TOSHIBA 1600XPi Series UPS Installation and Operation

TOSHIBA 1600XPi Series UPS Installation and Operation

Product Scope and Application

Product specifications: Single phase UPS, with a capacity coverage of 3.6/5.2/6/8/10/14/18/22 KVA, corresponding to output power (at 0.85 power factor) of 3.1/4.4/5.1/6.8/8.5/11.9/15.3/18.7 kW (22KVA is reduced to 18.7kVA at 50Hz)

Applicable scenarios: General electronic applications (computers, personal devices, office equipment, measuring equipment, industrial robots, household appliances, etc.)

Prohibited scenarios (DANGER): medical operating room equipment, life support equipment, fire-fighting equipment; Special scenarios (such as nuclear power plants, communication equipment, transportation equipment) require consultation with professional technical personnel (Warning)

Core Security Standards

Personnel qualification requirements

Only qualified personnel are allowed to install, operate, and maintain, and must meet the following requirements:

Read the complete manual to master the construction and operation of the equipment

Received safety training on circuit switching, grounding, locking and tagging (LOTO), etc

Master the usage of protective equipment (insulated gloves, safety helmets, etc.)

Having first aid skills and understanding of battery handling precautions

Safety symbols and signal words

Safety symbols: including safety warning (potential personal injury), prohibition (not operable), mandatory (must be executed), grounding (position of grounding conductor), electric shock (internal high voltage), explosion (components may explode), etc

Signal word grading:

DANGER: Immediate danger that may result in death/serious injury if not avoided (e.g. prohibited for use in life support equipment)

Warning: Potential danger, failure to avoid may result in death/serious injury (professional consultation is required for special situations)

CAUTION: Potential danger, may cause minor/moderate injury if not avoided (such as insulation tools required for battery operation)

NOTICE: Potential danger, may cause equipment/property damage if not avoided (if ventilation space is required for installation)

Key operation taboos

After power failure, wait for 5 minutes until the internal capacitor is completely discharged before opening the cover

Unauthorized modification of equipment (without written permission from Toshiba) is prohibited, otherwise all warranties will be invalidated and may result in UL/CHUL/CE/ETL certification being invalidated, causing personal injury or equipment damage

Batteries are prohibited from being baked or disassembled by fire (harmful electrolyte). Replacement must be carried out by authorized personnel from Toshiba, and the same type of battery pack must be used

Installation and wiring specifications

Installation environment requirements

Ventilation: Install in a well ventilated area, leaving at least 4 inches (10cm) of space around for ventilation and maintenance

Temperature: Operating temperature 0-40 ℃ (60Hz), 0-33 ℃ (50Hz); Storage temperature -20-40 ℃, optimal storage temperature 21 ℃

Other: Avoid moisture (30-90% humidity without condensation), dust/metal particles, direct sunlight, electrical noise sources, liquid intrusion, and place horizontally (without excessive vibration)

Input/output protection configuration

The user needs to configure a circuit breaker between the UPS input (mains) and output (load), with specifications as shown in the table below:

240VAC specification 3.6 kVA 5.2/6 kVA 8 kVA 10 kVA 14 kVA 18 kVA 22 kVA

Input circuit breaker 30 A 50 A 60 A 70 A 100 A 100 A 125 A

Output circuit breaker 20 A 35 A 45 A 60 A 80 A 100 A 125 A

Note: The above specifications are for equipment with 80% rated value

Terminal wiring and cable requirements

Terminal block type:

Type 1: Input at 208/240V, output at 120/208/240V, to be tripped according to the input voltage (208V short circuited to terminals 11-12, 240V short circuited to terminals 12-13)

Type 2: 240V input, 100/200V output, 100V output connected to 4-6 or 6-7 terminals, 200V output connected to 4-7 terminals

Cable specifications: All input, output, and grounding wires require 90 ℃ copper wire. The cable size and torque are shown in the following table:

Project Terminal Number Cable Size (AWG) -3.6kVA Cable Size (AWG) -5.2-6kVA Cable Size (AWG) -8kVA Cable Size (AWG) -10kVA Cable Size (AWG) -14-18kVA Cable Size (AWG) -22kVA Tightening Torque (lb. - in./N · m)

AC input line  1、2 10（8） 8（8） 8（1/0） 6（1/0） 4（1/0） 1（1/0） 14.2（1.56）

AC output line  4、5、7 12（8） 10（8） 8（1/0） 6（1/0） 4（1/0） 1（1/0） 14.2（1.56）

AC output neutral line  6 12（8） 10（8） 8（1/0） 6（1/0） 4（1/0） 1（1/0） 14.2（1.56）

ground wire  3、8 12（8） 10（8） 8（1/0） 6（1/0） 4（1/0） 1（1/0） 14.2（1.56）

EPO switch 14, 15 16 16 16 16 16 16 9.0 (0.99)

Remote switch 16, 17 16 16 16 16 16 16 9.0 (0.99)

Note: The maximum cable size that the terminal can accommodate is indicated in parentheses

Operation process and operating mode

Initial Startup (First Power Up)

Login: Log in with ADMIN privileges (default password ADMIN)

Parameter settings:

Enter the rated voltage (208V/230V/240V) and confirm with Write

Output rated voltage (208V/230V/240V), confirm with Write

Set date (format: Day mm/dd/yyyy, such as Mon 10/05/2009)

Set time (in 12 hour format, such as 12:15 PM)

Charging: After initial startup, the battery needs to be charged for at least 24 hours (with the input circuit breaker open), otherwise the backup time will be shortened

Normal start and stop

Start: Open the rear main circuit breaker (MCCB) of the UPS and confirm that the "On Line" green light on the front panel is on; If it's not on, press the RUN button for 3 seconds (hear a beep sound)

Stop: Press the STOP button for 3 seconds (after a beep, the "On Line" light goes out and enters bypass mode); To completely stop, turn off the MCCB circuit breaker (all sensitive loads must be turned off first)

Core operating mode

Static Bypass mode: Automatically switches when UPS overload or internal failure occurs, with power directly supplied to the load through the bypass from the input, with a switching time of less than 1/4 cycle (no load interruption); After overload relief, it can automatically switch back (AutoXfer parameter needs to be enabled)

On Line mode: Normal operation mode, the input AC is converted to DC through a rectifier (including a boost chopper circuit), and the charging battery is simultaneously supplied to the inverter to generate high-quality sine wave AC output. The battery is always in a charging state

Battery Backup Mode: When the mains power is interrupted, the battery immediately supplies DC to the inverter and converts it to AC output; Backup time is 5-8 minutes (full load, depending on model), and the power supply will automatically stop when the battery voltage drops to the "shutdown voltage (Vmin)"

EPO mode (Emergency Power Off): remotely close the EPO switch (normally open), immediately cut off the UPS input circuit breaker, output, and battery circuit; After activation, wait for 5 minutes for discharge before maintenance

Battery management and maintenance

Key parameters of battery

Nominal voltage (Vnom): 3.6KVA is 144Vdc, 5.2-6KVA is 216Vdc, 8-22KVA is 288Vdc

Low voltage alarm (Vlow): 3.6KVA is 130Vdc, 5.2-6KVA is 192Vdc, 8-22KVA is 246Vdc

Shutdown voltage (Vmin): 3.6KVA is 114Vdc, 5.2-6KVA is 170Vdc, 8-22KVA is 227Vdc

Charging parameters: Charging is divided into three stages (constant current 1A → constant voltage → float charging), and it takes 24 hours to fully charge (12 hours for 90% charging)

Battery testing and storage

Test:

Automatic testing: Enable at startup, wait for the 'Battery Test Frequency (CMD 655)' time before re enabling after completion

Manual testing: In UPS online mode, log in with ADMIN privileges, set CMD 652=Disable, CMD 653=Enable, and CMD 655=0, and press the "BattTest" button on CMD 609; Test failed with 'BTSTFL' warning displayed

Storage:

Before storage: Start up and run without load for 24 hours to fully charge the battery, stop UPS and turn off MCCB

Storage conditions: Original packaging, wooden/metal tray, temperature -20-40 ℃, avoid humidity/dust/vibration

Maintenance: Charge every 9 months for temperatures below 20 ℃, every 6 months for temperatures between 20-30 ℃, and every 3 months for temperatures between 30-40 ℃

Preventive maintenance and component replacement

Daily maintenance: Keep the ventilation openings clean and regularly remove dust (using a vacuum cleaner for dusty environments)

Component replacement cycle:

Aluminum electrolytic capacitor: every 7 years

Fuse: Every 7 years

Cooling fan: Every 3.5 years for environments between 30-40 ℃, and every 5 years for environments below 30 ℃ (non hot swappable, needs to be replaced after disconnecting and discharging)

Battery: Depending on the ambient temperature, 20-25 ℃ is 5 years, 30 ℃ is 3.5 years, 35 ℃ is 2.5 years, 40 ℃ is 1.8 years, and 45 ℃ is 1.25 years (requiring overall replacement, using the same model of battery pack)

Fault Handling and Technical Appendix

Fault and warning codes

Fault code (partially critical):

BYPOH: Bypass overheating, check the fan/ambient temperature (>40 ℃ needs to be cooled down), if the issue is not resolved within 1 hour, the bypass will stop

CHRGOV: Charger overvoltage, UPS failure, record operating conditions and contact Toshiba service

DCOV: DC bus overvoltage, check input wiring/load (such as motor load), restart ineffective, contact service

Warning code (partially critical):

AOH: If the environment is overheated (internal temperature>50 ℃), check the air conditioning/fan. If it is overheated, turn off the device

BLFE: End of battery life (5-year cycle), contact Toshiba for replacement

LB: Low battery (<90% capacity), immediately turn off the load in an orderly manner and press the STOP button

Technical specifications (core parameters)

Input: Voltage 208/240V ± 10% to -30%, frequency 45-65Hz (automatic detection), power factor 0.98 (typical), THD<5% (linear load)

Output: Voltage regulation ± 3%, THD<3% (linear load)/<6% (nonlinear load), overload capacity 125%/30 seconds, 150%/10 seconds, bypass overload 125%/10 minutes, 1000%/1 cycle

Efficiency: AC-DC-AC efficiency ≥ 83% (3.6-10KVA),>86% (14-22KVA)

Size and communication interface

Size and weight (example):

Model size (H × W × D, in./mm) Unit weight (lb./kg) Shipping weight (lb./kg)

3.6KVA 22.1×10×34 / 561×254×864 260 / 118 308 / 140

22KVA 39.0×17.5×36.1 / 991×445×917 866 / 393 928 / 421

Communication interface:

Standard: Remote Contacts (DB9 male), RS-232C (DB9 female), RemotEye 4 network card (supports SNMP/HTTP)

Optional: EMD environmental monitoring equipment (monitoring temperature, humidity, dry contact signals)