Uninterruptible Power System (UPS) single phase - 3.6-RoHS/3.6/6/8/10/14/18/22 1600EP SERIES instruction MANUAL March 2008 Part # 55288-002 Manufactured in the USA © Copyright 2008 TOSHIBA International Corporation All rights reserved.
Product Use and Warranty Restrictions 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 or where a malfunction or failure may cause loss of human life or bodily injury (Unintended Usage).
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 36 months from the shipment date (see Toshiba International Corporation bill of lading). Unless otherwise specified, the warranty period for a UPS battery is 24 months from the shipment date (see Toshiba International Corporation bill of lading).
Purpose This manual provides information on how to safely install 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.
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Table of Contents General Safety Instructions..............................................................................1 Symbols....................................................................................................1 Signal Words............................................................................................2 IMPORTANT SAFETY INSTRUCTIONS............................................................3 QUALIFIED PERSONNEL ONLY.........................................................
Operating Keys.........................................................................................28 Light Emitting Diodes (LED).....................................................................28 Display Screens.................................................................................................29 Screen Arrangement.................................................................................29 System Overview Screens...................................................................
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. 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.
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. DANGER warning caution caution attention The word DANGER in capital letters preceded by the safety alert symbol indicates that an imminently hazardous situation exists, if not avoided, will result in loss of life or serious injury to personnel.
IMPORTANT SAFETY INSTRUCTIONS This manual contains important instructions that should be followed during the installation and maintenance of the UPS and its batteries. Hardwire-type UPS units are not equipped with an over-current protection device nor an output disconnect for the AC output. A circuit breaker should be provided by the user between the UPS output and the load input. This device should be rated as follows: 240VAC RATING 3.6RoHS kVA 3.
Caution Misuse of this equipment may result in human 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 use of this equipment. Caution DO NOT dispose of the battery module in a fire. The batteries inside may explode. Caution DO NOT open or mutilate the batteries. Released electrolyte is harmful to the eyes and skin and could also be toxic.
Product Description An uninterruptible power system is a system that is installed between the commercial power and the load equipment. The UPS provides steady AC output power during commercial power short-term blackouts or brownouts. This power is provided for a long enough time so that the load can be shut down in an orderly fashion. This prevents loss of data and possible damage to both hardware and software. During normal operation, the UPS uses commercial AC power.
Inspection/Storage/Disposal 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. The warranty does not apply to damage incurred during shipping.
Installation Precautions Caution 1. Install the unit in a well-ventilated location; allow at least 4 inches (10 cm) on all sides for air ventilation and for maintenance. 2. Install the unit in a stable, level and upright position that is free of excessive vibration. 3. Install the unit where the ambient temperature is within the range specified on pages 16 and 19. 4. DO NOT install the UPS in areas that are subject to high humidity. 5. DO NOT install the UPS in areas that allow exposure to direct sunlight.
Operating Precautions 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 range of +10% to -30% of the rated input voltage. The input frequency must be within the rated input frequency range. Voltages and frequencies outside of the permissible range may activate the internal protection devices. 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.
Equipment Warning Labels Below and on the following page are examples of warning labels that may be attached to either the interior or exterior of the UPS. Do not remove or cover any of the labels. If the labels are damaged or if additional labels are required, contact your equipment representative for additional labels.
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UPS Connections Terminal Block The following illustration is a detail view of the terminal block and wiring connections used for 208/240 volt units (see pages 49-50 for terminal block location). Note 1 – If AC input power is 208 Vac rated, short terminals 11 and 12 with a jumper wire. DO NOT jumper terminal 13 to 12 or 11. Factory Setting is 208Vac. Use the jumper wire provided by Toshiba. DO NOT add any additional jumpers.
Communication Interfaces Remote Contacts The remote contacts interface is provided as a set of solid state relay switch contacts. The switches are available through a DB9 male connector on the rear of the UPS. The following chart shows the pin assignment for each signal.
UPS Stop Signal Operation When the UPS stop signal is sent to the UPS through pin 2 and 3 of the external contact interface, it is possible to automatically reset the following operating systems (OS), which can automatically implement the shutdown function and restart the operation: Applicable OS: Windows NT, IBM OS/2 LAN server, LANtastic When the power fails, the OS receives the power failure signal from the UPS and starts the shutdown process.
RS-232C The RS232C port can be used by authorized service personnel. The port is provided using a DB9 female connector located on the rear of the UPS. For reference, the pinout of the connector is illustrated below.
UPS Specifications Standard Models: 3.6kVA-RoHS; 3.6kVA; 6kVA; 8kVA Unit (Capacity) 3.6 kVA-RoHS (3.1 kW)1 3.6 kVA (3.1 kW)1 6 kVA (5.1 kW)1 8 kVA (6.8 kW)1 General Topology True On-line Certifications UL, CUL, ISO 9001, NEMA/PE1-1993 Input Characteristics Input Voltage Single-phase, 208/240 Vac, -30% – +10% Input Frequency 45 – 65 Hz (auto-sensing) Input Capacity 3.6 kVA 6.0 kVA Input Power Factor 8.0 kVA > 0.
Standard Models: 3.6kVA-RoHS; 3.6kVA; 6kVA; 8kVA (cont’d) Unit (Capacity) 3.6 kVA-RoHS (3.1 kW)1 3.6 kVA (3.1 kW)1 6 kVA (5.1 kW)1 8 kVA (6.
Standard Models: 3.6kVA-RoHS; 3.6kVA; 6kVA; 8kVA (cont’d) Unit (Capacity) 3.6 kVA-RoHS (3.1 kW)1 3.6 kVA (3.1 kW)1 6 kVA (5.1 kW)1 8 kVA (6.8 kW)1 Mechanical Design Topology Unit enclosure is made from sheet metal meeting NEMA1 and UL Type 1 Size (HxWxD) (max) 21 x10 x 33 in. (533x254x838 mm) Paint System Fan Panel 27.5 x 10.0 x 33.0 in. (698 x 254 x 838 mm) 28.4x 13 x 33.5 in.
Standard Models: 10kVA; 14kVA; 18kVA; 22kVA Capacity 10 kVA (8.5 kW)1 14 kVA (11.9 kW)1 18 kVA (15.3 kW)1 22 kVA (18.7 kW)1 General Topology True On-line Certifications UL, CUL, ISO 9001, NEMA/PE1-1993 Input Characteristics Input Voltage Single-phase, 208/240 VAC, +10% to –30% 1 1 Input Frequency Input Capacity 45-65 Hz (auto-sensing) 10 kVA 14 kVA Input Power Factor 18 kVA > 0.
Standard Models: 10kVA; 14kVA; 18kVA; 22kVA (cont’d) Capacity 10 kVA (8.5 kW)1 14 kVA (11.9 kW)1 18 kVA (15.3 kW)1 22 kVA (18.7 kW)1 Environment Operating temperature (15 – 25° C recommended) 60 Hz (0 – 40 °C) ; 50Hz (0 – 33 °C) Storage Temperature -20 – 40 °C (-4 – 104 °F) To be installed in a well ventilated area free of airborne dust, metal particles or flammable gas, allow at least 4 inches on all sides Installation Area Operating Humidity 30 – 90% (no condensation) Altitude < 3200 ft.
Standard Models: 10kVA; 14kVA; 18kVA; 22kVA (cont’d) Capacity 10 kVA (8.5 kW)1 14 kVA (11.9 kW)1 18 kVA (15.3 kW)1 22 kVA (18.7 kW) 1 Mechanical Design Enclosure Size (HxWxD) (max) Enclosure of unit made from sheet metal meeting NEMA1 and UL Type 1 28.4 x 13 x 33.5 in. (721 x 330 x 851 mm) Paint System 39.1 x 17.5 x 34.8 in. (993 x 444 x 889 mm) Powder coating. Panel mounted on back of UPS to allow for easy replacement of fans without turning UPS off.
Operating the UPS Battery Backup Time and Discharge Process The UPS batteries provide about 5-7 minutes of back-up time depending on the 1600EP unit kVA rating. These times are valid when the unit is operating under full load and at the rated power factor. The exact length of these times will depend on the UPS model used, condition of the batteries, amount and type of load, temperature and other variables. See battery backup time in ‘Standard Specifications’ beginning on pages 15-20.
Starting the UPS Turn the main circuit breaker (MCCB) on the back of the UPS (see pages 47-48) to the ON position. The breaker should normally remain in the ON position. Verify that the ON-LINE LED on the front panel (see page 32 and 33) lights green. All LED’s on the front panel may light for a moment when the input breaker is turned on. This is normal. The UPS will now be supplying power in the bypass mode.
Battery Recharging The illustration below shows a graphical representation of the UPS battery recharge process after a full discharge. Current voltage charging current icharge Battery charge voltage vmax vmin Discharge shut-off point Fully Charged 0 time 0 period 1 period 2 period 3 The recharge process usually consists of three periods. During the first period, the current is maintained at approximately 1 ampere.
Online Mode Online Mode (Run operation) The following illustration shows circuit power flow when the UPS is operating normally in the Online mode. The UPS rectifier, including a boost chopper circuit, converts AC input power to DC power. The boost chopper circuit maintains a constant voltage, with current limiting, for charging the batteries. It also supplies a DC voltage of the proper level to the inverter section. The inverter section generates a high quality sine wave output voltage.
Battery Backup Mode (On batteries) The following illustration shows power flow during the battery backup mode. When commercial AC power failures occur, the UPS’s batteries instantly begin supplying DC voltage to the UPS’s main inverter circuit. This circuit changes (inverts) the DC power into AC power. The AC power is available at the output of the unit. This back-up process will continue until the UPS’s battery voltage drops below a specific minimum level.
Audible Alarm Functions Audible alarms will sound when the UPS is in the battery backup mode, has a fault, has low battery voltage, or is in an overload condition. The following chart shows the audible alarm pattern durations for each condition. Time units are shown in seconds. The audible alarm can be silenced by pressing Shift Select + Run key on the front panel (see page 27).
Display and Keys Front Panel Layout The front panel consists of several elements for monitor and operation of the UPS. Panel components are shown in the illustration below: Liquid crystal display screen Reset operating keys light emitting diodes Run Shift Select On-Line/ Fault Set Cancel Monitor AC Input Stop Alarm Timer Liquid Crystal Display (LCD) Functions The LCD screen is a 2-line by 16-character wide liquid crystal display. The LCD displays information about the operation of the UPS.
Operating Keys Refer to this illustration for all UPS front panel operating procedures. Key Shift Select Reset Cancel Set Monitor Functional Description Press and hold this key while pressing one of the other keys to execute the function marked above the upper line of the key. Pressing this key alone enters the mode set on the internal data setting LCD screen (see page 33). Scrolls the display upward or with shift key resets the display.
Display Screens Screen Arrangement The display screens are organized into three groups that can be cyclically selectable by pressing the SELECT key. The groups are: Screen Arrangement Groups 1 System Overview Screens Provides operational status summary 2 Data Display Screens Provides detailed UPS data monitoring 3 Data Settings Screens Provides system configuration System Overview Screens The System Overview screens provide a summary of the current operational state of the UPS.
Only if the UPS is instructed to enter its online (normal) mode, will the UPS attempt transfer into such operation mode. To enter the normal mode, the RUN key is pressed or the AUTO RUN has been configured to YES (AUTO RUN setup is described in the Data Screen Settings actions on pages 33 - 38.
Data Display Screens The Data Display screens sequentially display the data parameters that can be monitored by operator. To enter the series of Data Display screens, press UP or DOWN arrows while the current System Overview Screen is appearing. Notes 1. If the SET/MONITOR key is pressed from any of the Data Display screens then the display will advance to the Data Setting screens. See page 33. 2. Displays 240V output voltage. INPUT VOLTAGE ###V INPUT FREQUENCY ##.
Special Display Screens The special Data Display screens show below depict settings that can be viewed (but not changed locally) on the LCD panel. These settings can only be changed through the RS232C or optional RemotEye network card. Continued from Timer Start Data screen page 31 START TIME 1 DAY ##HR ##MIN ##SEC Continued from Timer Stop Data screen page 31 STOP TIME 1 DAY ##HR ##MIN ##SEC Continued from Weekly Schedule Data screen page 31 WEEKLY (MON) ###.## - ###.
Data Setting Screens The ‘Data Setting screens’ sequentially display the data variables that can be set. Each variable is displayed as the Down arrow key is pressed. The Up arrow can also be pressed at any time to back up to the previous screen: Notes 1. When the automatic battery test mode has been set to YES then the this screen is displayed when scrolling through the Data Setting screens.
Data Setting Screens (Cont’d) Cont’d from Key Lock data setting screen page 33 The following screens show the procedure for setting the data variables.
Data Setting Screens (Cont’d) Cont’d from Auto Retransfer data setting screen page 33 The following screens show the setting procedure for setting the data variables.
Data Setting Screens (Cont’d) Cont’d from Date and Day data setting screen page 33 The following screens show the procedure for setting the data variables.
Data Setting Screens (Cont’d) Cont’d from Baud Rate data setting screen page 33 The following screens show the procedure for setting the data variables. They are accessed from the main Data Setting screens (see page 33) when the Shift/Select key is pressed: BAUD RATE: 1200 TO ACCEPT: SET Shift Select + Set BAUD RATE: 1200 TO CHANGE:SELECT Monitor Default is 9600 baud.
Data Setting Screens (Cont’d) Cont’d from Buzzer data setting screen page 33 Cont’d from Bat Test Interval data setting screen page 33 The following screens show the setting procedure for setting the data variables.
System Warning Messages Warning messages will be displayed when an abnormal operating condition occurs. The following chart shows possible messages and their meaning. LCD Message LED Message OVERLOAD: 132% Alarm OL: REDUCE LOAD Alarm BATTERY LOW 90% Alarm Amber LED Flashes Amber LED Flashes Amber LED Flashes Meaning/Action Meaning: The UPS is overloaded (110% or above). Unit will switch to bypass operation or shut down if no action is taken.
System Fault Messages When an abnormal operating condition occurs the following fault message will be displayed FAULT OPER) FaUlt(BYP (byp oper) OUT-0V DC-0V oUt-oV DC-oV > If the input voltage is normal when the fault occurs then the UPS will switch immediately to the bypass mode to continuously feed power to the load. If the input power is abnormal while in the bypass mode the UPS will shut down the output to prevent load equipment damage.
Status Change Indications Warning messages will be displayed when an abnormal operating condition occurs. The following chart shows possible messages. LCD Message AUTO RETRANSFER Meaning/Action Meaning: The UPS has automatically entered the bypass mode because it detected an output current that is larger than the inverter can normally handle. Action: Remove excess load equipment to reduce the output current.
UPS Protection System System Protection Features The following schematic shows the electrical locations of the protection devices on the UPS. Overheating Overcurrent Current Limit Overload Overvoltage/ Undervoltage Input Abnormal Low Battery Level System Protection Functions The following charts show the built-in system fault protection functions on all the UPS models.
Built-In UPS Fault Protection Functions (cont’d) Protection Item LCD Message Cause Operation Mode After Fault Internal Overheat DC Circuit Overvoltage DC Circuit Overcurrent OVERHEAT DC-OV DC-OC Fan failure; High ambient temperature Chopper malfunction Inverter/chopper fault Shutdown – No output Bypass operation – Chopper and inverter are stopped Inverter OL – Transfer to bypass Audible Alarm Yes – Continuous buzzer Visible Alarm Red Fault LED on Relay Contact Alarm Fault relay closed Bypa
Preventive Maintenance/Parts Replacement Preventive Maintenance Toshiba 1600EP Series of uninterruptible power systems have been designed to provide years of troublefree operation requiring a minimum of preventive maintenance. The best preventive measure that the UPS user can take is to keep the area around the unit, particularly the air inlet vents, clean and free of moisture and dust accumulations.
Optional Receptacle Panel Installation Instructions These are the instructions for installing the optional Modular Output Receptacle Panels for the 1600EP Series UPS. These instructions apply to all UE3-RP-XX panel options. WARNING: The work outlined in these instructions is to be performed only on a completely un-energized UPS system. Refer to Figure 1 for location of UPS referenced material. Refer to Figure 2 for material referring to the receptacle panel module.
Optional MB (Maintenance Bypass) Units The following illustration shows the circuit power flow when the UPS is operating in the optional Maintenance Bypass Mode. The input on the UPS must be set for 240 VAC. Caution Ensure the UPS is in Static Bypass before switching the unit from UPS to Maintenance Bypass mode or from Maintenance Bypass to UPS mode. Failure to do so could result in damage to the maintenance bypass switch or the UPS. This Maintenance Bypass unit can only be used for 240 V applications.
The following connections must be made to the Utility Panel and the Load Panel. The Main UPS output is located on the terminal block on the back of the UPS. (TB-4(X1) and TB-7(X3) 240 VAC.
External Layouts/Dimensions/Shipping Weights Dimensional Data Dimensional data 3.6 kVA-RoHS 3.6 kVA A 21 in. (533 mm) 27.5 in. (699 mm) 27.5 in. 28.4 in. 28.4 in. 39.1 in. 39.1 in. 39.1 in. (699 mm) (721 mm) (721 mm) (993 mm) (993 mm) (993 mm) B 10 in. ( 254 mm) 10 in. (254 mm) 10 in. 13 in. 13 in. 17.5 in. 17.5 in. 17.5 in. (254 mm) (330 mm) (330 mm) (445 mm) (445 mm) (445 mm) C 33 in. (838 mm) 33 in. (838 mm) 33 in. 33.5 in. 33.5 in. 34.8 in. 34.8 in. 34.8 in.
External Layout for 3.6 kVA-RoHS, 3.6 kVA, and 6 kVA units.
External Layout for 8 kVA, 10 kVA, 14 kVA, 18 kVA, and 22 kVA units.
Index Communication interface 12 Conduit Knock-out, sizes 48 Cooling fan 44 A D AC input mode 24 , .
G battery warning light 39 capacitors, Aluminum electrolytic 44 ground fan, cooling 44 Importance of, 7 fuses 44 RS-232C 14 Liquid Crystal Display (LCD) Functions 27 terminals 11 Low Voltage Tolerance 21 Grounding 7 M H Maintenance Bypass, switching to and from 46 Humidity 19 , Maintenance Bypass, voltage restrictions 46 humidity 6 7 Maintenance Bypass Unit 46 I maximum ambient operating temperature 3 Mode Input Capacity 18 AC Input 24 Input Frequency 18 , warning 8 41 Battery Back
Power Conditioning 5 Status Change Indications 41 Power factor Stopping the UPS 22 41 input 18 Stop Signal Operation 13 , 12, 13 output, rated load 18 21 Power failure signal , , , Storage 6 19 temperature 19 Precautions 7 8 synchronization frequency tolerance 41 Preventive Maintenance 44 System Fault Messages 40 Protection System 42 System Warning Messages 39 R T Real Time Clock 19 Terminal Block 11 Receptacle Panels 45 Theory of operaton 5 Recharge Time 18 23 torque, tightening 11
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