Hot-swap PDUs allow maintenance or replacement of UPS systems without interrupting power to connected equipment by using a manual bypass switch and dual input connections.

Safety and Preparation

• Grounding: Ensure the PDU is connected to a properly grounded 2-pole + ground (2P + G) socket to prevent electrical hazards .
• Leakage Current: Verify that the combined leakage current of the PDU and connected devices does not exceed 3.5 mA .
• AC Input Protection: Connect the PDU to a protected electrical network using a fuse or circuit breaker .

Operational Steps

1. Normal Operation
   • Set the manual bypass switch to the Normal position.
   • The load is supplied by the UPS.
   • Confirm the green LED labeled "UPS ON - OK to switch" is illuminated, indicating the UPS is active and ready for hot-swap operations .
2. Bypass Mode
   • Move the manual bypass switch to the Bypass position.
   • The load is now supplied directly by the AC mains, bypassing the UPS.
   • The red LED on the PDU will illuminate, confirming that the load is powered by the AC source .
3. UPS Maintenance or Replacement
   • With the switch in Bypass, the UPS can be safely powered down, disconnected, or replaced without affecting connected equipment .
   • Perform battery replacement, module exchange, or other maintenance tasks as required.
4. Return to Normal Operation
   • After maintenance, reconnect the UPS and set the switch back to Normal.
   • Verify the green LED is on and the red LED is off, confirming that the load is now supplied by the UPS .

Key Features and Benefits

• Dual Input Cables: Support connection to both utility and UPS power sources, ensuring continuous power availability .
• Manual Bypass Switch: Enables live maintenance without downtime, protecting mission-critical equipment .
• LED Indicators: Provide clear visual confirmation of load source and UPS status .

Additional Considerations

• Always follow the UPS and PDU manufacturer's installation manuals for specific models.
• Ensure personnel are trained in hot-swap procedures to prevent accidental power interruptions.
• For high-density or high-voltage systems, consider consulting the PDU or hot-swap controller datasheets for inrush current management and fault protection . By following these steps, facility personnel can safely perform maintenance or replacement of UPS systems while keeping connected equipment operational, minimizing downtime and maintaining high availability.