Staco Energy FirstLine P User manual

003-2622 REV A 03/17/20
FIRSTLINE P
Maintenance Bypass Switch Cabinet
480V 60Hz
300 to 500kVA
USER MANUAL

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No reproduction of any part of this manual, even partial, is permitted without the
authorization of Staco Energy Products Company. The Staco Energy Products Company
reserves the right to modify the product described herein, in order to improve it, at any time
and without notice.
2425 Technical Dr. • Miamisburg, Ohio 45342
U.S. Toll Free 866-261-1191
[phone] • Fax: [phone]
Web site: www.stacoenergy.com
Thank you for choosing our product.

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Table of Contents
1. Safety Warnings............................................................................................................ 1
1.1 Protective Equipment.................................................................................................. 2
1.2 General Precautions ................................................................................................... 2
2. Introduction ................................................................................................................... 3
Overview........................................................................................................................... 3
Applicability....................................................................................................................... 3
3. Cabinet Setup ............................................................................................................... 4
3.1 Inspecting the Equipment ........................................................................................... 4
3.2 Floor Loading.............................................................................................................. 4
3.3 Clearances ................................................................................................................. 4
3.4 Unloading the Cabinet(s) ............................................................................................ 4
4. Electrical Installation ..................................................................................................... 6
4.1 Overview..................................................................................................................... 6
4.2 Wiring Preparation ...................................................................................................... 7
4.3 Wiring Installation ....................................................................................................... 8
4.4 Control Connections ................................................................................................... 8
4.4.1 Control Wire Connections .................................................................................... 8
4.4.2 Terminal Strip Torque Requirements ................................................................... 9
4.4.3 Switch Settings................................................................................................... 10
5. Operation .................................................................................................................... 11
5.1 Maintenance Bypass Switch (MBS).......................................................................... 11
5.2 To transfer from normal mode to maintenance bypass............................................. 12
5.3 To transfer from normal mode to maintenance bypass with SKRU .......................... 12
5.4 To transfer from MBS to normal mode...................................................................... 12
5.5 To transfer from MBS to normal mode with SKRU ................................................... 12
5.6 Normal start-up with load unpowered ....................................................................... 12
5.7 REPO (Option).......................................................................................................... 13
5.8 Potential Issues: ....................................................................................................... 13
6. Maintenance ............................................................................................................... 14
7. Technical Specifications................................................................................................. 15
Table 1 - Model Floor Loadings............................................................................................ 4
Table 2 - Maintenance Bypass Switch States .................................................................... 13
Table 3 – Recommended Wire Size................................................................................... 15
Table 4 - Terminal Tightening Torques .............................................................................. 15
Table 5 - Environmental Specifications .............................................................................. 15
Table 6 - Electrical Specifications ...................................................................................... 15
Figure 1 - The FirstLine P Maintenance Bypass Switch Cabinet.......................................... 3
Figure 2 - Pallet Mounting Hardware.................................................................................... 4
Figure 3 - Inside View of Maintenance Bypass Switch Cabinet............................................ 6
Figure 4 – Bus bar details .................................................................................................... 7
Figure 5 – Standard Customer Low Voltage Connection Terminal Block............................. 9
Figure 6 –Customer Low Voltage Connection Terminal Block with SKRU Option ............... 9
Figure 7 - Options Control Board Assembly....................................................................... 10
Figure 8 – System 1-line .................................................................................................... 11

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1. SAFETY WARNINGS
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
•Do not use outdoors.
•Do not route wiring across or near hot surfaces.
•Do not install near gas or electric heaters.
•Equipment should be installed where it will not readily be subjected to tampering by
unauthorized personnel.
•The use of accessory equipment not recommended by the manufacturer may cause
an unsafe condition.
•Do not use this equipment for other than intended use.
•This equipment connects to the output of an uninterruptible power supply.
Hazardous voltages may be present even when the electrical supply to this
equipment is turned off.
•If equipped with a maintenance bypass switch, control connections between this
equipment and the ups must be present to prevent the possibility of backfeed.
•Read and follow the instructions that came with the associated UPS or emergency
lighting system before operating this equipment.
DANGER
This equipment contains lethal voltages. All repairs and service should only be
performed by authorized service personnel. There are no user serviceable
parts inside this equipment. Operation of switches and breakers require access
to the cabinet interior and should only be performed by qualified personnel
exercising appropriate caution.
WARNING
This equipment connects to the output of a UPS which contains its own energy
source (batteries). The UPS output may carry live voltage even when the UPS
is not connected to an AC supply.
To reduce the risk of fire and electric shock, install this equipment in a humidity
controlled, indoor environment, free of conductive contaminants. Do not
operate near water or excessive humidity (95% maximum). If condensation is
present, the equipment must be allowed to completely dry before operation.
The UPS associated with this equipment contains batteries. Batteries can
present a risk of electrical shock or burn from high short circuit current. Read,
understand, and follow all instructions in the UPS manual before attempting any
operations involving the battery.

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Symbols Used In the Manual
In this manual, some operations are shown by graphic symbols to alert the reader to the dangerous
nature of the operations:
Danger / Risk of Electric Shock
This symbol indicates possibility of serious injury or substantial
damage to the unit, unless adequate precautions are taken.
Warning
This symbol indicates important information which must be
understood and any stated precautions taken
Note
1.1 Protective Equipment
No maintenance operations shall be carried out on the unit without wearing the Personal
Protective Equipment (PPE) described below. Personnel involved in the installation or
maintenance of the unit must be properly clothed.
The following signs show the protective equipment that should be worn. The various items
of PPE must be selected and sized according to the nature of the hazard (particularly
electrical) posed by the unit.
Accident
prevention
footwear
Protective
eyewear
Protective
clothing
Helmet
Work gloves
1.2 General Precautions
This manual contains detailed instructions for the use, installation and start-up of the unit.
Read the manual carefully before installation. For information on using the unit, the manual
should be kept close at hand and consulted before carrying out any operation on the unit.
This Bypass Cabinet has been designed and manufactured in accordance with the
standards for the product, for normal use and for all uses that may reasonably be
expected. It may under no circumstances be used for any purposes other than those
envisaged, or in any other ways than those described in this manual. Any
interventions should be carried out in accordance with the criteria and the time-
frames described in this manual.

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2. INTRODUCTION
Overview
The FirstLine P Maintenance Bypass Switch Cabinet for 300 kVA, 400 kVA, 500 kVA with
480 V Input and Output is a steel cabinet providing the maintenance bypass function. The
cabinet has conduit attachment points at the top and the bottom for maximum flexibility in
wiring the source and load power connections. Please refer to Figure 1for the outline
drawing of the cabinet.
Figure 1 - The FirstLine P Maintenance Bypass Switch Cabinet
Applicability
This equipment is design to work with UPS models FLU-300-00, FLU-400-00, and FLU-
500-00.

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3. CABINET SETUP
3.1 Inspecting the Equipment
If any equipment has been damaged during shipment, keep the shipping and packing
materials for the carrier or place of purchase and file a claim for shipping damage.
3.2 Floor Loading
When planning the installation, consider the battery cabinet weight for floor loading. The
strength of the installation surface must be adequate for point and distributed loading. The
approximate weights are shown in Table 1.
Table 1 - Model Floor Loadings
MODEL
MAXIMUM WEIGHT
FLU-P-300-MBPS
436 lbs (198 kg)
FLU-P-500-MBPS
460 lbs (209 kg)
3.3 Clearances
The following clearances are recommended for the FirstLine P Maintenance Bypass Switch
Cabinet. Other clearances may be needed based on site conditions.
From Front of Cabinet
36” (91.4 cm) working space
Other surfaces
No Clearance requirements
3.4 Unloading the Cabinet(s)
The following tools are required for unloading the cabinet(s):
Wrenches for 3/8” lag bolts.
Forklift or pallet jack
The cabinets are heavy (see Table 1). Unloading the cabinets requires at least
two people to safely remove the cabinets from the pallet.
To remove the Maintenance Bypass Switch cabinet from the ship pallet:
1. Make sure the forklift is rated for the cabinet weight.
2. Make sure the path traveled has sufficient support for the combined weight of the
forklift and the cabinet.
3. Make sure forks are at maximum separation.
4. Use a very strong ratchet strap (or similar device) of sufficient strength to tie the
upper part of the cabinet to the forklift tower before moving.
5. Keep people out of the fall zone. If the cabinet topples over, stand clear
6. With a Phillip’s screwdriver, remove the two kick panels. These will be remounted
when the cabinet is in place.
7. Remove all banding, wrapping and foam protection.
8. Remove the six 3/8” lag bolts securing the cabinet to the pallet. See Figure 2
Figure 2 - Pallet Mounting Hardware

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9. Lift the cabinet with a forklift one to two inches (1”-2” [2.5-5cm]) above the pallet.
10.Slide the pallet completely away from the raised cabinet.
11.Carefully move the cabinet to the desired location and slowly lower the cabinet to the
floor or other appropriate flat surface.
12.Remount the two kick panels.

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4. ELECTRICAL INSTALLATION
4.1 Overview
Each of the pieces of equipment covered by this manual has four sets of power
connections:
1. Input from the power source, typically, from the electric utility.
2. Power routed to the input of the UPS.
3. Power from the output of the UPS.
4. Power to the load
There are four control connections between the Maintenance Bypass Switch Cabinet and
the UPS that must be made.
A user accessible disconnect device must be provided (by other’s) between the output of
this cabinet and the load. Refer to Error! Reference source not found. for current
requirements.
WARNING
Only qualified service personnel (such as a licensed electrician) should perform
the installation and initial startup. There is a risk of electrical shock.
Figure 3 - Inside View of Maintenance Bypass Switch Cabinet

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4.2 Wiring Preparation
1. Verify that the equipment is the proper type. The Maintenance Bypass Switch
Cabinet (MBS) can be used in delta-delta or wye-wye applications, but the UPS
must be properly configured (refer to the UPS manual).
For delta-delta applications where an input neutral is not provided, the output
neutral connection must not be used and the MBS to UPS neutral connections
should be omitted.
2. Plan the locations of conduits. Two Conduit landing plates are provided at the top
(see Figure 1) and bottom of the cabinet.
a. Connection from Utility source and connection to the critical load can entry
the unit from top or bottom.
b. Connections between the MBS and UPS must be made at the bottom.
c. The low voltage control connection wires must be routed through the wire
duct below the terminal block to the bottom landing plate in the rear of the
cabinet to ensure physical separation between them and the power wiring.
3. All wiring is to be in compliance with all applicable codes. See Table 3for
recommended cable sizes
4. Verify that the source circuit capability is in compliance with the requirements shown
in Table 3.
Figure 4 – Bus bar details

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4.3 Wiring Installation
1. Switch off utility power to the distribution point where the UPS will be connected. Be
absolutely sure that there are no hazardous voltages present.
2. Remove as many panels as needed for adequate access for wiring the cabinet.
3. Open the front door of the MBS Cabinet. If necessary, remove the top and bottom
shield cover panels located in front of and below the circuit breakers by removing the
screws that mount each panel in place.
4. Connect wires from the "TO UPS INPUT" terminal block to the input terminals in the
UPS. (Refer to the UPS manual).
a. The terminals must be properly torqued (see Table 4).
b. Ensure proper phasing of the cables.
5. Connect wires from the "FROM UPS OUTPUT" terminal block to the output
terminals in the UPS. (Refer to the UPS manual).
a. The terminals must be properly torqued (see Table 4).
b. Ensure proper phasing of the cables.
6. Connect wires from the "OUTPUT TO LOAD" terminal block to the load.
a. The load may be an external distribution panel, etc.
b. If neutral is not needed by the load, then it does not need to be supplied.
c. The terminals must be properly torqued (see Table 4).
d. Ensure proper phasing of the cables.
7. Connect wires from the "UTILITY INPUT" terminal block to the input source power
from the building distribution.
a. The terminals must be properly torqued (see Table 4).
b. Ensure proper phasing of the cables. The source needs to have A-B-C phase
sequence.
8. Check all work. Replace the panels that were removed for access. Insure that the
shield cover panels have been mounted in place. Failure to do so could
subject personnel to lethal voltages.
4.4 Control Connections
Control connections must be installed from the "CUSTOMER LOW VOLTAGE
CONNECTION TERMINAL BLOCK" to the Remote Commands and Alarm Connections in
the front of the UPS cabinet.
•These control wires must be physically separated from any power wires.
•The length of the control wires is limited to 30 feet or 10 meters.
•Refer to Figure 5regarding the Low Voltage Terminal Block and to the UPS manual
that shows the connection point in the UPS.
•It is also recommended that the wires are shielded twisted pairs.
4.4.1 Control Wire Connections
Figure 5is an electrical wiring schematic summarizing the connections to the Low Voltage
Connection Terminal Block.
1. Wire from terminal 3 of the Low Voltage Connection Terminal Block (LVTB) of the
Maintenance Bypass Switch Cabinet to terminal 11 of the Remote Commands and
Alarms Connections on the UPS (RCA-UPS). Second wire from terminal 4 of LVTB
to terminal 12 of RCA-UPS.
2. Wire from terminal 10 of LVTB to terminal 1 of RCA-UPS. Second wire from terminal
11 of LVTB to terminal 2 of RCA-UPS.
The optional REPO switch connections are also shown in Figure 5.
•Normally Open Switch - connects across terminals 5 and 6 while the

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•Normally Closed Switch - connects across terminals 8 and 9.
•Terminal 7 has a limited amount of unregulated dc power available to power an LED
lamp to permit the use of a lighted switch for REPO. Contact Staco Energy Products
Company for details if you desire to use this feature.
Please also note that the Options Control Board in the MBS must be properly
configured for the normally closed REPO switch to work.
4.4.2 Terminal Strip Torque Requirements
The terminals on the Customer Low Voltage Connection Terminal Block must be torqued to
5.3 to 7.0 inch-lbs. The terminals on the Control Connections (on the UPS) must be torqued
to 4.4 inch-lbs.
Figure 5 – Standard Customer Low Voltage Connection Terminal Block
Figure 6 –Customer Low Voltage Connection Terminal Block with SKRU Option

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4.4.3 Switch Settings
Switch "S2" on the Options Control Board (refer to Figure 7) is a four position "DIP" switch.
Pushing on the top half of each switch section turns it ON, pushing on the lower half turns
the switch OFF. There are labels on the board to help identify the switch section.
The first section "PLT" enables "Power Loss Trip" (or Manual Restart), and should be OFF
unless you want the Bypass and Inverter Output Breakers to trip on loss of power.
The second section "NCR" enables the Normally Closed REPO input and should be OFF
unless there is a normally closed REPO switch connected.
The third section "OTT" is not implemented and should be turned OFF to avoid confusion.
The fourth section is not used and should be turned OFF to avoid confusion.
Figure 7 - Options Control Board Assembly
DS1
J201
J202
J203
J204
J205
J206
TB9
TB8
TB1
TB7
OTHT
1
1
1
1
1
TB6
TB5
TB4
TB3TB2
TB11TB10
1 2 3 4
1 2 1 2 4321 5
653 4 651 2 3 4
PLT NCR OTT
S2

DS4
ATTENTION
ELECTROSTATIC
SENSITIVE DEVICE
1 2

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5. OPERATION
Refer to the User's Manual for the UPS for instructions on operating the UPS part of the
system.
If the UPS is part of a parallel system, special operating instructions apply.
5.1 Maintenance Bypass Switch (MBS)
The purpose of the Maintenance Bypass Switch (MBS) is to facilitate servicing the UPS
without removing power from the load. The main functional components of the MBS are
three circuit breakers that are used as disconnect switches. The breakers each have three
positions: off (down), on (up), and tripped (in between off and on). If a breaker will not reset
or trips as being turned on, backfeed prevention interlock is active and the proper
conditions (as described below) will have to be present before the breaker can be operated.
BKR1 supplies power from the supply (utility) to the bypass input of the UPS. For single
input UPS configurations, it also supplies power to the rectifier input.
BKR2 bypasses the path through BKR1, the UPS, and BKR3 and connects the supply
directly to the load.
BKR3 connects the output of the UPS to the load.
BKR2 and BKR3 must never be closed at the same time unless the UPS is in
bypass mode. Control signals support an interlock function to prevent BKR2 from
being closed unless BKR3 is open or the UPS is in bypass mode.
*Optional
Figure 8 – System 1-line

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WARNING
Always observe proper switching sequence to avoid loss of power to the load.
5.2 To transfer from normal mode to maintenance bypass
1. Transfer the UPS to Bypass Mode.
2. Close BKR2.
3. Open BKR3.
4. Open BKR1 to completely isolate the UPS.
5.3 To transfer from normal mode to maintenance bypass with SKRU
1. Transfer the UPS to Bypass Mode.
2. While pressing the SKRU push-button, rotate and remove key.
3. Insert key into k2 and retract bolt.
4. Set circuit breaker 2 to the closed/on position.
5. Set circuit breaker 3 to the open/off position.
6. Rotate key in k3 to extend bolt and remove key.
7. Place key into SKRU and rotate key to capture.
8. Open BKR1 to completely isolate the UPS.
5.4 To transfer from MBS to normal mode
1. Close BKR1.
2. Place the UPS in Bypass Mode.
3. Close BKR3.
4. Open BKR2.
5. Complete any UPS start-up required.
5.5 To transfer from MBS to normal mode with SKRU
1. Close BKR1.
2. Place the UPS in Bypass Mode.
3. While pressing the SKRU push-button, rotate and remove key.
4. Insert key into k3 and retract bolt.
5. Set circuit breaker 3 to the closed/on position.
6. Set circuit breaker 2 to the open/off position.
7. Rotate key in k2 to extend bolt and remove the key.
8. Place the key into SKRU and rotate key to capture.
9. Complete any UPS start-up required.
5.6 Normal start-up with load unpowered
1. Verify that BKR2 is open; open it if closed.
2. Close BKR1 and BKR3.
3. Perform a normal UPS start-up as per the UPS manual.

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5.7 REPO (Option)
User provided switch circuits are required to activate the REPO. Upon activation, the
REPO function trips Breaker 2 (if closed) and Breaker 3 (if closed), interrupting power to
the load. See Section for REPO installation details
To restart the system after activation of the REPO, make sure that the REPO switch is in
the non-activated state before continuing. Then, use the Startup procedure for the MBS.
This REPO only opens the breakers in the Bypass cabinet. The UPS requires
separate REPO wiring isolated from the Bypass Cabinet REPO wiring. See UPS
Manual
Table 2 - Maintenance Bypass Switch States
Breaker 1 = UPS Input
Breaker 2 = Bypass
Breaker 3 = UPS Output
State Name
Breaker
1
Breaker
2
Breaker
3
Normal
closed
open
closed
Overlap
closed
closed
closed
UPS Unloaded
closed
closed
open
Maintenance
open
closed
open
Load Off
open
open
open
Test UPS
closed
open
open
Test Battery
open
open
closed
Not Allowed
open
closed
closed
5.8 Potential Issues:
MBS will not allow BKR2 to close—
1. Check to see that the UPS is on bypass (SWMB is closed).
2. The UPS controls must be powered (BKR1 and SWBY should be closed).
3. Verify that the backfeed prevention interlock signals were properly wired as part of
the installation and that this wiring has not been damaged.
BKR2 in the MBS trips when power is applied—
1. This is likely due to a procedural error. Note that BKR2 and BKR3 must not be
closed at the same time unless the UPS is powered and the UPS is in bypass mode.
2. It is likely that BKR3 is closed and the backfeed prevention interlock function is
preventing BKR2 from staying closed.
3. Since the UPS is not powered, the signal that indicates that the UPS is in bypass
mode cannot be generated.
4. Open BKR3 and close BKR2. BKR2 should close and stay closed.
5. If power to the UPS is not required, open BKR1.

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6. MAINTENANCE
There are no wear items in the MBS that require periodic replacement. However, regular
care will assure maximum availability of power.
Keep the ventilation openings in the cabinet free of dust and debris.
Wipe the cabinet exterior with a soft cloth, slightly dampened with water, to remove dust.
Consider performing periodic infrared temperature measurements on the circuit breaker
terminations. This will require access to the cabinet interior. There are hazardous voltages
present and any work must be performed using caution. Only trained service personnel
should perform this work. Elevated temperatures of the terminations usually are the sign of
a loose connection, but can also signal that a breaker is failing. Loose connections should
only be serviced after removal of power.
If the system is powered down, consider removing accumulated dust from the cabinet
interior using a vacuum cleaner.

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7. TECHNICAL SPECIFICATIONS
Table 3 – Recommended Wire Size
kVA Rating Input/Output Ground
300
(2) 350kcmil
1/0 AWG
400
(3) 300kcmil
3/0 AWG
500
(3) 300kcmil
3/0 AWG
*Wire must be rated 75°C or higher
Table 4 - Terminal Tightening Torques
Power Terminal Torque
Bolt Size
Torque Load
5/16 13-17 lbf-ft 18-23 Nm
3/8 27-34 lbf-ft 36-46 Nm
½ 44-59 lbf-ft 60-80 Nm
Low Voltage Terminal Torque
Wire Size
Torque
# 26-10 AWG
5.3 – 7.0 inch - pounds
Table 5 - Environmental Specifications
Altitude
De-rate load capability above 1000 meters 1% per 100 meters.
Operating Temperature
40oC Maximum
Humidity
Maximum 95%RH, Non-condensing
Table 6 - Electrical Specifications
300kVA
400kVA
500kVA
Rated voltage
480/277
480/277
480/277
Breaker Rating
600A
800A
800A