6 F 3 H 1 0 0 1 Uninterruptible Power System (UPS) TOSNIC-7000S Instruction Manual (OPERATION) REQUIREMENT • This manual should be delivered to the persons who will ultimately use and maintain the UPS. • Read this manual carefully before operating the UPS. • Store the manual in a safe place so it can be referred to when needed. July 1999 © ALL Rights Reserved.
6 F 3 H 1 0 0 1 Definitions (1) Main unit c UPS: Uninterruptible Power System * If required by the custom specifications, the unit will be marked as a CVCF device. CVCF: Constant Voltage Constant Frequency (2) Main circuit switches c d MCCB: ACB: Molded Case Circuit Breaker Air Circuit Breaker (3) Storage cells c d e f g Individual battery system: A parallel UPS system in which there is a battery for each UPS in the system.
6 F 3 H 1 0 0 1 1. Introduction This manual is designed to ensure the safe and correct operation of the TOSNIC-7000S Uninterruptible Power System (hereafter referred to as "UPS unit"). Please read the "Safety Precautions" and "Operation" sections of this manual carefully before use and make sure you have a thorough understanding of the information in these two sections. Keep the manual handy in a place near the unit so you can refer to it instantly when needed.
6 F 3 H 1 0 0 1 2. Safety Precautions (continued) Use Special considerations (*) are required when using equipment that affects the lives and safety of human beings (**) or has a critical effect on maintaining public services (***). Be sure to contact Toshiba in such cases. The use of such equipment without special consideration may result in serious accidents.
6 F 3 H 1 0 0 1 2. Safety Precautions (continued) WARNING If the unit begins to emit smoke or strange odors, immediately turn off circuit breakers 52R and 72B. Continued use may result in fire. Contact the Toshiba Service Center. MANDATORY Contact the Toshiba Service Center in the event of malfunction or failure. This unit should be repaired only by authorized Toshiba service personnel. Servicing by untrained personnel may increase the scale of the failure or result in electric shock or injury.
F 3 H 1 0 0 1 2. Safety Precautions (continued) WARNING Do not open the rear door. The parts inside carry high voltage. Touching them may result in electric shock, burns or failure. PROHIBITED CAUTION Operators should be qualified* personnel. Operation of the UPS by unqualified or untrained personnel may result in electric shock, injury or failure. * In accordance with customer stipulations MANDATORY Make sure the air vents on the front and top of the unit are not blocked.
6 F 3 H 1 0 0 1 2. Safety Precautions (continued) Checking warning labels (1) The locations of the warning labels on the UPS are shown in Figure 2.1. Check to make sure that these warning labels are in place. Note that the placement and content of the warning labels may differ depending on the capacity of the UPS. Verify the locations by referring to the warning label placement figure provided with the "Maintenance & Inspection 6F3H1002" manual.
6 F 3 H 1 0 0 1 3. Handling Precautions Perform daily and periodic inspections as noted in the maintenance and inspection plan. In order to ensure a long service life and optimal performance, the equipment must be installed in a suitable environment, must be operated correctly, and must be given the proper daily and periodic inspections. Maintenance and inspections are particularly effective in preventing accidents caused by changes in components that will occur over time.
6 F 3 H 1 0 0 1 3. Handling Precautions (continued) Do not turn the circuit breakers ON when control power source switch (8A) is OFF. This may result in failure. Certain units also have a control power source switch (8D). This switch has the same functions as the switch 8A. PROHIBITED Do not turn the control power source switch (8A) to the OFF position when the circuit breakers are ON. This may result in failure. Certain units also have a control power source switch (8D).
6 F 3 H 1 0 0 1 3. Handling Precautions (continued) When the unit has stopped due to failure, be sure to remove the memory card before resetting the LCD Failure Error screen on the panel. Resetting (restarting) the UPS without removing the memory card will delete the data needed to determine the cause of the failure. Do not leave the unit for long periods of time (1 week) with control power source switch (8A) in the OFF position.
6 F 3 H 1 0 0 1 4. Contents 1. Introduction ····························································································································2 2. Safety Precautions ·················································································································2 3. Handling Precautions ············································································································7 4.
6 F 3 H 1 0 0 1 5. Appearance Only open the front panel when performing necessary operations.* WARNIN G Operating parts and high-voltage areas inside the UPS have been provided with covers as a safety precaution. Still, touching areas other than those that must be touched to perform necessary operations may result in electric shock, burns or other injuries.
6 F 3 H 1 0 0 1 6. Controls and Circuit Configuration WARNIN G If the unit begins to emit smoke or strange odors, immediately turn off circuit breakers 52R and 72B. Continued use may result in fire. Contact the Toshiba Service Center . 6.1 Panel Controls Figure 6.1 and Table 6.1 show the locations and functions of the controls used for the circuit configurations (see Figures 6.2) on the UPS. Do not turn the circuit breakers ON when control power source switch (8A) is OFF. This may result in failure.
6 F 3 H 1 0 0 1 Table 6.1 No. Device c 52R d 72B e 52C f 52M g 52L h 8A i 6CH Control Functions Name / Function Normal Status During Operation Main circuit AC input circuit breaker When the AC input is normal, power is supplied to the UPS through this circuit breaker. Main circuit DC input circuit breaker When AC input has been cut off, power is supplied from the battery to the UPS through this circuit breaker.
6 F 3 H 1 0 0 1 6.3 Panel Controls When the unit has stopped due to failure, be sure to remove the memory card before resetting the LCD Failure Error screen on the panel, so you can give it to the service person. Resetting (restarting) the UPS without removing the memory card will delete the data needed to determine the cause of the failure. NOTES Every effort has been made to ensure safety in unit handling. However, when removing the memory card, do not touch the other sections of the unit.
6 F 3 H 1 0 0 1 6.3.1 Panel Key-switch Table 6.2 shows the function of the key-switch on the graphic display panel. Table 6.2 No. c Key-switch Function Name Function Remarks OPERATION LOCK Setting this key-switch to the "OPERATION" side enables operation using the buttons on the panel; setting it to the "OPERATION INHIBITED" side prevents operation. When the switch is set to the "OPERATION INHIBITED" side, buttons d - h and k in Table 6.
6 F 3 H 1 0 0 1 Table 6.3 No. Key Functions (For HS or AHH individual battery systems) (continued) Name h FLOAT / EQUAL** *** i SCROLL UP j SCROLL DOWN k RESET * , Function Remarks Changes the battery charging mode. Pressing this key during UPS operation changes the status to equalized charge (If it is currently set to floating charge) or floating charge (If it is currently set equalized charge). These keys switch the screen displayed on the LCD. For details, see Section 9.2.
6 F 3 H 1 0 0 1 7. Panels 7.1 Graphic Display Panel Figure 7.1.1 and 7.1.2 and Table 7.1 show the locations and functions of the controls on the graphic display panel.
6 F 3 H 1 0 0 1 11 SCROLL 12 13 14 16 WARNING UPS SUPPLY FAULT 17 15 20 ~ ~ AC INPUT ~ UPS 24 INVERTER CONVERTER AC FLOAT CHARGE BATTERIES ~ SWITCH DISCHARGE AC OUTPUT 25 ~ 19 BYPASS BYPASS INPUT UPS 23 AC SWITCH FAULT OPERATION OPERATION INHIBITED 22 Figure 7.1.2 18 STOP RUN BYPASS UPS RESET Graphic Display Panel Control (Graphic Display Panel of the type without the equalized charge mode and the protection charge mode).
6 F 3 H 1 0 0 1 Table 7.1 No. Display Panel Functions (For HS or AHH individual battery systems) Name Function 11 LCD INDICATOR Displays help messages, measurement data and warning descriptions. For more information, see Section 7.2 "LCD Display." 12 UPS SUPPLY LED This LED lights up when the UPS is operating. 13 WARNING LED This LED blinks in the event of an warning. 14 FAULT LED This LED lights up in the event of a UPS failure.
6 F 3 H 1 0 0 1 7.2 LCD Display The LCD Display screens consist of the following screens. (1) Normal Display screen ............. Initial display, operation guidance, and measurement value display (2) Failure Data Display screen ..... Displays detailed data when a failure occurs. (3) Warning Data Display screen ... Displays detailed data when a warning occurs. The operator can switch between these screens by pressing the scroll keys.
6 F 3 H 1 0 0 1 7.2.1 Normal Display Screen The Normal Display screen indicates the operational status of the UPS and provides a total of nine screens: one Operation Guidance Display screen and eight Measurement Value Display screens. Table 7.2 presents examples of these screens. Table 7.2 No. 1 Normal Display Screen LCD Screen Description Help screen (Example 1) Operation status Shows the status of the UPS at the top and help messages or measurements underneath.
6 F 3 H 1 0 0 1 Table 7.2 5 Measurement screen (Example) Output frequency Normal Display Screen (continued) Shows the output frequency. O/P FREQUENCY FREQ. 6 60.0[Hz] Measurement screen (Example) AC input Shows the frequency and voltage values for AC input. AC INPUT AC I/P-V 200[V] FREQ. 60.0[Hz] 7 Measurement screen (Example) Bypass input Shows the frequency and voltage values for bypass input. BYPASS INPUT BYP I/P-V 200[V] FREQ. 60.
6 F 3 H 1 0 0 1 7.2.2 Failure Display Screen The Failure Display screen indicates the presence or absence of failure data and displays that data if present. Table 7.3 Failure Display Screen LCD Screen Description Presence or absence of failure data This screen indicates the presence or absence of failure data. This screen is displayed if there is no failure data, or if all failure data has been reset with the "fault display rest" key.
6 F 3 H 1 0 0 1 7.2.4 LCD Screen Switching The △ and ▽ scroll buttons on the front of the panel are used to switch the screen displayed on the LCD. See figure 6.3.1 for the location of the △ and ▽ scroll buttons. Symbol Name Description ▲ SCROLL UP Moves to the previous screen (see Figure 7.2) ▼ SCROLL DOWN Moves to the next screen (see Figure 7.
6 F 3 H 1 0 0 1 8. Operation Operators should be qualified* personnel. Operation of the UPS by unqualified or untrained personnel may result in electric shock, injury or failure. * CAUTION In accordance with customer stipulations Make sure you understand the meaning of the warning labels on the equipment, and follow the precautions indicated. Operating the equipment with an inadequate understanding of these matters may result in electric shock or burns.
6 F 3 H 1 0 0 1 8.1 Types of Operation This section summarizes the types of operations covered in this manual and their objectives. Refer to the attached operating procedures document for specific details on the operating procedures. No. Operation General Description/Objective Page No. 1 Startup Starts up and operates the stopped UPS. Page 27 2 Switch Power Supply Switches between UPS power supply and bypass power supply. Page.31 3 Stop Stops a UPS that is operating.
6 F 3 H 1 0 0 1 8.3 Procedures 8.3.1 Startup Table 8.1 shows the procedure used to start up the UPS. LED status : Unlit : Lit Table 8.1 Step 1 Procedure : Blinking Startup Procedures LCD/LED Status (After Execution) Turn on the control power supply switch (8A) on the panel. OPERATION GUIDANCE MOVE #52C AND #52L TO ‘ON’ POSITION ~ ~ AC INPUT ~ CONVERTER BATTERIES UPS INVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH ~ AC OUTPUT DISCHARGE ~ BYPASS BYPASS INPUT The "BYPASS" LED lit.
6 F 3 H 1 0 0 1 Table 8.1 Step 4 Procedure Startup Procedures (continued) LCD/LED Status (After Execution) Wait several seconds.** BYPASS MOVE #52R TO ‘ON’ POSITION ~ ~ AC INPUT ~ CONVERTER BATTERIES UPS INVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH ~ AC OUTPUT DISCHARGE ~ BYPASS BYPASS INPUT 5 When the message appears, turn on the main circuit AC input circuit breaker (52R).
6 F 3 H 1 0 0 1 Table 8.1 Step 7 Procedure Startup Procedures (continued) LCD/LED Status (After Execution) Hold down the "RUN" key (d in Figure 6.3.1 on page 14) for at least 0.5 second. BYPASS UPS START-UP ~ ~ AC INPUT ~ CONVERTER BATTERIES UPS INVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH ~ AC OUTPUT DISCHARGE ~ BYPASS BYPASS INPUT The "CONVERTER" and "INVERTER" LEDs blinking. 8 Wait several seconds for the startup process to finish.
6 F 3 H 1 0 0 1 Table 8.1 Step 10 Procedure Startup Procedures (continued) LCD/LED Status (After Execution) Hold down the “UPS” key (g in the Figure 6.3.1 on page14) for at least 0.5 second. * → The will start the power supply changing process. UPS SUPPLY AC-VO AC- I O ~ ~ AC INPUT ~ CONVERTER BATTERIES 200[V] 50[%] UPS INVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH ~ AC OUTPUT DISCHARGE ~ BYPASS BYPASS INPUT The "BYPASS" LED unlit and “UPS” LED lit.
6 F 3 H 1 0 0 1 8.3.2 Switch Power Supply (UPS → Bypass) Table 8.2 shows the procedure used to switch between UPS power supply and bypass power supply. Table 8.2 Step 1 Procedure UPS Power Supply → Bypass Power Supply LCD/LED Status (After Execution) Check to make sure power is being supplied to the UPS.
6 F 3 H 1 0 0 1 Toshiba Service Center. Do not manually operate the solenoid contactor (which is part of AC switch).
6 F 3 H 1 0 0 1 8.3.3 Stop Table 8.3 shows the procedure used to stop the UPS. Table 8.3 Step 1 Procedure Stop LCD/LED Status (After Execution) Change to bypass supply as described in Table 8.2 on page 31. BYPASS AC-VO 200[V] 50[%] AC- I O PRESS ‘UPS’ SWITCH ~ ~ AC INPUT CONVERTER BATTERIES ~ UPS INVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH ~ AC OUTPUT DISCHARGE ~ BYPASS BYPASS INPUT The “UPS” LED unlit and “BYPASS” LED lit. 2 Hold down the "STOP" key (e in Figure 6.3.
6 F 3 H 1 0 0 1 Table 8.2 Step 3 Procedure Stop (continued) LCD/LED Status (After Execution) Turn off the main DC input circuit breaker(72B). BYPASS RESTART : PRESS ‘RUN’ SWITCH SHUTDOWN : MOVE #52R TO ‘OFF’ ~ ~ AC INPUT CONVERTER BATTERIES ~ UPS INVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH ~ AC OUTPUT DISCHARGE ~ BYPASS BYPASS INPUT The “BATTERIES” LED unlit.
6 F 3 H 1 0 0 1 8.3.4 Complete Shutdown This section describes the procedure used to turn off the control power source and shut down the UPS completely (to turn everything up to the control power source off). Table 8.4 Step 1-4 5 Procedure Complete Shutdown LCD/LED Status (After Execution) Same as steps 1-4 in Section 8.3.3 "Stop." When the message appears, turn off the main circuit AC input circuit breaker (52R).
6 F 3 H 1 0 0 1 Table 8.4 Step 8 Procedure Complete Shutdown (continued) LCD/LED Status (After Execution) Turn off the precharge circuit switch (6CH). OPERATION GUIDANCE MOVE #6CH TO ‘OFF’ POSITION WAIT ABOUT 20 MINUTES MOVE #8A TO ‘OFF’ POSITION ~ ~ AC INPUT ~ CONVERTER BATTERIES UPS INVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH ~ AC OUTPUT DISCHARGE ~ BYPASS BYPASS INPUT 9 Wait about 20 minutes until the DC capacitor has been discharge.
6 F 3 H 1 0 0 1 8.3.5 Changing Between Floating Charge and Equalized Charge (For HS or AHH individual battery systems) This section describes the procedure used to change the charging mode. This operation does not apply to shared battery systems. (1) Table 8.5 shows the procedure used to change manually from floating charge to equalized charge. Table 8.
6 F 3 H 1 0 0 1 (2) Table 8.5 shows the procedure used to change manually from equalized charge to floating charge. After the charging mode has been changed to equalized charge using the procedure on the previous page, the mode will automatically change back to floating charge after a set period of time has elapsed. Therefore, normally there is no need to change the mode manually as described below. Table 8.
6 F 3 H 1 0 0 1 8.3.6 Changing to Floating Charge etc. (for MSE individual battery) Table 8.7 shows the procedure used to change manually from protective charge to floating charge. This operation does not apply to shared battery systems. (1) An MSE battery normally operate in floating charge mode. (2) To prevent the battery temperature from rising, the mode changes automatically to protective charge mode when a "BATT FAULT1" (BATTERY OVER TEMP.) warning occurs.
6 F 3 H 1 0 0 1 8.3.7 Changing the Power Supply to Maintenance Bypass This UPS must be completely shut down when performing maintenance and inspections. In such cases, the power supply to the load will go through the maintenance bypass. Table 8.8 shows the procedure used to change the power supply to this maintenance bypass. Table 8.9 shows how to change the power supply from the maintenance bypass back to the UPS. Table 8.
6 F 3 H 1 0 0 1 Table 8.9 Step 1 Changing From Maintenance Bypass to UPS Power Supply Procedure LCD/LED Status (After Execution) Same as steps 1-4 in Section 8.3.1 “Startup” BYPASS MOVE #52R TO ‘ON’ POSITION ~ ~ AC INPUT ~ BATTERIES UPS INVERTER CONVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH ~ AC OUTPUT DISCHARGE ~ BYPASS BYPASS INPUT MCCB 2 Turn OFF maintenance bypass AC circuit breaker , , 52M.
6 F 3 H 1 0 0 1 9. Troubleshooting When an error occurs on the UPS, error data is displayed on the LCD screen and the waveform is saved. This section will describe the types of errors, the error messages displayed on the LCD screen, the process of saving waveforms and the procedures used to correct the errors. 9.1 Types of Errors The following types of errors may occur on the UPS: No. Name Description 1 Fault (Trip) The UPS has been tripped and has stopped operating.
6 F 3 H 1 0 0 1 9.2 LCD Failure Displays When a failure occurs, a screen such as that shown in Figure 9.1, and when a warning occurs, a screen such as that shown in Figure 9.2, will be displayed on the LCD. ▲ FAULT STOP FAULT 1 SERVICEMAN CALL ▼ 52R TRIP 98-09-09 08:05:30 ↓ANOTHER ITEM Select the desired failure data with the scroll buttons. Detailed failure data can be displayed. Figure 9.
6 F 3 H 1 0 0 1 9.2.2 Warning Data Screen These screens appear when a warning has occurred. Up to 10 screens can be displayed. Figure 9.4 and Table 9.2 show an example of this type of screen and describe the data shown in the screen. WARNING c 1 72B MIS OPE 98-09-09 08:05:30 ↓ANOTHER ITEM Figure 9.4 Table 9.2 No. d e f Sample Warning Data Screen Warning Data Screen Descriptions Name Description c No. The number of the message in the order that it was detected (1 - 10).
6 F 3 H 1 0 0 1 9.2.3 Failure Messages Figures 9.6 show the locations for failure detection. Tables 9.4 through 9.8 list the failure messages described in Section 9.2.1 "Failure Data Screen". The content and display text for the failure and warning messages in Tables 9.4 through 9.8 have been created based on the standard protective configuration shown in Figures 9.6.UPS units can be shipped with different protective configurations from the standard if this is specified by the customer.
6 F 3 H 1 0 0 1 Table 9.4 Fault (Trip) # Item LCD Message Indication Description 1 52RT 52R TRIP AC input circuit breaker #52R tripped. 2 72BT 72B TRIP DC input circuit breaker #72B tripped. 3 71BF DC FUSE BLW DC Main circuit fuse blew. 4 86MU MU FAULT1 An inverter or converted fuse blew. 5 WDCPU WDCPU An error occurred in the main control microprocessor (CPU). 6 80PS CONT. PS. ERR The control power supply voltage fell.
6 F 3 H 1 0 0 1 Table 9.7 Warning-3 (Operation control) # Item LCD Message Indication Description 1 59C BYPASS OV Bypass input voltage is high. 2 27C BYPASS UV Bypass input voltage is low. 3 95C BYPASS ASY Bypass input frequency error. Table 9.8 Warning - 4 and 5 (Guidance) # Item LCD Message Indication Description 1 49H LOAD LIMIT Load has exceeded prescribed level. 2 51LI O/P OC (PEAK) Load current peak value is high. 3 72BO 72B MIS OPE.
6 F 3 H 1 0 0 1 9.2.4 Scrolling Through LCD Screens in the Event of Failure NOTES When the unit has stopped due to failure, be sure to remove the memory card before resetting the LCD Failure Error screen on the panel, so you can give it to the service person. Resetting (restarting) the UPS without removing the memory card will delete the data needed to determine the cause of the failure. Every effort has been made to ensure safety in unit handling.
6 F 3 H 1 0 0 1 Table 9.9 No. Scroll Keys Name Description i SCROLL UP Scrolls to the previous screen (see Figure 9.9) j SCROLL DOWN Scrolls to the next screen (see Figure 9.9) k RESET Deletes the stored waveform and failure and warning data from the memory card. (*) Normal Data Display screen (**) Failure Data Display screen i ii (**) Warning Data Display screen i ii Remarks * See section 7.2.
6 F 3 H 1 0 0 1 9.3 Saving Waveforms NOTES When the unit has stopped due to failure, be sure to remove the memory card before resetting the LCD Failure Error screen on the panel, so you can give it to the service person. Resetting (restarting) the UPS without removing the memory card will delete the data needed to determine the cause of the failure. Every effort has been made to ensure safety in unit handling. However, when removing the memory card, do not touch the other sections of the unit.
6 F 3 H 1 0 0 1 9.4 Restoring UPS Operation Contact the Toshiba Service Center in the event of malfunction or failure. This unit should be repaired only by authorized Toshiba service personnel. Servicing by untrained personnel may increase the scale of the failure or result in electric shock or injury. Do not attempt to modify or move the unit yourself or to have this done by a third party.
6 F 3 H 1 0 0 1 Table 9.11 Step 1 Procedure Restoring UPS Operation (Example) LCD/LED Status (After Execution) Check the LCD screen. Also check for other Failure Data screens by scrolling with scroll keys i and j on the panel. 2 Turn 6CH OFF. FAULT 1 ~ AC INPUT BATTERIES 52R TRIP 98-09-09 08:05:30 ↓ANOTHER ITEM ~ CONVERTER ~ UPS INVERTER FLOAT CHARGE AC EQUAL CHARGE SWITCH DISCHARGE ~ AC OUTPUT ~ BYPASS BYPASS INPUT 3 Remove the memory card in the panel and insert a new memory card.