Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012

User and Installers Guide Hardwired Maintenance Bypass Switches To Suit Eaton UPS

www.eaton.com/powerquality
6M1004Rev9

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012

TABLE OF CONTENTS
1.0 Important Safety Notices ..................................................................................................................... 2 2.0 Introduction ......................................................................................................................................... 2 3.0 Description of Operation ...................................................................................................................... 3 4.0 Installation ........................................................................................................................................... 5 5.0 Inverter Interlock Types ....................................................................................................................... 7 6.0 Wiring Diagram Selection .................................................................................................................... 7 7.0 Troubleshooting ................................................................................................................................... 9

LIST OF FIGURES
Figure 1. MBS in Off position .................................................................................................................. 3 Figure 2. MBS in Normal Position ........................................................................................................... 3 Figure 3. MBS in Test Position ................................................................................................................ 3 Figure 4. MBS in Bypass position ........................................................................................................... 4 Figure 5. MBB Type MBS with Inverter Interlock ....................................................................................... 5 Figure 6: Identifying MBS Part number ...................................................................................................... 7 Figure 7: Identifying UPS Part number ...................................................................................................... 7

LIST OF TABLES
Table 1: Inverter Interlock Contact types for various Eaton UPS models. ................................................. 7 Table 2: Wiring Diagram Selection Table.................................................................................................. 8

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012 Congratulations on the purchase of your Eaton Maintenance Bypass Switch (MBS). This switch has been specifically designed to operate in conjunction with your Eaton UPS, ensuring seamless operation of your critical load during maintenance and testing, or during the unlikely event of a UPS failure. Please take the time to read these instructions carefully, and ensure they are on hand at all times.

1.0 Important Safety Notices

CAUTION
UPS units are capable of supplying dangerous voltages even when turned off. Before attempting to install this MBS the UPS must be completely switched off and removed from supply, battery isolated (where appropriate), and mains supply isolated. Eaton Maintenance Bypass Switches must be installed by qualified and trained electricians, strictly in accordance with Australian standards and these instructions. Failure to properly install and test the Maintenance Bypass Switch may result in severe damage to your UPS or load equipment.

2.0 Introduction
The purpose of a Maintenance Bypass Switch is to isolate all AC input and output supplies from a UPS to allow maintenance technicians to safely work on the UPS, while the critical load equipment continues to be powered from the input supply, normally raw mains. DC supplies and batteries are not disconnected by the MBS as they are fitted with their own specialised isolators. In addition to the normal bypass function described above, all Eaton MBS have a Test position which allows a Maintenance Technician to apply power to the UPS for test purposes without disturbing the critical load equipment, while it continues to be fed from raw mains. The MBS also has an Off position which provides the isolation function required by AS3000 Clause 4.8.4.3.1. All Maintenance Bypass Switches feature an electrical/mechanical pushbutton interlock to prevent UPS damage due to improper switch operation.

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012

3.0 Description of Operation

Eaton Maintenance Bypass Switches feature 4 positions, at the 10 Oclock, 12 Oclock, 2 Oclock, and 4 Oclock positions. The function of each position is described below. Note: Figures 1-4 are for descriptive purposes only, for specific wiring, please refer to the relevant wiring diagram at the back of the manual. Off. In the Off position the AC Mains supply, UPS, and critical load equipment are all isolated from each other. In other words all equipment is off. (See Figure 1.)

Bypass Input Rectifier Input

To Load
MBS UPS

Rectifier

Inverter

Static Switch

Figure 1. MBS in Off position Normal In the Normal position the UPS is fed from the AC Mains supply and the critical load equipment is fed from the output of the UPS. In this position the critical load is protected by the UPS (See Figure 2.)

Bypass Input Rectifier Input

MBS UPS

To Load Rectifier Inverter Static Switch

Figure 2. MBS in Normal Position Test The Test position connects the load equipment directly to raw AC Mains supply. AC input power continues to be fed to the UPS to facilitate UPS testing. The output of the UPS is disconnected from the load equipment. The critical load is no longer protected by the UPS. (See Figure 3.)

Bypass Input Rectifier Input

UPS MBS

To Load Rectifier Inverter Static Switch

Figure 3. MBS in Test Position

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012

3.0 Description of Operation (cont.)

Bypass The Bypass position connects the load equipment directly to raw AC Mains supply. AC input power is disconnected from the UPS to facilitate maintenance or component replacement. The critical load is not protected by the UPS. In this position the entire UPS can be removed or replaced without disturbing the load equipment. (See Figure 4.)

Bypass Input Rectifier Input

MBS

To Load
UPS

Rectifier

Inverter

Static Switch

Figure 4. MBS in Bypass position Note: Figures 1-4 show MBS with Separate Bypass Inputs. For MBS without Separate Bypass Inputs, the UPS Rectifier Input terminal is tied to the UPS Bypass Input terminal. For further clarification refer to the relevant wiring diagram in Appendix A. Eaton Maintenance Bypass Switches are a Make Before Break type switch, or MBB for short. This type of switch provides continuity of supply to the load when switching between all positions except Off. Load supply continuity is achieved by overlapping the opening and closing of input and output switch contacts when switching between positions. This means that the input supply voltage and output supply are connected together momentarily when switching between the adjacent Normal and Test positions. When used on a double conversion type UPS the inverter must be off and the load fed from the UPS bypass, or inverter damage is highly probable. All Eaton MBS feature an interlock to ensure the inverter is turned off automatically before the MBS can be moved between positions. This interlock takes the form of a pushbutton integral to the switch assembly. Depending on which model UPS you have, either a normally open or closed contact on the rear of the pushbutton is connected to the inverter control circuits to allow normal operation while the pushbutton is in the released position (see Sec. 5: Table 1 for type of Inverter Interlock). The red pushbutton is also mechanically interlocked to the MBS to prevent the switch being physically moved between positions accidentally. When it is desired to change the mode of the MBS the pushbutton must be depressed to release the mechanical interlock. Depressing the pushbutton causes the normally open/closed contact (see Sec. 5: Table 1) connected to the inverter control circuit to toggle positions, causing the inverter to turn off and the critical load to be fed from the UPS bypass. A keylock can be substituted for the pushbutton interlock at the time of purchase. This option is specified by adding the suffix KL to the switch part number. The different functional positions of the MBB type switches are shown in Figure 5 (see overleaf).

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012

4.0 Installation
Normal Off Test

Bypass

Figure 5. MBB Type MBS with Inverter Interlock (shown in Normal Position) Eaton MBS are supplied loose for installation by a licensed electrician. They are rear mounted and are enclosed in metal enclosures providing a degree of protection of IP40 or better. The enclosures are intended for wall mounting via keyhole slots provided. Cable entry knockouts are provided for glanding incoming cables. Inverter interlock circuits must be wired in 240 VAC rated two-core screened cable of minimum size 1 mm . This cable must be run with a minimum spacing of 50 mm from all AC mains cabling. Note: For 3 to 1 no separate bypass (MBS31-NSB-XX-BW) switches, the incoming 3 feed cables must each be rated for the total UPS single phase bypass current.

4.1 Installation Procedure:

1. Mount the MBS enclosure in a suitable location for safe and convenient operation, adjacent to the UPS. Issues to consider are operator access and visibility and convenience for cabling. 2. Refer to Section 5: Inverter Interlock Types for your Inverter Interlock connection. Refer to Table 2 (on page 8) for the appropriate connection diagram. 3. Remove the gland plate and knockout cable entries that suit your cable glands. 4. Gland and connect cables in accordance with the connection diagram on Table 2: Selection Table. Connection points inside the enclosure are labelled as per the appropriate Connection Drawing. 5. Connect the Earth conductors to the Earth studs on the gland plate. The MBS enclosure will provide Earth continuity, however this must be tested. 6. Identify the correct operation label from Table 2 on page 8 and affix to the MBS front panel.

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012

4.0 Installation (cont.)

4.2 Test Procedure:
NOTE: We strongly recommend that a dummy load be used to commission and confirm correct operation of the MBS before placing it into service. At all stages in the commissioning the output to the load should be monitored to confirm correct phase, voltage and polarity during MBS transfer operations. Eaton will accept no responsibility for any damage or loss resulting from an incorrectly installed MBS. Functional tests should be performed in addition to the tests required by AS3000:2000, Wiring Rules. Our service department can provide commissioning and functional testing services by factory trained service technicians, and it is strongly recommended that you avail yourself of this service.

The Red Button must be pushed before the MBS switch can be rotated. 1. Depress and hold the Red Button, then rotate the MBS switch to the Bypass position and apply input power supply. This will allow the critical load to be tested with raw AC power. 2. Place the bypass switch into the Test position. The UPS can now be started in accordance with the UPS Users Manual. 3. Check the Inverter Interlock function by depressing and holding down the Red Button on the front of the MBS. NOTE: Do not rotate the switch. Observe the operation of the UPS. The UPS must transfer from Normal Mode to Bypass Mode. IF THE UPS DOES NOT TRANSFER TO BYPASS MODE DO NOT PROCEED FURTHER. CONTACT YOUR LOCAL EATON EATON SERVICE REPRESENTATIVE. 4. If the correct Inverter Interlock function is confirmed as per Step 3, the UPS can then be used to support the critical load by depressing and holding the Red Button, and rotating the MBS switch to the Normal position then releasing the Red Button. The UPS will revert automatically to Normal Mode. 5. The UPS should now operate normally and will support the critical load. Please refer to the relevant UPS manual for information on how to confirm correct UPS operation.

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012

5.0 Inverter Interlock Types

UPS PB1000 PB4000 PW9120 PW9155S/N PW9170 PW9305 PW9340 PW9355 PW9390 Inverter Interlock Contact Type Normally Closed Normally Open Normally Closed Normally Open Normally Open Normally Open Normally Open Normally Open Normally Open

Table 1: Inverter Interlock Contact types for various Eaton UPS models.

6.0 Wiring Diagram Selection

STEP ONE: Identify your MBS unit by its part number:
Cable Entry: BW = Bottom Wired TW = Top Wired Current Rating (Amps)

eg: MBS 11 NSB 32 BW

Number of phases: 11 = 1 to 1 ph 31 = 3 to 1 ph 33 = 3 to 3 ph Bypass Configuration NSB = No Separate Bypass SB = Separate Bypass

Figure 6: Identifying MBS Part number STEP TWO: Identify your UPS model by the model number located on the rating label on your UPS. Eg: 9120 UPS Model 0700A UPS Size (VA)

Figure 7: Identifying UPS Part number STEP THREE: From Table 2 overleaf, locate your MBS and UPS combination, and select the wiring diagram and operating instructions labels to suit.

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012 WIRING DIAGRAM SELECTION TABLE: MBS UPS Type Wiring Diagram Page Operating Label # (included with unit)

MBS11-NSB-XX-BW MBS11-NSB-XX-BW MBS11-NSB-XX-BW

1 to 1 no separate bypass 9120 A4D0219R2 A1 9155S A4D0230R1 A2 9170 A4D0231R0 A3 1 to 1 with separate bypass 9120 A4D0218R4 A4 9155S A4D0229R2 A5 3 to 1 no separate bypass (3) 9155N A4D0224R1 A6 PB1000 A4D0263R1 A7 3 to 1 with separate bypass 9155N A4D0213R2 A8 PB1000 A4D0264R1 A9 3 to 3 no separate bypass 9305 A4D0249R0 A10 9340 A4D0250R0 A11 9355 A4D0251R1 A12 9390 A4D0261R3 A13 PB4000 A4D0252R1 A14 3 to 3 with separate bypass 9305 A4D0225R3 A15 9340 A4D0246R1 A16 9355(8-15kVA) A4D0247R2 A17 9355(20-40kVA) A4D0303R1 A18 9390 A4D0262R3 A19 PB4000 A4D0248R2 A20 1 to 1 Tail End bypass switch GENERIC A4D0321R1 A21 3 to 1 UPS Tail End bypass switch GENERIC A4D0365R0 A22 3 to 3 Tail End bypass switch GENERIC A4D0319R1 A23

A4L0136 A4L0169 A4L0170

MBS11-SB-XX-BW MBS11-SB-XX-BW

A4L0136 A4L0169

MBS31-NSB-XX-BW MBS31-NSB-XX-BW

A4L0169 A4L0169

MBS31-SB-XX-BW MBS31-SB-XX-BW

A4L0169 A4L0169

MBS33-NSB-XX-BW MBS33-NSB-XX-BW MBS33-NSB-XX-BW MBS33-NSB-XX-BW MBS33-NSB-XX-BW

A4L0169 A4L0169 A4L0169 A4L0169 A4L0169

MBS33-SB-XX-BW MBS33-SB-XX-BW MBS33-SB-XX-BW MBS33-SB-XX-BW MBS33-SB-XX-BW MBS33-SB-XX-BW

A4L0169 A4L0169 A4L0169 A4L0169 A4L0169 A4L0169

MBS11-TE-XX-BW

A4L0153A

MBS31-TE-XX-BW

A4L0153A

MBS33-TE-XX-BW

A4L0153A

Table 2: Wiring Diagram & Operating Label Selection Table Notes: 1) XX = Maximum MBS current rating 2) Suffix BW means Bottom Wired, TW means Top Wired. Labels and connection drawings are identical for each type. 3) For 3 to 1 no separate bypass, refer to 4.0 Installation, for notes on cable sizing.
8

Maintenance Bypass Switches

6M1004Rev 9 Issue Date: 09/07/2012

7.0 Troubleshooting
If you have a question or problem, or need assistance please contact Eaton Services on 1300 303 059, or contact your local Eaton Customer Service office.

Eaton Services NATIONAL SERVICE Phone 1300 303 059

When calling please specify: 1. Part Number of MBS and UPS. 2. Serial Number of the unit. 3. Original Date of Purchase of the Maintenance Bypass Switch. Parts, orders and all correspondence regarding repairs under the warranty should be addressed to Eaton Service Department at the address below, or to the service depot address advised by our Service staff.

Eaton Industries Pty Ltd

ABN 66 103 014 571 Office: 4 Caribbean Drive. Scoresby, Victoria 3179 Phone:03-9839 1144 Fax: 03-9839 1177