Forza FDC-BS10KMR User manual

2-
year
warranty
User guide
Maintenance bypass switch module
FDC-BS10KMR

1. Introduction
Thank you for purchasing the Maintenance bypass switch from Forza. This module is used as an external maintenance bypass switch
to provide continuous power without shutting down the connected loads during UPS scheduled maintenance or battery replacement. It
is perfect to use in conjunction with 6K/10KVA UPS systems.
Important safety instructions
You must first read and closely follow all installation and operation instructions contained in this manual. Keep this guide in a safe place
for future reference.
2. Preliminary steps
Unpacking and inspection
Upon opening the box, make sure the following items are included:
• Maintenance bypass switch module (1)
• Signal control cable (1)
• Mounting bracket and M4 screw kit (1)
• User guide (1)
NOTE: Carefully inspect the unit before installation. Make sure that nothing inside the package is damaged or loose. Please keep the
original package in a safe place for future use.
3. Product overview
1. Input/ output terminal block (Refer to diagram 2 for details)
2. UPS input breaker on bypass
3. Two-position maintenance bypass switch
4. Output signal control slot
5. Output terminal (to load)
6. UPS output terminal
7. UPS input terminal
8. Utility input terminal
9. Grounding terminal
4. Initial setup
4.1. Rack mount the unit
The bypass switch module can be mounted to a 19-inch rack or enclosure, using he supplied hardware. Refer to the image below.
1 2 3 4
Diagram 1: Rear panel View
Diagram 2: Terminal overview
956789

4.2. Installation and configuration
Important safety instructions
Installation and wiring must be performed by qualified personnel, and in accordance with the local electrical regulations and
codes. Also, you must observe the following guidelines:
1. Make sure the mains wire and breakers in the building are enough for the rated capacity of the UPS to avoid the hazards of electric
shock or fire.
Do not use the wall receptacle as the input power source for the UPS, as its
rated current is less than the UPS's maximum input current. Failure to do so may result in a broken or burned out receptacle.
2. For safety considerations, turn off the mains switch in the building before installation.
3. Turn off and shut down the connected UPS
4. Wiring sizes should be installed in accordance with the following table:
NOTE 1: The cable for 6K/6KL should be able to withstand currents of over 40A. It is recommended to use a 6 AWG or thicker wire for
safety and efficiency.
NOTE 2: The cable for 10K/10KL should be able to withstand currents of over 63A. It is recommended to use an 4 AWG or thicker wire
for safety and efficiency.
NOTE 3: The color selection of wires should be made according to the local electrical codes and regulations.
5. Remove the terminal block cover on the rear panel of the bypass switch module. Then connect the wires according to the terminal
block diagrams included in the section below.
4.3. Connection of the UPS to the external maintenance bypass switch module
1. Remove the terminal block cover on the rear panel of the bypass switch module.
2. Then connect the output terminals of the UPS to the UPS output terminals located on the bypass switch module.
3. Proceed to connect the utility input terminals of the UPS to the UPS input terminals on the bypass switch module.
4. Connect the signal slots of the UPS and the switch module using the supplied signal control cable.
5. Connect main utility line to utility input on the bypass switch module.
6. Finish by connecting the desired load to the bypass switch module output terminals (load).
UPS model
6K/6KL
10K/10KL
Wiring specification
6 AWG
4 AWG
Input neutral
Input line
Ground
Output line
Output neutral/ Ground
Input ground
Input neutral
Input 2 line
Input 1 line
Output neutral
Output ground
Output X1 line
Output X2 line
Output neutral
Output X3 line
Maintenance bypass ground
Utility input neutral
Utility input line
Maintenance bypass UPS input neutral
Maintenance bypass UPS input line
Maintenance bypass ground
Maintenance bypass output line
Maintenance bypass output neutral
Maintenance bypass UPS output line
Maintenance bypass UPS output neutral
Terminal block wiring of the maintenance bypass switch with breaker
Terminal block wiring diagram of the UPS
Terminal block wiring diagram of the isolation transformer

NOTE: Make sure that the wires are connected tightly to the terminals.
7. Put the terminal block cover back on the rear panel of the module.
5. Operation
Transfer from UPS to maintenance bypass mode
To manually change from UPS to maintenance bypass function, follow the steps included below:
Step 1: Press the OFF button of the UPS unit to transfer to bypass mode.
Step 2: Open the maintenance switch cover. If step 1 is not executed first, then the UPS unit will transfer to bypass mode automatically
with the output control signal connection when opening the maintenance switch cover.
Step 3: Turn the switch to its BPS position and switch off the UPS input breaker on the bypass switch module. Every device will be
directly fed from utility as the current flowing through the UPS will be interrupted. The output and input terminals of the UPS are now
isolated from the system. Ensure that the UPS is off, and that battery power is disconnected as well, with the terminals completely
de-energized before performing any maintenance on the unit.
Transfer from maintenance bypass to UPS mode
After the system has been placed into service mode, it must be returned to UPS state to resume normal operation.
Step 1: Switch the input breaker of the bypass switch module back on and reconnect the UPS battery power. This will cause the UPS
to enter into bypass mode.
Step 2: Turn the maintenance switch to its UPS position. All loads will be then powered by utility power through the UPS bypass mode.
Step 3: Close the maintenance switch cover and press the ON button of the UPS unit. At this stage, the connected equipment is again
being powered and protected by the UPS.
NOTE: If maintenance will be executed in a different location, follow the steps under Transfer from UPS to maintenance bypass
mode before removing the power supply unit and the bypass switch module.
Step 4: Finish by disconnecting all the wires between the UPS and the bypass switch module for complete isolation.
6. Specification of critical components
Input breaker
Bypass switch
Input/output terminal
Current
Voltage
Current
Voltage
Current
Voltage
63A
250V
63A
690V
60A
600V
Parameter Max.
Full installation with maintenance bypass and isolation transformer (110V or 220V operation)
MAINTENANCE
BYPASS
UPS
BATTERY PACK
ISO (output to load)
Full installation with maintenance bypass (220V operation only)
MAINTENANCE
BYPASS
(Output to load)
UPS
BATTERY PACK