Generator Set Start Module Caterpillar

Electrical Connections

Usage:

Electrical Connections

The Generator Set Start Module should be installed per the National Electrical Code (NEC) and other applicable codes. The size of the cable and the size of the conduit should be based on Start Module specifications. Class 1 wiring methods should be used.

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Illustration 1	g00822212
Generator Set Start Module - Right Side View (1) 24 DCV Output/Control Power/Ground - Bottom Entry or Side Entry Options (2) ACV Input - Bottom Entry Option or Side Entry Option (A) 310 mm (12.20 inch)

In order to allow for cables to enter into the Start Module, holes must be drilled in the bottom of the lower access panel or holes must be drilled in the side of the lower access panel (1, 2). Refer to Illustration 1. The location of the holes will depend on whether the floor mounting option is employed or the wall mounting option is employed. The input cables and the output cables must be routed in separate conduits.

Generator Set Start Module Control Power (UPS 250 Model Only)

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Illustration 2	g00822251
Generator Set Start Module Terminal Block (3) Output - To Generator Set +24 DCV (4) Output - To Generator Set -24 DCV (5) Input - From Generator Set +24 DCV (6) Input - From Generator Set -24 DCV

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The inside compartments of the Generator Set Starting Module can contain the risk of electric shock or hazardous energy levels. Personal inuury can result from Electric Shock. Do not touch live electric parts.

The Generator Set Start Module's Control Power Signals come from the connected generator and from the UPS. During starting attempts, either the battery for the generator set or the Caterpillar UPS will provide power for the Generator Set Control Circuits.

Note: Used on UPS 250 models only.

Use the following information to assemble the wires:

Wire size must be between #10 AWG and #14 AWG.
In order to connect the wire to the terminals, attach ring lugs (# 8 AWG) to the wire.
Maximum length of the wire is 15.24 m (50.00 ft).

Generator Set Start Module 24 DCV Output Cable

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Illustration 3	g00822262
24 DCV Output Power Cable connection location (7) AC Connector (B) 610 mm (24.00 inch) (C) 914 mm (36.00 inch) (D) 24 DCV terminal locations (3/8 inch hardware)

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Use the "+" terminal and the "-" terminal (D) in order to connect the 24 DCV output power cable to the generator. The "+" terminal and the "-" terminal (D) are located in the lower access compartment of the Generator Set Start Module. Refer to Illustration 3.

Configure the cable as follows:

3/0 cable minimum
3/8 inch lug hardware
maximum cable length from the generator set is 7.62 m (25.00 ft)
torque the wiring at these terminals to 63.72 N·m (47 lb ft)
nonferrous type conduit in order to avoid heating

UPS to Generator Set Start Module Cable

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Illustration 4	g00822493
Generator Set Start Module AC Input Connector (8) Cable shielding (9) Terminal lugs (#6 AWG wire) for 1/4 inch studs (10) AC input connector (11) "A" phase (12) Ground (13) "B" phase (14) "C" phase

The cable that is used to connect to the UPS must comply with the following parameters. This cable is not included.

Maximum length of the cable is 152.4 m (500 ft).
Cable must be run in conduit.
Cable must comply with all local ordinances.

Connect one end of the Generator Set Start Module AC cable to the Start Module's AC Input Connector (7) .

Note: Penetration of the cabinet wall requires a female threaded fitting on the end of the conduit in order to accommodate strain relief.

The remaining end of the Generator Set Start Module AC cable is connected to the AC output terminal blocks which are located inside the UPS. Depending on the UPS model, the UPS AC Output Terminals can be found in one of two locations. Refer to Illustration 5 and Illustration 6.

In order to connect the Generator Set Start Module AC cable to the AC output terminal blocks, perform the following steps:

Strip a sufficient amount of cable shielding from the cable so that terminal lugs can be attached.

Attach terminal lugs to the cable. Terminal lugs should be sized for 1/4 inch studs.

Attach the cable to the Caterpillar UPS AC Output Terminals.

UPS 250 AC Out Terminal Location

On the UPS 250 (the 50 Hz and 60 Hz units), the AC output terminals are located on the AC capacitor bank panel. The ground connection is located on the Generator Set Start Module Inductor Panel.

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Illustration 5	g00822978
UPS 300 AC Output terminal location.

UPS 300 Series AC Output Terminal Location

On the following models, the AC Output terminals and the ground terminal are located on the Generator Set Start Module Inductor Panel:

UPS 250 (50 Hz unit)
UPS 300 (60 Hz unit)
UPS 500 (50 Hz unit)
UPS 600 (60 Hz unit)
UPS 750 (50 Hz unit)
UPS 900 (60 Hz unit)

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Illustration 6	g00822965
UPS 250 Series AC Out terminal location

Grounding

The grounding wire should meet the following parameters:

# 6 AWG wire
a lug which will accommodate a 1/4 inch stud
maximum length of 15.24 m (50 ft)

If the 24 DCV output cable is shorter than the Generator Set Start Module's AC cable, run a ground wire from the generator set to the ground stud. The ground stud is located in the lower access compartment. Disconnect and insulate the AC ground from the upper cabinet.

If the 24 DCV output cable is longer than the Generator Set Start Module's AC cable, no modification is necessary. Do not run a ground wire from the generator set.

Disconnecting the Generator Set Start Module

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In order to disconnect the Generator Set Start Module from the UPS power source, unplug the Generator Set Start Module's AC cable connector. The Generator Set Start Module's AC cable connector (7) is located inside the Lower Access Compartment. Refer to Illustration 3. Ensure that the start module is not attempting to start the engine.