Powerware 30-160kVA User Manual
Maintenance Bypass
Module
30--160kVA
315
9
Installation/Operation
Manual
164201177 Rev. C
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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. You should follow these instructions during the
installation and maintenance of the UPS, options, accessories, and batteries.
Cette notice contient des instructions importantes
concernant la sécurité.
This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference when the equipment is
operated in a commercial environment. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and used in accordance with
the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful
interference in which case the user will be required to correct the interference at
their own expense.
WARNING:
This is a product for restricted sales distribution to informed partners. Installation
restrictions or additional measures may be needed to prevent disturbances.
ii
Powerware 9315 Maintenance Bypass Module 30-160kVA
164201177 Rev. C 041500
Table of Contents
1 Introduction 1............................................
Using This Manual 2............................................
Conventions Used in This Manual 2...............................
For More Information 3..........................................
Getting Help 3..................................................
2 Getting Started 5.........................................
Preparing the Site 6.............................................
Creating an Installation Plan 6....................................
Environmental Considerations 6..................................
Preparing for Wiring the Maintenance Bypass Module 6.............
Inspecting and Unpacking the Maintenance Bypass Module 7........
Unloading the MBM from the Pallet 9..............................
3 Installing and Wiring the Maintenance Bypass Module 11....
LineandLoadWiring 13..........................................
4 Maintenance Bypass Module Operation 15..................
Preliminary Checks and Startup for UPS Equipped with
Maintenance Bypass Module 15................................
Maintenance Bypass Module Operation 15.........................
MBM Operation Without Kirk Key Interlocks 16......................
MBM Operation With Kirk Key Interlocks (Optional) 17................
Kirk Key Solenoid Release Unit (SKRU) 17..........................
MBM Transfer Sequences 17......................................
Maintenance 19.................................................
Short Circuits 19.................................................
Maintenance Bypass Module Diagrams 19..........................
Appendix A A ---1.................................................
Powerware 9315 Maintenance Bypass Module 30 --- 160kVA
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List of Figures
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) 11..................................
Figure 6. Typical Power Wiring Terminations of UPS Module
and Maintenance Bypass Module (30---160kVA) 13............
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Powerware 9315 Maintenance Bypass Module 30-160kVA
164201177 Rev. C 041500
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. Figure 1 shows a typical MBM cabinet
with isolation transformer for a Powerware 9315 30---160kVA UPS and MBM cabinet
without isolation transformer for a Powerware 9315 30 ---160kVA UPS.
The equipment and devices described in this manual are provided for operation with the
specific UPS Modules (model and rating) described in the appendix.
BREAKER ANNUNCIATION
UTILITY INPUT,
IF BIB BREAKER
IS NOT
INSTALLED
MBP
MIS
BIB1
BIB2
CRITICAL LOAD
CONNECTIONS
UPS/PTC OUTPUT
CONNECTION
NEUTRAL
CONNECTIONS
OPTIONAL UPS
BYPASS
INPUT CONNECTIONS
UTILITY INPUT,
IF BIB BREAKER
INSTALLED
Figure 1. Typical 30---160kVA MBM with or without Isolation Transformer.
Powerware 9315 Maintenance Bypass Module 30 --- 160kVA
164201177 Rev. C 041500
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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.
· Chapter 4 contains operating information for the MBM.
· Appendix A contains important information for planning and installing the MBM,
including wiring data and illustrations of cabinets.
Conventions Used in This Manual
This manual contains installation and operation procedures for the Maintenance
Bypass module.
· Bold type highlights important concepts in discussions, key terms in
procedures, and menu options.
· Italic type highlights notes, references to other system manuals, references
to other sections of this manual, and new terms where they are defined.
· Rectangular boxes containing bold type are warnings or cautions that pertain
to the system or its electrical connections. This important information indicates
possible dangers pertaining to personnel safety, equipment damage, critical
load protection, or operational concerns.
2
Powerware 9315 Maintenance Bypass Module 30-160kVA
164201177 Rev. C 041500
For More Information
For more information on the installation and operation of the UPS system and its
accessories, refer to the following:
164200252 Powerware
Each manual describes the UPS cabinet, Control Panel, and
Monitor Panel, and explains the functions of the UPS; discusses
the s tandard features of the UPS and optional accessories;
provides procedures for starting and stopping the UPS, and
information about maintenance and responding to system events.
T h es e a l so de s c r ib e t h e R S --- 4 8 5 a n d RS --- 2 3 2 s e r i a l
communications capabilities of the UPS system; discuss the two
communications ports on the Customer Interface Panel inside the
UPS and how to connect optional remote accessories to your
UPS system; and provide information about enabling, disabling,
and customizing building alarms.
164200253 Powerware
164200292 Powerware
Each manual contains the following information: how to prepare
the site and plan for installation, detailed step-by-step procedures
for installing each component of your system, how to join
cabinets in a line-up-and-match system, detailed illustrations of
cabinets and optional accessories, including dimensions and
connection points.
9315 30--- 160 kVA UPS Operation
9315 30--- 80 kVA UPS Installation
9315 100--- 160 kVA UPS Installation
Contact the local Powerware Field Service office for information on how to obtain
copies of these manuals.
Getting Help
If you have a question about any of the information in this manual, or if you have a
question this manual does not answer, please call Powerware Field Service:
United States 1-800-843-9433
Canada 1-800-461-9166
Outside the U.S. Call your local representative
Powerware 9315 Maintenance Bypass Module 30 --- 160kVA
164201177 Rev. C 041500
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Powerware 9315 Maintenance Bypass Module 30-160kVA
164201177 Rev. C 041500
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.
The basic sequence of the installation steps is:
1. Prepare the site for the MBM installation.
2. Inspect, unpack, and unload the MBM.
3. Create an installation plan for wiring the MBM to the UPS system.
4. Prepare for wiring.
5. Complete the installation checklist from the PowerwareR 9315 Installation manual.
6. Have authorized service personnel perform preliminary checks and startup.
NOTE: Startup and operational checks should be performed only by authorized
service personnel. This service is usually offered as part of the sales
contract for your UPS system.
Figure 2. Front and Side View of Typical Maintenance Bypass Module on
Shipping Pallet (30---160kVA with or without XFMR)
Powerware 9315 Maintenance Bypass Module 30 --- 160kVA
164201177 Rev. C 041500
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Preparing the Site
For the MBM to o perate 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. If the MBM is to be operated at an altitude higher than 1500
meters (5000 feet), contact the local sales or service office for important information
about high altitude operation.
The basic environmental requirements for operation of the MBM are:
Ambient Temperature Range 0 --- 4 0 ˚C (32 ---104˚F)
Recommended Operating Range 20---25˚C (68--- 77˚F)
Maximum Relative Humidity 95%
The MBM uses convection cooling to regulate internal component temperature. Air
inlets are in the front of the cabinet, and outlets are in the top. Clearance in front of
and above each cabinet for proper air circulation is essential.
Creating an Installation Plan
Before beginning to install the MBM, read and understand how this manual applies
to the system being installed. It is important to note that UPS module installation
procedures are contained in the PowerwareÒ 9315 Installation manual provided
with the UPS system. It is recommended to first understand how to install the UPS
modules. The information in Chapter 2 of this manual is a guide for installation of
the MBM to the UPS modules.
Environmental Considerations
Thelifeofthemaintenancebypassmoduleisadverselyaffectediftheinstallation
does not meet the following guidelines:
1. The MBM must be installed on a sealed concrete pad or floor.
2. The MBM must be installed in a dust-free environment.
3. The MBM must be installed in a humidity-controlled environment.
Preparing for Wiring the Maintenance Bypass Module
See Tables A-1 through A-6 in Appendix A of this manual for wiring requirements.
The power wiring for this equipment is rated at 90_C. Ifwireisruninanambient
temperature greater than 30_C, higher temperature rating and/or larger size wire
may be necessary. Wiring should be installed through the bottom or top entry of
the module. For UPS external wiring requirements, including minimum AWG size
of external wiring, see the PowerwareÒ 9315 Installation manual provided with the
UPS system.
NOTE: Material and labor for external wiring are to be provided by designated
personnel.
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Powerware 9315 Maintenance Bypass Module 30-160kVA
164201177 Rev. C 041500
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
PACKAG I N G
LAMINATED PLYWOOD
AND POLYFOAM SKIDS
Figure 3. MBM as Shipped, with Outer Packaging and Pallet
Powerware 9315 Maintenance Bypass Module 30 --- 160kVA
164201177 Rev. C 041500
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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. Set the pallet on a firm, level surface, allowing a minimum clearance of
4.6m (15 ft) on each side for removing the MBM from the pallet.
4. Cut the steel bands around the MBM.
5. Remove the protective cardboard covering from the MBM, cutting where
indicated, using a knife blade no longer than 25 mm (1 in.).
NOTE: Do not discard the packaging material. Instructions for unloading the MBM
from the pallet are printed on the cardboard. Please to refer to them.
6. Remove the plastic bag and foam packing material. Please discard or recycle
them in a responsible manner.
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Powerware 9315 Maintenance Bypass Module 30-160kVA
164201177 Rev. C 041500
Unloading the MBM from the Pallet
The MBM pallet consists of four metal angle supports secured to plywood /pol y f oam
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. The unit should only be raised approximately
3mm(
1. Remove the doors. Remove the retaining screw located inside each door at
2. Locate the field kit packed inside the unit. Lo cate the four ½-in. jacking bolts
1/8 in.) above the floor (just enough to remove polyfoam skids).
the bottom hinge pivot point, then lift off the door. Save the retaining screws
for reinstallation of the doors.
and install them in the threaded holes in the front and rear supports. Place a
floor protector underneath each jacking bolt, and screw the bolts down until
they contact the floor protectors. The floor protectors prevent the floor from
being damaged by the jacking bolts.
WARNING:
Module may fall. Do not loosen hardware attaching the side or front/rear
shipping supports to the module base. Also, do not loosen the shipping
supports from each other. The module must be lowered using jacking
bolts before the shipping supports can be removed.
3. Loosen, but do not remove the hardware holding the plywood/polyfoam skids
to the front and rear supports (labeled “1” in Figure 4 --- 8 places).
4. Turn each jacking bolt clockwise sequentially, no more than two full turns each,
until the foam cushions clear the floor by approximately 3 mm (
1/8 in.).
5. After the plywood/polyfoam skids clear the floor, remove the hardware
loosened in step 3. Pull the skids out from under the MBM. Discard or recycle
them in a responsible manner.
Powerware 9315 Maintenance Bypass Module 30 --- 160kVA
164201177 Rev. C 041500
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DOOR
POLYFOAM
SKID
1
FLOOR
PROTECTOR
(4 PLACES)
2
(USE FRONT AND REAR)
FRONT SIDE
SUPPORT
JACKING BOLT
SUPPORT
1
REAR
SUPPORT
2
1
POLYFOAM
SKID
10
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. Discard or
recycle them in a responsible manner.
8. Removethehardwarelabeled“2”inFigure4,holdingthefront,rearandside
supports to the module base (14 places). Discard or recycle the hardware and
support brackets in a responsible manner.
9. Install the doors removed in step 1. The MBM is now ready to be rolled to its
final location.
Powerware 9315 Maintenance Bypass Module 30-160kVA
164201177 Rev. C 041500
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. Top, Bottom, and Front View of Maintenance Bypass Module
(30---160kVA with or without XFMR)
Powerware 9315 Maintenance Bypass Module 30 --- 160kVA
164201177 Rev. C 041500
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