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 . . .
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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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Operating Manual
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