Unpacking Instructions for UPS 1000S and 1200S{4480} Caterpillar

Uninterruptible Power Supply:

UPS 1000S (S/N: CZS1-UP)

UPS 1200S (S/N: CZT1-UP)

Introduction

The following instructions are to be used in unpacking the UPS 1000S and 1200S. Please adhere to the following instructions.

Receiving and Handling

The UPS 1000 / UPS 1200 can consist of as many as 7 cabinets. Refer to the following list for the cabinets that are included:

• Maintenance Bypass

• Input/Output

• Static Switch

• Controls

• Inverter

• Energy Storage Cabinet

Note: The Maintenance Bypass is optional.

External Inspections

1. Inspect the cabinets before the shipping company unloads the cabinets. Inspect the equipment and the shipping container for any signs of damage. Do not attempt to install the system if damage is apparent. If any damage is noted, file a claim with the shipping company within 24 hours. Inform Caterpillar of the claim and the condition of the equipment.

2. Compare the contents of the shipment with the bill of material. Report any missing items to the carrier and to Caterpillar immediately.

3. Check the nameplate on the cabinet in order to verify that the model number and the serial number corresponds with the numbers that are specified on the document (shipping).

4. Record the model and serial numbers in the front of this installation manual. A record of this information is necessary if any servicing is required.

5. Inspect tilt and shock indicators. A 30 degree tilt is the acceptable maximum. The shock indicator should be clear (not showing red).

   IMPORTANT: If the tilt indicator has registered a tilt of over 30 degrees or if the shock indicator is red and indicating it has registered an unacceptable shock, you must suspect hidden damage.

   Photograph the tilt and shock indicators in place on the cabinet for assistance in processing a damage claim.

Internal Inspections

1. Verify that all items have been received.

2. Verify the arrival of spare parts that have been ordered.

3. Open the doors and remove cabinet panels in order to check for shipping damage to internal components.

4. Check for loose connections or unsecured components inside the cabinet.

5. Check for any unsafe condition that may be a potential safety problem.

Note: While the system is waiting to be installed, protect the system from any harmful contaminants which may include the following: moisture and dust. Any damage to the system that is caused by improper storage may invalidate the warranty.

Unpacking the UPS

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Risk of electric shock or energy hazard. Parts inside this UPS are energized by the flywheel even when the AC power is disconnected.

Illustration 1	g01159967
Center of Gravity Symbol

IMPORTANT: Unpack the Inverter/Control cabinets first. Save the packing lumber and 107.95 mm (4.25 inch) X 95.25 mm (3.75 inch) blocks for use in unpacking the other cabinets.

• Locate the center of gravity symbols

• Lift the cabinets only in the locations shown.

• Test lift the cabinets and balance the cabinets before transporting.

• Maintain minimum tilt from vertical at all times.

• Use a suitable material handling device to move the cabinets to their final installation location.

• When moving a 3-wire system, it is recommended that a forklift with a minimum capacity of 3.0 tons, typical width 508.00 mm (20 inch) X 38.10 mm (1.5 inch), but less than 609.60 mm (24 inch) must be used.

• When moving a 4-wire system, it is recommended that a forklift with a minimum capacity of 4.0 tons, typical width 508.00 mm (20 inch) X 317.50 mm (12.5 inch), but less than 609.60 mm (24 inch)must be used.

1. Proper planning will aid in the efficiency of the installation.

2. Install the system in a restricted location in order to prevent access by unauthorized personnel.

3. Plan the routing of the cabinets in order to make sure that the system can be routed without risking damage. If the system must be moved by an elevator, check the size of the door opening and the weight capacity of the elevator.

4. Make sure that the floor at the final location for the system and along the path to the site of the installation can support the weight of the system plus the weight of any equipment that is used in order to move the system.

Serial Number Location

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Serial Number Location (Typical)

The serial number is located in the Control cabinet. This number is stamped into the metal.

1. Verify that the serial number corresponds with the one that is specified on the document (shipping).

2. Record the serial number in the space that is provided. A record of this information is necessary if any servicing is required.

Shipping Configuration

When the cabinets are shipped, the cabinets are bolted to a wooden skid. The cabinets are protected with outer protective packing material or a wooden crate. The skid provides protection from shock and vibration. The skid is secured to the cleats of the cabinets by bolts. Wood blocks are attached to the skid for added support. A kickplate that is attached to the left side of the skid protects the cabinets from damage by a fork lift during moving. Use the following procedures to unpack the UPS.

Handling and Unpack Instructions for Use with Forklift

1. Using a forklift, carefully move the cabinets to a convenient unpacking area. Ideally, a convenient location allows easy access for moving the equipment to the final install location.

2. Unbolt the kickplate from the shipping skid.

3. Unbolt the shipping skid bolts securing the shipping skid to the cabinet cleats.

4. Insert the forklift jacks between the cleats form the front of the cabinets, then lift.

5. Remove the shipping skid and lower cabinets to the ground.

6. Remove any outer protective packing from the cabinets.

International Crating Forklift Unpack Instructions-Optional

1. Remove the wooden crate.

2. Remove and discard the bolts to the cabinets tops (if applicable).

3. Insert the bolts provided with the cabinet into the holes in the cabinet tops.

4. Unbolt the kickplate from the shipping skid.

5. Unbolt the shipping skid bolts securing the shipping skid to the cabinet cleats.

6. Insert the forklift jacks between the cleats from the front of the cabinets, then lift.

7. Remove the shipping skid and lower cabinet onto the ground.

8. Remove any outer protective packing from the cabinets.

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Crushing Hazard. Use extreme care when handling this equipment due to the uneven weight distribution of the cabinets. Locate the center of gravity symbols. Lift the cabinets only in the locations that are shown. Test the lift and balance the cabinets before transporting the cabinets. Maintain a minimum tilt from vertical at all times. Use a suitable material handling device in order to move the cabinets to the final destination. If a forklift is used, it must have a minimum capacity of 3 tons. The forks must have a width of 520.70 mm (20.50 inches) but needs to be less than 609.60 mm (24.00 inches). Failure to adhere to this warning can result in personal injury or death.

The system is shipped with required spacers (2 X 4s and/or 2 X 6s, and laminated 107.95 mm (4.25 inch)95.25 mm (3.75 inch) blocks) to allow you to handle and unpack the system safely.

IMPORTANT: Unpack the Inverter/Control Cabinets first and retain the lumber for use in unpacking the remaining cabinets.

Handling and Unpack Instructions for Use with a Pallet Jack

Illustration 3	g01159970
Laminated 107.95 mm (4.25 inch) X 95.25 mm (3.75 inch) Spacer Block Orientation

For safety and handling ease, using a pallet jack that conforms to the following specifications is recommended for deskidding and positioning the units.

Note: The Inverter/Control cabinet requires two pallet jacks for handling.

1. Move the skidded cabinets to a convenient unpacking area.

2. Remove the kick plate from the end of the pallet.

3. Unscrew any blocks form the shipping skid.

4. Unbolt the shipping skid bolts securing the shipping skid to the cabinet cleats.

5. Insert a pallet jack under the cleats from the side of the cabinet.

6. Remove the shipping skid material.

7. Insert on laminated 107.9 mm (4.25 inch) by 95.2 mm (3.75 inch)

   Note: A cabinet with more than two cleats or a cabinet with sidecar will require six laminated 107.9 mm (4.25 inch) by 95.2 mm (3.75 inch) spacer block.

8. Lower the cabinet onto the laminated 107.9 mm (4.25 inch) by 95.2 mm (3.75 inch).

9. Remove the pallet jack.

10. Place one of the provided 2 x 4s on each of the pallet jack.

11. Lift the cabinet enough to clear the laminated 107.9 mm (4.25 inch) by 95.2500 mm (3.75 inch) spacer blocks.

12. Remove the laminated 107.9 mm (4.25 inch) by 95.2 mm (3.75 inch) spacer blocks.

13. Place 2 x 4s under cleats.

14. Lower the cabinet.

15. Remove the 2 x 4s from the pallet jack tines.

16. Lift the cabinet from the front.

17. Remove 2 x 4s that were placed under cleats.

18. Position the cabinet.

19. Lower the cabinet.

20. Remove the pallet jack.

21. Remove any outer protective packing from the cabinet.

Pallet Jack International Crating Unpack and Handling Instructions

1. Remove the wooden crate material.

2. Remove and discard the bolts securing drawing item 5 to the cabinet tops (if applicable).

3. Insert the bolts provided with the cabinet into the holes in the cabinet tops.

4. Move the skidded cabinets to a convenient upacking area.

5. Remove the kickplate from the end of the pallet.

6. Unscrew any blocks from the shipping skid.

7. Unbolt the shipping skid bolts securing the shipping skid to the cabinet cleats.

8. Insert a pallet jack under the cleats form the side of the cabinet, then lift.

9. Remove the shipping skid material.

10. Insert one laminated 107.9 mm (4.25 inch) by 95.2 mm (3.75 inch) spacer block provided under each cleat corner.

    Note: A cabinet with more than two cleats or a cabinet with sidecar will require six laminated 107.9 mm (4.25 inch) by 95.2 mm (3.75 inch) spacer block.

11. Lower the cabinet onto the laminated 101.6 mm (4 inch) by 95.2500 mm (3.75 inch) spacer blocks.

12. Remove the pallet jack.

13. Move the pallet jack to the front of the cabinet.

14. Place one of the provided 2 x 6s on each tine of the pallet jack.

15. Lift the cabinet enough to clear the laminated 101.6 mm (4 inch) by 95.2500 mm (3.75 inch) spacer blocks.

16. Remove the laminated 101.6 mm (4 inch) by 95.2500 mm (3.75 inch) spacer blocks.

17. Place 2 x 6s under cleats.

18. Lower the cabinet.

19. Remove the 2 x 6s from the pallet jack tines.

20. Lift the cabinet from the front.

21. Remove 2 x 6s that were placed under cleats.

22. Position the cabinet.

23. Lower the cabinet.

24. Remove the pallet jack.

25. Remove any outer protective packing from the cabinet.

Unpacking Instructions for International Shipments

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Illustration 4	g01021520

1. Remove the wooden crate.

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Illustration 5	g01021526

2. Remove the bolts that are securing the frame (shipping) (1) to the top of the cabinet.

   Note: Do not discard the bolts. Insert the bolts back into the top of the cabinets.

3. Insert the bolts that were removed in step 2 back into the top of the cabinet.

4. Unbolt the wood block from the skid.

5. Unbolt the bolts (skid) that are securing the skid to the cleats of the cabinets.

6. Insert the forks of the fork lift between the cleats from the front of the cabinets.

7. Carefully lift the cabinets.

8. Remove the skid and lower the cabinet onto the ground.

The procedure for unpacking the Bypass Cabinet (Maintenance) and the Input/Output cabinet and removing the skid for the Bypass Cabinet (Maintenance) and the Input/Output cabinet is complete.

Uncrating Diagrams

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