UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, UPS 750 and UPS 900 Uninterruptible Power Supplies Caterpillar

The wireway provides the means for routing the following cables between the Multiple Module Units and the System Cabinet: AC input, AC output and interface.

Note: Before installing the wireway, make sure that the gap dimension that is between all of the cabinets is 25.40 mm (1.00 inch).

Installation (Wireway)

Illustration 1	g00921775
Example of Wireway

Caterpillar preassembles the components for the wireway before shipment. Some of the components will need to be disassembled and assembled during the installation of the wireway. Before installation of the wireway is performed, make sure that the correct number of holes are punched for the conduit. Make sure that the locations of the holes are correct. Refer to the Illustration 2 for the location of the holes.

Illustration 2	g01152410
Installation Diagram

Table 1

Item Number	Name	Size
(1)	Wireway 1384.30 mm (54.50 inch)	304.80 mm (12.00 inch) by 304.80 mm (12.00 inch)
(2)	Cover (Wireway) 1384.30 mm (54.50 inch)	1377.95 mm (54.25 inch) by 342.90 mm (13.50 inch)
(3)	Pan head Screw (PH)(HD)	1/4-20 inch by 12.70 mm (0.50 inch)
(4)	Wireway 1092.2000 mm (43.00 inch)	304.80 mm (12.00 inch) by 304.80 mm (12.00 inch)
(5)	Cover (Wireway) 1092.2000 mm (43.00 inch)	1377.95 mm (54.25 inch) by 342.90 mm (13.50 inch)
6	Pan head Screw (PH)(HD)	1/4-20 inch by 12.70 mm (0.50 inch)
(7)	Cable Entry Plate (System Cabinet)	914.40 mm (36.00 inch) by 355.60 mm (14.00 inch)
(8)	Tray Wireway Control Wiring System Cabinet	1219.20 mm (48.00 inch) by 76.20 mm (3.00 inch)
(9)	Tray Wireway Control Wiring MMU Cabinet	1162.05 mm (45.75 inch) by 76.20 mm (3.00 inch)
(10)	End Plate (Wireway)	330.20 mm (13.00 inch) by 323.85 mm (12.75 inch)
(11)	Bolt (Hex) (HD) (Cap)	1/4-20 inch by 19.05 mm (0.75 inch)
(12)	Nut (Hex) (Keps)	1/4-20 inch by 4.83 mm (0.19 inch)
(13)	Locknut (Conduit)	88.90 mm (3.50 inch)
(14)	Bushing (Conduit) (Plastic)	88.90 mm (3.50 inch)
(15)	Bushing (Conduit) (Plastic)	38.10 mm (1.50 inch)
(16)	Locknut (Conduit)	38.10 mm (1.50 inch)
(17)	Nipple (Conduit)	38.10 mm (1.50 inch) by 254.00 mm (10.00 inch)
(18)	Coupling (Rigid Conduit)	38.10 mm (1.50 inch)
(19)	Chase Nipple (Conduit)	88.90 mm (3.50 inch)
(21)	Nipple (Conduit)	38.10 mm (1.50 inch) by 177.80 mm (7.00 inch)
(22)	Chase Nipple (Conduit)	76.20 mm (3.00 inch)
(23)	Coupling (Rigid Conduit)	76.20 mm (3.00 inch)
(24)	Nipple (Conduit)	76.20 mm (3.00 inch) by 228.60 mm (9.00 inch)
(25)	Locknut (Conduit)	76.20 mm (3.00 inch)
(26)	Bushing (Conduit) (Plastic)	76.20 mm (3.00 inch)
(27)	Chase Nipple (Conduit)	101.60 mm (4.00 inch)
(28)	Coupling (Rigid Conduit)	101.60 mm (4.00 inch)
(29)	Nipple (Conduit)	101.60 mm (4.00 inch) by 228.60 mm (9.00 inch)
(30)	Locknut (Conduit)	101.60 mm (4.00 inch)
(31)	Bushing (Conduit) (Plastic)	101.60 mm (4.00 inch)
(32)	Coupling (Rigid Conduit)	88.90 mm (3.50 inch)
(33)	Nipple (Conduit)	88.90 mm (3.50 inch) by 228.60 mm (9.00 inch)
(34)	Nipple (Conduit)	38.10 mm (1.50 inch) by 228.60 mm (9.00 inch)
(40)	Cable Entry Plate (MMU Cabinet)	317.50 mm (12.50 inch) by 177.80 mm (7.00 inch)

Illustration 3	g00949606
Cable Entry Plate (System Cabinet) and Cable Entry Plate (MMU Cabinet) The numbers that are in the circles refer to the destination (MMU) of the conduit. (7) Cable Entry Plate (System Cabinet) (35) Conduit (Customer Communication Cable) (36) Inputs (37) Outputs (38) Conduit (Control Wiring) (39) Conduit (Generator Set) (40) Cable Entry Plate (Multiple Module Unit)

Note: Refer to Table 1 in order to successfully complete the following installation instructions.

The holes that are punched should correlate to the type of system that is being installed.

1. Punch holes in the following components: plate (7), plate (40), wireway (1) and wireway (4) .

   Note: For an overview of the wireway, refer to Installation 2.

2. If the cable for the generator set start module is routed through end plate (10), make sure that additional cable is available for any additional MMU that is added to the UPS.

Each additional MMU that is added to the system will reposition end plate (10). The new position will be an additional 1092.20 mm (43.00 inch) to the right of the original position of the end plate.

Note: The UPS is viewed from the front.

There will be no additional cable that is required if the top of wireway (1) or the top of wireway (4) is selected in order to route the cable.

Assembly of Conduit for the System Cabinet Control Wiring

Illustration 4	g00950386
(7) Entry Plate (17) Locknut (38.10 mm (1.50 inch)) (19) Coupling (38.10 mm (1.50 inch)) (16) Bushing (38.10 mm (1.50 inch)) (18) Nipple (38.10 mm (1.50 inch)) (34) Nipple (38.10 mm (1.50 inch))

Illustration 5	g00921776

Illustration 6	g00921778

1. Remove bushing (15) and one locknut (16) from the conduit assembly.

2. Insert the conduit assembly into plate (7) .

3. Adjust until there is a clearance of 266.70 mm (10.50 inch) between the top of coupling (18) and plate (7) .

4. Reinstall the locknut and tighten.

5. Reinstall the bushing.

6. Repeat steps 1 through 5 for each MMU that is installed in the system.

7. Proceed to "Assembly of Conduit for the System Cabinet Input Wiring".

Assembly of Conduit for the System Cabinet Input Wiring

1. Remove the bushing (26). Remove one locknut (25) from the conduit assembly.

2. Insert bushing (26) into plate (7) .

3. Remove Chase Nipple (22) from conduit assembly.

4. Adjust until there is a clearance of 26.67 cm (10.5 inches) between the top of coupling (23) and plate (7) .

5. Reinstall the locknut and tighten.

6. Reinstall the bushing.

7. Repeat steps 1 through 6 for each MMU that is installed in the system.

8. Proceed to "Assembly of the Conduit for the System Cabinet Output Wiring".

Assembly of the Conduit for the System Cabinet Output Wiring

1. Remove the bushing (31) and one locknut (30) from the conduit assembly.

2. Insert the conduit assembly into plate (7) .

3. Adjust until there is a clearance of 26.67 cm (10.5 inches) between the top of coupling (28) and plate (7) .

4. Reinstall the locknut (30) and tighten.

5. Reinstall bushing (31) .

6. Repeat steps 1 through 5 for each MMU that is installed in the system.

7. Proceed to "Assembly of the Conduit for the Input and the Output Wiring of the MMU Cabinet".

Assembly of the Conduit for the Input and the Output Wiring of the MMU Cabinet

Illustration 7	g00921780
Conduit (MMU Cabinet)

1. Unscrew plate (40) from the top of the MMU cabinet(s). NOTE: Make sure that plate (40) is reinstalled so that the part number is seen from the top of the cabinet.

2. Remove the bushing (15) and one locknut (14) from the conduit assembly.

3. Insert the conduit assembly into plate (7) .

4. Remove Chase Nipple (20) from conduit assembly.

5. Adjust until there is a clearance of 26.67 cm (10.5 inches) between the top of coupling (32) and plate (7) .

6. Reinstall the locknut and tighten.

7. Reinstall the bushing.

8. Repeat steps 1 through 7 for each MMU that is installed in the system.

9. Proceed to "Assembly of the Conduit for the MMU Cabinet Control Wiring".

Assembly of the Conduit for the MMU Cabinet Control Wiring

1. Remove bushing (16) and one locknut (17) from the conduit assembly.

2. Insert the conduit assembly into plate (7) .

3. Adjust until there is a clearance of 26.67 cm (10.5 inches) between the top of coupling (19) and plate (40) .

4. Reinstall the locknut and tighten.

5. Reinstall the bushing.

6. Repeat steps 1 through 5 for each MMU that is installed in the system.

7. Go to step 8 and 9 if there is no generator set start module that is being installed. If a generator set start module is being installed, proceed to "Assembly of the Tray (Conduit) for the Wiring for the Generator Set Optional".

8. Reinstall plate (40) with the assembled conduit back to the top of the MMU cabinets(s).

9. Proceed to "Installation of the Wireway for the System Cabinet".

Assembly of the Conduit for the Power Cable for the Generator Set Optional

Note: The first Conduit for the Power Cable for the Generator Set will be installed in the last MMU Cabinet in the system. This will be the MMU that is farthest to the right of the System Cabinet as you face the front of the unit. The positioning of the cabinets begins with the Input/Output Cabinet. The System Cabinet will be immediately to the right of the Input/Output Cabinet. The first MMU cabinet will be next to the System Cabinet.

This cabinet is designated "MMU-1". The MMU to the right of "MMU-1" will be "MMU-2", etc. If you need to install more than one generator set, install the additional conduit for the power cable for the generator set in the wireway for the MMU that is in the next lower position. For example, if the system has four Multiple Module Units, install the conduit for the power cable of the first generator set to the "MMU-4" wireway. Then, install the conduit for the power cable of the second generator set in "MMU-3" wireway. Proceed in this manner. Refer to Illustration 2.

1. Remove bushing (16) and one locknut (17) from the conduit assembly.

2. Insert the conduit assembly into plate (40) .

3. Adjust until there is a clearance of 26.67 cm (10.5 inches) between the top of coupling (19) and plate (40) .

4. Reinstall the locknut and tighten.

5. Reinstall the bushing.

6. Repeat steps 1 through 5 for each generator set that is installed in the system.

7. Reinstall plate (40) with the assembled conduit back to the top of the MMU cabinets.

8. Proceed to "Installation of the Wireway for the System Cabinet".

Installation of the Wireway for the System Cabinet

Illustration 8	g00921781

1. Remove the six screws (3) that secure the cover (2) to wireway (1) and remove cover (2) .

2. Install end plate (10) on the left end of wireway (1) and secure end plate (10) with the hex bolt (11) and hex nut (12) .

3. Proceed to Step 5 if any of the following conditions are true:
   • There is no generator set start module that is being installed in "MMU-1".

   • A generator set start module will be installed at a later date.

   • The cable for the generator set will exit through end plate (10) at the right hand end of the system.

   Note: The UPS is viewed from the front.

4. Punch a hole in the top of wireway (1) if the following conditions are true:

   Note: Punch the hole directly above the knockout hole for the conduit that is for the wiring (generator set).

   • A generator set start module is being installed in "MMU-1" at this time.

   • The cable for the generator set needs to exit through the top of wireway (1) .

5. Position wireway (1) onto the top of Couplings (Rigid Conduit) (19), (28), (23), and (32). The first MMU also connects to the wireway for the system cabinet.

6. Install Chase Nipples (22) through wireway (1) and into Couplings (Rigid Conduit) (23) and tighten.

7. Install Chase Nipples (27) through wireway (1) and into the Couplings (Rigid Conduit) (28) and tighten.

8. Install locknuts (17) onto Nipples (Conduit) (34) .

9. Install nipples (34) through wireway (1) and into the Couplings (Rigid Conduit) (19) and tighten.

10. Proceed to "Installation of wireway (MMU cabinet)".

Installation of wireway (MMU cabinet)

1. Remove the six screws (6) that secure cover (5) to wireway (4) and remove the cover.

2. Proceed to Step 4 if any of the following conditions are true:
   • There is no generator set start module in this MMU.

   • A generator set start module will be installed at a later date.

   • The cable for the generator set will exit through end plate (10) at the right hand end of the system.

   Note: The UPS is viewed from the front.

3. If a generator set start module is being installed in this MMU at this time and the cable for the generator set will exit through the top of wireway (4), punch a hole in the top of wireway (4). The location of this hole needs to be directly above the knockout hole for the conduit for the wiring (generator set).

4. Position wireway (4) onto the top of Couplings (Rigid Conduit) (19), and Couplings (Rigid Conduit) (32) .

5. Install the Chase Nipple (20) through wireway (4) and into the Coupling (Rigid Conduit) (32) and tighten.

6. Connect wireway (4) to the adjacent wireway. Use bolts (11) and nuts (12) and tighten.

7. Install locknut (17) onto the Nipple (Conduit) (34) .

8. Install nipple (34) through wireway (4) and into coupling (19) and tighten.

   Note: Install the end of the nipple with the locknut.

9. Repeat steps 1 through 8 for any additional MMU wireways in your system.

10. Position end plate (10) onto the end of the last wireway (4). Secure end plate (10) with bolts (11) and nuts (12) .

11. Proceed to "Assembly of the Tray (Conduit) for the Wiring of the System Cabinet and the MMU".

Assembly of the Tray (Conduit) for the Wiring of the System Cabinet and the MMU

Illustration 9	g00921804

1. Remove bushing (16) from the assemblies (conduit).

2. Install locknuts (17) onto the top of all nipples (33) .

   Note: When the conduit is properly configured, there are locknuts on both ends.

Show/hide table



Illustration 10	g00921775

3. Between the system cabinet and the first MMU, insert tray (8) onto nipple (34) so that tray (8) rests on locknut (17) .

4. Between each of the Multiple Module Units, insert tray (9) onto nipple (34) so that tray (9) rests on locknut (17) .

   Note: Make sure that the tray is oriented correctly. Refer to Illustration 2. There should be no gaps between the trays.

5. Install the plastic conduit bushing (15) onto each nipple (33) and tighten.

6. Tighten all locknuts (16) in order to secure tray (8) and tray (9) .

Assembly of the Tray (Conduit) for the Wiring for the Generator Set Optional

Single Generator Set Start Module in last MMU or Multiple Generator Set Start Modules

Note: This procedure is for units with cables that are exiting through the top of the wireway.

1. Insert customer supplied 1 1/2 inch conduit through the hole that is located in the top of wireway (4). Install locknut (17) .

2. Install customer supplied 1 1/2 inch conduit through bottom wireway (4) and into coupling (18) and tighten.

3. Tighten locknut (17) in order to secure the wireway.

4. Discard the tray (wireway) for the generator set and supplied parts.

Multiple Generator Set Start Modules

Note: This procedure is for units with cables that are exiting through the end plate of the wireway.

1. Remove bushing (16) and one locknut (16) from conduit assembly.

2. Install the end of nipples (21) with the locknut through wireway (4) and into coupling (19) and tighten.

   Note: You must not allow wire to chafe against the wireway knockout hole.

   Note: There must be no gaps between the conduit and the tray (wireway).

3. Install locknut (17) onto the top of all nipples (20) and tighten.

4. Between each of the Multiple Module Units, insert tray (9) onto nipple (21) so that tray (9) rests on locknut (17) .

   Note: Make sure that the tray is oriented correctly. Refer to Illustration 2. There should be no gaps between the trays.

5. Install locknut (17) onto the bottom of nipple (21) in order to secure the wireway.

6. Install the plastic conduit bushing (15) onto each nipple (21) and tighten.

7. Tighten all locknuts (17) to secure tray (9) .

Final Installation Adjustments

Note: Make sure that all hardware is tight before installing the cables.

The assembly of the Wireway is complete. Installation can now continue with AC power connections for the Input/Output Cabinet.

Installation of the Expansion Multiple Module Units

The following instructions explain the procedures that are required to assemble Expansion Multiple Module Units.

Note: Select the illustration that best represents your system before proceeding.

Method 1

Illustration 11	g00921979

Note: Illustration 11 represents the UPS with the following components: System Cabinet, Multiple Module Unit(s) and Expansion Multiple Module Unit. This configuration does not include any Generator Set Start Modules.

Illustration 12	g00921980

Note: Illustration 12 represents the UPS with the following components: System Cabinet, Multiple Module Unit(s) and Expansion Multiple Module Unit. This configuration shows a MMU with a Generator Set Start Module and an Expansion Multiple Module Unit without a Generator Set Start Module. The cable for the Generator Set Start Module exits through the top of the cable tray on this configuration.

1. Remove end plate (10) from the end of the last wireway (4) by removing bolts (11) and nuts (12) .

2. Perform the "Assembly of the Conduit for the Control Wiring in the System Cabinet" procedure.

3. Perform the "Assembly of Conduit for the System Cabinet Input Wiring" procedure.

4. Perform the "Assembly of the Conduit for the System Cabinet Output Wiring" procedure.

5. Perform the "Assembly of the Conduit for the Input and the Output Wiring of the MMU Cabinet" procedure.

6. Perform the "Assembly of the Conduit for the MMU Cabinet Control Wiring" procedure.

7. Perform the "Installation of wireway (MMU cabinet)" procedure.

8. Perform the "Assembly of the Tray (Conduit) for the Wiring of the System Cabinet and the MMU" procedure.

9. Perform the "Final Installation Adjustments" procedure.

   Note: Discard the conduit for the generator set and the cable tray that was included with the hardware.

Method 2

Illustration 13	g00921983
Method 2

Note: Illustration 13 represents the UPS with the following components: System Cabinet, Multiple Module Unit(s) and Expansion Multiple Module Unit. This configuration shows a MMU with a Generator Set Start Module and an Expansion Multiple Module Unit without a Generator Set Start Module. The cable for the Generator Set Start Module exits through the end plate on this configuration.

Note: The end plate is shifted on this configuration for the Expansion Multiple Module Unit.

Illustration 14	g00921988
Method 2

Note: Illustration 14 represents the UPS with the following components: System Cabinet, Multiple Module Unit(s) and Expansion Multiple Module Unit. This configuration shows a MMU and an Expansion Multiple Module Unit with Generator Set Start Modules. The cable for the Generator Set Start Module exits through the top of the cable tray and through the end plate on this configuration.

Note: The end plate is shifted on this configuration for the Expansion Multiple Module Unit.

1. Remove end plate (10) from the end of the last wireway (4) by removing bolts (11) and nuts (12) .

   This end plate should have a cable (generator set) that is installed. This end plate will need to be adjusted in order to move the panel 1092.20 mm (43.00 inch) to the right for each additional MMU that is added.

2. Perform the "Assembly of the Conduit for the Control Wiring in the System Cabinet" procedure.

3. Perform the "Assembly of Conduit for the System Cabinet Input Wiring" procedures.

4. Perform the "Assembly of the Conduit for the System Cabinet Output Wiring" procedure.

5. Perform the "Assembly of the Conduit for the Input and the Output Wiring of the MMU Cabinet" procedure.

6. Perform the "Assembly of the Conduit for the MMU Cabinet Control Wiring" procedure.

7. Perform the "Assembly of the Conduit for the Power Cable for the Generator Set" procedure.

Note: This step is for units with cable that are exiting through the end plate.

8. Perform the "Installation of wireway (MMU cabinet)" procedure.

9. Perform the "Assembly of the Tray (Conduit) for the Wiring of the System Cabinet and the MMU" procedure.

10. Perform the "Assembly of the Tray (Conduit) for the Wiring of the Generator Set" procedure.

11. Perform the "Multiple Generator Set Start Modules" procedure.

12. Reinstall end plate (10) from the end of the last wireway (4) with the use of bolts (11) and nuts (12) .

    This end plate needs to have a cable (generator set) that is installed. This end plate will need to be adjusted in order to move the panel 1092.20 mm (43.00 inch) to the right for each additional MMU that is added.

13. Perform the "Final Installation Adjustments" procedure.

Method 3

Illustration 15	g00921983
Method 3

Note: Illustration 15 represents the UPS with the following components: System Cabinet, Multiple Module Unit(s) and Expansion Multiple Module Unit. This configuration shows a MMU with a Generator Set Start Module and an Expansion Multiple Module Unit without a Generator Set Start Module. The cable for the Generator Set Start Module exits through the end plate on this configuration.

Note: The end plate is shifted on this configuration for the Expansion Multiple Module Unit.

Illustration 16	g00921988
Method 3

Note: Illustration 16 represents the UPS with the following components: System Cabinet, Multiple Module Unit(s) and Expansion Multiple Module Unit. This configuration shows a MMU and an Expansion Multiple Module Unit with Generator Set Start Modules. The cable for the Generator Set Start Module exits through the top of the cable tray and through the end plate on this configuration.

Note: The end plate is shifted on this configuration for the Expansion Multiple Module Unit.

Illustration 17	g00921989
Method 3

Note: Illustration 17 represents the UPS with the following components: System Cabinet, Multiple Module Unit(s) and Expansion Multiple Module Unit. This configuration shows a MMU and an Expansion Multiple Module Unit with Generator Set Start Modules. The cable for the Generator Set Start Module exits through the top of the cable tray and through the end plate on this configuration.

Note: The end plate is shifted on this configuration for the Expansion Multiple Module Unit.

1. Remove end plate (10) from the end of the last wireway (4) by removing bolts (11) and nuts (12) .

2. Perform the "Assembly of the Conduit for the Control Wiring in the System Cabinet" procedure.

3. Perform the "Assembly of Conduit for the System Cabinet Input Wiring" procedures.

4. Perform the "Assembly of the Conduit for the System Cabinet Output Wiring" procedure.

5. Perform the "Assembly of the Conduit for the Input and the Output Wiring of the MMU Cabinet" procedure.

6. Perform the "Assembly of the Conduit for the MMU Cabinet Control Wiring" procedure.

7. Perform the "Installation of wireway (MMU cabinet)" procedure.

8. Perform the "Assembly of the Tray (Conduit) for the Wiring of the System Cabinet and the MMU" procedure.

9. Perform the "Assembly of the Tray (Conduit) for the Wiring of the Generator Set" procedure.

Note: This step is for units with cables that are exiting through the top of the wireway.

10. Perform the "Single Generator Set Start Module in Last MMU or Multiple Generator Set Start Modules" procedure.

11. Perform the "Final Installation Adjustments" procedure.

    Note: Discard the following items: the conduit for the generator set and cable tray with hardware.