UNINTERRUPTIBLE POWER SYSTEM THREE-PHASE 15/ 25/ 30/ 33/ 50 kVA UPS 4200FA USER'S MANUAL MANUFACTURED IN THE U.S.A.
TOSHIBA 4200FA THREE PHASE- 15/25/30/33/50 kVA UNINTERRUPTIBLE POWER SYSTEM OPERATION MANUAL FOR MODELS T42F3F150X#MBN T42F3F150F#MBN T42#3#150##MXN T42F3F250X#MBN T42F3F250F#MBN T42#3#250##MXN T42F3F300X#MBN T42F3F300F#MBN T42#3#300##MXN T42F3F330X#MBN T42F3F330F#MBN T42#3#330##MXN T42F3F500XAMBN T42F3F500F#MBN T42#3#500##MXN TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Rd.
TOSHIBA Notice These Instructions are not intended to cover all of the details or variations in equipment, nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. This manual may change without notice. Contact your local Toshiba sales office to verify that this is the latest revision.
TOSHIBA Manual’s Purpose and Scope This manual provides information on how to safely install, operate, and maintain your TIC 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.
TOSHIBA General Safety Instructions DO NOT attempt to install, operate, maintain or dispose of this equipment until you have read and understood all of the product safety information and directions that are contained in this manual. Safety Alert Symbol The Safety Alert Symbol indicates that a potential personal injury hazard exists. The symbol is comprised of an equilateral triangle enclosing an exclamation mark.
TOSHIBA Special Symbols To identify special hazards, other symbols may appear in conjunction with the DANGER, WARNING and CAUTION signal words. These symbols indicate areas that require special and/or strict adherence to the procedures to prevent serious injury to personnel or death. Electrical Hazard Symbol A symbol which indicates a hazard of injury from electrical shock or burn. It is comprised of an equilateral triangle enclosing a lightning bolt.
TOSHIBA Equipment Warning Labels DO NOT attempt to install, operate, maintain, or dispose of this equipment until you have read and understood all of the product warnings and user directions that are contained in this instruction manual. Shown below are examples of warning labels that may be found attached to the equipment. DO NOT remove or cover any of the labels. If the labels are damaged or if additional labels are required, contact your Toshiba representative for additional labels.
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TOSHIBA TABLE OF CONTENTS 1.0 1.1 1.2 1.3 1.4 2.0 2.1 2.2 2.3 2.3 2.4 2.5 3.0 3.1 3.2 3.3 4.0 Product Description ................................................................................................ 13 Theory of Operation............................................................................................................................ 13 Application and Use............................................................................................................................
TOSHIBA 5.15 LCD (Liquid Crystal Display) Functions.............................................................................................. 43 5.15.1 Line-1 System Messages ............................................................................................................ 43 5.15.2 Line-2 System Fault Messages ................................................................................................... 43 5.15.3 Line-3 System Messages ....................................................
TOSHIBA IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during the installation, maintenance, and operation of the UPS and its batteries to assure safe and proper operation 1. Turn off, lockout, and tagout all power sources before connecting the power wiring to the equipment or when performing maintenance. 2.
TOSHIBA The maximum ambient temperatures in which the Uninterruptible Power System (UPS) should be operated is 104°F (40°C) or 89° F (32°C) if the battery cabinet is subject to the same ambient. The nominal battery voltage for all internal battery models is 288VDC. The nominal battery voltage for all external battery models is 288VDC. An Authorized Toshiba Service Representative who is knowledgeable of batteries and the required precautions should perform service on the batteries.
TOSHIBA To be performed by Qualified Personnel only. 1) Verify that the UPS is off and that the power cord is disconnected from the power source. 2) Remove watches, rings or other metal objects. 3) Use tools with insulated handles to prevent inadvertent shorts. 4) Wear rubber gloves and boots. 5) Do not place tools or any metal parts on top of batteries. 6) Determine if the battery is inadvertently grounded. If inadvertently grounded, remove source of ground.
TOSHIBA 1.0 Product Description 1.1 Theory of Operation An Uninterruptible Power Supply (UPS) is a system that is installed between the commercial power and the critical load. The UPS provides steady AC output power during commercial power fluctuations and interruptions. During “Normal Operation” the UPS utilizes commercial AC power and removes high voltage spikes and transients caused by switching and faults on the utility. The result of this process is maximum power conditioning and regulation.
TOSHIBA 2.0 Uncrating/Inspection/Storage/Disposal 2.1 Uncrating the new UPS equipment 15/25/30/33kVA: Upon receipt of the UPS, a careful inspection for shipping damage should be made. Units shipped within North America are shrink-wrapped, those outside North America are crated. 1. Remove packing material. 1a. For international units, remove the screws that attach the shipping crate to the pallet. Remove the crate and foam packing material. 2.
TOSHIBA 2.2 Uncrating the new UPS equipment 50kVA: Upon receipt of the UPS, a careful inspection for shipping damage should be made. Units shipped within North America are shrink-wrapped, those outside North America are crated. 1. Remove packing material. 1a. For international units, remove the screws that attach the shipping crate to the pallet. Remove the crate and foam packing material. 2. Unbolt the rails from both the unit and the shipping pallet. Place the rails on the front of the pallet.
TOSHIBA Inspection of the new UPS equipment After Uncrating: 1) Check the unit for loose, broken, bent or other damaged parts. If damage has occurred during shipment, keep all original crating and packing materials for return to the shipping agent. The equipment warranty will not apply to units that are damaged during shipment. 2) Check to see that the rated capacity and the model number specified on the nameplate conform to the order specifications. 2.
TOSHIBA 3.0 Installation Precautions Based on the 4200FA UPS external dimensions and the way the outer panels are removed; minimum amounts of unobstructed space around the unit are necessary for ventilation and maintenance access. Figure 3.1 shows the minimum clearances required for proper UPS site installation. 3.1 Equipment Placement 1) Do not install the UPS on an inclined surface, or areas that are subject to frequent vibrations or jolting. This could damage UPS circuits.
TOSHIBA 3.2 System Preparation (Pre-Power) Before connecting the UPS to a power source; move the Circuit Breakers (ON/OFF), on the front panel, to the OFF position and move the operation STOP/RUN key switch, on the front panel, to the STOP position. 3.3 Operating Precautions 1) The UPS should not be powered up until the entire operation manual has been reviewed, and understood. 2) The input power source voltage must be within +10% to -15% (to start UPS) of the rated input voltage.
TOSHIBA 4.0 UPS Connections 4.1 Power Connections 15/25/30/33 kVA with Internal Batteries The following illustrates the wiring connections from the power distribution panel (not part of the UPS) to the terminal block of the 15/25/30/33 kVA UPS Models 4.1.
TOSHIBA Power Connections 15/25/30/33kVA with Internal Transformer The following illustrates the wiring connections from the power distribution panel (not part of the UPS) to the terminal block of the 15/25/30/33 kVA UPS Models CUSTOMER-PROVIDED AC DISTRIBUTION PANEL TO BATTERY SYSTEM GND TB1 INPUT GROUND RESISTANCE LESS THAN 10 OHMS Optional Bypass Input: 3-Phase, 3-Wire *208V requires 3-Phase, 4-Wire Wye TB4 20
TOSHIBA 4.1.2 Recommended Wire Size and Torque Requirements UPS Input and Output Terminals Minimum Wire Size and Torque Requirements UPS Input and Output Terminals 15/25/30/33 kVA (USE MINIMUM 75° C INSULATED COPPER WIRING) Phase: (A) (B) (C) 15 kVA 25 kVA 30/33 kVA Input: (H1) (H2) (H3) AWG Torque AWG Torque AWG Torque 208 8 51 in-lbs. 4 51 in-lbs. 2 87 in-lbs. 220 8 51 in-lbs. 4 51 in-lbs. 2 87 in-lbs. 240 8 51 in-lbs. 4 51 in-lbs. 2 87 in-lbs. 380 10 35 in-lbs. 8 51 in-lbs. 6 51 in-lbs.
TOSHIBA 4.1.3 Power Connection Cable Routing and Conduit Placement The following illustrates the proper cable routing that should be followed during the power connection process of the 15/25/30/33 kVA. CONDUIT MOUNTING PANEL INPUT CONDUIT OUTPUT CONDUIT BATTERY CONDUIT Note: 1) Input and Output conductors shall be installed in separate conduits, and installed in accordance with the latest edition of NEC and the Local Authority having jurisdiction.
TOSHIBA 4.2 Control Circuit and External Battery Interface Connections 15/25/30/33 kVA The following illustrates the wiring connections of the Control Circuits, and Battery Interface Circuits. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) 4.2.1 Battery Connection (+) Positive (-) Negative Low Battery Battery Discharge Fault Not Used Inverter Supply Inverter Supply P24A3 Remote Run P24A3 Remote Stop Bypass GND EPO EPO (3) Battery Shunt Trip (4) Battery Shunt Trip (5) Battery Aux.
TOSHIBA 4.
TOSHIBA 4.3.1 Recommended Wire Size and Torque Requirements For UPS Input and Output Terminals Minimum Wire Size and Torque Requirements UPS Input and Output Terminals 50 kVA (USE MINIMUM 75° C INSULATED COPPER WIRING) INPUT: OUTPUT: (H1) (H2) (H3) AWG NEUTRAL AWG NEUTRAL (L1)(L2)(L3) Tightening AWG AWG Torque 208 1/0 250MCM 208/120 1/0 250MCM 200 in-lbs. 220 1/0 4/0 220/127 1/0 4/0 200 in-lbs. 240 1 N/A 240 1 N/A 200 in-lbs. 380 4 1/0 380/220 4 1/0 200 in-lbs. 400 4 1/0 400/230 4 1/0 200 in-lbs.
TOSHIBA 4.3.2 Power Connection Cable Routing The following illustrates the proper cable routing that should be followed during the power connection process for the 50kVA.
TOSHIBA 4.4 Control Circuit and External Interface Connections The following illustrates the wiring connections of the Control Circuits, and Battery Interface Circuits for the 50kVA. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) 4.4.1 Low Battery Battery Discharge Fault Not Used Inverter Supply Inverter Supply P24A3 Remote Run P24A3 Remote Stop Bypass GND EPO EPO (3) Battery Shunt Trip (4) Battery Shunt Trip (5) Battery Aux. (6) Battery Aux.
TOSHIBA 4.5 Communication Interface 4.5.1 Remote Contact This interface is a standard feature and is available as dry switch contacts through a DB9 male connector located on the front of the UPS. The following schematic shows the contact state and pin assignment for each signal and the associated DB9 connector pin-out.
TOSHIBA 4.5.2 RS-232C The RS-232C serial communication interface is available through a DB9 female connector located on the backside of the UPS. This interface allows control of the UPS from a computer network running Toshiba RemotEyeII™ software. The computer and the UPS are connected through a serial RS-232C communication port.
TOSHIBA 5.0 Technical Data 5.
TOSHIBA 5.2 4200FA 15/ 25kVA w/Internal Transformer Model Number Frequency Slew Rate Voltage Transients (Recovery time: 50 msec) Inverter Overload Capacity Bypass Overload Capacity Crest Factor Neutral Line Conductor Harmonic Voltage Distortion T42#3*150#AMXN T42#3*250#AMXN # =(B: 208; H: 220; C: 240; N: 380–415; D: 480; M: 600) VAC *=(F: 208; H: 220 wye; J: 240; P: 380–415 wye; K: 480 wye: M:600) 15 kVA 25 kVA 20” x 36.25” x 59.85” 508mm x 90.75mm x 1520.
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TOSHIBA 5.5 4200FA 50kVA @ 208 VAC Input/ 208 VAC Output w/Internal Batteries Frequency Slew Rate Voltage Transients (Recovery time: 50 msec) Inverter Overload Capacity Bypass Overload Capacity Crest Factor Neutral Line Conductor Harmonic Voltage Distortion T42F3F500XAMBN T42F3F500##MBN 50 kVA 35.6” X 38.9” X 59.4” (904mm x 970mm x 1509mm) 208 VAC +10% to -30%; (-15% to -30%) **** 50 / 60 Hz 3 ∅; 4 Wire + GND 3 ∅; 4 Wire + GND Greater than 0.98 when in inverter mode 55.
TOSHIBA 5.6 4200FA 50kVA w/Internal Transformer Model Number Frequency Slew Rate Voltage Transients (Recovery time: 50 msec) Inverter Overload Capacity Bypass Overload Capacity Crest Factor Neutral Line Conductor Harmonic Voltage Distortion T42#3*500#AMXN # =(B: 208; H: 220; C: 240; N: 380–415; D: 480; M: 600) VAC *=(F: 208; H: 220 wye; J: 240; P: 380–415 wye; K: 480 wye; M:600) 50 kVA 35.6” X 38.9” X 59.
TOSHIBA Operating the UPS 5.7 Operating the UPS 5.7.1 AC Input Mode (Normal Operation) The following illustration shows circuit power flow when the UPS is operating normally in the AC Input Mode. The rectifier includes a boost chopper circuit that converts the AC input power into DC power. The boost chopper circuit maintains a constant voltage with current limiting abilities for charging the batteries. The rectifier supplies a DC voltage of the proper level to the inverter section.
TOSHIBA MBS Bypass Power Bypass Isolation Transformer Model Converter Inverter MCCB Input Power Output Power Chopper Batteries Power flow in Bypass mode for the Alternate Input Models 5.7.3 Battery Backup Mode The following illustration shows power flow during the battery backup mode. When commercial AC power failures occur, the batteries instantly begin supplying DC voltage to the main inverter circuit. This circuit inverts (hence; Inverter) the DC power into AC power.
TOSHIBA 5.8 Battery Backup Time and Discharge Process The UPS system, when used in conjunction with a Toshiba designed Battery System, is designed to provide several minutes of back-up time (Refer to the Battery System Manual for back-up times). These times are valid when the unit is operating under full load. When these models are operating at half load, the batteries can provide approximately 2 times the specified value.
TOSHIBA 5.10 Battery Recharging The illustration below shows a graphical representation of the UPS battery recharge process after a full discharge. The recharge process usually consists of three steps. During the first step, the charging current is maintained at approximately 4.0 amperes for the 15/25/30/33kVA and approximately 11.5 amperes for the 50 kVA. This current is the maximum value that can be used to charge the batteries (for minimal recharge time) while assuring safety and long battery life.
TOSHIBA 5.11 Front Panel Layout (All Units) Refer to the following illustration for the entire UPS front panel operating procedures. 4-line liquid crystal display screen (see Section 6.9) Emergency power off switch (see Section 6.6) line-1 line-2 line-3 line-4 MONI BATT IN OUT STOP/RUN key switch UPS F1 STOP BATT TEST RUN EPO BUZZ MENU ENTER STOP AC IN INV BYP BATT FAULT RESET 4200 Series ON-LINE UNINTERRUPTIBLE POWER SYSTEM Green light emitting diodes (LED) (see Section 6.8) 5.
TOSHIBA pattern duration for each condition. Time intervals are shown in seconds. The audible alarm can be silenced, by pressing “BUZZ STOP” on the keypad. Condition Audible pattern UPS in Battery Backup Mode (Battery Voltage 100-92%) 7S UPS Low Battery (Battery Voltage < 92%) 1S 1S Overload .5 S .5 S .5 S Fault 41 .
TOSHIBA 5.14 AC IN GREEN LED (Light Emitting Diode) Functions The following list describes the conditions necessary for each LED lamp to be "on." This green LED lamp is "on" when the UPS is operating normally within specifications. If there is no power failure and the input voltage is in an under-voltage condition, the AC IN lamp will be "off." If there is no power failure and the input voltage is in an over-voltage condition, the AC IN lamp will flicker on and off rapidly (0.4 sec "on" and 0.
TOSHIBA 5.15 LCD (Liquid Crystal Display) Functions The LCD screen is a 4-line by 20-character wide display. The LCD display contains information about the operation of the UPS. It should be used in conjunction with the LED display and the audible alarms for total system monitoring. The LCD displays certain information only on specific lines of the display. The UPS operating mode and conditions determines the information shown. These messages are shown in the following line message charts. 5.15.
TOSHIBA 5.15.4 Line-4 System Messages Line-4 messages reflect the UPS operating conditions. Warning messages will be displayed when an abnormal operating condition occurs. The following chart shows the allowable Line-4 messages. Line-4 Messages Displayed Message PHEI I/O NOT SYNCHRONIZE * AUTOTRANSFER * * LOW BATTERY * * UPS OL: REDUCE LOAD * * DCOC * * DCOV * * DCUB * * OL * * FUSE * * INOV * * INUV * * BATT.
TOSHIBA 5.16 Initial Battery Charge The UPS Battery System must be charged before it is used for the first time or when the unit has not been used (AC power source removed) for more than 10 days. Use the following procedure to recharge the UPS Battery System: 1) Switch on power at the UPS input distribution panel, and battery disconnects. 2) Move the UPS MCCB1 (Circuit Breaker 1) power switch on the rear panel to "on." The UPS battery charging circuit is now activated. The AC IN lamp will be "on.
TOSHIBA 5.17 Start-up Procedure The UPS batteries must be charged before the UPS is used for the first time or if the unit has not been used (AC power source removed) for more than 10 days. If the batteries are charged then use the following start-up procedure: 1) Verify that all power switches are off, and that the "STOP/RUN” Switch on the UPS is in the “STOP” position. 2) Switch on the power at the Customer Provided UPS input distribution panel. 3) Move the UPS Circuit Breakers to "on.
TOSHIBA 5.18 Shutdown Procedure When turning off the UPS, the following shutdown procedure should be used: Move the “STOP/RUN” key switch, located on the front panel, to “STOP." Operation of the inverter stops. Output power is now provided to the load through the unit's Bypass circuit. While in this state of operation; if a power failure occurs in the commercial power source, the UPS will lose power. Power to the critical load device will be interrupted.
TOSHIBA 5.19 Maintenance Bypass Procedure When operating the Maintenance Bypass, the following operation procedure should be used: WARNING Failure to adhere to the following instructions could result in damage to your equipment and/or you risk removal of power to any equipment attached to the UPS. From UPS to Maintenance Bypass 1) Move the “STOP/RUN” key switch, located on the front panel, to “STOP." Operation of the UPS inverter stops. Output power is now provided to the load through the Bypass circuit.
TOSHIBA 5.20 Keypad Overview The following illustrates the 12-key data entry pad with each key functionally labeled. MONI BATT F1 IN OUT BATT TEST BUZZ STOP MENU ENTER RESET MONI Press to display system-monitoring screens. BATT Press to display UPS battery conditions. F1 Press to change settings of various menus. IN Press to display UPS input conditions. OUT Press to display UPS output conditions. BATT TEST Press to execute On-Line Battery test.
TOSHIBA 5.21 Key Functions 5.21.1 MONI After the UPS has been successfully started, the system will be in the normal 'AC Input Mode' of operation. The LCD screen will automatically display the main MONI (monitor) function. If the MONI key is pressed at this time the screen output will not change. The MONI function automatically monitors the entire UPS system. The LCD screen will automatically switch "off" after a period of keypad inactivity and switch "on" if any key is pressed.
TOSHIBA 5.21.4 BATT Key When the BATT key is pressed during normal 'AC Input Mode' of operation, the LCD screen displays details about the battery capacity. The following system message is displayed: - UPS ON-LINE BATTERY VOLTAGE=324V CHARGE CURR.=0% If an AC input power failure occurs, and no abnormal operating conditions are present, the UPS will switch to standard 'Battery Backup Mode'.
TOSHIBA When the battery test is completed, the previous operation will be resumed and the main system MONI screen will be displayed.
TOSHIBA 5.22 Menu Data Screens 5.22.
TOSHIBA Press the F1 key to display the LCD-Idle mode setting adjustment screen: DISPLAY DURATION SET <3 MIN> 30 MIN >∆/∇: CHANGE DATA >ENTER:ACCEPT CHANGE Press the 'up' or 'down' arrow key to move the marker between the two available idle mode times. Press the ENTER key to save the change or press the MENU key to exit to the main menu and discard the change.
TOSHIBA 5.22.6 Output Voltage Adjustment When the MENU key is pressed and held 3-4 seconds during normal 'AC Input Mode' of operation, the LCD screen displays the output voltage on the present output voltage adjust screen: OUTPUT VOLT. ADJUST OUTPUT VOLTAGE.=###% >F1:DATA SET MODE > ∆/∇ :PREV/NEXT SCREEN Press the F1 key to display the following active adjustment screen: OUTPUT VOLT.
TOSHIBA 5.22.
TOSHIBA After the load is reduced, if the STOP/RUN key switch is in the RUN position, the UPS will automatically return to 'Inverter Operation’ after a period of time.
TOSHIBA Press the F1 key again to display the record relating to each subsequent discharge event. BACKUP HISTORY ( #) #MIN##SEC VB=324V BT *PF OL >∆/∇: EXIT F1: NEXT Press the ‘up’ or ‘down’ arrow keys to return to the Battery Discharge Count screen. BATT DISCHARGE COUNT # TIMES > F1: FOR DETAILS >∆/∇: TO SCROLL Press the ‘up’ or ‘down’ arrow keys to display the Fault Count screen.
TOSHIBA 6.0 UPS Protection System 6.1 System Protection Features The preceding one-line schematic illustrates the electrical locations of the protection devices on all UPS models. Input Abnormal MBS Overheat Bypass Overload Isolation Transformer Model Converter Inverter MCCB Input Power Output Power Chopper Over-voltage/ Under-voltage Overcurrent Batteries Low Battery 6.2 System Protection Functions The following chart shows the built-in UPS fault protection functions on all models.
TOSHIBA Protection Item Memory error (EERR) Internal overheat (OH) DC circuit overvoltage (DCOV) DC circuit overcurrent (DCOC) LCD Message Cause Operation Mode after Fault Audible Alarm Visible Alarm Relay Contact Alarm Auto-Retransfer MAIN EEPROM ERROR Control board chip error OVERHEAT; INTERNAL Fan failure; high ambient DC OVERVOLTAGE Chopper malfunction DC OVERCURRENT Inverter / chopper fault Start is inhibited Bypass operation; chopper and inverter are stopped Yes; continuous buzzer RED fault
TOSHIBA 7.3 Parts Replacement The following list shows intervals for periodic maintenance and replacement of certain UPS parts. 1) Batteries: VRLA (Valve Regulated Lead Acid) batteries do not require the adding of water or electrolyte. The charging voltage, temperature, performance and connection resistance must be monitored periodically. Necessary corrective maintenance must be made in order to assure the UPS supplies safe reliable power.
TOSHIBA 8.0 External Layouts / Dimensions / Weights 8.
TOSHIBA 8.
TOSHIBA 8.3 Shipping Dimensions and Weights Models 15 kVA 25/30/33 kVA 50 kVA Shipping Dimensions W” x D” x H” (WmmxDmmxHmm) 36.5” x 43.0” x 69.5” (927mm x 1092mm x 1765mm) 36.5” x 43.0” x 69.5” (927mm x 1092mm x 1765mm) 55.0” x 44.5” x 69.5” (1397mm x 1130mm x 1765mm) 64 Internal Model Battery Transformer Battery Transformer Battery Transformer Shipping Weights Lbs. (kg) 1,303 lbs. (591 kg) 1,260 lbs. (572 kg) 1,321 lbs. (599 kg) 1,275 lbs. (579 kg) 2,548 lbs. (1156 kg) 2,523 lbs.
TOSHIBA TOSHIBA INTERNATIONAL CORPORATION INDUSTRIAL DIVISION 13131 West Little York Road, Houston, Texas 77041 Tel: (713) 466-0277 Fax: (713) 896-5212 Telex: 762078 E-mail: Toshibaups@tic.toshiba.com Printed in the U.S.A.