Series Operation Manual for important instructions on operating the UPS. 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 customary equivalent. Keep the Installation Manual and the Operation Manual near the UPS for necessary reference.

SAVE THESE INSTRUCTIONS

G8000 Series Installation and Operation Manual



1

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 are used throughout this manual. When symbols are used in this manual they will include important safety information that must be carefully followed.

Safety Alert Symbol indicates that a potential personal injury hazard exists.

Prohibited Symbol indicates DO NOT take action.

Mandatory Symbol indicates that the following instruction is required.

Ground Symbol indicates the location of the equipment grounding conductor.

Electrical - Voltage & Shock Hazard Symbol indicates parts inside may cause electric shock.

Explosion Hazard Symbol indicates parts may explode.

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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

DANGER

The word DANGER in capital letters preceded by the safety alert symbol indicates that an imminently hazardous situation exists, and if not avoided will result in loss of life or serious injury to personnel.

WARNING

The word WARNING in capital letters preceded by the safety alert symbol indicates that a potentially hazardous situation exists, and if not avoided may result in loss of life or serious injury to personnel.

CAUTION

The word CAUTION in capital letters preceded by the safety alert symbol indicates that a potentially hazardous situation exists, and if not avoided may result in minor or moderate injury.

NOTICE

The word NOTICE in capital letters without the safety alert symbol indicates a potentially hazardous situation exists, and if not avoided may result in equipment and property damage.

Qualified Personnel

Installation, operation, and maintenance shall be performed by Qualified Personnel Only. A Qualified Person is one that has the skills and knowledge relating to the construction, installation, operation, and maintenance of the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of NFPA 70E for additional safety requirements). Qualified Personnel shall:

• Have read the entire operation manual. • Be familiar with the construction and function of the UPS, the equipment being driven, and the hazards involved.

• Be trained and authorized to safely energize, de-energize, ground, lockout/tagout circuits and equipment, and clear faults in accordance with established safety practices.

• Be trained in the proper care and use of protective equipment such as safety shoes, rubber gloves, hard hats, safety glasses, face shields, flash clothing, etc., in accordance with established safety practices.

G8000 Series Installation and Operation Manual



3

• 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 the Toshiba Customer Support Center for assistance in locating the factory authorized personnel nearest you.

3

Important Safety Instructions

The following contains important instructions that should be followed during the installation, operation, and maintenance of the G8000 Series UPS. Please refer to the battery manufacturer’s instructions for details on operating, maintaining and/or replacing the batteries for each system. Keep unauthorized personnel from batteries. Only a certified service representative with battery experience should perform service on batteries.

CAUTION Misuse of this equipment could result in personal injury and/or equipment damage. In no event will Toshiba Corporation be responsible or liable for either indirect or consequential damage or injury that may come from the use of this equipment. The UPS system input and output is NOT equipped with an over-current protection device, or an output disconnection at the AC output. The user should provide circuit breakers between the UPS AC input (or Bypass input) and the power sources and between the UPS output and the critical load input. The minimum device ratings are listed in Table 3.1. TABLE 3.1 UPS MINIMUM DEVICE RATINGS

Capacity

Rated Output

Input Breaker Rating

Output Breaker Rating

80 kVA

480 V/277 V

480 V – 150 A

480 V – 125 A

100 kVA

480 V/277 V

480 V – 200 A

480 V – 150 A

125 kVA

480 V/277 V

480 V – 200 A

480 V – 200 A

150 kVA

480 V/277 V

480 V – 300 A

480 V – 250 A

225 kVA

480 V/277 V

480 V – 400 A

480 V – 350 A

300 kVA

480 V/277 V

480 V – 600 A

480 V – 500 A

500 kVA

480 V/277 V

480 V – 800 A

480 V – 800 A

80/100/150/225/300 kVA Temperature restrictions: The maximum operating ambient temperature is 86 °F (30 °C) at 1.0 PF, and 104 °F (40 °C) at 0.8 PF. If the UPS is exposed to the same ambient temperature as the battery system, the maximum operating ambient temperature is 86 °F (30 °C) at 1.0 PF, 90 °F (32 °C) at 0.8 PF. Table 3.2 lists the nominal battery voltage.

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G8000 Series Installation and Operation Manual

TABLE 3.2 UPS NOMINAL BATTERY VOLTAGE

4

Capacity

Nominal Voltage

Float Voltage

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

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 Toshiba products are neither intended nor warranted for use in equipment that, if a malfunction or failure occurs, may result in loss of human life or bodily injury (collectively referred to as “Unintended Usage”). Unintended Usage includes atomic energy control instruments, airplane or spaceship instruments, transportation instruments, traffic signal instruments, combustion control instruments, medical operating room or life support equipment, all types of safety devices, etc. Unintended Usage of Toshiba products listed in this document shall be made at the customer’s own risk. The application of the UPS without special consideration for equipment that supports human safety and/or maintain public services may cause serious accidents.

4.1

Disclaimer

IN NO EVENT WILL TOSHIBA CORPORATION BE RESPONSIBLE OR LIABLE FOR EITHER INDIRECT OR CONSEQUENTIAL DAMAGE OR INJURY THAT MAY COME FROM THE MISUSE OF THIS EQUIPMENT. ANY MODIFICATIONS WITHOUT AUTHORIZATION BY TOSHIBA COULD RESULT IN PERSONAL INJURIES, DEATH OR DESTRUCTION OF THE UPS. TOSHIBA RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION OR DESIGN. TOSHIBA DOES NOT ASSUME ANY LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR UPS DESCRIBED HEREIN; NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR THE RIGHTS OF OTHERS.

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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. Use a vacuum cleaner to clean the UPS.

Only factory authorized personnel sould perform internal general maintenance on the UPS. Contact the authorized Toshiba Customer Support Center or an authorized Toshiba representative for informaton on proper disposal of UPS components. It is illegal to dispose of certain components without conforming to environmental regulations for indusrial/commercial waste.

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 Installation Manual: Chapter 8 - Transporting DO NOT tilt the UPS more than 10° from upright position. Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries.

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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 UPS to suffer shock or impact when unpacking. Tools used to remove packaging materials may cause damage to the UPS. DO NOT push or pull on the sides of the packaging.or the UPS to move it. Always use a crane, forklift, or pallet jack for transporting and positioning the UPS. Pushing/pulling on the sides of the unit to move it may result in damage to the UPS. See Figure 4.1 Exterior Handling label.

Do not push or pull from sides

BACK SIDE

Fig. 4.1 Exterior Handling label

BY CRANE: - Cables should have sufficient rating and equal length. - Keep UPS leveled when lifting/lowering and avoid impacts.

Do not push or pull from sides

BY FORKLIFT: - Verify forklift maximum load capacity. - Ensure that the forks are long enough to support the UPS and are inserted properly. - Do not swing or tilt the UPS when lifting and/or transporting. See manual for complete details.

FORKS (4 Ft. Minimum length) WARNING: Risk of tipping. For safe handling, lift UPS from back and sides only (as shown above)

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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 unit for loose, broken, bent or otherwise damaged parts. If damage has occurred during shipping, keep all original crating and packing materials for return to the shipping agent. NOTE: The factory warranty does not apply to damage incurred during shipping! Ensure that the rated capacity and the model number specified on the nameplate conform to the order specifications. Storage During periods of non-use, the following guidelines are recommended for storage. Storage Preparation 1) Power up the UPS and allow it to operate with no load for 24 hours to fully charge the batteries. 2) Stop the unit. 3) Place the Main Circuit Breaker switch in the “OFF” position. Storage Conditions • For best results, store the UPS in the original shipping container and place on a wood or metal pallet • Storage temperature range: -4 to 104 °F (-20 to 40 °C) • The optimum storage temperature is 70 °F (21 °C). A higher ambient temperature will require recharging more frequently during storage Avoid the following storage locations: • Locations that are subject to extreme temperature changes or high humidity • Locations that are subject to high levels of dust or metal particles • Locations that are subject to excessive vibration • Inclined floor surfaces

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G8000 Series Installation and Operation Manual

5

Installation Precautions

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 more than 10° from upright position. Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries and cause physical damage to internal components.

WARNING Keep the SPECIFIED CLEARANCE around the UPS. Inadequate space around the UPS makes it difficult to perform maintenance/inspections, will lead to insufficient ventilation, and/or cause malfunctions.

Install anchor bolts to secure the UPS to the installation floor. The UPS may fall during an earthquake if the anchor bolts are not installed and secured. Only factory authorized personnel should relocate, modify, or replace parts in the UPS after initial installation. Electrical shock, injury or UPS failure may occur if non-authorized technicians attempt to modify or relocate the UPS. Please contact Toshiba Customer Support Center if you plan to move or make modifications to the UPS

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9

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 floor wax that contains silicon in the UPS storage area and/or nearby rooms. Floor wax that contains silicon may cause static electricity.

WARNING The UPS should be installed per local and/or national electric codes by qualified personnel. Faults or improper operation may occur if the UPS is not installed properly. When an external maintenance bypass is installed for the UPS, before switching to external bypass, ensure that the UPS unit is switched to AC Bypass mode and the UPS control panel display verifies the unit is Bypass mode. Switching to the external bypass while the unit is in UPS mode may damage the UPS.

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G8000 Series Installation and Operation Manual

TABLE 5.1 - UPS INSTALLATION ENVIRONMENT STANDARDS

Item

Environment standard

Installation Location Indoors Minimum operating temperature: 32 °F (0 °C). Maximum operating temperature: 86 °F (30 °C) at 1.0 PF (UPS with/without battery system). Ambient Temperature

Maximum operating temperature: 90 °F (32 °C) at 0.8 PF (UPS with battery system). Maximum operating temperature: 104 °F (40 °C) at 0.8 PF (UPS only). Average 24-hour operating temperature: 86 °F (30 °C) at 1.0 PF and 41 – 95 °F (5 – 35 °C) at 0.8 PF.

Relative Humidity

The relative humidity must be between 30 and 90% noncondensing due to temperature changes.

Altitude

These specifications are for altitudes up to 3240 ft. (1000 m) above sea level. Consult with the factory to determine the derating factor for installations above 3240 ft. (1000 m). Installation environment must not have vibration frequencies 10 Hz – 20 Hz.

Vibration and Mechanical Shock

The acceleration due to vibrations less than 10 Hz must not exceed 0.5 G. The acceleration due to vibrations 20 Hz – 50 Hz must not exceed 0.5 G. The total amplitude due to vibrations 50 Hz – 100 Hz must not exceed 0.1 mm.

Dust

Dust must not exceed normal atmospheric levels and must not include conductive particles, silicone or oils. No flammable and/or explosive gas.

Flammable Gas

Hydrogen sulfide (H2S)

Less than or equal to 0.0001 PPM

Sulfurous acid gas (SO2)

Less than or equal to 0.05 PPM

Chlorine gas (Cl2)

Less than or equal to 0.002 PPM

Ammonia gas (NH3)

Less than or equal to 0.1 PPM

Nitrous acid gas (NO2)

Less than or equal to 0.02 PPM

Nitrous oxides (NOx)

Less than or equal to 0.02 PPM

Ozone (O3)

Less than or equal to 0.002 PPM

Hydrochloric acid mist (HCl)

Less than or equal to 0.1 mg/m3

Installation Precautions 1) Install the unit in a stable, level and upright position that is free of excessive vibration. 2) Install the unit where the ambient temperature is within the specified range. 3) DO NOT install the UPS in areas that are subject to high humidity. 4) DO NOT install the UPS in areas that allow exposure to direct sunlight. 5) DO NOT install the UPS in areas that allow exposure to high levels of airborne dust, metal particles, or flammable gases. 6) DO NOT install the UPS in areas near sources of electrical noise. Ensuring a proper earth ground will reduce the effects of electrical noise and will reduce the potential for electrical shock. G8000 Series Installation and Operation Manual



11

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 such interference is experienced, the UPS should be installed further away from the affected equipment and/or powered from a different source than that of the installed equipment. 8) The user should provide over-current protection for hardwired UPS systems between the UPS output and the load input. 9) After ensuring that all power sources are turned “OFF” and isolated in accordance with established lockout/tagout procedures, connect the power source wiring of the correct voltage to the input terminals of the UPS. NOTE: Ensure the input phasing is connected in clockwise rotation (CW). UPS internal circuitry is designed to disable further UPS operation if the input phasing is installed in counter-clockwise rotation (CCW). 10) Connect the output terminals of the UPS to the load (refer to NEC Article 300 - Wiring Methods and Article 310 - Conductors For General Wiring). Size the branch circuit conductors in accordance with NEC Table 310.16 as published 9/2007.

WARNING METAL CONDUIT IS NOT AN ACCEPTABLE GROUND.

Conductor Routing and Grounding 1) Use separate metal conduits for routing the input power, output power, and control circuits. 2) Follow the wire size and tightening torque specifications. 3) Always ground the unit to reduce the potential for electrical shock and to help reduce electrical noise. 4) A separate ground cable should be run inside the conduit with the input power, output power, and control circuits.

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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 earth ground terminal. A missing ground wire may cause an electrical shock hazard. Connecting to more than one ground may cause a ground loop. See Chapter 8 - UPS Wiring DO NOT force, bend, or pull wires. DO NOT damage wire insulation. DO NOT place heavy objects on top of UPS. Observe the above precautions when making wire connections or handling the wires. Failing to observe these precautions may damage the insulation of the wires or may cause a fire or an electric shock hazard.

NOTICE Follow the torque criteria for tightening screws. Loose connections may cause fire due to heating. See Chapter 11 - UPS Wiring

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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.

NOTICE Make sure all the warning labels are installed in the appropriate locations. If a label is missing or illegible, contact Toshiba Customer Support Center or an authorized representative.

(A) 48082

(B) 40308 DANGER

DANGER

HAZARDOUS VOLTAGES

AC VOLTAGE This UPS receives power from more than one source. Disconnect all AC sources before performing any service or testing inside this unit 48082

100, 150, 225 KVA (C) 56875 56875 FOR FOR80, 100, 150, 225KVA

Hazardous voltages are used in the operation of this equipment and could cause severe personal injury or loss of life. The following precautions should be observed to reduce the risk of injury or death. Only qualified technicians familiar with this equipment and the information supplied with it should be permitted to install and operate this equipment. Installation of electrical equipment must be done in accordance with National Electrical Code and any other state or local codes. Proper grounding and conductor sizing must be installed for safe operation. During operation, keep all covers in place and cabinet doors shut. When performing visual inspections and maintenance, if possible, be sure the UPS is turned off and the incoming AC feed is turned off and locked out. The UPS and Battery Cabinet will have hazardous voltages present even after the AC feed is turned off.

1

2

3

4

5

6

7

8

9

10

11

12

13

If it is necessary to make measurements with the power on, do not touch any electrical connection points. Remove all jewelry from wrists and fingers. Make sure test equipment is in good, safe operating condition.

U

V

W

U

V

W

N

U

V

W

N

-

+

While servicing, stand on some type of insulation, and be sure not to be grounded.

USE COPPER CONDUCTORS ONLY! REFER TO INSTRUCTION MANUAL FOR WIRE SIZE AND TIGHTENING TORQUE

480 V

480 V

480V

400 V

A C INPUT

BYPA SS INPUT

AC OUTPUT

BATTERY

Follow the safety instructions given in the equipment manual carefully and observe all danger, warning and caution notices. 40308

(D) 40830

(C) 58708 FOR 300KVA USE COPPER CONDUCTORS ONLY ! REFER TO INSTRUCTION MANUAL FOR WIRE SIZE AND TIGHTENING TORQUE 1

58708

U

2

3

4

V

W

-

5

6

7

+

U

V

8

9

10

W

N

U

11

12

V

W

480 V

400 V

480 V

480 V

A C INPUT

BATTERY

BYPASS INPUT

AC OUTPUT

WA R N I N G CRITICAL FUSE SIZING Incorrect fuse replacement size may result in fire or inadequate equipment protection. Replace only with same type and rating of fuse.

PN 40830

(E) 39561 14 DANGER RISK OF ELECTRIC SHOCK Capacitors stay c harged after power has been s hut off. Accidental contact with liv e parts can



G8000 Series Installation Operation Manual (F) 58705 SERIAL LABEL (G)and57055 UNINTERRUPTIBLE POWER SUPPLY

GND

(D) 40830

(C) 58708 FOR 300KVA USE COPPER CONDUCTORS ONLY ! REFER TO INSTRUCTION MANUAL FOR WIRE SIZE AND TIGHTENING TORQUE 1

58708

U

2

3

4

V

W

-

5

6

7

+

U

V

8

9

10

W

N

U

11

12

V

W

480 V

400 V

480 V

480 V

A C INPUT

BATTERY

BYPASS INPUT

AC OUTPUT

WA R N I N G CRITICAL FUSE SIZING Incorrect fuse replacement size may result in fire or inadequate equipment protection. Replace only with same type and rating of fuse.

PN 40830

(E) 39561

(F) 58705 SERIAL LABEL

(G) 57055

UNINTERRUPTIBLE POWER SUPPLY

DANGER

GND

RISK OF ELECTRIC SHOCK Capacitors stay c harged after power has been s hut off. Accidental contact with liv e parts can cause personal injury and death. Turn off and lock out all power sources. Wait at least five (5) minutes for power to dissipate then check voltage before servicing. 39561 58705 MFD. IN U.S .A. FR OM FOREIGN AND DOMES TIC C OMP ON ENTS HOUS TON , TE XAS

(I) 40831

LISTED 27E5

®

(J) 57053 CAUTION

CAUTION

8A

Heat sink not grounded.

(control power source switch)

Risk of electrical shock. Disconnect UPS and electrically test heat sink before touching.

6.1

®

Do not turn off while operating. PN 40831

Warning Label Locations

FIGURE 6.2 – 80/100/125 KVA UPS WARNING LABELS

G8000 Series Installation and Operation Manual



15

FIGURE 6.3 – 150/225 KVA UPS WARNING LABELS

FIGURE 6.4 - 300 KVA UPS WARNING LABELS

16

G8000 Series Installation and Operation Manual

FINAL LAYOUT NOT AVAILABLE AT THIS TIME: CONTACT THE FACTORY FOR ADDITIONAL INFORMATION

FIGURE 6.3 – 500 KVA UPS WARNING LABELS

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17

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)

1440 lb. (652 kg)

100 kVA

1740 lb. (789 kg)

1790 lb. (812 kg)

125 kVA

1740 lb. (789 kg)

1790 lb. (812 kg)

150 kVA

2467 lb. (1119 kg)

2556 lb. (1159 kg)

225 kVA

2980 lb. (1352 kg)

3069 lb. (1392 kg)

300 kVA

4575 lb. (2075 kg)

4725 lb. (2143 kg)

500 kVA (Input Cabinet)

1570 lb. (712 kg)

~1620 lb. (735 kg)1

500 kVA (Output Cabinet)

4950 lb. (2245 kg)1

1 - Weights are approximate.

18

1

~5100 lb. (2313 kg)1

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8

Transporting

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. DO NOT tilt the UPS more than 10° from upright position. Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries.

CAUTION DO NOT transport, move, store, or place the UPS on its side. Excessive force applied from 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 UPS to suffer shock or impact when unpacking. Tools used to remove packaging materials may cause damage to the UPS. DO NOT install the UPS where water may fall on it. Water may cause electrical shock, personal injury or UPS failure. DO NOT push or pull on the sides of the packaging.or the UPS to move it. Always use a crane, forklift, or pallet jack for transporting and positioning the UPS. Pushing/pulling on the sides of the unit to move it may result in damage to the UPS. (See Figure 4.1 Exterior Handling label.) 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. G8000 Series Installation and Operation Manual



19

8.1 8.1Transporting ByBy Crane Transporting Crane Cables should have sufficient ratings and be of the same length. Make sure the suspension cables are

Cables should have sufficient ratings andthe beangle of the same length. Make sure the suspension cables are hooked at eyebolts. See Figure 8.1. Keep less than 60° between cables. hooked at eyebolts. See Figure 8.1. Keep the angle less than 60° between cables. Refer to Chapter 7 - Weight and Dimension for UPS cabinet weight.

Refer to Chapter 7 - Weight and Dimension for UPS cabinet weight. leveled when lifting. DO NOT swing or tilt the UPS. Minimize the impact when lowering the KeepKeep UPSUPS leveled when lifting. DO NOT swing or tilt the UPS. Minimize the impact when lowering the UPS UPS to the floor. Figure 8.2 and 8.3 indicate unacceptable lifting. to the floor. Figure 8.2 and 8.3 indicate unacceptable lifting. Figure 8.4 and 8.5 show examples of acceptable and unacceptable operations. Figure 8.4 and 8.5 show examples of acceptable and unacceptable operations. Less than 60°

FIGURE 8.1 - CABLES AND EYEBOLTS TO LIFT THE UPS FIGURE 8.1 - CABLES AND EYEBOLTS TO LIFT THE UPS

More than 60°

FIGURE 8.2 - ANGLE MORE THAN 60°

FIGURE 8.2 - ANGLE MORE THAN 60°

FIGURE 8.4 - ACCEPTABLE OPERATION FIGURE 8.4 - ACCEPTABLE OPERATION G8000 Series Installation Manual

20

Uneven Cables

FIGURE 8.3 - UNEVEN CABLES

FIGURE 8.3 - UNEVEN CABLES

FIGURE 8.5 - UNACCEPTABLE OPERATION FIGURE 8.5 - UNACCEPTABLE OPERATION

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 forks are provided underneath the UPS. DO NOT swing or tilt UPS when lifting and/or transporting. Minimize the impact when lowering the UPS to the floor.

80 - 225 kVA

Base

Insert the forks here

Secure the forks against the base then lift

300 kVA

Base

Insert the forks here

Secure the forks against the base then lift

FIGURE 8.6 -TRANSPORTING 80-300 KVA UPS BY FORKLIFT

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21

500 kVA (Ships in two parts, Input and Output Cabinets) Input Cabinet

Output Cabinet

Insert the forks here.

Insert the forks here.

Secure forks against the base and then lift.

Secure forks against the base and then lift.

FIGURE 8.7 -TRANSPORTING 500 KVA UPS BY FORKLIFT (See Appendix C for cabinet mating insturctions)

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 factory authorized represnetative of guidance in starting the unit. Temperature fluctuations should be minimized. The optimal storage temperature range is 68 – 77 °F (20 – 25° C). A maximum temperature range of 32 – 104 °F (0 – 40 °C) should be observed. The optimal relative humidity at the storage location should be between 50 – 60%. Humidity must not exceed 90%. Avoid locations where UPS may be exposed to corrosive gas. Avoid locations with dirt and/or dust.

• • • • • • •

TABLE 9.1 - UPS STORAGE/OPERATING ENVIRONMENT STANDARDS

Item

Environment standard

Storage Location

Indoors

Ambient Temperature

Minimum storage temperature: 32 °F (0 °C) Maximum storage temperature: 104 °F (40 °C)

Relative Humidity

The relative humidity must be between 30 and 90% and without condensation due to temperature changes.

Altitude

This equipment is rated for installations up to 3240 ft. (1000m) above sea level. Consult with the factory to determine the derating factor for installations above 3240 ft. (1000m).

Dust

Dust must not exceed normal atmospheric levels and must not include conductive particles, silicone or oils. No flammable and/or explosive gas.

Flammable Gas

9.1

Hydrogen sulfide (H2S)

Less than or equal to 0.0001 PPM

Sulfurous acid gas (SO2)

Less than or equal to 0.05 PPM

Chlorine gas (Cl2)

Less than or equal to 0.002 PPM

Ammonia gas (NH3)

Less than or equal to 0.1 PPM

Nitrous acid gas (NO2)

Less than or equal to 0.02 PPM

Nitrous oxides (NOx)

Less than or equal to 0.02 PPM

Ozone (O3)

Less than or equal to 0.002 PPM

Hydrochloric acid mist (HCl)

Less than or equal to 0.1 mg/m3

Operating Precautions

Initial startup/comisioning of the UPS should be performed by factory authorized personnel. 1) The UPS should not be powered up until the entire operation manual has been read. 2) The voltage of the input power source must be within the rated input voltage range. The

G8000 Series Installation and Operation Manual



23

input frequency range must be within the rated input frequency range. 3) The UPS should not be used with a load that has a rated input that is greater than the rated output of the UPS. 4) If using the UPS to provide power to motors that require high starting current or with motors that require a long starting time, call Toshiba support for guidance in over sizing the UPS for lock rotor current. 5) DO NOT insert metal objects or combustible materials in the ventilation slots of the UPS. 6) DO NOT place, hang, or paste any objects on the exterior surfaces of the UPS. 7) The capacitors in the UPS maintain a residual charge for a while after turning the UPS off. The required discharge time for each UPS typeform is provided via a cabinet label and a CHARGE LED. Wait for at least the minimum time indicated on the label and ensure that the CHARGE LED has gone out before opening the door of the UPS once the UPS power has been turned off. 8) DO NOT attempt to disassemble, modify, or repair the UPS. Call your Toshiba sales representative for repair information. 9) Turn the power on only after installing ALL of the covers. 10) DO NOT remove any covers of the UPS when power is on. 11) If the UPS should emit smoke or an unusual odor or sound, turn the power off immediately. 12) Warning signs should be placed on or near the load as a notification that the load is being powered by the UPS. 13) Additional warnings and notifications shall be posted at the equipment installation location as deemed required by Qualified Personnel.

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 time that the breaker is placed in the “OFF” position for the UPS to shutdown power to the load.

CAUTION After an Emergency Power Off (EPO), DO NOT reset the breaker until the UPS internal circuits have been fully discharged. The UPS could be damaged if the unit is not fully discharged before the breaker is reset.

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) Hardwire type UPS units are not equipped with an over-current protection device, nor do they have an output disconnect for the AC output. A user-installed circuit breaker should be provided between the UPS output and the load input. 3) The maximum ambient operating temperature is 86 °F (30 °C) at 1.0 PF, and 104 °F (40 °C) at 0.8 PF. 4) Only factory authorized personnel should service the UPS. Contact Toshiba for the the nearest authorized service center. 5) Battery servicing should be performed by factory authorized personnel only. Contact your nearest factory authorized service center for battery replacement. Qualified Personnel ONLY! Qualified Personnel have the skills and knowledge relating to the construction, installation, operation, and maintenance of the electrical equipment and has received safety training on the hazards involved (Refer to the latest edition of NFPA 70E for additional safety requirements). Qualified Personnel shall: 1) Have read the entire operation manual. 2) Be trained and authorized to safely energize, de-energize, ground, lockout and tag circuits and equipment, and clear faults in accordance with established safety practices. 3) Be trained in the proper use and care of protective equipment such as safety shoes, rubber gloves, hard hats, safety glasses, face shields, flash clothing, etc., in accordance with established safety practices. 4) Be trained in rendering first aid. 5) Be knowledgeable of batteries and the required handling and maintenance precautions.

For further information on workplace safety visit www.osha.gov.

WARNING Misuse of equipment could result in injury and equipment damage. In no event will Toshiba Corporation be responsible or liable for either indirect or consequential damage or injury that may result from the misuse of this equipment.

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25

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 and high short circuit current.

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 help protect the Earth by contacting the environmental protection agencies in your area, the battery manufacturer, or call Toshiba toll-free at (877) 867-8773 for more information about recycling batteries.

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 Clearance DO NOT tilt the UPS more than 10° from upright position. Tilting the UPS more than 10° may cause crushing, trapping or other personal injuries. Install anchor bolts to secure the UPS to the installation floor. The UPS may fall during an earthquake if the anchor bolts are not installed and secured. DO NOT transport, move, store, or place the UPS on its side. Forces due to heavy components inside may damage the UPS. DO NOT allow the UPS to suffer shock or impact when unpacking. Tools used to remove packaging materials may cause damage to the UPS. DO NOT push or pull on the sides of the packaging.or the UPS to move it. Always use a crane, forklift, or pallet jack for transporting and positioning the UPS. Pushing/pulling on the sides of the unit to move it may result in damage to the UPS. See Figure 4.1 Exterior Handling label.

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27

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, allow enough space for forklift operations to unpack the UPS crate. Then remove the crate. Points to observe

• • • • •

Retain all small articles during unpacking and installation. Make sure that exterior paint is not scratched and that the UPS cabinet is not damaged. DO NOT damage the UPS when using tools to remove packaging materials. If provided, DO NOT remove the plastic sheet cover, until installation. Do not remove the fan covers until UPS start up. The fan covers should be removed by factory authorized personnel. Packing materials should be disposed by the appropriate means.

• Immediately report any abnormalities to Toshiba Customer Support Center or an authorized representative.

10.2

UPS Clearance

Maintain the indicated clearance during installation. See Figure 10.1. Ensure that the front and top air vents are NOT blocked.

Top 16 in. (400 mm)

Front 44 in. (1100 mm)

Back 0 in. (0 mm)

Side 0 in. (0 mm)

FIGURE 10.1 - UPS CLEARANCE

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G8000 Series Installation and Operation Manual

10.3

Anchor Bolts

Install the anchor bolts to secure the UPS on the floor. See Figure 10.2 for anchor bolt installation detail. Use 12mm (1/2”) diameter anchor bolts. There are 16mm (5/8”) diameter holes provided in the UPS base. See Figure 10.3 for the hole locations and dimensions for the specified UPS models. 150/225 kVA

(See Appendix B) Back 4 x 0.5 in. - Dia. (12 mm) 4 x 5/16 in. (16 mm) diameter screw holes

21.7 in. (551 mm)

Front 4 screw holes (Side View)

46.1 in. (1171 mm)

300 kVA

(See Appendix B) Anchor Bolt

Back 8 x 0.5 in. - Dia. (12 mm)

FIGURE 10.2 ANCHOR BOLT INSTALLATION DETAIL

25.6 in. (650 mm)

Front 22.5 in. (571 mm)

80/100/125 kVA

22.5 in. (571 mm)

22.5 in. (571 mm)

500 kVA

(See Appendix B)

(See Appendix B) 3.0 in. (76 mm) Back 4 x 0.5 in. - Dia. (12 mm)

Back 21.7 in. (551 mm)

Input Section

Front

30.0 in. (762 mm)

Output Section Front

29.7 in. (755 mm)

33.9 in. (862 mm)

20.0 in. (508 mm)

22.4 in. (568 mm)

20.0 in. (508 mm)

12 x 0.5 in. - Dia. (12 mm) FIGURE 10.3 HOLE LOCATIONS/DIMENSIONS ON BOTTOM OF UPS

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29

11 UPS Wiring

11 Figure UPS Wiring 11.1 illustrates the external wiring of the G8000 UPS. See corresponding section to each wiring

term. Note: Always consult your local and NEC electrical codes for wiring, cabling, and circuit protection device requirements.

Power cable connection at terminal blocks/buses and external breaker provision for the AC input/output, Bypass Input and DC input. Figure 11.1 illustrates the external wiring of the single-input G8000 UPS. See corresponding section to each • Earth ground wire at grounding terminal. wiring term. • Control wire terminal TB1 (battery cabinet and bypass breaker). •

• Power cable connection at terminal blocks/buses and external breaker provision for the AC input/output, Bypass Input and DC input. • Earth ground wire at grounding terminal. • Control wire terminal TB1 (battery cabinet and bypass breaker)

< UPS > Bypass 3φ4W

Contactor + Thyristor Bypass Breaker

Bypass Contactor

Input Contactor

AC Input 3φ3W Input Breaker

Output 3φ4W Rectifier

Inverter

Inverter Contactor

Output Breaker

Chopper Charger TB1 DC input Battery Breaker

Ground Wire

< Battery Cabinet >

FIGURE 11.1 - SINGLE INPUT EXTERNAL WIRING DIAGRAM

FIGURE 11.1 - EXTERNAL WIRING DIAGRAM

An external maintenance bypass may be installed in parallel with the UPS to allow servicing of the G8000 while maintaining power to the UPS load. Contact the Toshiba Customer Service for further information.

G8000 Series Installation Manual

30

27 G8000 Series Installation and Operation Manual

11 UPS Wiring Figure 11.1 illustrates the external wiring of the G8000 UPS. See corresponding section to each wiring term. • Power cablethe connection terminal blocks/buses external breaker provision for thesection AC Figure 11.2 illustrates external at wiring of the dual-inputand G8000 UPS. See corresponding to each wiring term.input/output, Bypass Input and DC input. •• Power Earth cable groundconnection wire at grounding terminal. at terminal blocks/buses and external breaker provision for the AC • input/output, Control wire terminal TB1 (battery cabinet Bypass Input and DC input.and bypass breaker). • Earth ground wire at grounding terminal. • Control wire terminal TB1 (battery cabinet and bypass breaker)

< UPS > Bypass 3φ4W

Contactor + Thyristor Bypass Breaker

Bypass Contactor

Input Contactor

AC Input 3φ3W Input Breaker

Output 3φ4W Rectifier

Inverter

Inverter Contactor

Output Breaker

Chopper Charger TB1 DC input Battery Breaker

Ground Wire

< Battery Cabinet >

FIGURE 11.2 - DUAL INPUT EXTERNAL WIRING DIAGRAM

FIGURE 11.1 - EXTERNAL WIRING An external maintenance bypass may be installed in parallel with DIAGRAM the UPS to allow servicing of the G8000 while maintaining power to the UPS load. Contact the Toshiba Customer Service for further information.

G8000 Series Installation Manual

G8000 Series Installation and Operation Manual



27

31

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 shown in Figure 11.3. Recommended external cable sizes for both 75 °C and 90 °C copper wire for a single battery string are listed in Table 11.1–11.2. For two or more battery strings consult with Toshiba Technical Support. Ensure that your installation adheres to local and NEC electrical codes. Use only copper wires for external cables.

1

2

3

4

5

6

7

8

9

10

11

12 13

+ U

V

W

AC INPUT

U

V

W

N

BYPASS INPUT

U

V

W

N

Note: Contact the factory if using more than one battery string.



BATTERY

AC OUTPUT

Cable Capacity of Terminal Blocks 1-11: 2 x #6 AWG to 2/0 Cable Capacity of Terminal Blocks 12-13: 2 x #6 AWG to 350 kcmil

FIGURE 11.3 - TERMINAL BLOCKS FOR 80/100/125 KVA UPS TABLE 11.1 RECOMMENDED CABLE SIZE & TIGHTENING TORQUE FOR 80 KVA UPS

Block Number

Cable Size (Min-Max)2 75 °C Copper Wire 90 °C Copper Wire

Tightening Torque

1

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

2

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

3

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

4

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

5

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

6

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

7

(2) 1/0 – (2 ) 2/0 AWG

(2) #1 – (2 ) 2/0 AWG

50 in.-lb. (5.6 N•m)

8

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

9

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

10

1/0 – (2) 2/0 AWG

#1 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

11

3

(2) 1/0 – (2 )2/0 AWG

(2) #1 – (2 ) 2/0 AWG

50 in.-lb. (5.6 N•m)

121,2

(2) 1/0 - (2) 3/0 AWG

(2) 2/0 - (2) 3/0 AWG

325 in.-lb. (36.7 N•m)

131,2

(2) 1/0 - (2) 3/0 AWG

(2) 2/0 - (2) 3/0 AWG

325 in.-lb. (36.7 N•m)

3

One battery string. (Consult factory if using more than one battery string.) Maximum cable size for terminal lugs 1-11: (2) x #6 to #2 AWG; Battery Terminals 12-13: (2) x#6 AWG to 350 kcmil. 3 Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear. 1 2

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G8000 Series Installation and Operation Manual

TABLE 11.2 RECOMMENDED CABLE SIZE & TIGHTENING TORQUE FOR 100 KVA UPS

Block Number

Cable Size (Min-Max) 2 75 °C Copper Wire 90 °C Copper Wire

Tightening Torque

1

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

2

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

3

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

4

(2) #1 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

5

(2) #1 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

6

(2) #1 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

(2) 2/0 AWG

(2) 2/0 AWG

50 in.-lb. (5.6 N•m)

8

(2) #1 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

9

(2) #1 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

7

3

10

(2) #1 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

3

(2) 2/0 AWG

(2) 2/0 AWG

50 in.-lb. (5.6 N•m)

12

1,2

(2) 3/0 - (2) 4/0 AWG

(2) 2/0 - (2) 3/0 AWG

325 in.-lb. (36.7 N•m)

13

1,2

(2) 3/0 - (2) 4/0 AWG

(2) 2/0 - (2) 3/0 AWG

325 in.-lb. (36.7 N•m)

11

One battery string. (Consult factory if using more than one battery string.) 2 Maximum cable size for terminal lugs 1-11: 2 x 6 to 2/0 AWG; Battery Terminals 12-13: 2 x 6 AWG to 350 kcmil. 3 Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear. 1

TABLE 11.2 RECOMMENDED CABLE SIZE & TIGHTENING TORQUE FOR 125 KVA UPS

Block Number

Cable Size (Min-Max) 2 75 °C Copper Wire 90 °C Copper Wire

Tightening Torque

1

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

2

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

3

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

4

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

5

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

6

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

(2) 2/0 AWG

(2) 2/0 AWG

50 in.-lb. (5.6 N•m)

8

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

9

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

10

(2) #3 – (2) 2/0 AWG

2/0 – (2) 2/0 AWG

50 in.-lb. (5.6 N•m)

11 3

(2) 2/0 AWG

(2) 2/0 AWG

50 in.-lb. (5.6 N•m)

12

1,2

(2) 3/0 - (2) 4/0 AWG

(2) 2/0 - (2) 3/0 AWG

325 in.-lb. (36.7 N•m)

13

1,2

(2) 3/0 - (2) 4/0 AWG

(2) 2/0 - (2) 3/0 AWG

325 in.-lb. (36.7 N•m)

7

3

One battery string. (Consult factory if using more than one battery string.) Maximum cable size for terminal lugs 1-11: 2 x 6 to 2/0 AWG; Battery Terminals 12-13: 2 x 6 AWG to 350 kcmil. 3 Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear. 1 2

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33

11.2

150, 225, 300, and 500 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, 300 and 500 kVA UPS units have buss strip power terminals. 1.75 in. (45 mm)

Figure 11.4 is a typical buss strip for a 150/225 kVA UPS. Figure 11.5 shows the arrangement of the terminal buss strips for the 150 and 225 kVA UPS units. The terminal buss strips are located inside, at the bottom of the UPS. The dashed line on terminals 1–13 indicates the side view of the bolt holes. Use 1/2 inch bolts to attach the lugs.

3 in. (77 mm) 0.5 in. Dia. (1.27 mm) 1.97 in. (50 mm)

Figure 11.6 shows the arrangement of the terminal buss strips for the 300 kVA UPS. The buss strips are located inside at the top of the unit.

1.77 in. (45 mm)

5.3 in. (135 mm) FIGURE 11.4 - TERMINAL BUS DETAIL

1

U

2

4

3

V

5

U

W

6

V

AC INPUT

W

7

8

N

U

9

V

10

W

11

12



N

AC OUTPUT

BYPASS INPUT

13

Flywheel Input (+)

(Optional Flywheel Input fuse. Flywheel (-) connects to Battery (-))

+

BATTERY

Note: Contact the factory if using more than one battery string, flywheel, or combination battery and flywheel.

FIGURE 11.5 - TERMINAL BUSS ARRANGEMENT FOR 150 AND 225 KVA UPS (Optional Flywheel Input fuse. Flywheel (-) connects to Battery (-))

Flywheel Input (+)

Note: Contact the factory if using more than one battery string, flywheel, or combination battery and flywheel.

1

2

3

U

V

W

AC INPUT 3-phase 3-wire

4

5



+

BATTERY

6

7

8

U

V

W

BYPASS INPUT 3-phase 4-wire

9

N

10

11

12

U

V

W

AC OUTPUT 3-phase 4-wire

FIGURE 11.6 - TERMINAL BUSS ARRANGEMENT FOR 300 KVA UPS

34

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 unit. The dashed line on terminals 1–13 indicates the side view of the bolt holes. Use 1/2 inch bolts to attach the lugs.

3-Phase AC Power Lugs

3-Phase Neutral and Battery (DC) Power Lugs

6 x 0.5625 in. Dia. (14.3 mm)

6 x 0.5625 in. Dia. (14.3 mm)

0.875 in. (22 mm)

0.875 in. (22 mm)

1.75 in. (44.5 mm)

1.75 in. (44.5 mm)

0.875 in. (22 mm)

0.875 in. (22 mm)

0.75 in. (19 mm)

0.75 in. (19 mm)

1.75 in. (44.5 mm)

1.75 in. (44.5 mm)

1.75 in. (44.5 mm)

5.5 in. (140 mm)

4 in. (102 mm) FIGURE 11.7 - TERMINAL BUSS DETAILS FOR 500KVA UPS

G8000 500KVA - INPUT SECTION

1

2

3

4

G8000 500KVA - OUTPUT SECTION

5

8

6

9

10

11

7 U

V

W

U

V

GND

W

U

V

12

13

14

N



+

W

AC INPUT N BYPASS INPUT

AC OUTPUT

BATTERY

FIGURE 11.8 - TERMINAL BUSS ARRANGEMENT FOR 500 KVA UPS

For UPS’ equipped with buss strip terminals for the A/C INPUT, BYPASS INPUT, A/C OUTPUT and BATTERY connections, Toshiba recommends using the compression lugs listed in Table 11.3, or their equivalent, for cable terminations to be mounted on the bus strips. G8000 Series Installation and Operation Manual



35

See Table 11.5 – Table 11.6 for recommended cable sizes for the 150, 225, 300 and 500 kVA UPS. TABLE 11.3 RECOMMENDED CRIMP TYPE COMPRESSION LUGS FOR BUS STRIP TERMINALS

Wire Size

Wire Strand Class

Recommendation

Crimp tool Required Burndy type Y35 or Y46

Vendor

Cat. No.

Color Key

Die Index

1/0

B I B

Burndy Ilsco Burndy

YA25 CRA-1/OL YA25-LB

Pink Pink Black

12 / 348 12 / 348 13

2/0

B I B

Burndy Ilsco Burndy

YA26 CRA-2/OL YA27-LB

Black Black Orange

13 13 14 / 101

3/0

B I B

Burndy Ilsco Burndy

YA-27 CRB-3/OL YA28-LB

Orange Orange Purple

14 / 101 14 / 101 15

4/0

B I B

Burndy Ilsco Burndy

YA28 CRB-4/OL YA29-LB

Purple Purple Yellow

15 15 16

300 MCM

B I B

Burndy Ilsco Burndy

YA30 CRA-30OL YA32-LB

White White Red

17 / 298 17 / 298 18 / 324

350 MCM

B I

Burndy Ilsco

YA31L CRA-350

Red Red

18 18

600 MCM

B I

Burndy Ilsco

YA36L CRA-600

Green Green

22 22

TABLE 11.4 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 150 KVA UNIT (USE 75 °C Copper Wire)

Recommended external cable sizes for both 75 °C and 90 °C copper wire for minimum battery configurations are listed in Table 11.4–11.7. For extended runtime battery strings configurations consult with Toshiba Technical Support. Ensure that your installation adheres to local and NEC electrical codes.

36

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) 75 °C Copper Wire 90 °C Copper Wire

Tightening Torque2

1

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

2

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

3

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

4

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

5

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

6

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

7

(2) 300 kcmil – (6) #1 AWG

(2) 250 kcmil – (6) #1 AWG

540 in.-lb. (61 N•m)

8

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

9

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

4

10

300 kcmil – (2) #1 AWG

250 kcmil – (2) #1 AWG

540 in.-lb. (61 N•m)

114

(2) 300 kcmil – (6) #1 AWG

(2) 250 kcmil – (6) #1 AWG

540 in.-lb. (61 N•m)

12

1

(2) 300 kcmil– (2) 350 kcmil

(2) 250 kcmil – (2) 350 kcmil

540 in.-lb. (61 N•m)

13

1

(2) 300 kcmil– (2) 350 kcmil

(2) 250 kcmil – (2) 350 kcmil

540 in.-lb. (61 N•m)

(2) AWG 2/0

(2) AWG 2/0

300 in.-lb. (33.9 N•m)

Flywheel Input (+)3

One battery string. (Consult factory if using more than one battery string.) Fastener torque specified for: 1/2 in. diameter grade 5 steel bolt. 3 Per flywheel unit 4 Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear. 1 2

TABLE 11.5 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 225 KVA UNIT (USE 75 °C Copper Wire)

Block Number

Cable Size (Min-Max) 75 °C Copper Wire 90 °C Copper Wire

Tightening Torque2

1

(2) 3/0– (2) 4/0 AWG

(2) 2/0– (2) 3/0 AWG

540 in.-lb. (61 N•m)

2

(2) 3/0– (2) 4/0 AWG

(2) 2/0– (2) 3/0 AWG

540 in.-lb. (61 N•m)

3

(2) 3/0– (2) 4/0 AWG

(2) 2/0– (2) 3/0 AWG

540 in.-lb. (61 N•m)

4

(2) 4/0– (2) 250 kcmil

(2) 3/0– (2) 4/0 AWG

540 in.-lb. (61 N•m)

5

(2) 4/0– (2) 250 kcmil

(2) 3/0– (2) 4/0 AWG

540 in.-lb. (61 N•m)

6

(2) 4/0– (2) 250 kcmil

(2) 3/0– (2) 4/0 AWG

540 in.-lb. (61 N•m)

7

4

(4) 4/0– (4) 250 kcmil

(4) 3/0 – (4) 4/0 AWG

540 in.-lb. (61 N•m)

8

(2) 4/0– (2) 250 kcmil

(2) 3/0– (2) 4/0 AWG

540 in.-lb. (61 N•m)

9

(2) 4/0– (2) 250 kcmil

(2) 3/0– (2) 4/0 AWG

540 in.-lb. (61 N•m)

10

(2) 4/0– (2) 250 kcmil

(2) 3/0– (2) 4/0 AWG

540 in.-lb. (61 N•m)

114

(4) 4/0– (4) 250 kcmil

(4) 3/0 – (4) 4/0 AWG

540 in.-lb. (61 N•m)

12

1

(4) 4/0 – (4) 250 kcmil

(3) 250 kcmil – (4) 3/0

540 in.-lb. (61 N•m)

13

1

(4) 4/0 – (4) 250 kcmil

(3) 250 kcmil – (4) 3/0

540 in.-lb. (61 N•m)

(2) AWG 2/0

(2) AWG 2/0

300 in.-lb. (33.9 N•m)

Flywheel Input (+)

3

One battery string. (Consult factory if using more than one battery string.) 2 Fastener torque specified for: 1/2 in. diameter grade 5 steel bolt. 3 Per flywheel unit 1

G8000 Series Installation and Operation Manual



37

4

Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear. TABLE 11.6 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 300 KVA UPS

Bus Number

Cable Size (Min-Max) 75 °C Copper Wire 90 °C Copper Wire

Tightening Torque2

1

(2) 250 kcmil – (3) 2/0

(2) 4/0 – (3) 1/0

540 in.-lb. (61 N•m)

2

(2) 250 kcmil – (3) 2/0

(2) 4/0 – (3) 1/0

540 in.-lb. (61 N•m)

3

(2) 250 kcmil – (3) 2/0

(2) 4/0 – (3) 1/0

540 in.-lb. (61 N•m)

4

1

(4) 300 kcmil – (4) 350 kcmil

(4) 300 kcmil – (4) 350 kcmil

540 in.-lb. (61 N•m)

51

(4) 300 kcmil – (4) 350 kcmil

(4) 300 kcmil – (4) 350 kcmil

540 in.-lb. (61 N•m)

6

(2) 300 kcmil – (3) 2/0

(2) 250 kcmil – (3) 1/0

540 in.-lb. (61 N•m)

7

(2) 300 kcmil – (3) 2/0

(2) 250 kcmil – (3) 1/0

540 in.-lb. (61 N•m)

8

(2) 300 kcmil – (3) 2/0

(2) 250 kcmil – (3) 1/0

540 in.-lb. (61 N•m)

9

4

(2) 300 kcmil – (3) 2/0

(2) 250 kcmil – (3) 1/0

540 in.-lb. (61 N•m)

10

(2) 300 kcmil – (3) 2/0

(2) 250 kcmil – (3) 1/0

540 in.-lb. (61 N•m)

11

(4) 300 kcmil – (4) 350 kcmil

(4) 250 kcmil – (4) 300 kcmil

540 in.-lb. (61 N•m)

(4) 300 kcmil – (4) 350 kcmil

(4) 250 kcmil – (4) 300 kcmil

540 in.-lb. (61 N•m)

(2) AWG 2/0

(2) AWG 2/0

300 in.-lb. (33.9 N•m)

12 Flywheel Input (+)

3

One battery string. (Consult factory if using more than one battery string.) Fastener torque specified for: 1/2 in. diameter grade 5 steel bolt. 3 Per flywheel unit 4 Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear. 1 2

TABLE 11.7 RECOMMENDED CABLE SIZE AND FASTENER TORQUE FOR 500 KVA UPS

Bus Number

Cable Size (Min-Max) 75 °C Copper Wire 90 °C Copper Wire

Tightening Torque1

1

(3) 250 kcmil – (3) 400 kcmil

(3) 4/0 kcmil – (3) 250 kcmil

540 in.-lb. (61 N•m)

2

(3) 250 kcmil – (3) 400 kcmil

(3) 4/0 kcmil – (3) 250 kcmil

540 in.-lb. (61 N•m)

3

(3) 250 kcmil – (3) 400 kcmil

(3) 4/0 kcmil – (3) 250 kcmil

540 in.-lb. (61 N•m)

4

(3) 400 kcmil – (3) 500 kcmil

(4) 400 kcmil – (4) 500 kcmil

540 in.-lb. (61 N•m)

5

(3) 400 kcmil – (3) 500 kcmil

(4) 400 kcmil – (4) 500 kcmil

540 in.-lb. (61 N•m)

6

(3) 400 kcmil – (3) 500 kcmil

(3) 400 kcmil – (3) 500 kcmil

540 in.-lb. (61 N•m)

7

2

(6) 400 kcmil – (6) 500 kcmil

(3) 400 kcmil – (3) 500 kcmil

540 in.-lb. (61 N•m)

8

3

1/0

1/0

540 in.-lb. (61 N•m)

9

(3) 400 kcmil – (3) 500 kcmil

(3) 400 kcmil – (3) 500 kcmil

540 in.-lb. (61 N•m)

10

(3) 400 kcmil – (3) 500 kcmil

(3) 400 kcmil – (3) 500 kcmil

540 in.-lb. (61 N•m)

11

(3) 400 kcmil – (3) 500 kcmil

(3) 400 kcmil – (3) 500 kcmil

540 in.-lb. (61 N•m)

12

2

(6) 400 kcmil – (6) 500 kcmil

(3) 400 kcmil – (3) 500 kcmil

540 in.-lb. (61 N•m)

13

(3) 400 kcmil – (3) 500 kcmil

(3) 400 kcmil – (3) 500 kcmil

540 in.-lb. (61 N•m)

14

(3) 400 kcmil – (3) 500 kcmil

(3) 400 kcmil – (3) 500 kcmil

540 in.-lb. (61 N•m)

Fastener torque specified for: 1/2 in. diameter grade 5 steel bolt. 2 Cable sized for neutral current=1.7Xphase current. Size cable appropriate to actual load type: balanced, unbalanced, non-linear. 3 Ground cables 1

38

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 upper conduit landing plate.), and at the top only of the 300/500kVA. The recommended conduit landing arrangements are illustrated in Figure 11.9 thru 11.13. The five (5) holes must be punched during installation. The dashed rectangle indicates the UPS opening behind the conduit landing plates.

0.78 in.

7.48 in. Recommended Conduit Placement Order in Top Conduit Landing Plate

AC INPUT

AC OUTPUT

BYPASS

BATTERY

0.78 in.

4.74 in.

3.37 in.

21.85 in.

CONTROL WIRES

23.74 in. BASE PLATES - DIMENSIONS

23.11 in.

UPS BASE

BOTTOM ENTRY DIMENSIONS

5.9 in. FRONT OF UPS

5.9 in.

23.73 in.

FIGURE 11.9 - BOTTOM CONDUIT LANDING PLATES FOR 80/100/125 KVA

G8000 Series Installation and Operation Manual



39

3.35 in.

17.72 in.

AC OUTPUT

BYPASS

Recommended Conduit Placement Order in Top Conduit Landing Plate

BATTERY

4.74 in.

AC INPUT

0.7 in.

0.7 in.

7.48 in.

21.85 in.

CONTROL WIRES

42.126 in. BASE PLATES - DIMENSIONS

23.11 in.

UPS BASE

BOTTOM ENTRY DIMENSIONS

5.9 in. FRONT OF UPS 21.5 in.

4.36 in.

FIGURE 11.10 - BOTTOM CONDUIT LANDING PLATES 100 KVA (T80S3K10KK6XSNH); 150/225 KVA 4.74 in. CONTROL WIRES

Recommended Conduit Placement Order in Top Conduit Landing Plate 4.27 in.

TOP ENTRY DIMENSIONS

21.5 in.

31.5 in.

AC OUTPUT

21.5 in.

FRONT OF UPS

BATTERY

BYPASS

0.7 in. 4.36 in. AC INPUT

FRONT OF UPS

0.7 in.

FIGURE 11.11 - TOP ACCESS CONDUIT LANDING PLATE (150 AND 225 KVA ONLY)

40

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.

AC INPUT

37.4 in.

BATTERY

BATTERY

AC OUTPUT

BYPASS

7.09 in.

0.76 in.

GROUND WIRE

8.66 in.

21.26 in.

7.09 in.

8.66 in.

3.15 in.

7.09 in.

8.66 in.

3.93 in.

CONTROL WIRES

0.76 in.

Recommended Conduit Placement Order in Top Conduit Landing Plates

56.70 in. CONDUIT LANDING PLATES - DIMENSIONS FIGURE 11.12 - TOP ACCESS CONDUIT LANDING PLATES (300 KVA)

Figure 11.13 shows the three (3) conduit landing plates provided at the top of the 500 kVA UPS. The dashed rectangle indicates the UPS opening behind the conduit landing plates. Ensure that your installation adheres to local and NEC electrical codes.

CABLE ENTRY PLATE (AC INPUT, BYPASS INPUT) 28.0” X 6.3” (711 MM X 161 MM)

CABLE ENTRY PLATE AC OUTPUT, DC INPUT 28.0” X 6.3” (711 MM X 161 MM)

CABLE ENTRY PLATE (CONTROL) 28.0” X 6.3” (711 MM X 161 MM)

FIGURE 11.13 - TOP CONDUIT LANDING PLATES FOR THE 500 KVA UPS

G8000 Series Installation and Operation Manual



41

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 position of the breakers. Table 11.7 shows the G8000 UPS minimum external breaker rating for each capacity. The Bypass, AC Input, and AC Output require 3-pole breakers. TABLE 11.7 UPS MINIMUM DEVICE RATINGS

Capacity

11.5

Rated Output

Input Breaker Rating

Output Breaker Rating

DC Input Breaker Rating

80 kVA

480 V/277 V

480 V – 150 A

480 V – 125 A

500 VDC – 300A

100 kVA

480 V/277 V

480 V – 200 A

480 V – 150 A

500 VDC – 350A

125 kVA

480 V/277 V

480 V – 200 A

480 V – 200 A

500 VDC – 400A

150 kVA

480 V/277 V

480 V – 300 A

480 V – 250 A

500 VDC – 600A

225 kVA

480 V/277 V

480 V – 400 A

480 V – 350 A

500 VDC – 900A

300 kVA

480 V/277 V

480 V – 600 A

480 V – 500 A

500 VDC – 1200A

500 kVA

480 V/277 V

480 V – 800 A

480 V – 800 A

600 VDC – 1200A

Grounding Wire

WARNING Be sure to ground the UPS as specified. Using the UPS without a proper ground will deteriorate the insulation, cause leakage of currents and electric shock.The resistance to ground should be less than or equal to 10 ohms.

The 80/100/150/225kVA earth grounding bus’ are located inside, at the bottom-front of the unit. The 300 kVA earth grounding bus is located inside, at the top-left of the unit. The 500 kVA earth grounding bus is located inside, at the bottom front of the units. Use a AWG 2 (or 38 mm2) or larger cable for the grounding wire. Run the grounding wire through the opening at the bottom, or through a hole in the top conduit landing plate (if available). See Figure 11.12. Connect either the top or bottom earth ground bus, but not both, to the grounding wire. The ground wire must have a crimp terminal with a 1/2 in. (12 mm) diameter bolt hole. The ground bus has 33/64 in. (13 mm) bolt hole. The connect the crimp terminal and ground bus together using a 7/16 in. (10 mm) diameter bolt.

42

G8000 Series Installation and Operation Manual

G8000 - 80/100 kVA

G8000 - 300 kVA Facility earth ground. Ground wire routing through top conduit landing plate.

Ground bus

10 mm or 7/16 in. Bolt

10 mm or 7/16 in. Bolt 12 mm or 1/2 in. Terminal

AWG 2 (38 mm2) ground wire

Through conduit landing plate on top (recommended)

Note: Use either the top or the bottom grounding point, but not both. Doing so may degrade the performance of the unit.

Feed-through opening

Ground bus

To facility earth ground Alternate ground wire location

G8000 - 150/225 kVA Facility earth ground. Alternate ground wire routing through top conduit landing plate.

Note: Use either the top or the bottom access for the ground wire to connect to the ground buss, but use only one ground wire.

Ground bus

10 mm or 7/16 in. Bolt 12 mm or 1/2 in. Terminal

AWG 2 (38 mm2) ground wire

Feed-through opening To facility earth ground

G8000 - 500 kVA

Ground bus

10 mm or 7/16 in. Bolt 12 mm or 1/2 in. Terminal

AWG 1/0 (50 mm2) ground wire

FIGURE 11.14 - EARTH GROUND WIRE CONNECTIONS

G8000 Series Installation and Operation Manual



43

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 during Backup Operation

3

Output

Fault

Closed if Faults present

4

Output

Inverter Supply

Closed during Normal Operation

5

Output

Warning

Closed if Warnings present

6

Input

7

Input

8

Input

} }

P24 Remote Run

Close to run UPS

P24

9

Input

Remote Stop

Close to stop UPS

10

Output

Bypass Supply

Close during Bypass Operation

11

Output

Output Signal Ground

(Ground for pin #1 – 5 & #10)

12

Input

P24

Battery’s

13

Input

Battery Overheat

Overheat B-contact

14

Output

15

Output

16

Output

17

Output

18

Output

19

Output

20 21

Output

22

Output

} } } } }

52C Trip Signal 72B Trip Signal

Bypass Breaker Shunt Trip Signal by EPO Battery Breaker shunt trip by EPO or Battery shutdown Battery breaker’s

72B Aux. Contact

Auxiliary A-contact

External EPO

Ext EPO (Customer) N.O. Contacts

External EPO

Ext EPO (Customer) N.O. Contacts

Note: All control wiring should be #18 AWG (0.823 mm2) or larger.

44

G8000 Series Installation and Operation Manual

The UPS battery cabinet and bypass breaker should be wired as shown below in Figure 11.15. Power Source

Jumper wire if battery OH is not applied

TC

To Bypass Input

Bypass Breaker

10 11 12 13

Power Source for trip coil

14 15 16 17

Overheat B-Contact

18 19

To DC Input

20 21 22

Auxillary Acontact

TB1 UPS Cabinet

Ext. EPO (Customer) N.O. Contacts

Battery Cabinet

FIGURE 11.15 - CONNECTION BETWEEN UPS, BATTERY CABINET & BYPASS BREAKER

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 must be made appropriately according to the system configuration.

11.7.1 Recommended configuration (for 4 wire input with Input Neutral grounded) Figure 11.16 shows recommended grounding configuration when the input neutral is grounded. The neutral line at the input source is usually grounded. The neutral terminal in the UPS cabinet should be disconnected from the ground bus. The neutral connection for the UPS bypass input should be grounded.

G8000 Series Installation and Operation Manual



45

Input Source

< UPS Cabinet >



3φ N

N



3φ G





G

N

N

G

G

To the Load

Remove Jumper Cable

FIGURE 11.16 - GROUNDING CONFIGURATION WITH INPUT NEUTRAL GROUNDED Input Source

< UPS Cabinet >

φ A 2 AWG (or 38 mm ) jumper3cable is provided between the neutral terminal and ground bus in the UPS cabinet. The qualified personnel should remove the jumper cable in this configuration. The jumper cable N location is illustrated below. N 2 3φ









80-225

G

To the Load

N

N

kVAG

500 kVA

G

G

Jumper Cable Remains in Place

Input Source

Ground Bus

Neutral Terminals

Ground Bus

Neutral Terminal 3φ

Ground Bus

< UPS Cabinet >

3φ Remove JumperN Cable





G

G





300 kVA

N

N G

G

Remove Jumper Cable Jumper Remains in Place Cable

To the Load

Neutral Terminal Ground

Input Source Bus



< UPS Cabinet >

3φ N

Bφ 3φ



Output Distribution

Remove Jumper Cable





N

3φ N

FIGURE CABLE BETWEEN THE NEUTRAL G 11.17 - JUMPER G G TERMINAL & GROUND BUS G

46

G8000 Series Remove Installation and Operation Manual Jumper Cable

To the Load

Input Source

11.7.2

Cabinet > Grounding< UPS Configuration (without input neutral)





When the input source is wye-connected, the neutral line out to the bypass input should be left open. The N N UPS is grounded by connecting the neutral terminal to the ground bus with the internal jumper cable. See 3φ 3φ φ 3φ Figure311.18. To the Load

N The jumper cable should stay in place. See Figure N11.17 for the jumper cable location. G

G

G

G

If a ground fault interrupter is installed, the UPS is likely to trip the interrupter during transferring to/from the bypass circuit. It is recommended that the ground faultRemove interrupter be set to a minimum delay of 0.5 Input Source Jumper Cable seconds. < UPS Cabinet > 3φ



N Input Source

3φ 3φ G N

N < UPS Cabinet >



N

G





G

G

N

N

G

G

To the Load





Remove N Jumper Cable

To the Load

N

G

Input Source









G Jumper Cable Remains in Place

< UPS Cabinet >

3φ FIGURE 11.18 - GROUNDING CONFIGURATION WITHOUT INPUT NEUTRAL N

N Input Source

11.7.3





3Recommended φ 3φ G

G





< UPS Cabinet >

N

N Configuration (for delta-input) G

G

N

To the Load

Jumper Cable If the input source is a delta-connection (3-phase 3-wire) withoutRemains ground, the neutral terminal in the UPS in Place 3φ 3φ φ 3 3 φ cabinet must be connected to the ground bus with the internal jumper cable as shown in Figure 11.19. To the Load

N The jumper cable should stay in place. See Figure 11.17 for the jumper cable location.N G

G

G

Input Source

G

Jumper Cable Remains in Place

< UPS Cabinet >



3φ N



Input Source G 3φ

3φ < UPS Cabinet > G3φ

N G

N

Bφ 3φ





Output Distribution N



G 3φ

Jumper Cable Remains in Place





N

N

G

Input Source

FIGURE 11.19 - GROUNDING CONFIGURATION FOR NON-GROUNDED DELTA-INPUT G

G

< UPS Cabinet >

G8000 Series Installation and Operation Manual 3φ 3φ N Bφ

To the Load

To the Load

G

Remove Jumper Cable



Output Distribution



47

Remains in Place

Input Source

< UPS Cabinet >



11.7.4

3φ N

Grounding Configuration (with corner-grounded delta-input) 3φ







N

N

To the

If one phase of delta-input source is grounded (B-phase for example), the ground bus in the UPSLoad cabinet G G G G should NOT be connected to the neutral terminal of UPS output. Jumper Cable

The jumper cable should be removed see Figure 11.17 for the jumper cable Remains in Place location. During normal operation the UPS output is floating relative to the ground. An isolation transformer is recommended at output distribution as shown in Figure 11.20.

Input Source



< UPS Cabinet >

Output Distribution







N

Bφ 3φ



G

G

N

3φ N G

To the Load

G Remove Jumper Cable

FIGURE 11.20 - GROUNDING CONFIGURATION WITH CORNER-GROUNDED DELTA-INPUT.

48

G8000 Series Installation and Operation Manual

12

UPS Specifications

12.1

Specification Table G8000 Specifications

Model Number Input

Rated Output Capacity

T80S3K08 KK6XSxx

T80S3K10 KK6XSxx

T80S3K12 KK6XSxx

T80S3K15 KK6Xxx

T80S3K22 KK6XSxx

T80S3K30 KK6XSxx

T80S3K50 KK6XSxx

80 kVA / 80 kW

100 kVA / 100 kW

125 kVA / 100 kW

150 kVA / 150 kW

225 kVA / 225 kW

300 kVA / 300 kW

500 kVA / 450 kW

329 kVA (340 kVA)

484 kVA (505 kVA)

396 A (409 A)

582 A (608 A)

Voltage

480 VAC (+10% to -15%)

Frequency

60 Hz (+/-5%)

Configuration Input kVA Normal (Charging)

3 Phase; 3 Wire + GND 89 kVA (100 kVA)

111 kVA (122 kVA)

112 kVA (123 kVA)

Power Factor

Bypass

EEPROM Upgrade 107 A (120 A)

134 A (147 A)

135 A (148 A)

196 A (209 A)

297 A (311 A)

Reflected THD

< 5% @ 100% Load < 6% @ 25% Load

Configuration

3-Phase; 4-Wire + Gnd

Voltage

480/277V (±10%)

Frequency

60 Hz (+/-5%)

Bypass Overload Capacity

Battery

247 kVA (258 kVA)

> 0.99 PF Lagging

Walk-in Function Maximum Input Current Normal (Charging)

163 kVA (174 kVA)

1000% for 1 Cycle, 500% for 2 Cycle

Number of Cells

180

Type

240

Lead Acid (Contact factory for alternative options)

DC Nominal

360V

480V

DC Minimum

288V

408V

405V

540V

Float Charge Ripple Current (without batteries)

AC Ripple on DC Bus: < 0.2% of DC Voltage

Back-up Time Max DC Charging Current Max Discharge Battery Capacity Required for Full Load Output

Application Specific 30 A

30 A

30 A

30 A

30 A

30 A

45 A

292 A

359 A

365 A

533 A

805 A

1073 A

1193 A

88 kWB

108 kWB

110 kWB

160 kWB

242 kWB

323 kWB

478 kWB

G8000 Series Installation and Operation Manual



49

G8000 Specifications Model Number Output

T80S3K08 KK6XSxx

T80S3K10 KK6XSxx

T80S3K12 KK6XSxx

Voltage

T80S3K15 KK6Xxx

T80S3K22 KK6XSxx

3-Phase; 4-Wire + Gnd

Voltage Regulation

±1% for 0-100%Balanced and Unbalanced Loads

Voltage Adjustment Range

±3% for 100% Linear Loads

Crest Factor

±5% for 100% Non-Linear Loads 2

Transient Voltage Response

±2% Max with a 100% Step Loads (without utilizing batteries) ±1.5% Max with Loss/Return AC input ±2% Max when load transfers To/From Bypass

Transient Recovery Time

<50 ms

Frequency

60 Hz

Frequency Synchronous Range

±0.5 Hz, ±1 Hz, + 1.5Hz (Selectable)

Frequency Slew Rate

1 Hz/Sec

Frequency Regulation

± 0.01% in free running mode

Overload Capacity

±2% for 0-100% Balanced and Unbalanced Loads

±5% (in increments of 1V)

Voltage Unbalance

Power Factor

T80S3K50 KK6XSxx

480Y/277V

Configuration

Current

T80S3K30 KK6XSxx

96 A

120 A

150 A

1.0 PF Lag: 32 - 86 °F (0 - 30 °C) 0.8 PF Lag: 86 - 104 °F (30 - 40 °C)

0.8 PF Lag: 32 - 104 °F (0 - 40 °C)

125% for 10 Minutes, 150% for 60 Seconds

110% for 5 Minutes, 120% for 60 Seconds

180 A

271 A

361 A

601 A

1.0 PF Lag: 32 - 86 °F (0 - 30 °C) 0.8 PF Lag: 86 - 104 °F (30 - 40 °C)

0.9 PF Lag 32 - 104 °F (0 - 40 °C)

125% for 10 Minutes, 150% for 60 Seconds

Voltage THD

<3% Max with 100% Linear Load / 5% Max with 100% Non-Linear Load

Withstanding Rating

65 kA (with optional fuse)

Reliability

MTBF

Environment

Cooling

Module only - 200,000 Hrs. / 3,000,000 Hrs. in Bypass Forced Air

Paint Color

Sherwin Williams HHT2-7055, 079 Beige Texture

Weight

1740 lb. (789 kg)

1740 lb. (789 kg)

2467 lb. (1119kg)

2980 lb. (1352 kg)

4575 lb. (2075 kg)

6520 lb. (2957 kg)

Weight (Shipping)

1790 lb. (812 kg)

1790 lb. (812 kg)

2556 lb. (1159 kg)

3069 lb. (1392 kg)

4725 lb. (2143 kg)

-TBD-

210 Lbs/ft² (1023 kg/m2)

210 Lbs/ft² (1023 kg/m2)

203 Lbs/ ft² (990 kg/ m2)

245 Lbs/ft² (1196 kg/ m2)

240 Lbs/ft² (1173 kg/ m²)

247 Lbs/ft² (1204 kg/m²)

Floor Loading

50

G8000 Series Installation and Operation Manual

G8000 Specifications Model Number Environment (cont.)

T80S3K08 KK6XSxx

T80S3K10 KK6XSxx

T80S3K12 KK6XSxx

T80S3K15 KK6Xxx

T80S3K22 KK6XSxx

T80S3K30 KK6XSxx

T80S3K50 KK6XSxx

Dimension - Width

36.8 in. (935 mm)

55.1 in. (1400 mm)

76.8 in. 1951 mm)

101.8 in. (2586 mm)

Depth

32.5 in. (826 mm)

31.8 in. (808 mm)

35.7 in. (907 mm)

37.4 in. (945 mm)

79.4 in. (2017 mm)

79.7 in. (2024 mm)

Height

79.2 in. (2012 mm)

Cable Access

Bottom Access

Minimum Clearance

Top or Bottom Access Top:

Top Access

15.75” (400 mm)

Front: 43 7/16” (1100 mm)

37 in. (940 mm)

Back/Left/Right Sides: Zero Enclosure Heat Loss to be Removed @ Full Load

NEMA 1 28,321 BTUs/hr

Audible Noise

33,746 BTUs/hr

65 dBA @ 1m Typical

Operating Temperature

68 dBA @ 1m Typical

89,011 BTUs/hr

110,262 BTUs/hr

72 dBA @ 1m Typical

78 dBA @ 1m Typical

Operating Altitude

3200 ft. (1000 m)

Listings/Standards

UL 1778; UL 17025, cUL 22.2, No. 107.1; ANSI C62.41 (IEEE 587 Cat B) NFPA 70; OSHA; ISO 9001; IEC298 IP20

Warranty

3 Years Parts and Labor

Dry Contacts Included

Yes, for input and output signals

RS232 Port

Display

Included SNMP; Modbus RTU; Modbus TCP; BACNET, METASYS LCD Touch Panel for Local Monitoring, Operation and control

Emergency Power Off

Configuration

67,667 BTUs/hr

30% to 90% Non-Condensing

Intelligent Monitoring (Optional)

EPO

38,524 BTUs/hr

32˚F to 86˚F (0˚C to 30˚C) for 1.0PF 32˚F to 104˚F (0˚C to 40˚C) for 0.8 PF

Operating Humidity

Monitoring

37,281 BTUs/hr

Included

Input Conv.

6-diode Bridge Rectifier

Battery Cct

IGBT Chopper

Out. Inv.

G8000 Series Installation and Operation Manual



IGBT Converter with PWM

51

12.2

Typical Efficiency vs. Load UPS

Efficiency at Percent Full Load* 25%

50%

75%

100%

80 kVA

83.9%

85.3%

90.0%

90.6%

100 kVA

86.4%

90.1%

91.2%

91.0%

125 kVA

88.5%

90.9%

90.9%

90.2%

150 kVA

86.9%

91.7%

92.3%

93.3%

225 kVA

87.9%

91.9%

92.3%

91.9%

300 kVA

88.8%

91.6%

92.2%

92.8%

500 kVA

91.6%

91.1%

90.2%

93.3%

* Actual efficiency may differ due to manufacturing variations and input power quality.

52

G8000 Series Installation and Operation Manual

13

Operator Interface

Table 13.1 shows the functions of the operating buttons on the graphic display panel.

NOTICE 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 UPS may not respond if the button press is too short.

TABLE 13.1 BUTTON AND INDICATOR FUNCTIONS (See fig. 13.1 and 13.2)

#

Name

Function

1

OPERATION LOCK

Enables/disables the buttons RUN, STOP, UPS, BYPASS, FLOAT/EQUAL, and RESET.

2

STOP BUTTON

Stops the UPS. Transfers to bypass power if available.

3

RUN BUTTON

Starts the UPS. Transfers the unit from bypass to UPS power.

4

FLOAT/EQUAL BUTTON

Changes recharge mode between float charge and equalize charge.

5

SCROLL UP BUTTON

Scrolls the LCD screens up.

6

SCROLL DOWN BUTTON

Scrolls the LCD screens down.

7

RESET BUTTON

Reset UPS faults and warnings shown on the LCD. (See Section 13.5)

8

UPS BUTTON

Transfers from bypass operation to normal operation.

9

BYPASS BUTTON

Transfers from normal operation to bypass operation.

10

EPO BUTTON

“ON” during Bypass Supply.

11

LCD DISPLAY

Displays the operational, status, and warning/fault messages.

12

UPS SUPPLY LED

“FLASHES” during START or STOP sequence “ON” when operating in inverter mode.

13

CONVERTER LED

“ON” after DC bus capacitors are fully charged through the converter.

14

AC INPUT LED

“ON” with nominal AC input. “FLASHES” with AC input under-voltage (85%).

15

FLOAT CHARGE LED

“ON” during float charge.

16

EQUALIZE CHARGE LED

“ON” during equalize charge or protection charge while battery OH contact open.

17

BATTERY LED

“ON” when battery is connected. (aux-contact on)

18

DISCHARGE LED

“ON” during battery discharge.

19

BYPASS INPUT LED

“ON” with nominal bypass input. “FLASHES” when bypass is under-voltage (85%).

20

WARNING LED

Normally “OFF”. “ON” when warning displayed on LCD. “FLASHES” when AC input is abnormal.

21

FAULT LED

Normally “OFF”. “ON” when faults occur.

22

INVERTER LED

Lamp “FLASHES” during START or STOP sequence. “ON” when inverter is operating.

23

UPS LED

“ON” when the inverter output is connected to the UPS output.

24

AC OUTPUT LED

“ON” with AC output connected to the bypass/inverter sources.

25

BYPASS LED

“ON” when the bypass power supplies the load

G8000 Series Installation and Operation Manual



53

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.

5

6

1

2

3

4

9

7

8 EPO

10

FIGURE 13.1 – GRAPHIC DISPLAY PANEL KEY-SWITCH/OPERATING BUTTONS

54

G8000 Series Installation and Operation Manual

13.2

LCD/LED Indicators

11

20 12

21

13 14

22 23

15 16

24

17 25

19

18

FIGURE 13.2 – GRAPHIC DISPLAY PANEL LCD/LED INDICATORS

G8000 Series Installation and Operation Manual



55

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.

Fault Display

Displays detailed data when a fault occurs.

Warning Display

Displays detailed data when a warning occurs.

NORMAL DISPLAY SCROLL UP FAULT DISPLAY SCROLL DOWN WARNIG DISPLAY

FIGURE 13.3 - CHANGING SCREENS WITH SCROLL BUTTONS

56

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 UPS Normal Display operational status screens. TABLE 13.3 - NORMAL DISPLAY SCREEN EXAMPLES

OPERATIONAL STATUS SCREENS

BYPASS

Shows the UPS status at the top and guidance message or measured data underneath.

PRESS ‘RUN’ SWITCH

UPS SUPPLY

Shows a guidance message at start up.

Shows the output voltage and current after start up.

AC-VO 480[V] AC- I O 50[%] OPERATION MODE

Shows the UPS Operation mode.

NORMAL OPERATION MODE SYNC.

MEASUREMENT SCREENS

O/P VOLTAGE

Output Voltage: Shows the output line-to-line output voltage.

VOLT. 480[V] FREQ. 60.0[Hz] O/P CURRENT (R.M.S.) U 50[%] V 50[%] W 50[%]

G8000 Series Installation and Operation Manual



Output Current: Shows the RMS output current (%) for each phase..

57

TABLE 13.3 - CONTINUED

MEASUREMENT SCREENS

O/P CURRENT (PEAK) U V W

50[%] 50[%] 50[%]

AC INPUT

Shows the peak output current peak (%) for each phase. Peak value of output current RMS value for rated current x 1.41

x 100 [%]

Shows the AC Input Voltage (line-to-line) and frequency.

AC I/P-V 480[V] FREQ. 60.0[Hz] Shows the Bypass Input Voltage (line-to-line voltage) and frequency.

BYPASS INPUT BYP I/P-V 480[V] FREQ. 60.0[Hz]

DC INPUT DC-V 632[V] BATT-V 400[V] BATT- I 0[A]

Shows the internal DC bus voltage, battery voltage and battery current.

MODE COUNT UPS BATTERY

Shows the cumulative UPS operation time, the cumulative battery backup time and the number of battery backup operations.

35[H] 56[MIN] 32[TIM]

CLOCK TIME 03-24-06 13:58

58

The battery current value displayed is negative during recharge and positive during discharge.

The current time is displayed if there are no faults recorded, or after the reset button is pressed. Date is displayed in the mm-ddyyy format. The unit does not calculate daylight savings time. Time is displayed in the 24-hour format (e.g. 1:58 P.M. = 1358 Hrs.)

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 for at least 5 seconds, even after the actual cause of the fault has been resolved. Note that the fault records are not deleted when the UPS is turned off. If the UPS is RESET while the system is in normal or bypass mode, the fault history is cleared and operation continues. If the UPS is RESET while the system is on backup mode, the system will power down, re-initialize, and restart. TABLE 13.4 FAULT & WARNING DISPLAY SCREEN EXAMPLES

FAULTS & WARNINGS 1 FUSE BLOWN 09-09-06 08:05:30 ↓ANOTHER ITEM

A fault record is shown with time stamp.

FAULTS & WARNINGS 1 UPS OVERLOAD 09-09-06 08:05:30 ↓ANOTHER ITEM

A warning record is shown with time stamp.

FAULTS & WARNINGS

This screen is displayed if there are no warnings recorded, or after the reset button is pressed.

NO ALARM NO WARNING

G8000 Series Installation and Operation Manual



An arrow indicates that another record can be displayed by pressing the up/down buttons.

An arrow indicates that another record can be displayed by pressing the up/down buttons.

59

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 next screen TABLE 13.5 DISPLAY SCREEN SCROLL SEQUENCE

UPS SUPPLY

FAULTS & WARNINGS

AC-VO 480[V] AC- I O 50[%]

NO FAULT NO WARNING

OPERATION MODE NORMAL OPERATION MODE SYNC.

(The LCD displays a diagram of the electrical power flow.)

AC



Alternating Current

DC



Direct Current

IO



Current Output

I/P



Input

O/P



Output

VO



Voltage Output

O/P VOLTAGE VOLT. FREQ.

U V W

60

UPS BATTERY

35[H] 56[MIN] 32[TIM]

BATTERY

50[%] 50[%] 50[%]

50[%] 50[%] 50[%]

MODE COUNT

DC-V 632[V] BATT-V 400[V] BATT- I 0[A]

480[V] 60.0[HZ]

O/P CURRENT (PEAK)

TIME 03-24-06 13:58

DC INPUT

O/P CURRENT (R.M.S.) U V W

CLOCK

Abbreveations

BACK-UP RATING 10[MIN] DISCHARGING 15[MIN]

AC INPUT AC I/P-V 480[V] FREQ. 60.0[HZ]

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.

WARNING If the UPS produces smoke or smells strange, immediately turn off all AC and DC input circuit breakers. Continued operation may result in fire. Contact Toshiba or Authorized representatives. DO NOT turn off the control power supply switch (8A) during UPS operation. This may result in UPS faults.

EPO Switch (Emergency Power Off Switch) See Section 14.9

Control Power Supply Switch

FIGURE 14.1 - EPO AND CONTROL POWER SUPPLY OPERATING SWITCHES

G8000 Series Installation and Operation Manual



61

14.1

Operation Types

The operation types are summarized below. TABLE 14.1 OPERATION TYPES

14.2

Operation

Description

Complete Shutdown

Turn off the control power supply. Shut down the UPS completely.

Float / Equalize Charge

Changing the battery recharge mode between float charge and equalize charge.

Protection Charge

Automatic recharge mode transition from protection charge to float charge.

Startup

Starting up and operating the UPS.

Stop

Stop the inverter and chopper/charger.

Switch Power Supply

Switching power supply source between UPS and Bypass.

Pre-operational Check

CAUTION Perform the pre-operational check before operating the UPS.

Before operating the UPS: 1. 2. 3. 4.

Make sure all covers/panels are in place and secured. Make sure the temperature in the UPS/Battery room is within specified limits. Before starting the UPS, check the power source to make sure AC input power is on. Make sure battery breaker’s auxiliary A-contact is connected to the terminal block TB1.

62

G8000 Series Installation and Operation Manual

14.3

Startup Procedures

The procedure to start the UPS is shown in Steps 1-5.

STEP 1

LED Key - LED Off - LED On - LED Flash

SYSTEM INITIALIZE

Turn on the control power supply switch. (Figure 14.1) and ensure the operation lock is set to OPERATION. (Figure 13.1 - 1)

UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

DISCHARGE

AC OUTPUT

BYPASS

BYPASS INPUT

STEP 2 BYPASS

Wait for a few seconds.

PRESS ‘RUN’ SWITCH UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

DISCHARGE

BYPASS

BYPASS INPUT

STEP 3

AC OUTPUT

BYPASS

Press the “RUN” button for at least 0.5 seconds.

UPS STARTING WAIT FOR A WHILE

CONVERTER LED is “ON” and INVERTER LED flashes.

UPS AC INPUT

CONVERTER FLOAT CHARGE EQUAL CHARGE

BATTERIES

BYPASS INPUT

G8000 Series Installation and Operation Manual



DISCHARGE

INVERTER

AC SWITCH

AC OUTPUT

BYPASS

63

Step 4-5 continues the procedure to start the UPS. LED Key - LED Off - LED On - LED Flash

STEP 4

BYPASS

Turn on the DC Input Breaker (72B) on the external battery cabinet.

MOVE 72B TO ‘ON’ POSITION

BATTERIES LED is “ON”. UPS AC INPUT

INVERTER

CONVERTER FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

DISCHARGE

AC OUTPUT

BYPASS

BYPASS INPUT

UPS SUPPLY

STEP 5

AC - Vo 480 V AC - Io 50%

*Press the “UPS” button for at least 0.5 seconds. This completes UPS startup procedure BYPASS LED is “OFF”.

UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE EQUAL CHARGE

BATTERIES

DISCHARGE

BYPASS INPUT

UPS LED is “ON”. AC SWITCH

AC OUTPUT

BYPASS

NOTE *If the AC switch does not function, contact Toshiba or authorized representatives.

If the bypass power source is out of specification, this operation will be inhibited. In order to switch manually, press the “UPS” button for 5 seconds or more.

64

G8000 Series Installation and Operation Manual

14.4

Switch Power Supply (UPS to Bypass)

The procedure to transfer between the UPS supply and the bypass supply is shown in Steps 1-3 LED Key - LED Off - LED On - LED Flash

STEP 1

UPS SUPPLY

Check AC INPUT LED and BYPASS LED are on to make sure power is being delivered to the UPS.

AC - Vo 480 v AC - Io 50% UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

DISCHARGE

BYPASS

BYPASS INPUT

STEP 2

AC OUTPUT

BYPASS

Press the “BYPASS” button for at least 0.5 seconds. UPS LED is “OFF”. BYPASS LED is “ON”.

UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

DISCHARGE

BYPASS

BYPASS INPUT

STEP 3

AC OUTPUT

BYPASS

Please wait until procedure is completed.

AC - Vo 480 V AC - Io 50% PRESS ‘UPS’ SWITCH UPS

NOTE To change from Bypass to UPS supply, follow the Startup Procedures - STEP 5. If the AC switch does not function, contact Toshiba or authorized representatives.

G8000 Series Installation and Operation Manual



AC INPUT

CONVERTER FLOAT CHARGE EQUAL CHARGE

BATTERIES

BYPASS INPUT

DISCHARGE

INVERTER

AC SWITCH

AC OUTPUT

BYPASS

65

14.5

Stop

The procedure to stop the UPS is shown in Steps 1-3. LED Key - LED Off - LED On - LED Flash

BYPASS

STEP 1

AC - Vo 480 V AC - Io 50% PRESS ‘UPS’ SWITCH

Transfer to Bypass supply as described in Switch Power Supply. UPS LED is “OFF”. BYPASS LED is “ON”.

UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

DISCHARGE

AC OUTPUT

BYPASS

BYPASS INPUT

BYPASS

STEP 2 Turn off the DC Input Breaker (72B) on the external battery cabinet, and, press the G8000 “STOP” button for at least 0.5 seconds.

MOVE #72B TO ‘OFF’ POSITION UPS AC INPUT

CONVERTER FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

BATTERIES LED is “OFF”.

INVERTER

DISCHARGE

INVERTER LED flashes then “OFF”. AC OUTPUT

FLOAT CHARGE LED and CONVERTER LED are “OFF”.

BYPASS

BYPASS INPUT

STEP 3

BYPASS

Wait until procedure is completed.

PRESS ‘RUN’ SWITCH UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE EQUAL CHARGE

BATTERIES

DISCHARGE

BYPASS INPUT

66

AC SWITCH

AC OUTPUT

BYPASS

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”.

BYPASS DC-V 0 [V] BATT-V 0 [V] BATT-I 0 [A]

STEP 2 Turn off the DC input breaker, and, press the “STOP” button for at least 0.5 sec. BATTERIES LED is “OFF”. INVERTER LED flashes then “OFF”. FLOAT CHARGE LED and CONVERTER LED are “OFF”.

STEP 3 Please wait until procedure is completed.

STEP 4 Scroll the LCD screen to see the DC INPUT and make sure DC bus voltage is 0V.

STEP 5 *Turn off the control power supply switch (8A). Nothing is displayed on the LCD.

NOTICE

All LED’s are “OFF”.

*STEP 5 - This operation is different from the instructions displayed on the screen.

STEP 6

Be sure to perform the procedure as specified in this manual.

Turn off all breakers at AC Input, Bypass Input, and AC Output. Shutdown is completed and UPS is isolated.

G8000 Series Installation and Operation Manual



67

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. LED Key - LED Off - LED On - LED Flash

STEP 1

UPS SUPPLY

Make sure that the FLOAT CHARGE LED is “ON”.

AC - Vo 480 V AC - Io 50% UPS AC INPUT

INVERTER

CONVERTER FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

DISCHARGE

AC OUTPUT

BYPASS

BYPASS INPUT

STEP 2

UPS SUPPLY

Press FLOAT/EQUAL button for at least 0.5 sec.

AC - Vo 480 V AC - Io 50%

Change completed. EQUAL CHARGE LED is “ON”.

UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE EQUAL CHARGE

BATTERIES

DISCHARGE

BYPASS INPUT

FLOAT CHARGE LED is “OFF” AC SWITCH

BYPASS

AC OUTPUT

STEP 3 Please wait until procedure is completed.

NOTE In equalize charge mode, the battery is charged for a programmed period at a specified voltage (depending on the battery spec), rather than the float charge, in order to prevent voltage deviations among battery cells. This should be done once every six months if possible. The G8000 UPS will automatically perform the equalize recharge after battery backup operation.

68

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. See the Note below for an explanation of float charge and protection charge.

STEP 1

LED Key - LED Off - LED On - LED Flash

UPS SUPPLY

Make sure that the EQUAL CHARGE LED is “ON”.

AC - Vo 480 V AC - Io 50% UPS AC INPUT

INVERTER

CONVERTER FLOAT CHARGE

AC SWITCH

EQUAL CHARGE

BATTERIES

DISCHARGE

AC OUTPUT

BYPASS

BYPASS INPUT

STEP 2 Make sure that the “BATT FAULT1” warning goes away.

UPS SUPPLY AC - Vo 480 V AC - Io 50%

STEP 3 Press “FLOAT/EQUAL” button for at least 0.5 seconds.

UPS AC INPUT

Procedure completed.

CONVERTER FLOAT CHARGE EQUAL CHARGE

BATTERIES

DISCHARGE

INVERTER

AC SWITCH

AC OUTPUT

NOTE The battery is normally being charged at float charge mode. To prevent thermal runaway of the battery, this mode will automatically be changed to protection charge when a “BATT FAULT1” (Battery over temperature) warning occurs.

BYPASS INPUT

BYPASS

In protection charge mode, the battery is automatically charged at a voltage about 5% lower than float charge. If the “BATT FAULT1” warning message goes away and a programmed duration is elapsed (about 24 hours), this mode will automatically be changed back to float charge. Thus, it is not usually required to change the recharge mode manually back to the float charge. G8000 Series Installation and Operation Manual



69

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. To Reset the UPS after triggering the EPO, do the following: 1. Shut Down the UPS as described in section 14.6. 2. Restart the UPS as described in section 14.3.

15

Troubleshooting

When an error occurs in the UPS, error data is displayed on the LCD screen. This section will describe the types of errors, the error messages displayed on the LCD screen and the procedures to correct the errors.

15.1

Types of Errors

The following types of errors may occur in the UPS: TABLE 15.1 OPERATION TYPES

Name Fault

Description Fault (Trip)

The UPS has been tripped and has stopped operating. The UPS is in Bypass mode.

Warning-1 (Input Power Failure)

Power is supplied from the battery. When the warning is corrected, power will automatically be supplied from the AC input.

Warning-2 (Stop and Restart)

The UPS transfers to Bypass supply and the UPS stops operating. When the warning is corrected, the UPS will automatically be restarted and revert to UPS supply.

Warning (Operation Control)

An error or a phenomena related to an error occurred. Since this problem does not directly affect operation, the system switches to synchronized mode.

(Guidance)

An error or indication of an error has occurred, but operation was not affected.

Warning

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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 1 UPS OVERLOAD 09-09-06 08:05:30 ↓ANOTHER ITEM

1

2 3 4

FIGURE 15.1 - SAMPLE FAULT DATA SCREEN

TABLE 15.2 - FAULT AND WARNING DATA SCREEN DESCRIPTIONS

#

Name

Description

1

Number

The number of the message in the order that it was detected (1 - 10). (Up to 10 screens of fault data can be displayed.)

2

Message

Shows the type of the fault or warning message.

3

Time

The date (mm-dd-yy) and time (in 24-hour format) the fault was detected. Indicates whether there is a fault screen before or after this screen.

4

Scroll Indicator

Indicates there is a fault screen before this screen. ↓ Indicates there is a fault screen after this screen. ↓ Indicates there are fault screens before and after this screen.

G8000 Series Installation and Operation Manual



71

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 FAULT STOP

FAULTS & WARNINGS 1 FUSE BLOWN 09-09-06 08:05:30

FIGURE 15.2 - FAULT DISPLAY

UPS SUPPLY AC-VO 480[V] AC- I O 50[%]

FAULTS & WARNINGS 1 UPS OVERLOAD 09-09-06 08:05:30

FIGURE 15.3 - WARNING DISPLAY

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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 message may be used to determine the physical location of the fault or warning by referring to Figure 15.4. The UPS unit may be shipped with different protective configurations from the standard shown in Figure 15.4, if specified by the customer. See the protective configuration indicated on the single line diagram for each UPS. 47S 95S 27S 59S

45 52R

76C 80B1

59I 271

49 83MC1 83MC

Battery Chopper 5E 80PS 30ST 48

Inverter

51I

76

30U 26

80B2

71F

26B

95C 59C 47C 27C

83BF

FIGURE 15.4 - PROTECTIVE DETECTOR LOCATIONS

TABLE 15.3 - FAULT (TRIP)

ITEM

LCD MESSAGE INDICATION

DESCRIPTION

26

OVER HEAT

HIGH TEMP IN THE CABINET.

30ST

(NO INDICATION)

AN ERROR OCCURRED IN THE MAIN CONTROL MICROPROCESSOR (CPU).

48

STARTUP ERR

STARTUP WAS NOT COMPLETED WITHIN THE NORMAL TIME FRAME.

5E

EMG.STOP

AN EMERGENCY STOP WAS ACTIVATED VIA THE EXTERNAL CONTACT.

71F

FUSE BLOWN

RECTIFIER, DC, OR INVERTER MAIN CIRCUIT FUSE BLOWN.

76

DC OC

DC OVER-CURRENT - EXCESSIVE CURRENT IN DC CIRCUIT.

80B2

BATT. UV

BATTERY VOLTAGE IS BELOW CUTOFF VOLTAGE.

80PS

CONT. PS. ERR

THE CONTROL POWER SUPPLY VOLTAGE FAILED.

TABLE 15.4 - WARNING – 1 (CONVERTER STOP/INPUT POWER ERROR)

ITEM

LCD MESSAGE INDICATION

DESCRIPTION

27S

AC I/P UV

AC INPUT UNDERVOLTAGE - AC INPUT VOLTAGE IS TOO LOW.

47S

AC PHASE ERR

AC INPUT PHASE ROTATION ERROR.

59S

AC I/P OV

AC INPUT OVERVOLTAGE - AC INPUT VOLTAGE IS TOO HIGH.

95S

I/P FREQ. ERR

AC INPUT FREQUENCY ERROR.

G8000 Series Installation and Operation Manual



73

TABLE 15.5 - WARNING - 2 (STOP AND RESTART)

Item

LCD Message Indication

Description

27I

AC O/P UV

AC output voltage is low.

30U

UNIT FAULT

IGBT Stack Failure.

45

DC OV

Over-voltage in DC circuit.

49

AC O/P OL

Output overload

51I

INV. OC

Inverter over-current.

59I

AC O/P OV

AC output voltage is high.

76C

BATT. OC

Over-current in Battery section. TABLE 15.6 - WARNING (OPERATION CONTROL)

Item

LCD Message Indication

Description

27C

BYPASS UV

Bypass input voltage is low.

47C

BYPASS ERR.

Bypass input phase rotation error.

59C

BYPASS OV

Bypass input voltage is high.

95C

BYPASS ASY.

Bypass input frequency error. TABLE 15.7 - WARNING (GUIDANCE)

Item

LCD Message Indication

Description

26B

BATT. OVER HEAT

Battery temperature is too high.

80B1

BATT. UV (ALM)

Battery voltage is near cutoff voltage.

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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 for details of the scroll buttons and how they are used for screen scrolling.

5 6

7

FIGURE 15.5 - POSITION OF SCROLL AND RESET BUTTONS

TABLE 15.8 - BUTTON FUNCTIONS

#

Name

Function

5

SCROLL UP

Scrolls to the previous screen.

6

SCROLL DOWN

Scrolls to the following screen.

7

RESET

Resets the UPS faults and warnings shown on the LCD and deletes fault history data stored in memory.

G8000 Series Installation and Operation Manual



75

15.6

Restoring UPS Operation

WARNING Contact Toshiba in the event of malfunction or fault. This UPS should be repaired only by factory authorized personnel. Servicing by untrained personnel may extend the fault or result in electric shock or personal injury.

Do NOT attempt to modify or relocate the UPS. Electric shock, personal injury or fault may result if unauthorized personnel attempt to modify or relocate the UPS. Be sure to contact toshiba customer service if you need to modify or relocate the UPS. Do not open the front and/or rear panels. The parts inside carry energy-high current. Touching them may result in electric shock, burns or fault.

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

LED Key - LED Off - LED On

Check the LCD screen. Also check other fault data screens with scroll buttons graphic panel.

BYPASS 1 INV. OC 07-15-07 08:05:30 ↓ ANOTHER ITEM

STEP 2 Contact Toshiba Customer Support and follow the directions given by the service personnel.

UPS AC INPUT

CONVERTER

INVERTER

FLOAT CHARGE EQUAL CHARGE

BATTERIES

DISCHARGE

BYPASS INPUT

76

AC SWITCH

AC OUTPUT

BYPASS

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 G8000 UPS should have scheduled maintenance performed on it annually by a factory-authorized service provider. The preventive maintenance should include at minimum:

• • • • •

Clean UPS exterior Clean UPS interior Verify power supply voltages Check for loose/overheated connections Scan error log and correct potential UPS-related issues

16.2

Parts Replacement

The following list shows the recommended intervals for periodic replacement of certain UPS parts.

• • • •

Aluminum electrolytic capacitors: Replace once every 7-10 years. Fuses: Replace once every 7-10 years Cooling fan: Replace once every 7-10 years Batteries (If applicable): See the Backup Battery Cabinet manual for specific test, maintenance and replacement instructions.

G8000 Series Installation and Operation Manual



77

78

G8000 Series Installation and Operation Manual

Appendix A - Installation Planning Guides

TOSHIBA G8000 Series UPS

80kVA IPG

Installation Planning Guide for 80kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx) General Mechanical Information

Dimensions (W x D x H) Inches

Floor Loading Lbs./ft. 2

Weight Lbs.

36.8” x 32.5” x 79.2”

1,740

Approximate Full-Load Heat Rejection Btu/Hr

210

Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back

28,321

15.75”

43.5”

0”

0”

0”

Primary AC Input (480V 3-Phase / 3-Wire)

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

89(100)

>0.99

107 (120)

150 A

1/0 – (2) x 2/0

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Maximum Input Power Demand

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

80

1.0

96

125 AT

1/0 – (2) x 2/0 // (2) x 1/0 – (2) x 2/0

DC Backup Input (Battery - 360VDC Nom./Flywheel 550VDC Nom.) Backup System

DC Capacity for Full Load Output

Maximum Discharge at Full Load Output

kWB

88 88

Battery Flywheel

Suggested External Overcurrent Protection*

External Feeder Wire Size: Min. – Max.

Amps DC

Amps

AWG or kcmil at 75º C Temp. Rating

292 158

300 A 175 A

(2) x 1/0 – (2) x 3/0 2/0

* If required. Most Battery and Flywheel Cabinets are equipped with built-in breakers.

AC Output (480/277V 3-Phase / 4-Wire)

Rated Output Power

Suggested External Overcurrent Protection

kVA

PF

Amps

Amps

80

1.0

96

125 A

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral AWG or kcmil at 75º C Temp. Rating

1/0 – (2) x 2/0 // (2) x 1/0 – (2) x 2/0

Important Notes: 1. CABLE ACCESS – Bottom only. 2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current. 3. Output load conductors are to be installed in separate conduit from input conductors. 4. Control wires and power wires are to be installed in separate conduits. 5. Recommended AC input and output overcurrent protection based on continuous full load current per NEC.

12. Cable sizing calculations based on the following assumptions: - Minimum size is smallest size based on ampacity at 30 °C. - Maximum size cable is based on cable bend radius limitations at the UPS terminals. - Neutral sized for 2X phase current. - Not more than 3 current-carrying conductors installed in conduit in ambient temperature of 30 °C. - Temperature rating of copper conductors/terminals: 75 °C. - Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

6. Wiring shall comply with all applicable national and local electrical codes. 7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15. - Primary AC Input: 3φ, 3-wire + ground. - Alternate AC Input: 3φ, 4-wire + ground. - AC Output: 3φ, 4-wire + ground. - DC Input: 2-wire (Positive/Negative) + ground. 8. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal). 9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC. 10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current. 11. Weights do not include batteries or other auxiliary equipment external to the UPS.

Rev. 2.2

G8000 Series Installation and Operation Manual



13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONAL CORPORATION

13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Page 1 of 3

G8000-IPG-80kVA

79

TOSHIBA G8000 Series UPS

Installation Planning Guide for 80kVA UPS

Top

Front

Right Side

Bottom Access Only Power Terminals: Two 2/0 AWG max. per terminal

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K08KK6XSxx)

G8000 80KVA OUTLINE DRAWING

G8000 80kVA UPS Cabling Connection Dimensions

Rev. 2.2

80

Page 2 of 3

G8000-IPG-80kVA

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) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 80kVA UPS

Rev. 2.2

G8000 Series Installation and Operation Manual



Page 3 of 3

G8000-IPG-80kVA

81

100kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 100kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx) General Mechanical Information

Dimensions (W x D x H) Inches

Floor Loading Lbs./ft. 2

Weight Lbs.

36.8” x 32.5” x 79.2”

1,740

Approximate Full-Load Heat Rejection Btu/Hr

210

Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back

33,746

15.75”

43.5”

0”

0”

0”

Primary AC Input (480V 3-Phase / 3-Wire)

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

110 (122)

>0.99

134 (147)

200 AT

(2) x #3 – (2) x 2/0

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Maximum Input Power Demand

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

100

1.0

120

150 AT

(2) x #3 – (2) x 2/0 // (2) 2/0

DC Backup Input (Battery - 360VDC Nominal)

Backup System

DC Capacity for Full Load Output

Maximum Discharge at Full Load Output

Suggested External Overcurrent Protection*

External Feeder Wire Size: Min. – Max.

kWB

Battery

108

Amps DC

Amps

AWG or kcmil at 75º C Temp. Rating

359

350 A

(2) x 3/0 – (2) x 4/0

* If required. Most Battery Cabinets are equipped with built-in breakers.

AC Output (480/277V 3-Phase / 4-Wire)

Rated Output Power

Suggested External Overcurrent Protection

kVA

PF

Amps

Amps

100

1.0

120

150 AT

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral AWG or kcmil at 75º C Temp. Rating

(2) x #3 – (2) x 2/0 // (2) 2/0

Important Notes: 1. CABLE ACCESS – Bottom only. 2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current. 3. Output load conductors are to be installed in separate conduit from input conductors. 4. Control wires and power wires are to be installed in separate conduits. 5. Recommended AC input and output overcurrent protection based on continuous full load current per NEC.

12. Cable sizing calculations based on the following assumptions: - Minimum size is smallest size based on ampacity at 30 °C. - Maximum size cable is based on cable bend radius limitations at the UPS terminals. - Neutral sized for 2X phase current. - Not more than 3 current-carrying conductors installed in conduit in ambient temperature of 30 °C. - Temperature rating of copper conductors/terminals: 75 °C. - Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

6. Wiring shall comply with all applicable national and local electrical codes. 7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15. - Primary AC Input: 3φ, 3-wire + ground. - Alternate AC Input: 3φ, 4-wire + ground. - AC Output: 3φ, 4-wire + ground. - DC Input: 2-wire (Positive/Negative) + ground. 8. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal). 9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC. 10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current. 11. Weights do not include batteries or other auxiliary equipment external to the UPS.

Rev. 2.2

82

13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONAL CORPORATION 13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Page 1 of 3

G8000-IPG-100kVA

G8000 Series Installation and Operation Manual

TOSHIBA G8000 Series UPS

Installation Planning Guide for 100kVA UPS

Top

Front

Right Side

Bottom Access Only Power Terminals: Two 2/0 AWG max. per terminal

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx)

G8000 100kVA UPS Cabling Connection Dimensions G8000 100KVA OUTLINE DRAWING

Rev. 2.2

G8000 Series Installation and Operation Manual



Page 2 of 3

G8000-IPG-100kVA

83

TOSHIBA G8000 Series UPS

Installation Planning Guide for 100kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K10KK6XSxx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 100kVA UPS

Rev. 2.2

84

Page 3 of 3

G8000-IPG-100kVA

G8000 Series Installation and Operation Manual

125kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 125kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx) General Mechanical Information

Dimensions (W x D x H) Inches

Floor Loading Lbs./ft. 2

Weight Lbs.

36.8” x 32.5” x 79.2”

1,740

Approximate Full-Load Heat Rejection Btu/Hr

210

Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back

33,746

15.75”

43.5”

0”

0”

0”

Primary AC Input (480V 3-Phase / 3-Wire)

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

112 (123)

>0.99

135 (148)

200 AT

(2) x #3 – (2) x 2/0

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Maximum Input Power Demand

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

125

0.8

150

200 AT

(2) x #1 – (2) x 2/0 // (2) 2/0

DC Backup Input (Battery - 360VDC Nominal)

Backup System

DC Capacity for Full Load Output

Maximum Discharge at Full Load Output

Suggested External Overcurrent Protection*

External Feeder Wire Size: Min. – Max.

kWB

Battery

110

Amps DC

Amps

AWG or kcmil at 75º C Temp. Rating

365

400 A

(2) x 3/0 – (2) x 4 /0

* If required. Most Battery Cabinets are equipped with built-in breakers.

AC Output (480/277V 3-Phase / 4-Wire)

Rated Output Power

Suggested External Overcurrent Protection

kVA

PF

Amps

Amps

125

0.8

150

200 AT

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral AWG or kcmil at 75º C Temp. Rating

(2) x #1 – (2) x 2/0 // (2) 2/0

Important Notes: 1. CABLE ACCESS – Bottom only. 2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current. 3. Output load conductors are to be installed in separate conduit from input conductors. 4. Control wires and power wires are to be installed in separate conduits. 5. Recommended AC input and output overcurrent protection based on continuous full load current per NEC.

12. Cable sizing calculations based on the following assumptions: - Minimum size is smallest size based on ampacity at 30 °C. - Maximum size cable is based on cable bend radius limitations at the UPS terminals. - Neutral sized for 2X phase current. - Not more than 3 current-carrying conductors installed in conduit in ambient temperature of 30 °C. - Temperature rating of copper conductors/terminals: 75 °C. - Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

6. Wiring shall comply with all applicable national and local electrical codes. 7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15. - Primary AC Input: 3φ, 3-wire + ground. - Alternate AC Input: 3φ, 4-wire + ground. - AC Output: 3φ, 4-wire + ground. - DC Input: 2-wire (Positive/Negative) + ground. 8. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal). 9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC. 10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current. 11. Weights do not include batteries or other auxiliary equipment external to the UPS.

Rev. 0

G8000 Series Installation and Operation Manual



13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONAL CORPORATION 13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Page 1 of 3

G8000-IPG-125kVA 0.8PF

85

TOSHIBA G8000 Series UPS

Installation Planning Guide for 125kVA UPS

Top

Front

Right Side

Bottom Access Only Power Terminals: Two 2/0 AWG max. per terminal

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K12KK6XS2xx)

G8000 UPS 125KVA OUTLINE DRAWING G8000 100kVA Cabling Connection Dimensions

Rev. 0

86

Page 2 of 3

G8000-IPG-125kVA 0.8PF

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) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 100kVA UPS

Rev. 0

G8000 Series Installation and Operation Manual



Page 3 of 3

G8000-IPG-125kVA 0.8PF

87

150kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 150kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx) General Mechanical Information

Dimensions (W x D x H) Inches

Floor Loading Lbs./ft. 2

Weight Lbs.

55.1” x 31.8” x 79.2”

2,467

Approximate Full-Load Heat Rejection Btu/Hr

203

38,754

Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back

15.75”

43.5”

0”

0”

0”

Primary AC Input (480V 3-Phase / 3-Wire)

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

167 (183)

>0.99

196 (209)

300 AT

300 kcmil - (2) x #1

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Maximum Input Power Demand

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

150

1.0

180

250 AT

300 kcmil - (2) x #1 // (2) x 300 kcmil - (4) x #1

DC Backup Input (Battery - 360VDC Nom./Flywheel 550VDC Nom.) Backup System

DC Capacity for Full Load Output

Maximum Discharge at Full Load Output

Suggested External Overcurrent Protection*

kWB

Amps DC

Amps

AWG or kcmil at 75º C Temp. Rating

Battery

160

533

600 A

(2) x 300 kcmil – (2) x 350 kcmil

* If required. Most Battery and Flywheel Cabinets are equipped with built-in breakers.

External Feeder Wire Size: Min. – Max.

AC Output (480/277V 3-Phase / 4-Wire)

Rated Output Power kVA

PF

Amps

150

1.0

180

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

Amps

AWG or kcmil at 75º C Temp. Rating

225 AT

300 kcmil - (2) x #1 // (2) x 300 kcmil - (4) x #1

Important Notes: 1. CABLE ACCESS – Top and Bottom. 2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current. 3. Output load conductors are to be installed in separate conduit from input conductors. 4. Control wires and power wires are to be installed in separate conduits. 5. Recommended AC input and output overcurrent protection based on continuous full load current per NEC.

12. Cable sizing calculations based on the following assumptions: - Minimum size is smallest size based on ampacity at 30 °C. - Maximum size cable is based on cable bend radius limitations at the UPS terminals. - Neutral sized for 2X phase current. - Not more than 3 current-carrying conductors installed in conduit in ambient temperature of 30 °C. - Temperature rating of copper conductors/terminals: 75 °C. - Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

6. Wiring shall comply with all applicable national and local electrical codes. 7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15. - Primary AC Input: 3φ, 3-wire + ground. - Alternate AC Input: 3φ, 4-wire + ground. - AC Output: 3φ, 4-wire + ground. - DC Input: 2-wire (Positive/Negative) + ground. 8. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal). 9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC. 10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current. 11. Weights do not include batteries or other auxiliary equipment external to the UPS.

Rev. 2.2

88

13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONAL CORPORATION 13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Page 1 of 3

G8000-IPG-150kVA

G8000 Series Installation and Operation Manual

TOSHIBA G8000 Series UPS

Installation Planning Guide for 150kVA UPS

G8000 150KVA OUTLINE DRAWING

Top

Front

Top/Bottom Access

Right Side

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx)

G8000 150kVA UPS Cabling Connection Dimensions

Rev. 2.2

G8000 Series Installation and Operation Manual



Page 2 of 3

G8000-IPG-150kVA

89

TOSHIBA G8000 Series UPS

Installation Planning Guide for 150kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K15KK6XSxx) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 150kVA UPS

Rev. 2.2

90

Page 3 of 3

G8000-IPG-150kVA

G8000 Series Installation and Operation Manual

225kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 225kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K22KK6XSxx) General Mechanical Information

Dimensions (W x D x H) Inches

Weight Lbs.

55.1” x 31.8” x. 79.2”

2,980

Floor Loading Lbs./ft. 2

Approximate Full-Load Heat Rejection Btu/Hr

245

Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back

67,667

15.75”

43.5”

0”

0”

0”

Primary AC Input (480V 3-Phase / 3-Wire)

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

247 (258)

>0.99

297 (311)

400 AT

(2) x 3/0 – (2) x 4/0

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire)

Maximum Input Power Demand

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

225

1.0

271

350 AT

(2) x 4/0 – (2) x 250 kcmil // (4) x 4/0 – (4) x 250 kcmil

DC Backup Input (Battery - 360VDC Nom./Flywheel 550VDC Nom.) Backup System

DC Capacity for Full Load Output

Maximum Discharge at Full Load Output

Suggested External Overcurrent Protection*

kWB

Amps DC

Amps

AWG or kcmil at 75º C Temp. Rating

Battery

242

805

900 A

(4) x 4/0 – (4) x 250 kcmil

* If required. Most Battery and Flywheel Cabinets are equipped with built-in breakers.

External Feeder Wire Size: Min. – Max.

AC Output (480/277V 3-Phase / 4-Wire)

Rated Output Power

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

225

1.0

271

350 AT

(2) x 4/0 – (2) x 250 kcmil // (4) x 4/0 – (4) x 250 kcmil

Important Notes: 1. CABLE ACCESS – Top and Bottom. 2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current. 3. Output load conductors are to be installed in separate conduit from input conductors. 4. Control wires and power wires are to be installed in separate conduits. 5. Recommended AC input and output overcurrent protection based on continuous full load current per NEC.

12. Cable sizing calculations based on the following assumptions: - Minimum size is smallest size based on ampacity at 30 °C. - Maximum size cable is based on cable bend radius limitations at the UPS terminals. - Neutral sized for 2X phase current. - Not more than 3 current-carrying conductors installed in conduit in ambient temperature of 30 °C. - Temperature rating of copper conductors/terminals: 75 °C. - Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

6. Wiring shall comply with all applicable national and local electrical codes. 7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15. - Primary AC Input: 3φ, 3-wire + ground. - Alternate AC Input: 3φ, 4-wire + ground. - AC Output: 3φ, 4-wire + ground. - DC Input: 2-wire (Positive/Negative) + ground. 8. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal). 9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC. 10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current. 11. Weights do not include batteries or other auxiliary equipment external to the UPS.

Rev. 2.3

G8000 Series Installation and Operation Manual



13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONAL CORPORATION 13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Page 1 of 3

G8000-IPG-225kVA

91

TOSHIBA G8000 Series UPS

Installation Planning Guide for 225kVA UPS

Top

Front G8000 225 KVA OUTLINE DRAWING

Top/Bottom Access

Right Side

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K22KK6XSxx)

G8000 225kVA UPS Cabling Connection Dimensions

92

Rev. 2.3



Page 2 of 3

G8000-IPG-225kVA

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) Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has four pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 225kVA UPS

Rev. 2.3

G8000 Series Installation and Operation Manual



Page 3 of 3

G8000-IPG-225kVA

93

300kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 300kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K30KK6XSxx) General Mechanical Information

Dimensions (W x D x H) Inches

Floor Loading Lbs./ft. 2

Weight

76.8” x 35.7” x 79.2”

Lbs.

4,575

240

Approximate Full-Load Heat Rejection Btu/Hr

89,011

Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back

15.75”

43.5”

0”

0”

0”

Primary AC Input (480V 3-Phase / 3-Wire)

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

326 (329)

>0.99

396 (409)

600 AT

(2) 250 kcmil – (3) x 2/0

Maximum Input Power Demand

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire) Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

300

1.0

361

500 AT

(2) 300 kcmil – (3) x 2/0 (2) 300 kcmil // (4) x 300 kcmil – (6) x 2/0

DC Backup Input (Battery - 360VDC Nom.)

Backup System

DC Capacity for Full Load Output

Maximum Discharge at Full Load Output

Suggested External Overcurrent Protection*

kWB

Amps DC

Amps

AWG or kcmil at 75º C Temp. Rating

Battery

323

1073

1200 A

(4) x 300 kcmil – (4) x 350 kcmil

* If required. Most Battery Cabinets are equipped with built-in breakers.

External Feeder Wire Size: Min. – Max.

AC Output (480/277V 3-Phase / 4-Wire)

Rated Output Power

Suggested External Overcurrent Protection

kVA

PF

Amps

Amps

300

1.0

361

450 AT

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral AWG or kcmil at 75º C Temp. Rating

(2) 300 kcmil – (3) x 2/0 (2) 300 kcmil // (4) x 300 kcmil – (6) x 2/0

Important Notes: 1. CABLE ACCESS – Top only. 2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current. 3. Output load conductors are to be installed in separate conduit from input conductors. 4. Control wires and power wires are to be installed in separate conduits. 5. Recommended AC input and output overcurrent protection based on continuous full load current per NEC.

12. Cable sizing calculations based on the following assumptions: - Minimum size is smallest size based on ampacity at 30 °C. - Maximum size cable is based on cable bend radius limitations at the UPS terminals. - Neutral sized for 2X phase current. - Not more than 3 current-carrying conductors installed in conduit in ambient temperature of 30 °C. - Temperature rating of copper conductors/terminals: 75 °C. - Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

6. Wiring shall comply with all applicable national and local electrical codes. 7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15. - Primary AC Input: 3φ, 3-wire + ground. - Alternate AC Input: 3φ, 4-wire + ground. - AC Output: 3φ, 4-wire + ground. - DC Input: 2-wire (Positive/Negative) + ground. 8. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal). 9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC. 10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current. 11. Weights do not include batteries or other auxiliary equipment external to the UPS.

Rev. 2.3

94

13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONAL CORPORATION

13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Page 1 of 3

G8000-IPG-300kVA

G8000 Series Installation and Operation Manual

TOSHIBA G8000 Series UPS

Installation Planning Guide for 300kVA UPS

G8000 Series Installation and Operation Manual

G8000 300kVA UPS Cabling Connection Dimensions



Front

Top

Cable Entry: Top Only

Right Side

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K30KK6XSxx)

95

TOSHIBA G8000 Series UPS

Installation Planning Guide for 300kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K30KK6XSxx)

Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. TheUPS base has eight pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 300kVA UPS

96

G8000 Series Installation and Operation Manual

500kVA IPG

TOSHIBA G8000 Series UPS

Installation Planning Guide for 500kVA UPS

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K50KK6XSxx) General Mechanical Information

Dimensions (W x D x H) Inches

Floor Loading Lbs./ft. 2

Weight

101.8” x 37.4” x 79.7”

Lbs.

6520

247

Approximate Full-Load Heat Rejection Btu/Hr

101,490

Mechanical Clearance (Inches)from UPS for Ventilation and Maintenance Access Top Front Bottom Sides Back

15.75”

37”

0”

0”

0”

Primary AC Input (480V 3-Phase / 3-Wire)

Maximum Input Power Demand Normal Mode (Recharge Mode)

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

484 (505)

>0.99

582 (608)

800 AT

(3) x 250 kcmil – (3) x 300 kcmil

Maximum Input Power Demand

Alternate (Bypass) AC Input (480V 3-Phase / 4-Wire) Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

500

0.9

601

800 AT

(3) x 400 kcmil – (3) x 500 kcmil // (6) x 400 kcmil – (6) x 500 kcmil

DC Backup Input (Battery - 480VDC Nom.)

Backup System

DC Capacity for Full Load Output

Maximum Discharge at Full Load Output

Suggested External Overcurrent Protection*

kWB

Amps DC

Amps

AWG or kcmil at 75º C Temp. Rating

Battery

478

1193

1200 A

(3) x 400 kcmil – (3) x 500 kcmil

* If required. Most Battery and Flywheel Cabinets are equipped with built-in breakers.

External Feeder Wire Size/pole: Min. – Max.

AC Output (480/277V 3-Phase / 4-Wire)

Rated Output Power

Suggested External Overcurrent Protection

External Feeder Wire Size: Min. – Max. Per Phase // Min. – Max. for Neutral

kVA

PF

Amps

Amps

AWG or kcmil at 75º C Temp. Rating

500

0.9

601

800 AT

(3) x 400 kcmil – (3) x 500 kcmil // (6) x 400 kcmil – (6) x 500 kcmil

Important Notes: 1. CABLE ACCESS – Top only. 2. Maximum Current required at Primary AC Input based on full load output and maximum battery charging current. 3. Output load conductors are to be installed in separate conduit from input conductors. 4. Control wires and power wires are to be installed in separate conduits. 5. Recommended AC input and output overcurrent protection based on continuous full load current per NEC.

12. Cable sizing calculations based on the following assumptions: - Minimum size is smallest size based on ampacity at 30 °C. - Maximum size cable is based on cable bend radius limitations at the UPS terminals. - Neutral sized for 1.7X phase current. - Not more than 3 current-carrying conductors installed in conduit in ambient temperature of 30 °C. - Temperature rating of copper conductors/terminals: 75 °C. - Reference: 2005 NEC Handbook, Table 310.16.

NOTE: Consult latest edition of applicable national and local codes for possible variations.

6. Wiring shall comply with all applicable national and local electrical codes. 7. Grounding conductors to be sized per NEC Article 250-122. Neutral conductors to be sized per NEC Article 310.15. - Primary AC Input: 3φ, 3-wire + ground. - Alternate AC Input: 3φ, 4-wire + ground. - AC Output: 3φ, 4-wire + ground. - DC Input: 2-wire (Positive/Negative) + ground. 8. Nominal battery voltage based on the use of VRLA type batteries (2.0 volts/cell nominal). 9. Maximum battery discharge current based on lowest permissible discharge voltage of 1.67 VPC. 10. DC wires should be sized to allow not more than a 2-volt drop at maximum discharge current. 11. Weights do not include batteries or other auxiliary equipment external to the UPS.

Rev. 0.0

G8000 Series Installation and Operation Manual



13. Ratings of wires and overcurrent devices are suggested minimums. Consult with a registered Professional Engineer within your local area for proper size selections.

TOSHIBA INTERNATIONAL CORPORATION 13131 West Little York Road Houston, TX 77041 Telephone: (877) 867-8773 Fax: (713) 896-5212 Web Site: www.toshiba.com/ind

Page 1 of 3

G8000-IPG-500kVA

97

TOSHIBA G8000 Series UPS

Installation Planning Guide for 500kVA UPS

Top

Front

Cable Entry: Top Only

Standard System: 480V Input, 480Y/277V Output (P/N T80S3K50KK6XSxx)

G8000 300kVA UPS Cabling Connection Dimensions 98

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)

Anchorage pattern: Install anchor bolts to secure the UPS to the floor. Use 1/2” (12mm) diameter anchor bolts. The UPS base has eight pre-drilled 5/8” (16 mm) holes provided. See the figure below for dimensions and locations.

Anchorage Pattern for G8000 500kVA UPS

Rev. 0.0

G8000 Series Installation and Operation Manual



Page 3 of 3

G8000-IPG-500kVA

99

100

G8000 Series Installation and Operation Manual

FIGURE B.1 - G8000 80/100/125 KVA OUTLINE DRAWING

Appendix B - Outline Drawings

G8000 Series Installation and Operation Manual



101

FIGURE B.2 - G8000 150/225 KVA OUTLINE DRAWING

102

G8000 Series Installation and Operation Manual

FIGURE B.3 - G8000 300 KVA OUTLINE DRAWING

G8000 Series Installation and Operation Manual



103

FIGURE B.4 - G8000 500 KVA OUTLINE DRAWING

104

G8000 Series Installation and Operation Manual

Appendix C - 500kVA Input- and Output- Cabinet Joining Instructions Joining the G8000 500kVA Sections 1. Remove Shipping Material (Retain Connection Kit Box and Manual). 2. On a leveled floor bring the two cabinets together. Input cabinet on the left side. See FIG. 1. Leave a gap of 0.25”-0.30” between the cabinets. See FIG. 2.

”-0.30” AP OF 0.25 LEAVE A G ABINETS C BETWEEN

ET

INPUT CABIN

NET

OUTPUT CABI FIG. 1

FIG. 2

3. 4. On Input cabinet: Open the door, remove back panel (retain hardware). See FIG. 3. Insert 1/2-13X1.75” bolt, flat & lock washer assembly (supplied); two in the front and two in the back. See FIG. 4 & FIG. 5.

G8000 Series Installation and Operation Manual



105

BACK REMOVE PANEL

, BOLT NCH AT I F L R, FL RT HA INSE K WASHE C ER LO WASH

OPEN R DOO

FIG. 3

INS ER LOC T HAL K W F-IN CH A WA SHER, BOLT SHE , FLA R T

FIG. 4

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). Insert Belleville washer between flat washer and nut. 6. Insert AC Bus (qty. 3) between the cabinets as shown in FIG. 5 & FIG. 6 and connect on corresponding output and input cabinet AC bus using 1/2-13X1.25” bolt, flat, belleville washer and nut (supplied). Insert Belleville washer between flat washer and nut. 7. Insert DC Bus (qty. 2) between the cabinets as shown in FIG. 5 & FIG. 6 and connect on corresponding output and input cabinet DC bus using 1/2-13X1.25” bolt, flat, belleville washer and nut (supplied). 106

G8000 Series Installation and Operation Manual

Insert Belleville washer between flat washer and nut.

NEU

TRA

L BU

S

DC BUS

FIG. 5

AC B

US

R CONTROL CONNECTO ) ET BIN CA UT (FROM INP

8. Connect the Control plug/connector (male) located in input cabinet to the mating connector (female) in the output cabinet thru conduit plate in the side panels. See FIG. 5 & FIG. 6. 9. Connect the Ground cable located in input cabinet to the Ground Bus located in the output cabinet thru the grommet hole in the side panels. NOTE: SEE MANUAL PAGE 38 FOR CONNECTING POWER CABLES & ANCHORING THE CABINETS TO THE FLOOR. AFTER CONNECTING THE CABLES. ENSURE NO LOOSE HARDWARE, METAL SHAVINGS, TOOLS, ETC. ARE LEFT BEHIND INSIDE THE CABINET. CLOSE THE CABINETS FRONT AND BACK. RECOMMENDED TORQUE VALUES OF 3/8” STEEL BOLT IS 220 IN-LBS, 1/2” STEEL BOLT IS 390 IN-LBS. G8000 Series Installation and Operation Manual



107

FIG. 6 US DC B

AC B

NE

US

US AL B UTR

108

G8000 Series Installation and Operation Manual



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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