Maintenance Bypass Breaker Cabinet 90881 Series Configuration 5 Installation and Operation Manual
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Copyright 2012 C&C Power, Inc. All rights reserved. C&C Power, Inc. 395 Mission Street Carol Stream, IL 60188 www.ccpower.com Technical Support: Phone: (630) 617-9022 Email: support@ccpower.com 03/13/2012 3 755-00084-C5 R03
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TABLE OF CONTENTS 1. Important Information About This Manual... 6 1.1 Manual Symbols... 6 2. Introduction:... 7 3. Safety Precautions... 8 4. Inspection Upon Receipt of Goods... 9 4.1 General... 9 4.2 Visible Damage... 9 4.3 Concealed Damage... 9 4.4 Return of Damaged Goods... 9 5. System Overview... 10 6. System Specifications... 11 6.1 AC Input/Output... 11 6.2 General Specifications... 11 7. Installation... 12 7.1 Preparation... 12 7.1.1 Equipment Inspection... 12 7.1.2 Necessary Equipment and Tools... 12 7.1.3 Installation Safety Precautions... 12 7.2 Installation Steps... 13 7.2.1 Equipment Location... 13 7.2.2 Equipment Mounting... 13 7.2.3 Equipment Connections... 13 8. System Operation: Configuration 5 Interlocks... 14 9. System Maintenance... 16 9.1 Fuse Replacement... 16 10. Reference Materials... 17 11. Warranty... 19 03/13/2012 5 755-00084-C5 R03
1. IMPORTANT INFORMATION ABOUT THIS MANUAL SAVE THESE INSTRUCTIONS! This manual contains important information that is needed during the installation and maintenance of the system. 1.1 MANUAL SYMBOLS Warning: Indicates information provided to protect the user against personal injury and/or safety hazards. Caution: Indicates information provided to protect the user against safety hazards and/or possible equipment damage. Important: Indicates information provided as an installation or operating instruction or tip as well as general important installation and system information. 03/13/2012 6 755-00084-C5 R03
2. INTRODUCTION: The C&C Power family would like to thank you for choosing a C&C Power Inc. product for your equipment needs. We know there are a lot of choices in the industry and we appreciate the opportunity to supply each of our customers with the highest quality power products manufactured in the United States today. All of C&C Power s solutions are factory tested to some of the highest standards in the industry. Sales support for future equipment needs or upgrades is provided by our regional sales staff and qualified representatives. All technical questions and service issues should be directed to our main office by dialing the number listed below. This is a 24-hour, 7-day service number. After normal working hours, please leave a detailed message with your phone number on the voice mail system and a qualified service representative will contact you as quickly as possible. C&C Power, Inc. 395 Mission Street Carol Stream, IL 60188 www.ccpower.com Technical Support: Phone: (630) 617-9022 Email: support@ccpower.com 03/13/2012 7 755-00084-C5 R03
3. SAFETY PRECAUTIONS Before installing or maintaining this system, it is extremely important to read this manual and be sure that all system drawings and schematics are reviewed and clearly understood. If there are any questions concerning this manual or any of the installation or maintenance procedures and/or requirements please contact a C&C Power representative before proceeding. When installing this power system, follow all applicable federal, state and local regulations as well as industry guidelines to insure proper system installation. Only qualified electricians should attempt to install or service this equipment. System installation and maintenance should always be performed with heavily insulated tools. Always wear eye protection when installing or maintaining batteries and/or power equipment. Maintenance Bypass Breaker Cabinet systems can be very heavy. Use a minimum of two people when unloading and setting equipment in place. For the safety of others, never leave an open cabinet or panel unattended. To reduce the risk of fire, replace fuses with the same type and rating of fuses supplied with the system. Be sure to fully read and understand this manual and verify that all electrical connections are correct and properly torqued. Use extreme caution when installing and maintaining the system! To avoid personal injury including electrical shock, severe burns and possible death, all jewelry including bracelets, rings and watches must be removed prior to installing or servicing this system. 03/13/2012 8 755-00084-C5 R03
4. INSPECTION UPON RECEIPT OF GOODS 4.1 GENERAL Special precautions and care have been taken to ensure the system arrives safe and undamaged. However, upon receipt, you should inspect the entire shipment, including the crate and any boxes for evidence of damage that may have occurred during transit. 4.2 VISIBLE DAMAGE It is the responsibility of the person receiving the shipment to inventory and fully inspect all materials against the bill of lading or weigh bill IMMEDIATELY while the carrier representative is still present. Insure that all items are accounted for, including number of skids and quantity of boxes. Also note any visible external damage that may have occurred during transit. Make all applicable notations on the delivery receipt before signing and file a damage report with the carrier. 4.3 CONCEALED DAMAGE Within 3 to 30 days of receipt (depending on courier), unpack the system and check for any concealed damage. Check the materials received against the detailed packing list to verify the quantity and the condition as complete and satisfactory. Note any damage to the internal packaging, then request an inspection by the carrier and file a concealed damage claim. If there is a material shortage, contact a C&C Power representative at the main office to file a claim. Please contact your shipping company for all shipping damage. C&C Power is not responsible for any shipping damage. 4.4 RETURN OF DAMAGED GOODS Should equipment be damaged and require return to C&C Power for repair, a representative will provide instructions along with an RMA number to expedite the return. A RMA number must be obtained before returning equipment to C&C Power, Inc. 03/13/2012 9 755-00084-C5 R03
5. SYSTEM OVERVIEW The C&C Power 90881 Series Maintenance Bypass Breaker Cabinet (MBBC) is used in conjunction with a an Uninterruptable Power Supply (UPS) to maintain total continuity of power to connected load circuits when bypass of the UPS equipment is required for performance of regular service and maintenance. The 90881 Series MBBC s are available with current capacities ranging from 250 to 400 Amperes with multiple input voltage options available. The MBBC contains three Cutler Hammer Series C circuit breakers that are protected by a Kirk Key interlock system. 03/13/2012 10 755-00084-C5 R03
6. SYSTEM SPECIFICATIONS 6.1 AC INPUT/OUTPUT Voltage: Multiple options available. (See equipment label for configuration specific information) 208 VAC, 3-Phase, 4-Wire System Capacity: 250 to 400 Amperes (See equipment label for configuration specific information) Circuit Breakers: UL Listed, Multiple voltage rating options available, AIC ratings from 35kAIC to 65kAIC. (See equipment label for configuration specific information) AC Input/Output Terminations: Mechanical lugs are used for both terminations. Wire Size and Type: Per NEC and/or all applicable national and local codes. 6.2 GENERAL SPECIFICATIONS Cabinet Size: 30 W x 11 D x 42 H Operating Temperature: 0 C to 40 C (32 F to 104 F) Weight (approximate): 115 lbs. 03/13/2012 11 755-00084-C5 R03
7. INSTALLATION 7.1 PREPARATION 7.1.1 EQUIPMENT INSPECTION Remove the equipment from the packaging material and inspect for any shipping damage that may have been overlooked upon receipt of goods. Verify that the system includes all necessary hardware for installation. 7.1.2 NECESSARY EQUIPMENT AND TOOLS o Heavily insulated assortment of hand tools 7.1.3 INSTALLATION SAFETY PRECAUTIONS Before proceeding with system installation, be sure to review and understand all of the SAFETY PRECAUTIONS in this manual! AC VOLTAGE WARNING! The input/output voltage in this equipment can be up to 480 VAC. Be sure to fully read and understand this manual and verify that all AC connections are correct and properly torqued. Use extreme caution when installing and maintaining the system! 03/13/2012 12 755-00084-C5 R03
7.2 INSTALLATION STEPS Before installing or maintaining this system, it is extremely important to read this manual and be sure that all system drawings and schematics are reviewed and clearly understood. If there are any questions concerning this manual or any of the installation or maintenance procedures and/or requirements please contact a C&C Power representative before proceeding. 7.2.1 EQUIPMENT LOCATION This equipment is intended to be installed in a restricted access location. Prior to installation verify all applicable codes pertaining to the related equipment. Clearance around the equipment should be as suggested by NEC and/or all applicable national and local codes. 7.2.2 EQUIPMENT MOUNTING Place the Maintenance Bypass Breaker Cabinet in an upright position on the floor of the designated installation area with the rear of the cabinet abutting a rigid vertical structure (e.g. a wall). Secure the cabinet to the rigid vertical structure with appropriate anchoring hardware utilizing the four 0.375 inch diameter mounting holes located in the back panel of the cabinet (see drawings in Reference Materials section) to assure maintaining the cabinet in a stable upright position. 7.2.3 EQUIPMENT CONNECTIONS The Product Schematic Drawing for this specific MBBC configuration is included in the Reference Materials Section of this manual. Follow this schematic drawing for cable connections relative to 3-phase main lug input/output and feeds associated with UPS input and output. Cable ingress and egress can be facilitated through knockouts fabricated in either the top or bottom panels of the cabinet. 03/13/2012 13 755-00084-C5 R03
Do not operate the MBB circuit breaker unless the UPS is in BYPASS mode! Failure to follow the operating instructions for this equipment could result in equipment damage, fire, severe injury or death! 8. SYSTEM OPERATION: CONFIGURATION 5 INTERLOCKS The following User Instructions are for a three circuit breaker MBBC configured to be controlled by a 2-Interlock, 1 Solenoid Key Release Unit (SKRU), 2-Key breaker interlock system: NORMAL OPERATION The UPS Input Breaker UIB is Closed/On. The Maintenance Bypass Breaker MBB is Locked Open/Off with the interlock locking bolt in the extended position. The Maintenance Isolation Breaker MIB is Closed/On with the interlock locking bolt in the withdrawn position and Key B1 held captive. Key A1 is held captive in the solenoid key release unit (SKRU). TRANSFER TO MAINTENANCE BYPASS 1. Transfer the UPS to the Bypass mode. The lamp on the illuminated push button will turn on to verify the UPS is in Bypass mode. 2. Depress and hold the illuminated push button in order to unlock and remove Key A1 from the solenoid key release unit (SKRU). 3. Insert Key A1 into the interlock on the MBB breaker and turn it to unlock the MBB breaker. 4. Close/Turn-On the MBB breaker. Key A1 is now held captive. 5. Open/Turn-Off the MIB breaker. 6. Turn Key B1 in the interlock on the MIB breaker to lock the MIB breaker in the Open/Off position. Key B1 is now free. 7. Insert Key B1 into the solenoid key release unit (SKRU) and turn to lock. Key B1 is now held captive. 8. The UPS is now ready for routine maintenance. 9. If further maintenance requires a total shutdown of the UPS and isolation from the input, the UIB breaker must be Opened/Turned-Off and the battery supply to the UPS must be disconnected. Refer to your UPS manual for proper shutdown procedures. RETURN THE UPS AND BYPASS SWITCH TO NORMAL OPERATION 1. If the UIB breaker was Opened/Turned-Off for maintenance, then follow the UPS manual for proper startup procedures. To restore input power to the UPS, Close/Turn-On the UIB breaker. Make sure the UPS is in Bypass mode before proceeding! 2. The lamp on the illuminated push button will turn on to verify the UPS is in Bypass mode. 3. Depress and hold the illuminated push button in order to unlock and remove Key B1 from the solenoid key release unit (SKRU). 4. Insert Key B1 into the interlock on the MIB breaker and turn it to unlock the MIB breaker. 03/13/2012 14 755-00084-C5 R03
5. Close/Turn-On MIB Breaker. Key B1 is now held captive. 6. Open/Turn-Off MBB Breaker. 7. Turn Key A1 in the interlock on the MBB breaker to lock the MBB breaker in the Open/Off position. Key A1 is now free. 8. Insert Key A1 into the solenoid key release unit (SKRU) and turn to lock. Key A1 is now held captive. 9. Transfer the UPS from bypass mode to normal mode. 03/13/2012 15 755-00084-C5 R03
9. SYSTEM MAINTENANCE Before proceeding with system maintenance, be sure to review and understand all of the SAFETY PRECAUTIONS in this manual! 9.1 FUSE REPLACEMENT To avoid risk of fire, replace only with the same type and rating of fuses supplied with the system! Maintenance bypass breaker cabinets with the Configuration 5 Interlock option have fuses associated with the circuitry powering the solenoid key release unit (SKRU). Refer to the Product Schematic provided in the Reference Materials section of this manual. For the Configuration 5 Interlock Option, there is one replaceable fuse in the SKRU circuitry [identified as F1 in the product schematic]. Fuse Amps Voltage Type F1 1 600VAC ATQR1 The fuse is located on the solenoid key release panel located at the front of the cabinet. 03/13/2012 16 755-00084-C5 R03
10. REFERENCE MATERIALS 03/13/2012 17 755-00084-C5 R03
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11. WARRANTY LIMITED WARRANTY AND EXCLUSIONS C&C Power, Inc. strives to produce quality products at reasonable prices. If you are not satisfied with our product because of a defect, we will repair or replace the defective part or parts free of charge for a period of one year from the date of purchase. In the event you claim that the product contains a defect, simply notify C&C Power, Inc. of the defect, and we will arrange for repair or replacement. The sole and exclusive remedy against C&C Power, Inc. relating in any way to a product defect shall be the repair or replacement of defective parts as provided for under this LIMITED WARRANTY. No other remedy, including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss, is available. This LIMITED WARRANTY shall not be deemed to have failed of its essential purpose so long as C&C Power, Inc. is willing and able to repair or replace defective parts in the manner prescribed in this LIMITED WARRANTY. Certain integrated products, which are not manufactured by C&C Power; will be warranted by the applicable manufacturer. These warranties shall be between the manufacturer and the user. Terms and conditions may vary. These integrated products include, but may not be limited to, the following products: Batteries, Inverters and UPS Systems. Any action for breach relating to the sale of a C&C Power, Inc. product must be commenced within one year after the cause of action has accrued. THIS LIMITED WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EXPRESS OR IMPLIED, AND ALL SUCH WARRANTIES ARE EXCLUDED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 03/13/2012 19 755-00084-C5 R03
C&C Power, Inc. 395 Mission Street Carol Stream, IL 60188 Phone: 630.617.9022 www.ccpower.com