Uninterruptible Power Supply (UPS) 250 Caterpillar

Site Preparation

• Place the system in a reasonably clean environment that is free of dust. The air must be free to circulate around the unit. Cooling air enters the unit on the bottom section of the front of the enclosure. The cooling air exhausts through the top of the enclosure.

• Avoid placing the unit in direct sunlight or near other heat sources.

• Verify that the floor is a minimum of 2000 psi concrete that is capable of supporting 325 pounds per square foot.

• Verify that the ambient temperature will not exceed -20 °C to 40 °C (-4 °F to 104 °F). Refer to Specifications.

• A clearance of 914 mm (36 inches) is required from the front of the unit for service. See the illustrations in Operation and Maintenance Manual, SEBU7311, "Anchoring". The sides of the system can be placed against walls. A minimum distance from the edge of the slab should be maintained. However, several feet of additional space is preferable for improved airflow, maintenance, and easier cable connections. There is a minimum clearance of 610 mm (24 inches) that is needed between the top of the system and the ceiling in order to have proper airflow. See the illustrations in Operation and Maintenance Manual, SEBU7311, "Anchoring". The cooling air exhausts at a rate of 2500 cfm. A clearance of 457 mm (18 inches) between the top of the system and the ceiling is acceptable if there is an adequate airflow on the sides of the unit.

• Torque the anchoring bolts to 41 N·m (30 lb ft).

• The system should not be operated in a sealed room or a sealed container. If the system must be operated in a sealed room adequate climate control must be provided. If HVAC is necessary, note that the heat that is generated from the system may exceed the specifications when the system is protecting loads with a low power factor or non-linear loads.

• The floor must be within 2 to 3 degrees of being level. The floor should be concrete or some other suitable substance that can meet the load requirements of the anchor bolts. Refer to Operation and Maintenance Manual, SEBU7311, "Anchoring".

• A 110/120VAC power outlet must be located within 9 m (30 ft) of the system. The outlet will be used in order to power the vacuum pump during maintenance and initial start-up.

• An adequately sized neutral is required on the input and on the output of the system.

• An optional cabinet for the termination of the wires adds approximately 425 mm (16.75 inch) to the width of the system. The following conditions will require a cabinet: The cables enter the top of the unit. and The cable size is greater than 2 by 400 MCM per phase. The cable lugs that are provided for the input and for the output of the system are rated for two cables. The cable size must be between 2 AWG and 600 MCM. The cables can be copper or the cables can be aluminum.

Electrical Connections

Open the front doors of the system. Remove the two sheet metal panels from the front of the cabinet for the flywheel. See illustration 1. This will provide access to the terminal block on the lower left panel.

The lugs may be repositioned in order to accept the wires from the top or from the bottom. Tighten the lugs to 45 N·m (33 lb ft). Tighten the wiring to 57 N·m (42 lb ft).

Illustration 1	g00647815

Illustration 2	g00682817
(1) System I/O Interface Board (2) Ground Terminal (3) AC Input Terminals (4) Neutral Terminals (5) Output Terminals (6) EMI Filter PWA

Ensure that the electrical connections are properly located. Also ensure that the phase rotation is maintained. See illustration 2.

Access can be obtained from either the top or from the bottom. Use care when you pull the cable from the top in order to avoid damage to the system components. Large cables require the optional cabinet for the termination of the wires. This makes the connections easier.

Interface Connections

To install the customer interfaces, refer to Operation and Maintenance Manual, SEBU7311, "Interfaces".

National Electric Code

The system should be installed per the National Electrical Code (NEC) and the local codes. The size of the cable and the conduit should be based on the following system specifications.

The system is designed for the cable to enter the top or the bottom. The removable access plates should be punched in order to accommodate the size of the conduit. The cables for input and cables for output must be run in separate conduits.

The connection terminals will accept a cable from number 2 AWG up to 600 MCM (2 per phase). The terminals can be oriented for top entry or for bottom entry. This is done in order to minimize the requirements for bends. The use of 600 MCM is not recommended. Space limitations require the use of smaller parallel cables. This will reduce the risk of damage to the unit while the cable is pulled. If the size of the cable is greater than 350 MCM and the top entry method is used, the optional termination cabinet should be used. This will make the wires easier to connect.

Refer to "National Electric Code Article 210-19" and "National Electric Code Table 310-16" for the correct cable size.

Refer to "National Electric Code Article 250-95" for the correct ground size.

Refer to "National Electric Code Article 310-15" for the correct neutral size.

The torque for the wire connections is 57 N·m (42 lb ft).

Note: A service disconnect device must be installed. This device must be properly rated for the output power.

Mechanical

The system must be anchored to a foundation. The foundation should be a concrete slab that is fully cured. The slab should be poured with a minimum of 2000 psi concrete. The floor must be capable of supporting a load of 325 pounds per square foot. Refer to Operation and Maintenance Manual, SEBU7311, "Anchoring" for more information.

Existing slabs should be free from cracks and seams in the vicinity of the installation. Refer to Operation and Maintenance Manual, SEBU7311, "Anchoring" in order to determine the requirements for the positioning of the slab.

Bearing Retainers

Before the system is placed in operation, the shipping retainers must be removed and the operating retainers must be installed.

When the system is moved, the shipping retainers must be installed. These retainers protect the bearing cartridges. Store the retainers in a safe place for later use.

Removal of the Shipping Retainers

Illustration 3	g00698583
Exploded View of the Shipping Retainers (1) Two Bolts for the Upper Retainer (2) Upper Shipping Retainer (3) O-Ring (4) Lower Shipping Retainer (5) Two Bolts for the Lower Retainer

1. Remove three sheet metal panels. The panels are located inside the system.

2. Loosen and remove two bolts (1) on the upper retainer (2). A quarter turn of rotation on each bolt should be used until the bolts are loose.

3. Slowly pull out the retainer. Do not use any tools in order to remove the retainer. This will damage the bearing cartridge.

4. Store the retainer in a safe place for later use.

5. Loosen and remove two bolts (5) on the lower retainer (4). A quarter turn of rotation on each bolt should be used until the bolts are loose.

6. Slowly pull out the retainer. Do not use any tools in order to remove the retainer. This will damage the bearing cartridge.

7. Store the retainer in a safe place for later use.

8. Proceed to "Installation of the Bearing Retainers".

Installation of the Operating Retainer

Illustration 4	g00698867
Operating Retainer (1) Screw (2) Commutation Sensor Assembly (3) O-ring (4) Bolt (5) Commutation Sensor Wheel (6) Spacer (7) Screw (8) Screw (9) Plug (10) O-ring (11) Operating Retainer (12) Polished Bolt (13) O-ring (14) Rotor Static Discharge Drain (15) Screw

1. Apply a small amount of 7M-7456 Bearing Mount Compound to the threads on bolt (12) .

2. Install retainer (11) and bolt (12) .

3. Torque bolt (12) to 38 N·m (28 lb ft).

4. Apply a small amount of 6V-2055 High Vacuum Grease to O-ring (13) .

5. Install O-ring (13) on rotor static discharge drain (14) .

6. Install drain (14), O-ring (13), and four screws (15) .

7. Install spacer (6). The lip on the Operating Retainer (11) should face the flywheel.

8. Apply a small amount of 7M-7456 Bearing Mount Compound to the threads on bolt (4).

9. Install commutation sensor wheel (5) and bolt (4).

10. Torque bolt (4) to 38 N·m (28 lb ft).

11. Apply a small amount of 6V-2055 High Vacuum Grease to O-ring (3) .

12. Install commutation sensor assembly (2) and three screws (1) .

13. Apply a small amount of 6V-2055 High Vacuum Grease to O-ring (10) .

14. Install O-ring (10), plug (9), and two screws (8) .

15. Apply power to the vacuum pump. This requires an extension cable.

    Vacuum should be achieved as soon as possible. When the humidity is high and/or the flywheel was open for an extended time, the pump may require several hours in order to achieve the proper vacuum.

16. Install thermistor sensing cables. Damage to the connector pins can result from improperly mated connectors.

17. Install the three sheet metal panels.

    Note: Before the UPS is moved, install the shipping retainers. Install the bottom retainer first. Tighten the bolts for the bottom retainer. Install the top retainer and tighten the bolts.