www.mgeups.com Maintenance Bypass Switch Operating Manual IMPORTANT SAFETY INSTRUCTION SAVE THESE INSTRUCTIONS — This manual contains important instructions for the Maintenance Bypass Switch that must be followed during installation, operation and maintenance of the equipment. WARNING OPENING ENCLOSURES EXPOSES HAZARDOUS VOLTAGE S . A LWAYS REFER SERVICE TO QUALIFIED P E R S ON N E L O N LY. WARNING As standards, specifications, and designs are su b je c t to ch an g e , please ask for conf irmat ion of th e in fo rmatio n g iven in t his publicat ion. T h i s i s a c o n t ro l l e d d o c u m e n t . Pag e s s h o u l d n o t in d ivid u a lly b e re moved f rom t his binder. This manual covers this model: 6410M-9 6421M-9 Maintenance Bypass Switch Operating Manual For service call 1-800-523-0142 86-153815-00 B00 09/02 Copyright © 2002 MGE UPS Systems, Inc. All rights reserved. Printed in U.S.A. MGE UPS Systems, Inc. 1660 Scenic Avenue Costa Mesa, CA 92626 (714) 557-1636 1660 Scenic Avenue Costa Mesa, CA 92626 (714) 557-1636 Maintenance Bypass Switch Warranty The liability of MGE UPS Systems, Inc. hereunder is limited to replacing or repairing at MGE UPS Systems, Inc.’s factory or on the job site at MGE UPS Systems, Inc.’s option, any part or parts which are defective, including labor, for a period of 12 months from the date of purchase. The MGE UPS Systems, Inc. shall have the sole right to determine if the parts are to be repaired at the job site or whether they are to be returned to the factory for repair or replacement. All items returned to MGE UPS Systems, Inc. for repair or replacement must be sent freight prepaid to its factory. Purchaser must obtain MGE UPS Systems, Inc.’s Return Materials Authorization prior to returning items. The above conditions must be met if warranty is to be valid. MGE UPS Systems, Inc. will not be liable for any damage done by unauthorized repair work, unauthorized replacement parts, from any misapplication of the item, or for damage due to accident, abuse, or Act of God. In no event shall the MGE UPS Systems, Inc. be liable for loss, damage, or expense directly or indirectly arising from the use of the units, or from any other cause, except as expressly stated in this warranty. MGE UPS Systems, Inc. makes no warranties, express or implied, including any warranty as to merchantability or fitness for a particular purpose or use. MGE UPS Systems, Inc. is not liable for and Purchaser waives any right of action it has or may have against MGE UPS Systems, Inc. for any consequential or special damages arising out of any breach of warranty, and for any damages Purchaser may claim for damage to any property or injury or death to any person arising out of its purchase of the use, operation or maintenance of the product. MGE UPS Systems, Inc. will not be liable for any labor subcontracted or performed by Purchaser for preparation of warranted item for return to MGE UPS Systems, Inc.’s factory or for preparation work for field repair or replacement. Invoicing of MGE UPS Systems, Inc. for labor either performed or subcontracted by Purchaser will not be considered as a liability by the MGE UPS Systems, Inc. This warranty shall be exclusive of any and all other warranties express or implied and may be modified only by a writing signed by an officer of the MGE UPS Systems, Inc. This warranty shall extend to the Purchaser but to no one else. Accessories supplied by MGE UPS Systems, Inc., but manufactured by others, carry any warranty the manufacturers have made to MGE UPS Systems, Inc. and which can be passed on to Purchaser. MGE UPS Systems, Inc. makes no warranty with respect to whether the products sold hereunder infringe any patent, U.S. or foreign, and Purchaser represents that any specially ordered products do not infringe any patent. Purchaser agrees to indemnify and hold MGE UPS Systems, Inc. harmless from any liability by virtue of any patent claims where Purchaser has ordered a product conforming to Purchaser’s specifications, or conforming to Purchaser’s specific design. Purchaser has not relied and shall not rely on any oral representation regarding the Product sold hereunder and any oral representation shall not bind MGE UPS Systems, Inc. and shall not be part of any warranty. There are no warranties which extend beyond the description on the face hereof. In no event shall MGE UPS Systems, Inc. be responsible for consequential damages or for any damages except as expressly stated herein. Service and Factory Repair - Call 1 - 800 - 523 - 0142 Direct questions about the operation, repair, or servicing of this equipment to MGE UPS Systems, Inc. Technical Support Services. Include the part number and serial number of the unit in any correspondence. Should you require factory service for your equipment, contact MGE UPS Systems, Inc. Technical Support Services and obtain a Return Materials Authorization (RMA) prior to shipping your unit. Never ship equipment to MGE UPS Systems, Inc. without first obtaining an RMA. Proprietary Rights Statement The information in this manual is the property of MGE UPS Systems, Inc., and represents a proprietary article in which MGE UPS Systems, Inc., retains any and all patent rights, including exclusive rights of use and/or manufacture and/or sale. Possession of this information does not convey any permission to reproduce, print, or manufacture the article or articles shown herein. Such permission may be granted only by specific written authorization, signed by an officer of MGE UPS Systems, Inc. IBM, PC-AT, ES/9000, and AS/400 are trademarks of International Business Machines Corporation. MGE and MGE UPS Systems are trademarks of MGE UPS Systems, Inc. Other trademarks that may be used herein are owned by their respective companies and are referred to in an editorial fashion only. Revision History Maintenance Bypass Switch Operating Manual 86-153815-00 Copyright © 2002 MGE UPS Systems, Inc. Revision: A00 ECN-002762 B00 ECN#:002873 ii All rights reserved 07/02 09/02 Printed in U.S.A. Contents Introduction section 1.0 . . . 1.1 . . . 1.2 . . . 1.3 . . . 1.4 . . . 1.5 . . . 1.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 . . . . . . . . . . . . . . . 1.8 . . . . . . . . . . . . . . . 1.9 . . . . . . . . . . . . . . . 1.10 . . . . . . . . . . . . . . description page number General description 1—1 Specifications 1—1 Shipping and handling 1—3 Installation 1—3 Electrical 1—3 Operation 1—3 Front panel controls and indicators 1—5 Procedure to bypass the inverter 1 — 6 Procedures to return to normal (inverter) operation 1—6 DC breaker trip reset jumper 1—7 Maintenance 1—7 Drawings number description page number 1-1 . . . . . . . . . . . . . . . Major internal components, MBPS 1—2 1-2 . . . . . . . . . . . . . . . MBPS front panel 1—5 1-3 . . . . . . . . . . . . . . . Indicator lamp plate removal 1—8 1-4 . . . . . . . . . . . . . . . Failed indicator lamp replacement 1—8 D6421M-S. . . . . . . . . . Schematic or Maintenance Bypass Switch appendix Tables number description 1-1 . . . . . . . . . . . . . . . Power connections 1-2 . . . . . . . . . . . . . . . Control connections page number 1—4 1—4 iii Maintenance Bypass Switch How to use this manual This manual is designed for ease of use and easy location of information. This manual uses Noteboxes to convey important information. Noteboxes come in four varieties: WARNING A WARNING notebox indicates i n fo r m a t i o n provided to protect the user and service personnel against safety hazards and/or possible equipment damage IMPORTANT An IMPORTANT notebox indicates i n fo r m a t i o n provided as an operating instruction, or as an operating tip. iv CAUTION A C AU T I O N n o t e b o x indicates infor mation provided to protect the user and service personnel against possible equipment damage. NOTE A N OT E notebox indicates infor mation provided as an operating tip or an e q u i p m e n t fe a t u r e . Introduction 1.0 This manual contains the installation, operation, and maintenance information for the maintenance bypass switch (MBPS). This product is designed for use in the MGE Topaz Inverter Plant, which consists of the equipment rack, MBPS, AC distribution panel, and an inverter. The MBPS allows a load to remain powered while the inverter unit is taken off line for maintenance or other purposes. A schematic diagram of the MBPS is included in this manual (drawing number 6421M-S). General description The MBPS contains two major electrical components, a DC breaker (CB1) that provides DC power to the inverter and the maintenance bypass switch (S1) that switches the load between the inverter or static bypass, and utility. For location of the major components see Figure 1-1. 1.1 Specifications Electrical: AC Input: 120/220/230/240 VAC, 50/60 Hz Rating: 6421M - 21 kVA, 6410M - 10.5 kVA Wires: L1, L2, (Neutral) & Safety Ground Note: An external AC input circuit breaker or fuse should be used at the AC source. DC Input: -48 VDC nominal Rating: 6410M - 2-pole, 175A/pole; 6421M - 3-pole, 250A/pole Wires: +, -, safety ground Note: An external DC input circuit breaker or fuse should be used at the DC source. AC Output: Rating: Wires: Mechanical: Dimensions (in/cm): Mounting: Weight (lb/kg): 120/220/230/240 VAC, 50/60 Hz 6410M - 10.5 kVA, 6421M - 21 kVA L1, L2, (Neutral) & Safety Ground 12 inches (30.48cm) H x 18.5 inches (47cm) D x 17 inches (43.18cm) W Shipped with mounting brackets for 19”(48.26 cm)/23” (58.42 cm) mounting. 25” (63.5 cm) mounting brackets available as an option 52 lbs./23.65kg 1—1 Maintenance Bypass Switch Figure Major internal components, MBPS 1-1 FOR 3/4" (19 mm), 1" (25.4 mm), 1-1/2" (38.1 mm) CONDUITS (TYP) MAINTENANCE BYPASS SWITCH NORM SBP MBP TOP VIEW WITH PUNCH OUT HOLES BRACKET MOUNTING HOLES FOR CENTER MOUNTING MAINTENANCE BYPASS SWITCH KNOCKOUT FOR DC INPUT WIRING (EXTERNAL DC SUPPLY) (1" (25.4 mm), 2" (50.8 mm), 3" (76.2 mm) Conduit) MAINTENANCE BYPASS SWITCH DC BREAKER NORMAL NORMAL AC AC PRESENT INPUT ON INV AC INV OUTPUT OUTPUT TRIPPED DC OFF DC ON INPUT BYPASS BYPASS OPERATING INSTRUCTION BRACKET MOUNTING HOLES FOR FLUSH MOUNTING FRONT VIEW LEFT SIDE VIEW KNOCKOUT FOR AC WIRING/ CONDUIT, MBPS-INVERTER (1" (25.4 mm) Con (1-1/2" (38.1 mm) (1" (25.4 mm) Con (3/4" (19 mm) Con REAR PANEL TB3 TB1 KNOCKOUT FOR AC WIRING/ CONDUIT, MBPS-ACDP (1" (25.4 mm) Con RIGHT SIDE VIEW TB2 TB4 FOR SUPPLY CONNECTIONS USE MINIMUM 75°C RATED INSULATED COPPER WIRE AC INPUT 120/240 V L1 1 E9 LOAD OUTPUT N(L2) 2 GROUND 3 4 L1 5 6 N(L2) 7 INVERTER OUTPUT GND 8 L1 N(L2) 9 10 AC IN L1 11 N(L2) 12 TB4 1 2 3 4 5 6 7 8 9 10 11 12 A TB4 1—2 A REAR VIEW WITHOUT PANEL E10 DETAIL A E11 Introduction A Operating manual 1.2 Shipping and handling 1.3 Installation 1.4 Electrical 1.5 Operation After accepting the shipment from the freight carrier, inspect all exterior surfaces for damage. Damage claims should be filed directly with the carrier. The maintenance bypass switch (MBPS) may be shipped pre-installed in the Topaz S4 Inverter Plant. If so, installation of the plant is necessary, follow standard Topaz S4 Inverter Plant installation procedures. If the MBPS is shipped as a stand-alone unit, it must be installed in the existing equipment. Using the supplied hardware and Figure 1-1, install the mounting brackets to each side of the MBPS. The electrical requirements for the MBPS are defined in the specifications section above. Figure 1 shows the location of knockouts and terminals for input and output cabling. Size power cables according to the capacity of the inverter. The MBPS is connected to utility power, DC power, inverter, and the AC distribution panel. Follow the installation instructions provided for the AC distribution cabinet and the inverter, in addition to these instructions. Before applying any power to the MBPS, check to make sure all wiring is correct. Refer to Table 1-1, Table 1-2, the schematic, and Figure 1-1 for installation and wiring information. Introduction 1—3 Maintenance Bypass Switch Table 1-1 Power connections (see Note 1) From (external to MBPS) To Description (internal to MBPS) DC Power Source (+) + (E10) DC Supply Return DC Power Source (-) - (E11) DC Supply -48 VDC 120 / 220 / 230 / 240 VAC (L1) TB4-1 (L1) AC Supply Line Neutral (L2) TB4-2 (N, L2) AC Supply Neutral (L2) Safety Ground TB4-3 (G) Safety Ground Inverter DC + terminal E10 + DC Supply Return Inverter DC - terminal E9 - DC Supply -48 VDC Inverter L-In TB4-11 Bypass Input Line Inverter N-In TB4-12 Bypass Input Neutral Inverter N-out TB4-10 Output Neutral (L2) Inverter L-out TB4-9 Output LIne Inverter Safety Ground TB4-8 Safety Ground Load AC (L1) TB4-6 AC Distribution Panel "AC Input Line" Load Neutral (L2) TB4-7 AC Distribution Panel "Return" (Neutral) (L2) Load Safety Ground TB4-5 AC Distribution Panel Safety Ground Note 1&2 Note 1&2 Note 1&2 NOTE 1: The equipment is preset at the factory for operation at 120 VAC. To configure for 220/230/240 VAC operation, remove the #16 AWG wire from TB2-1 and TB2-3. Refer to the schematic diagram (6421M-S) provided with this manual. NOTE 2: The screw tightening torque for AC input and AC output terminal block (TB4) is 45-50 in. lb. (5.08 Nm - 5.65 Nm). Table 1-2 Control connections From (external to MBPS) To (internal to MBPS) Description Remote Alarm Circuit TB3-1 N.O. contact TB3-2 Common TB3-3 N.C. contact NOTE: Contacts common — N.O. shall be closed when S1 is switched to SBP or MBP position. 1—4 Introduction Operating manual Figure MBPS front panel 1-2 POWERMARK MAINTENANCE BYPASS SWITCH NORMAL DC BREAKER ON AC INPUT MAINTENANCE BYPASS SWITCH INV AC OUTPUT NORM DC INPUT 175A SBP TRIPPED BYPASS OFF OPERATING INSTRUCTIONS PROCEDURE TO BYPASS INVERTER 1. CHECK THAT ALL NORMAL INDICATOR LAMPS ARE ON. 2. TURN MAINT. BYPASS SWITCH CLOCKWISE FIRST TO SBP, THEN TO MBP POSITION. 3. CHECK THAT DC INPUT BREAKER HAS TRIPPED AND BYPASS LAMP IS ON. DC INPUT LAMP WILL REMAIN ON FOR A FEW SECONDS DUE TO CHARGED CAPACITORS IN THE INVERTER. 1.6 PROCEDURE TO RETURN TO NORMAL OPERATION 1. TURN MAINT. BYPASS SWITCH COUNTER CLOCKWISE FIRST TO SBP, THEN TO NORM POSITION 2. RESET DC CIRCUIT BREAKER BY OPERATING TO OFF POSITION, THEN TO ON POSITION. 3. CHECK ALL NORMAL INDICATORS ARE ON AND BYPASS LAMP IS OFF. 4. FOLLOW INVERTER STARTUP INSTRUCTIONS TO TURN ON INVERTER. Front panel The MBPS is a three position rotary switch. Under normal operating conditions, the handle is in the “NORM” position. This indicates the inverter is providing power to the load controls and (inverter or bypass mode). When the handle is placed clockwise in the “SBP” (static bypass) position, the DC indicators breaker is tripped and the load is powered by utility via the inverter static bypass switch. When the handle is placed clockwise in the “MBP” position, power to the load is provided by the AC input directly through the MBPS, and all power sources to the inverter are electrically removed. Figure 1-2 shows the front panel. The DC breaker provides input to the inverter. Under normal operating conditions, the handle is in the “ON” position. When the MBPS places the load in maintenance bypass, this circuit breaker is tripped and the handle goes to the “tripped” position. In order to place it back to the “on” position, the handle must be reset to the “off” position first, then placed in the “on” position. NOTE W h e n t h e by p a s s sw i t c h i s p l a c e d i n t h e s t a t i c by p as s (S B P ) posit ion, AC ut ilit y is st ill connect ed to th e inv e r ter. Work caref ully whenever volt ag e is p re s e n t. Introduction 1—5 Maintenance Bypass Switch There are four indicator lamps on the front panel: Indicator Color Description AC INPUT Green On when there is AC voltage at the input terminals of the MBPS INV AC OUTPUT Green On when the Inverter is providing power to the load (inverter or bypass mode) DC INPUT Green On when DC Breaker is closed on the MBPS BYPASS Red On when the AC utility is providing power to the load and the inverter is electrically isolated Note that the “AC INPUT,” “INV AC OUTPUT,” and “DC INPUT” (grouped as “normal” on the front panel) will be on during normal operating conditions. 1.7 Procedure to bypass the inverter 1. Check that all normal indicator lamps are lit. 2. Turn the MBPS clockwise to the “SBP” position, then to the “MBP” position. 3. Check that DC breaker has tripped and bypass lamp is on. “DC ON” lamp will remain on for a few seconds due to charged capacitors in the inverter and then turn off. NOTE: For your safety, the Maintenance Bypass Switch (MBPS) DC breaker remains tripped and cannot be turned on with the rotary bypass switch in the MBP position (See DC breaker trip reset jumper). During this process, the form C contacts at TB3 change state. The common and NC terminals were closed prior to the operation and are opened after the operation. The common and NO terminals were open prior to, and are closed after the operation. 1.8 Procedures to return to normal (inverter) operation 1. Turn the maintenance bypass switch counter-clockwise to the “SBP” position, then turn to the “NORM” position. 2. Reset the DC breaker by toggling the handle from the “TRIP” position to the “OFF” position, then to the “ON” position. 3. Check that all normal indicator lamps are lit and the “BYPASS” lamp is off. 4. Follow the inverter startup instructions to turn on the inverter. During this process, the form C contacts at TB3 change state. The common and NO terminals were closed prior to the operation and are opened after the operation. The common and NC terminals were open prior to, and are closed after the operation. 1—6 Introduction Operating manual 1.9 DC breaker trip reset jumper If your application requires DC power to the inverter during the maintenance, DC breaker trip feature may be disabled by removing the jumper on TB2-1&2 inside the MBPS. When this jumper is removed, the DC breaker can be reset and turned on from tripped position with the rotary bypass switch in the MBP position during maintenance, while the load is supported by utility AC source. 1.10 Maintenance The MBPS has four indicator lamps on the front panel. These lamps can be removed from the front panel without interrupting power to the load. MGE offers a spare indicator lamp kit for this purpose: Description Part Number SPARE LAMP INDICATOR KIT 16289MBSK2 If a front panel indicator lamp fails to operate properly and the installation, setup and operation of the MBS have been rechecked, replace lamp with a new one per the following instructions: WARNING H ig h vo ltag e is present at t he P1 plug. Inst all or re move P 1 by holding t he plug on t he sides. Do not to u ch p lu g if wires are exposed. 1. Remove four screws from indicator lamp plate (Figure 1-3). 2. Lift indicator lamp plate from the front panel. 3. Carefully disconnect P1 connector from J1. Remove lamp assembly away from MBPS. 4. Remove lamp shield from assembly. Remove quick-disconnect terminals from lamp to be replaced. Remove failed lamp(s). Replace with new lamp(s). Make sure new lamp manufacturer part number is correct (Figure 1-4). 5. Reinstall quick-disconnect terminals (flat side close to the lamp) and secure lamp shield. WARNING H ig h vo ltag e is present at t he P1 plug. Inst all or re move P 1 by holding t he plug on t he sides. Do not to u ch p lu g if wires are exposed. Introduction 1—7 Maintenance Bypass Switch 6. Carefully reconnect P1 to J1 connector. 7. Reinstall indicator lamp assembly to the front panel. If further assistance is required, call MGE hotline service at 1-800-523-0142. Figure Indicator lamp plate removal 1-3 P1 AC T PU IN C A V T N I TPU U O C D T PU IN S S PA BY LAMP ASSEMBLY 1—8 Introduction Operating manual Figure Failed indicator lamp replacement 1-4 P1 7 6-32 KEPS NUT 8 5 3 6 4 1 SHIELD, LAMP 2 LAMP, GREEN NEON 250V ID PART NUMBER 1053QA5 PLATE, LAMP LAMP, GREEN INCAND 28V IDI PART NUMBER 1090QA5-28V LAMP, RED NEON 250V IDI PART NUMBER 1051QA1 Notes Maintenance Bypass Switch Notes Appendices E9 E10 NOTES: UNLESS OTHERWISE SPECIFIED. INSTALL #16 AWG JUMPER WIRE BETWEEN TB2-1 & TB2-3 WHEN AC INPUT IS 120VAC. (REMOVE JUMPER FOR 240 ONLY) - + 1 + ST CB1,250A IF JUMPER BETWEEN TB2-1 & TB2-2 IS REMOVED, CB1 MAY BE RESET IN MBP MODE AND POWER WILL BE PRESENT. E10 - 3 G E11 2 N L1 2 DC INPUT 40V-57VDC AC INPUT 120V/(240V) PART OF TB4 1 SBP (YEL) (BLK) (BLU W/STRIP) (BLK) MAINTENANCE BYPASS SWITCH MBP NORM TB1 1 1 3 5 5 3 7 7 1 J1 P1 DS1 3 DS4 BYPASS DS3 DC ON DS2 680 W R1 1 1 1 2 2 2 2 2 INV OUTPUT 1 AC PRESENT LAMP ASSY 2 4 6 8 TB4 4 10 9 MK. B. BRK XFR C O 3 1 11 9 7 5 3 1 O C 10 8 6 4 2 8 4 2 12 N(L2) L1 CONTACT PAIRS 7-8 9-10 O C Y O C 5-6 C MOMENTARY CLOSURE C O 3-4 O X O Y C 1-2 C PART OF 2 4 6 8 P1 J1 MBP SBP S1 POSITION NORM O O X 1-2 O C O 3-4 O 11 12 S1 (SHOWN IN NORM POSITION) O C 11-12 C A B K1 1 7 4 6800 W R2 TB3 1 2 3 3 2 TB2 1 5 7 6 PART OF TB4 N.O. COMM. N.C. N G L1 1 2 TO LOAD Appendices a—1 Maintenance Bypass Switch a—2 Appendices Reorder form 1660 Scenic Avenue Costa Mesa, CA 92626 Use this form to order additional copies of this document, or to report any errors, omissions, or other problems you have experienced. 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