User s Guide. Eaton Bypass Power Module (BPM) For use with the following: Eaton 9155 UPS (8 15 kva)

Transcription

1 Eaton Bypass Power Modue (BPM) User s Guide For use with the foowing: Eaton 9155 UPS (8 15 kva) Eaton UPS (3 18 kva) Eaton 9PX Spit-Phase UPS (6 10 kva)

2 Specia Symbos The foowing are exampes of symbos used on the UPS or accessories to aert you to important information: RISK OF ELECTRIC SHOCK - Observe the warning associated with the risk of eectric shock symbo. CAUTION: REFER TO OPERATOR'S MANUAL - Refer to your operator's manua for additiona information, such as important operating and maintenance instructions. This symbo indicates that you shoud not discard the UPS or the UPS batteries in the trash. This product contains seaed, ead-acid batteries and must be disposed of propery. For more information, contact your oca recycing/reuse or hazardous waste center. This symbo indicates that you shoud not discard waste eectrica or eectronic equipment (WEEE) in the trash. For proper disposa, contact your oca recycing/reuse or hazardous waste center. Eaton is a registered trademark of Eaton. A other trademarks are properties of their respective companies. Copyright 2017 Eaton, Raeigh NC, USA. A rights reserved. No part of this document may be reproduced in any way without the express written approva of Eaton.

3 Tabe of Contents Tabe of Contents 1 INTRODUCTION Bypass Overview INSTALLATION Bypass Power Modue Dimensions Rackmount Instaation A BPM Rackmount Hardwired Instaation A Linecord Input BPM Rackmount Instaation Wamount Instaation Wamount Hardwired BPM Instaation A Wamount Linecord BPM Instaation Input Current and Wire Ratings Signa Wire Routing Connection Diagrams OPERATION No Break Transfer from UPS Mode to Service Mode Lock-out/Tag-out No Break Transfer from Service Bypass to UPS Mode SPECIFICATIONS Rear Pane Outet Options Eaton Bypass Power Modue (BPM) User s Guide P Rev 2 i

4 Tabe of Contents ii Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

5 Chapter 1 Introduction The Eaton Bypass Power Modue (BPM) is designed to be a maintenance bypass switch that aso contains fexibe output power distribution and mounting options. The BPM is a bypass modue that can be used with a variety of Eaton UPS modes incuding the 9170+, 9155, and 9PX SP. The BPM provides added reiabiity to Eaton uninterruptabe power suppy (UPS) systems by ensuring seamess, uninterrupted, no-break transfer as we as a ock-out/tag-out (LOTO) feature to ensure the greatest safety for UPS technicians and eectricians. The BPM aso offers output distribution in order to simpify wiring in a rackmount IT environment, potentiay removing the need for a paneboard, breakers, and conduit for distribution. Athough the BPM is designed to be safe, the bypass can carry high eves of votage and current. The BPM shoud ony be operated by an experienced user, famiiar with UPS behavior and functionaity. Instaation for modes requiring hardwire connections shoud be performed by a quaified eectrician foowing oca eectrica codes. Pease refer to the instaation chapter of your UPS manua for the BPM wiring diagram. Bypass Overview The BPM has three operating positions (see Tabe 1). Faiure to understand the correct bypass sequence and position may cause the critica oad to be dropped. Consider both the operating state of the UPS and the BPM when protecting your critica oads. NOTE In the UPS or LINE position, AC input power is sti connected to the input terminas inside the UPS. Eaton Bypass Power Modue (BPM) User s Guide P Rev 2 1

6 Introduction Tabe 1. BPM Positions Switch Position UPS Description The norma operating state of the system occurs when the BPM switch is in the UPS position. Utiity power is fed to the bypass, where power is then fed to the UPS. The UPS provides critica battery backup and power conditioning and power is then fed back to the bypass switch and then the critica oad. LINE When the switch is in the LINE position, utiity power is directy connected to the critica oad and the output of the UPS is disconnected. In this state the UPS remains powered, which is often beneficia for troubeshooting, obtaining ogs, or updating firmware. SERVICE Like the LINE position, the SERVICE position connects the oad directy to AC input power and disconnects UPS output; however, because SERVICE aso disconnects AC input from the UPS, this is the appropriate position for UPS maintenance or repair. In the SERVICE position, the UPS can be competey removed from the system. 2 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

7 Chapter 2 Instaation This chapter expains: Dimensions Rack Instaation Wamount Instaation Input Current and Wiring Ratings Signa Wire Routing WARNING Risk of eectrica shock. Ony quaified service personne (such as a icensed eectrician) shoud perform the eectrica instaation. CAUTION To prevent eectrica shock or damage to the equipment, verify that the Eaton UPS is OFF before you remove the entrance pane. The circuit breaker or disconnect switch must aso be off at the AC input service pane. Aso, turn OFF the AC disconnect and bypass switches before you connect any wires to the bypass switch termina strip. Eaton Bypass Power Modue (BPM) User s Guide P Rev 2 3

8 Instaation Bypass Power Modue Dimensions Figure 1 shows the dimensions of the Bypass Power Modue (BPM) in miimeters (inches). 663 (26.1) 603 (23.7) (5.1) Figure 1. BPM Dimensions (in miimeters) 440 (17.3) 4 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

9 ) Instaation Rackmount Instaation 125A BPM Rackmount Hardwired Instaation CAUTION The BPM distributes high density power in a sma form factor. Read the compete instaation procedure before beginning any eectrica wiring. To insta the BPM in a rack: 1. Insta the 4-post rai kit incuded with the BPM (see Figure 2). Figure 2. Insta Rai Kit 2. Pace the BPM on the rais and push the BPM into the rack. Verify that the breakers are facing the front of the rack and the BPM wiring terminas are facing the rear of the rack. 3. Push the BPM past the back of the rack to aow access to the rear wire access-point covers and the wire access pane cover (see Figure 3). Figure 3. Push BPM into the Rack 4. Remove the wire access-point covers (see Figure 4). Figure 4. Remove the Wire Access-Point Covers Eaton Bypass Power Modue (BPM) User s Guide P Rev 2 5

10 Instaation 5. Remove the access pane cover (see Figure 5). Figure 5. Remove the Access Pane Cover 6. To wire the BPM, see Signa Wire Routing on page After wiring is compete, repace the covers removed in Step 4 and Step Push the BPM past the front of the rack to aow access for the mounting ears instaation. 9. Insta the mounting ears to the BPM using the provided screws (see Figure 6). Figure 6. Insta the Mounting Ears 10. Push the BPM into the rack and secure the mounting ears to the rack using the provided screws (see Figure 7). Figure 7. Secure the BPM to the Rack 6 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

11 Instaation 30A Linecord Input BPM Rackmount Instaation CAUTION The BPM distributes high density power in a sma form factor. Read the compete instaation procedure before beginning any eectrica wiring. To insta the BPM in a rack: 1. Insta the 4-post rai kit incuded with the BPM (see Figure 8). Figure 8. Insta Rai Kit 2. Pace the BPM on the rais and push the BPM into the rack, eaving enough room to aow access for the mounting ears instaation. Verify that the breakers are facing the front of the rack and the BPM wiring terminas are facing the rear of the rack. 3. Insta the mounting ears to the BPM using the provided screws (see Figure 9).. Figure 9. Insta the Mounting Ears 4. Push the BPM into the rack and secure the mounting ears to the rack using the provided screws (see Figure 10). Figure 10. Secure the BPM to the Rack 5. Remove the knockouts in the bottom of the BPM as needed for wiring. Eaton Bypass Power Modue (BPM) User s Guide P Rev 2 7

12 Instaation 6. To wire the BPM, see Signa Wire Routing on page Connect the UPS to the BPM as shown in Figure 11. Output to UPS Input from UPS Main Utiity Input Wamount Instaation Figure 11. Connect the UPS to the BPM Wamount Hardwired BPM Instaation CAUTION The BPM distributes high density power in a sma form factor. Read the compete instaation procedure before beginning any eectrica wiring. To insta the BPM in a wamount form factor: 1. Seect a mounting ocation for the bypass switch within sight of the UPS. NOTE The bypass switch shoud be mounted securey to a sturdy surface. You may need to turn the cabinet 90 degrees (on its side) to enabe operator access to the switch hande. 2. Use the provided wamount brackets to firmy secure the BPM to the wa (Figure 12). 8 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

13 Instaation Figure 12. BPM with Wamount Brackets 3. Remove the six (6) screws on the BPM front cover and remove the cover. Remove any packing materia inside the BPM. 4. Remove the knockouts in the bottom of the BPM as needed for wiring (see Figure 13). MBP INPUT WIRING Remove cover to gain access to the wiring termina bocks Auxiary Singe UPS Contacts Refer to UPS manuas for proper wiring connections Figure 13. BPM Hardwired Overview Wire routing Refer to UPS manuas for proper wiring connections Eaton Bypass Power Modue (BPM) User s Guide P Rev 2 9

14 Instaation 5. To wire the BPM, see Signa Wire Routing on page After wiring is compete, repace the cover removed in Step 3. 30A Wamount Linecord BPM Instaation CAUTION The BPM distributes high density power in a sma form factor. Read the compete instaation procedure before beginning any eectrica wiring. To insta the BPM in a wamount form factor: 1. Seect a mounting ocation for the bypass switch within sight of the UPS. NOTE The bypass switch shoud be mounted securey to a sturdy surface. You may need to turn the cabinet 90 degrees (on its side) to enabe operator access to the switch hande. 2. Use the provided wamount brackets to firmy secure the BPM to the wa (Figure 14). Figure 14. BPM with Wamount Brackets 3. Use the provided wamount brackets to firmy secure the BPM to the wa. 4. Remove the six (6) screws on the BPM front cover and remove the cover. Remove any packing materia inside the BPM. 5. Remove the knockouts in the bottom of the BPM as needed for wiring. 6. To wire the BPM, see Signa Wire Routing on page After wiring is compete, repace the cover removed in Step Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

15 Instaation Input Current and Wire Ratings Wiring to the BPM varies based on the UPS seection. Refer to the UPS manua for recommended input breaker size. To easiy expand the system, it is recommended that initia instaation of the BPM and UPS contains wiring to support the maximum capacity of the UPS system. For exampe, if the UPS is now designed to be a 12 kva system with an 80A input, but can be expanded to 18 kva requiring 125A input in the future, then 125A wiring woud be used initiay to prevent rewiring costs during future expansion. Loca eectrica codes shoud aways be foowed, but be sure to check with the termina bock sizing on both the UPS and the BPM. The UPS termina bock sizing can be found in the UPS manua, whie the BPM termina bock sizing can be found in Tabe 2. Tabe 2. RBPM Termina Bock Sizing BPM Termina Bock Sizing 75 C Copper Wire Size Conductor Screw Torque Wire Size Range BPM 125A Modes 42.1 mm 2 (1 AWG) 6.6 Nm (50 b in) 10-1/0 AWG BPM 30A Modes 8.4 mm 2 (8 AWG) 4.5 Nm (40 b in) 14-6 AWG! IMPORTANT FOR U.S. INSTALLATIONS, READ THIS IMPORTANT NOTE Tabe 2 ists the mm 2 and AWG wire size for each circuit breaker size shown on the wiring diagrams. The minimum recommended circuit breaker sizes for each mode and votage appication are isted on the wiring diagrams. Conductor sizes sha be no smaer than the 75 C wire size based on the ampacities given in Tabe of the Nationa Eectrica Code (NEC ), ANSI/NFPA , and artice 220. A circuit conductors, incuding the neutra conductor, must be the same size (ampacity) wire. Code may require a arger AWG size than shown in this tabe because of temperature, number of conductors in the conduit, or ong service runs. Foow oca code requirements. Signa Wire Routing CAUTION The auxiiary contacts must be wired to the BPM from the UPS for proper functionaity. These auxiiary contacts signa the UPS to go to Interna Bypass mode to provide a synchronized transfer. Faiure to wire the auxiiary contacts can be dangerous and resut in system faiure. NOTE 1 NOTE 2 NOTE 3 Refer to the UPS manua and Input Current and Wire Ratings on page 11 for breaker, termina bock, and wire sizing. Provide enough fexibiity in the conduit for the BPM to be firmy mounted in the rack (see step 7, Figure 9). Connection diagrams can be found on pages 9-11 for wiring detais. To route signa wires (customer suppied): 1. Route the signa wires through the provided insuation. 2. Pass the insuated wires through the opening in the rear pane (Figure 15). 3. Connect termina bocks to signa wires. 4. Pug in the termina bocks into their proper ocations. Eaton Bypass Power Modue (BPM) User s Guide P Rev

16 Instaation 5. Pace the insuated wires into the two wire cips as shown. Signa Wire Openin g Insuation Wire Cips Signa Wirings Termina Bocks Rear of BPM Figure 15. Signa Wire Routing 12 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

17 Instaation Connection Diagrams 9155 UPS to BPM Connection Diagram BPM 9155 UPS Termina Bock 2a1 2a2 Figure 16. Eaton 9155 UPS to BPM Connection Diagram Eaton Bypass Power Modue (BPM) User s Guide P Rev

18 Instaation UPS to BPM Connection Diagram BPM UPS Contacts shown in UPS position Figure 17. Eaton UPS to BPM Connection Diagram 14 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

19 Instaation 9PXSP UPS to BPM Connection Diagram BPM 9PXSP UPS Aux Contacts BPM/ROO L2 N L1 L2 N L1 Contacts shown in UPS position 9PXSP UPS INPUT TERMINAL BLOCK L1 N L2 L1 N L2 OUTPUT INPUT Aux Contacts BPM/ROO Figure 18. Eaton 9PX SP UPS to BPM Connection Diagram Eaton Bypass Power Modue (BPM) User s Guide P Rev

20 Instaation This page intentionay eft bank. 16 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

21 Chapter 3 Operation This chapter contains information for operating the Bypass Power Modue (BPM). No Break Transfer from UPS Mode to Service Mode CAUTION It is critica that the foowing steps are foowed to ensure correct and safe operation. To turn the BPM to SERVICE: 1. Press and hod the red button and turn the switch to LINE (see Figure 19). NOTE Pressing the red button sends the UPS into Interna Bypass mode. This aows the UPS output to synchronize with utiity for safe, uninterrupted transfer. The UPS is now in LINE mode. The critica oad is fed directy from utiity and the UPS remains energized from utiity power. The UPS may be eft in this mode whie trying to troubeshoot, gather aarms from the UPS, or perform other preventative maintenance activities. Figure 19. From UPS to LINE 2. Turn the switch from LINE to SERVICE (see Figure 20). The critica oad is fed directy from utiity and the UPS is now competey disconnected from AC power. Ensure that the UPS is off and the terminas are competey de-energized before performing any maintenance on the UPS. Figure 20. From LINE to SERVICE Eaton Bypass Power Modue (BPM) User s Guide P Rev

22 Operation Lock-out/Tag-out The BPM comes with a Lock-out/Tag-out (LOTO) feature to keep the BPM bypass switch ocked in SERVICE mode whie quaified service personne works on the UPS. To use the LOTO feature: 1. Press and hod the red bar (see Figure 19). Figure 21. LOTO Feature 2. Insta a ock and tag in any opening at the base of the switch according to LOTO procedures. 3. Remove the ock and tag to reset the LOTO position. No Break Transfer from Service Bypass to UPS Mode After the system has been paced into SERVICE mode, it must be returned to UPS state to resume norma operation. CAUTION It is critica that the foowing steps are foowed to ensure correct and safe operation. To turn the BPM to UPS mode: 1. Turn the switch from SERVICE to LINE (see Figure 22). The UPS is now in LINE mode and is energized. It is often best practice to check the UPS status and configure settings in this mode before transitioning to UPS mode. Simpy check the status of the UPS through the front LCD menu to ensure the UPS is prepared for use. 18 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

23 Operation 1 Figure 22. From SERVICE to LINE 2. To transition the UPS from LINE to UPS, press and hod the red button and turn the switch to UPS (see Figure 23). NOTE 1 NOTE 2 Pressing the red button sends the UPS into Interna Bypass mode. This aows the UPS output to synchronize with utiity for safe, uninterrupted transfer. In UPS mode, the UPS resets from Interna Bypass to UPS Norma mode (onine mode). This transition may take as ong as 60 seconds. 2 3 Figure 23. From LINE to UPS 3. Once the switch is in UPS mode and the UPS is in Norma mode (onine mode), the system is in norma operation and prepared to provide uninterrupted power to the critica oad. Eaton Bypass Power Modue (BPM) User s Guide P Rev

24 Operation 20 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

25 Chapter 4 Specifications This chapter provides the foowing specifications: Dimensions and weights Eectrica connections Rear Pane Outet Options Tabe 3. Mode Dimensions HXWXD (mm/inch) Weight (kg/b) BPM30XX 130 x 440 x 663 / 5.1 x 17.3 x /34 BPM125XX 130 x 440 x 663 / 5.1 x 17.3 x /38 Tabe 4. Mode Input Connection BPM30XX L14-30 or Hardwired (L1, L2, N, G) BPM125XX Hardwired (L1, L2, N, G) Eaton Bypass Power Modue (BPM) User s Guide P Rev

26 Specifications Rear Pane Outet Options L14-30R L6-20R L6-30R 5-20R C19 Bank Pane 1 Pane 2 22 Eaton Bypass Power Modue (BPM) User s Guide P Rev 2

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