Powerware 30-160kVA User Manual

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9315

Maintenance Bypass

Module 30-160kVA

Installation/Operation

Manual

164201177 Rev. C

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.

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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

Line and Load Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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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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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

 

CRITICAL LOAD

MBP

CONNECTIONS

 

UPS/PTC OUTPUT

CONNECTION

MIS

NEUTRAL

CONNECTIONS

 

OPTIONAL UPS

BYPASS

INPUT CONNECTIONS

BIB1

UTILITY INPUT,

IF BIB BREAKER

INSTALLED

BIB2

Figure 1. Typical 30---160kVA MBM with or without Isolation Transformer.

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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.

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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.

These also describe the RS---485 and RS---232 serial 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 9315 30---80 kVA UPS Installation 164200292 Powerware 9315 100---160 kVA UPS Installation

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.

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

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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.

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)

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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. 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---

40˚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

The life of the maintenance bypass module is adversely affected if the installation 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. If wire is run in an ambient 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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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

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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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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. The unit should only be raised approximately 3 mm (1/8 in.) above the floor (just enough to remove polyfoam skids).

1.Remove the doors. Remove the retaining screw located inside each door at the bottom hinge pivot point, then lift off the door. Save the retaining screws for reinstallation of the doors.

2.Locate the field kit packed inside the unit. Locate the four ½-in. jacking bolts 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.

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DOOR

 

 

 

REAR

POLYFOAM

 

 

 

 

 

 

SUPPORT

SKID

2

FRONT

SIDE

 

 

2

 

 

SUPPORT

SUPPORT

1

 

 

 

 

FLOOR

 

 

 

 

PROTECTOR

 

 

 

 

(4 PLACES)

 

 

 

 

 

 

 

 

1

 

 

 

 

POLYFOAM

 

 

JACKING BOLT

 

SKID

 

(USE FRONT AND REAR)

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. Discard or recycle them in a responsible manner.

8.Remove the hardware labeled “2” in Figure 4, holding the front, rear and side 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.

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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)

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