9315 Maintenance Bypass Module 30--160kVA Installation/Operation Manual 164201177 Rev.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- IMPORTANT SAFETY INSTRUCTIONS Instructions Importantes Concernant La Sécurité SAVE THESE INSTRUCTIONS Conserver Ces Instructions This manual contains important instructions for your Uninterruptible Power Supply (UPS) system.
Table of Contents 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Getting Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures iv Figure 1. Typical 30---160kVA MBM with Isolation Transformer . . . . . . . . 1 Figure 2. Front and Side View of Typical Maintenance Bypass Module on Shipping Pallet (30---160kVA w/XFMR) . . . . . . . . . . 5 Figure 3. MBM as Shipped, with Outer Packaging and Pallet . . . . . . . . . 7 Figure 4. Detail of Shipping Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Figure 5. Top, Bottom, and Front View of Maintenance Bypass Module (30---160kVA w/XFMR) . . .
Introduction The Powerware 9315 Maintenance Bypass Module (MBM) is a floor-mounted, enclosed cabinet containing a UPS module, Maintenance Isolation circuit breaker (MIS), and a maintenance Bypass circuit breakr (MBP). An optional UPS Module Input Bypass circuit breaker (BIB) is available. The MBM can be either free-standing or line-up-and-match.
Using This Manual This manual contains installation and operation procedures for the MBM. Before installation and operation, read through each procedure. · Chapter 1 provides an overview of this manual and references for further information. · Chapter 2 tells you how to prepare your site for the installation of the MBM. It discusses equipment environmental requirements, inspecting, and unpacking cabinets. · Chapter 3 describes how to install the MBM cabinet.
For More Information For more information on the installation and operation of the UPS system and its accessories, refer to the following: 164200252 Powerware 9315 30 ---160 kVA UPS Operation Each manual describes the UPS cabinet, Control Panel, and Monitor Panel, and explains the functions of the UPS; discusses the standard features of the UPS and optional accessories; provides procedures for starting and stopping the UPS, and information about maintenance and responding to system events.
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Getting Started This section describes how to install the Powerware 9315 Maintenance Bypass Module (MBM). It contains instructions for installing the MBM and basic site preparation procedures. Figure 2 shows the front and side view of the MBM with or without transformer for a Powerware 9315 30---160kVA module. The MBM is shipped as a separate item. Use a forklift or pallet jack to move the packaged cabinet to the installation site, or as close as possible to the site, before unloading.
Preparing the Site For the MBM to operate at peak efficiency, the installation site should meet the environmental parameters outlined in the PowerwareÒ 9315 Operation manual provided with the UPS system. The operating environment must meet the size and weight requirements supplied in the PowerwareÒ 9315 Installation manual provided with the UPS system.
Inspecting and Unpacking the Maintenance Bypass Module The first task in preparing for installation of the MBM is inspecting and unpacking the unit. The MBM arrives covered with protective packaging material as shown in Figure 3. OUTER PACKAGING LAMINATED PLYWOOD AND POLYFOAM SKIDS Figure 3. MBM as Shipped, with Outer Packaging and Pallet Powerware 9315 Maintenance Bypass Module 30---160kVA 164201177 Rev.
1. Carefully inspect the outer packaging for evidence of damage during transit. CAUTION: Do not install a damaged MBM. Report any damage to the carrier and contact the local sales or service office immediately. 2. Use a forklift or other material handling equipment to move the MBM to a convenient unpacking area. Insert the forklift jacks between the laminated plywood/polyfoam skids on the bottom of the unit. CAUTION: Do not tilt unit more than 10 degrees from vertical. 3.
Unloading the MBM from the Pallet The MBM pallet consists of four metal angle supports secured to plywood/polyfoam laminated skids. The skids act as shock absorbers for the MBM during shipment. WARNING: Unit is extremely heavy. If unloading instructions are not closely followed, the unit may tip and cause serious injury. Turning the jacking bolts unevenly may cause the unit to become unbalanced. To prevent tipping, raise and lower the jacking bolts evenly and sequentially.
DOOR POLYFOAM SKID REAR SUPPORT 2 FRONT SUPPORT SIDE SUPPORT 2 1 FLOOR PROTECTOR (4 PLACES) 1 JACKING BOLT (USE FRONT AND REAR) POLYFOAM SKID 1 Figure 4. Detail of Shipping Supports 6. Carefully and evenly lower the MBM by turning each jacking bolt counterclockwise in sequence no more than two full turns each (maximum) until the supports contact the floor, and the module is no longer supported by the jacking bolts. 7. When the module is resting on the floor, remove the jacking bolts.
Installing and Wiring the Maintenance Bypass Module When the maintenance bypass module (MBM) has been moved to its installed location, unpacked, and inspected, it is ready for installation. This section discusses the typical process of installing the MBM in both the line-up and match and free-standing situations. The MBM is shown in Figure 5. Cooling Air Inlets (Front) Cable Entry, Top Plan View (Front) Cable Entry, Bottom Plan View Figure 5.
Refer to the following while installing the MBM: · · · Dimensions in this manual are in millimeters and (inches). · Terminals are UL and CSA rated at 90˚C. A hex key tool is required to attach wires to the terminals. · Details about power wiring are provided in the tables of Appendix A of this manual. Do not tilt the unit more than 10˚ during installation. Remove the conduit landing plates to add conduit landing holes as required. Plate material is 16 gauge steel (0.06 in. thick).
The recommended location, for the Maintenance Bypass Module, is as close to the installed UPS module as possible. Refer to the tables in Appendix A for wire rating and sizing information The MBM is packaged in a module similar to the UPS modules (same height, width, depth). The MBM is designed as a standard line-up-and-match accessory for the 30---160 KVA rated modules.
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Maintenance Bypass Module Operation This chapter provides preliminary checks, maintenance operations and a schematic diagram of the maintenance bypass module. Preliminary Checks and Startup for UPS Equipped with Maintenance Bypass Module (MBM) Installation inspection and startup procedures must be performed only by a Powerware Corporation authorized service person. The procedure is normally part of the sales contract for the UPS system.
MBM Operation Without Kirk Key Interlocks The following transfer sequence is the recommended procedure for the step-by-step load transfer from and back to the UPS when required. This information is provided on a label located on the deadfront panel behind the right front door of the MBM. From UPS Bypass to Maintenance Bypass: 1. Confirm BIBs, if installed, are closed. 2. Transfer UPS from Normal to Bypass mode (see UPS Operation manual).
MBM Operation With Kirk Key Interlocks (Optional) The following transfer sequence is the recommended procedure for the step-by-step load transfer from and back to the UPS when required. This information is provided on a label located on the deadfront panel behind the right front door of the MBM. Kirk Key Solenoid Release Unit (SKRU) The 120 VAC operating power for the Kirk Key Solenoid Release Unit (SKRU) is derived from the Maintenance Bypass source.
From Maintenance Bypass to UPS Bypass: 1. Confirm BIBs, if installed, are closed. 2. Transfer UPS to Bypass mode (see UPS Operation manual). NOTE: For Parallel Redundant systems, transfer both UPS modules to Bypass mode. 3. Depress pushbutton on the Solenoid Key Release Unit (SKRU). Turn and remove key “A”. 4. Insert key “A” into MIS lock, retract bolt, close MIS breaker. Remove key “B”. CAUTION: Failure to close MBP breaker results in loss of power to the critical load. 5.
Maintenance Maintenance should be scheduled on a periodic basis, recommended not to exceed one year. More frequent intervals are recommended if the equipment is subjected to highly repetitive operations. CAUTION: Refer to Section 9 -- Maintaining the UPS System of the Powerware 9315 30-- 160kVA Operation manual, Powerware part number 164200252, before beginning maintenance or repairs on the UPS equipment. WARNING: Dangerous and life-threatening voltages are present when the UPS is operating.
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Appendix A --- Customer Information The information in this appendix will help you plan for and install your Maintenance Bypass Module cabinet.
Table A-- 1. Ratings & External Wiring Requirements for Powerware 9315 MBM 30---160kVA, 480:208VAC/600:208VAC Rating and External Wiring Requirement Units Basic unit rating at 0.
Table A-- 2. Ratings & External Wiring Requirements for Powereware MBM 30---160kVA, 480:480VAC/600:600VAC 9315 Rating and External Wiring Requirement Units Basic unit rating at 0.
Table A-- 3. Ratings & External Wiring Requirements for Powerware MBM 30---160kVA, 208:208VAC Rating and External Wiring Requirement Units Basic unit rating at 0.
Table A-- 4. Rating and External Wiring Requirements for Powerware 9315 MBM 50---160KVA, 380:380VAC, 400:400VAC, 415:415VAC RATING AND EXTERNAL WIRING REQUIREMENT BASIC UNIT RATING AT 0.
Table B. Circuit Breaker Requirements for Powerware 9315 MBM 30---160KVA, 380:380VAC, 400:400VAC, 415:415VAC, 600:600VAC, 480:208VAC, 600:208VAC, 208:208VAC, 480:480VAC. MBM FAMILY MBM 50 30KVA 40KVA 50KVA MBM 80 50KVA 65KVA MBM Model No.
Table B. Circuit Breaker Requirements for Powerware 9315 MBM 30---160KVA, 380:380VAC, 400:400VAC, 415:415VAC, 600:600VAC, 480:208VAC, 600:208VAC, 208:208VAC, 480:480VAC. MBM FAMILY MBM 80 MBM Model No.
Table C-- 1.
Table C-- 2. Control Wiring Requirements and Termination Requirement for Reverse Transfer (RT) System. Connecting Point in MBM Cabinet Size of Pressure Termination (lb-in) Connection Point in UPS Size of Pressure Termination (lb-in) Recommended Wire Size Maximum Voltage and Current Remarks TB1---12 TB1---14 #18 #8 #18---#8 (55) TB6---1 TB6---2 #18 #8 #18---#8 (55) #18 #14 #18---#14 120VAC 1.0A See Fig 1. (Twisted Pair) Table C-- 3.
DESCRIPTION: Dimensions are in millimeters (inches) A ---10 TYPICAL MBM CABINET -30-160kVA with or without XFMR DRAWING NO: REVISION: SHEET: 164201177---2 A DATE: 1 of 3 080498 Powerware 9315 Maintenance Bypass Module 30-160kVA 164201177 Rev.
BREAKER ANNUNCIATION UTILITY INPUT, IF BIB BREAKER IS NOT INSTALLED CRITICAL LOAD CONNECTIONS MBP UPS/PTC OUTPUT CONNECTION NEUTRAL CONNECTIONS MIS OPTIONAL UPS BYPASS INPUT CONNECTIONS BIB1 UTILITY INPUT, IF BIB BREAKER INSTALLED BIB2 DESCRIPTION: TYPICAL MBM CABINET -30-160kVA with or without XFMR INTERIOR COMPONENTS DRAWING NO: REVISION: Powerware 9315 Maintenance Bypass Module 30---160kVA 164201177 Rev.
TOP VIEW BOTTOM VIEW DESCRIPTION: TYPICAL MBM CABINET -30-160kVA with or without XFMR TOP and BOTTOM VIEW Dimensions are in millimeters (inches) DRAWING NO: REVISION: A ---12 SHEET: 164201177---2 A DATE: 3 of 3 080498 Powerware 9315 Maintenance Bypass Module 30-160kVA 164201177 Rev.
PDM CABINET (optional) MBM CABINET (optional) INPUT TRANSFORMER CABINET (optional) BATTERY CABINET (optional) UPS CABINET 30---160kVA UPS System with MBM DESCRIPTION: DRAWING NO: REVISION: Powerware 9315 Maintenance Bypass Module 30---160kVA 164201177 Rev.
Read and understand the following notes while planning your installation: 1. Refer to national and local electric codes for acceptable external wiring practices. 2. Material and labor for external wiring requirements are to be provided by others. 3. For external wiring requirement, including the minimum AWG size of external wiring, see the appropriate column in Table A-2 and A-4. The power wiring for this equipment is rated at 90 degrees Celsius. 4. The output of the UPS is not a separately derived source.
Read and understand the following notes while planning your installation: 1. Refer to national and local electric codes for acceptable external wiring practices. 2. Material and labor for external wiring requirements are to be provided by others. 3. For external wiring requirement, including the minimum AWG size of external wiring, see the appropriate column in Table A--- 1. The power wiring for this equipment is rated at 90 degrees Celsius. 4. The output of the UPS is a separately derived source.
Read and understand the following notes while planning your installation: 1. 2. 3. Refer to national and local electric codes for acceptable external wiring practices. Material and labor for external wiring requirements are to be provided by others. For external wiring requirement, including the minimum AWG size of external wiring, see the appropriate column in Table A--- 3. The power wiring for this equipment is rated at 90 degrees Celsius. 4. The output of the UPS is not a separately derived source.
Read and understand the following notes while planning your installation: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Refer to national and local electric codes for acceptable external wiring practices. Material and labor for external wiring requirements are to be provided by others. For external wiring requirement, including the minimum AWG size of external wiring, see the appropriate column in Table A--- 2 and A--- 4. The power wiring for this equipment is rated at 90 degrees Celsius.
Read and understand the following notes while planning your installation: 1. Refer to national and local electric codes for acceptable external wiring practices. 2. Material and labor for external wiring requirements are to be provided by others. 3. For external wiring requirement, including the minimum AWG size of external wiring, see the appropriate column in Table A--- 1. The power wiring for this equipment is rated at 90 degrees Celsius. 4. The output of the UPS is a separately derived source.
Read and understand the following notes while planning your installation: 1. 2. 3. Refer to national and local electric codes for acceptable external wiring practices. Material and labor for external wiring requirements are to be provided by others. For external wiring requirement, including the minimum AWG size of external wiring, see the appropriate column in Table A--- 3. The power wiring for this equipment is rated at 90 degrees Celsius. 4. The output of the UPS is not a separately derived source.
(NOTE 4) LINE UP AND MATCH ARRANGEMENT #1 Applicable to POWERWARE 9315 30---160 kVA UPS modules only. 160kVA UPS is shown. DESCRIPTION: LINE UP AND MATCH ARRANGEMENT #1 DRAWING NO: REVISION: A ---20 SHEET: 164201177---10 A DATE: 1 of 4 080498 Powerware 9315 Maintenance Bypass Module 30-160kVA 164201177 Rev.
(NOTE 5) (NOTE 5) (NOTE 2) (NOTE 4) LINE UP AND MATCH ARRANGEMENT #2 Applicable to POWERWARE 9315 30---160 kVA UPS modules only. 160kVA UPS is shown. DESCRIPTION: LINE UP AND MATCH ARRANGEMENT #2 DRAWING NO: REVISION: Powerware 9315 Maintenance Bypass Module 30---160kVA 164201177 Rev.
(NOTE 3) (NOTE 4) (NOTE 4) LINE UP AND MATCH ARRANGEMENT #3 Applicable to POWERWARE 9315 30---160 kVA UPS modules only. 160kVA UPS is shown. DESCRIPTION: LINE UP AND MATCH ARRANGEMENT #3 DRAWING NO: REVISION: A ---22 SHEET: 164201177---10 A DATE: 3 of 4 080498 Powerware 9315 Maintenance Bypass Module 30-160kVA 164201177 Rev.
1 Line up and match power and control interconnection wiring from MBM to UPS/Input Transformer cabinet is applicable for Reverse Transfer (Single UPS module) connection only and sold separately by Powerware Corporation. 2 Run power cables underneath the transformer. 3 External wiring is required and supplied by others. 4 The PDM cabinet is applicable IF AND ONLY IF the MBM and UPS module outputs are 3 phase, 60Hz, 280VAC.
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