Installation Procedures for the 259-4020 Voltage Regulator Assembly (for use with Caterpillar Power Modules Equipped with Legacy Switchgear that Utilize the 131-5374 Annunciator Module Control Group ){4467} Caterpillar

Power Module:

PM3412 (S/N: CAJ1-UP; 5FL1-UP)

PM3508 (S/N: BLM1-UP; BPY1-UP)

PM3512 (S/N: BRF1-UP; BNR1-UP)

PM3516 (S/N: CAC1-UP; BPD1-UP)

Introduction

As a product improvement option, the 259-4020 Voltage Regulator Assembly is now being offered. The functional purpose of the 259-4020 Voltage Regulator Assembly is to provide a regulated +24VDC power supply specifically for the 131-5374 Annunciator Module Control Group , the 131-5377 Flasher Assembly , and the LED Alarm Status Indicators. The 259-4020 Voltage Regulator Assembly also serves as a power source filter for voltage anomalies that might exist on the +24VDC power supply input line.

Precautions

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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

Prior to performing the installation procedure, the service technician should take the following precautions.

1. Ensure that the Genset Start Key is in the "Off" position. Remove the key to prevent the inadvertent start of the machine.

2. From inside the Switchgear control panel, locate the primary DC supply circuit breakers ("CB1" and "CB2"). These circuit breakers are typically located in the upper cubicle or the upper right cubicle on the interior left sub-panel.

3. Place "CB1" and "CB2" in the "Off" position.

Requirements

In order to successfully complete these instructions, the service technician must have a copy of the appropriate Caterpillar Switchgear Schematics in their possession.

Procedure

1. From within the upper switchgear cabinet cubicle, locate the 131-5377 Flasher Assembly ("FM") and the 131-5374 Annunciator Modules ("AN1" to"AN9") that are mounted on the DIN rail. The DIN rail is attached to the interior left sub-panel.

2. Ensure that the DIN rail has sufficient length to insert the new 259-4020 Voltage Regulator Assembly . Refer to Illustration 1.

3. If the DIN rail does not have sufficient length to insert the 259-4020 Voltage Regulator Assembly , you will have to add an additional length of DIN rail to the same sub-panel. Move either the diode blocks or the timer devices to the newly-added DIN rail. This will allow you to insert the 259-4020 Voltage Regulator Assembly in the proper sequence.

   Note: Ensure that you locate the new DIN rail in a position that will allow you to utilize the existing conductors.

4. Insert the 259-4020 Voltage Regulator Assembly as shown in Illustration 1.

   Note: It will be necessary to reposition and secure the DIN rail "end blocks".

5. Remove the cover to the Panduit wire way. The Panduit wire way is located directly above the DIN rail where the 259-4020 Voltage Regulator Assembly was just installed. Place the cover in a location outside of your work area.

6. Reconfigure the necessary wiring for either the diode blocks or the timer devices that were moved in Step 3.

7. Locate wiring terminal #4 on the 131-5377 Flasher Assembly (FM).

8. From wiring terminal #4 on the 131-5377 Flasher Assembly (FM), detach and isolate the single conductor. The single conductor is the primary +24VDC source supplied to terminal #4 on the 131-5377 Flasher Assembly (FM). This particular conductor is typically sourced from TB-17. Refer to you switchgear schematic for confirmation.

9. Re-label the end of the single conductor to read TB-17 < DCDC1-3.

10. Secure this same conductor (TB-17 < DCDC1-3) to terminal #3 on the 259-4020 Voltage Regulator Assembly .

11. Using standard THHN stranded 16 AWG wire, create a jumper from DCDC1-12 to wiring terminal #4 on the 131-5377 Flasher Assembly (FM). Secure the conductor at both terminal locations.

12. Using standard THHN stranded 16 AWG wire, create an electrical connection between DCDC1-9 to TB-2 of the switchgear. Secure the conductor at both terminal locations.

13. Install the Panduit wire way cover that was removed in Step 5.

14. Perform a final visual inspection of all applicable terminal connections and placement of components. Use Illustration 2 and Illustration 3 as a reference schematic. The installation of the 259-4020 Voltage Regulator Assembly will result in a wiring schematic with the electrical connections shown in Illustration 2 and Illustration 3.

15. Place the Genset Start key in the "ON" position.

16. Place the switchgear circuit breakers "CB1" and "CB2" in the "ON" position.

17. Perform a switchgear lamp test in order to confirm that the installation of the DCDC1 device is complete and accurate.

18. The installation of the 259-4020 Voltage Regulator Assembly is now complete.

Illustrations

Illustration 1 - 259-4020 Voltage Regulator Assembly Wiring Schematic (page 1).

Illustration 2 - 259-4020 Voltage Regulator Assembly Wiring Schematic (page 2).

Illustration 3 - New 259-4020 Voltage Regulator Assembly installed on DIN rail.

Illustration 1	g01118762

Illustration 2	g01117957

Illustration 3	g01118742