UPS 1000S/ UPS 1200S Uninterruptible Power Supplys Caterpillar

Illustration 1	g01281063
Inverter Cabinet Lower Left Panel Fuse Location (12) Fan Fuses F1-F3 (13) Fuse F33 (14) Fan Fuses F4-F5

Illustration 2	g01281066
Inverter Cabinet Neutral Bus Fuse Location, Upper Left Panel, Version 1 Hardware (15) Neutral Bus Fuses

Illustration 3	g01281067
Inverter Cabinet Neutral Bus Fuse Location, Upper Left Panel, Version 2 Hardware (15) Neutral Bus Fuses

The lower left panel of the cabinet holds one fuse and the upper left panel holds either five or six Neutral Bus Fuses. The Neutral Bus Fuses protect the inverters.

Each complete inverter assembly contains three fuses. One each for the positive, negative, and AC connections to the inverter.

Illustration 4	g01280695
Inverter Cabinet - Left View (2) DC Bus (5) Upper Left Panel (6) Heat Sink (7) Current Transformer (8) Lower Fan Plenum (9) Fan x5 (10) Lower Left Panel (11) Inverter Assembly x6

Illustration 5	g01281088
Inverter Assembly Fuses

Refer to Illustration 4 for the location of the upper and lower left panels in the cabinet. Refer to Illustration 1 for the location of the fuse blocks on the lower left panel. Refer to Illustration 2 or Illustration 3 for the location of the Neutral Bus Fuse blocks on the upper left panel. Refer to Illustration 5 for the locations of Inverter fuses in the system.

There is also a set of fuses for the five fans in the system. These fuses are located on the lower left panel below the General Purpose Interface Board. Refer to Illustration 1 for the fan fuse location.

Wire diagrams for lower left panel fuses are shown in Illustration 6. Wire diagrams for the Neutral Bus Fuses are shown in Illustration 7.

Illustration 6	g01281097
Inverter Cabinet Lower Left Panel Fuse Wire Connections

Illustration 7	g01281098
Inverter Cabinet Neutral Fuse Wire Connections - Version 1 Hardware, Five Fuses

Illustration 8	g01281123
Inverter Cabinet Neutral Fuse Wire Connections - Version 2 Hardware, Six Fuses

Neutral Bus Fuse Removal

1. Perform steps in the Systems Operation, Testing and Adjusting, "Internal Component Preremoval Steps (Inverter Cabinet)" in order to de-energize the system and gain access to internal components.

2. Remove the Fuse Switch from the fuse that is being replaced by removing the two cross tip screws.

3. Remove the nuts that are holding the bus bar to the output fuse contacts. Use a 229 mm (9/16 inch) socket.

4. Remove the bus bar.

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Illustration 9	g01281132
(20) Nut (21) Split Washer (22) Flat Washer (23) Output Bus Bar (24) Fuse Input (25) Black Insulated Input Terminal (26) Steel Panel (27) Input Wire Lug

5. Remove the top nut that is holding the fuse to the input contact. Use a 229 mm (9/16 inch) socket.

6. Remove the white input wire from the fuse input connector.

   The wires locations are labeled.

7. Remove fuse.

Neutral Bus Fuse Installation

1. Position fuse across input and output connectors.

2. Place the correct white input wire lug on the input fuse terminal.

3. Fasten the fuse input terminal with one nut. Refer to Illustration 9 for hardware connections.

4. Place the output bus bar across all five output fuse terminals.

5. Fasten the bus bar to the fuse terminals with the nuts. Refer to Illustration 9 for hardware connections.

6. Tighten the nuts to 21.6931 N·m (16 lb ft).

7. Attach the Fuse Switch to the fuse using two cross tip screws.

   Refer to Systems Operation, Testing and Adjusting, RENR7654, "Fuse Switch" for additional information.

DC Bus Fuse Removal

1. Perform steps in the Systems Operation, Testing and Adjusting, "Internal Component Preremoval Steps (Inverter Cabinet)" in order to de-energize the system and gain access to internal components.

2. Remove the Fuse Switch from the fuse to be replaced by removing the two cross tip screws.

3. Remove the nut connected to the bolt that holds the fuse to the input and output contacts and to the red insulator. Use a 229 mm (9/16 inch) socket.

4. Remove the fuse.

DC Bus Fuse Installation

1. Position fuse across input and output bus bars.

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Illustration 10	g01281174
DC Bus Fuse Hardware Connections (30) Bolt (31) Split Washer (32) Steel Washer (33) Bus Bar (DC Bus) (34) Fuse (35) Capacitor Bus Bar (36) Steel Washer (37) Split Washer () Bolt (39) Switch

2. Insert two bolts through the input, the fuse and the output connectors with the appropriate washers.

   Refer to Illustration 10 for hardware connections.

3. Tighten the bolts firmly with a 229 mm (9/16 inch) socket to 26 N·m (19 lb ft).

4. Attach the Fuse Switch to the fuse using two cross tip screws.

   Refer to Systems Operation, Testing and Adjusting, RENR7654, "Fuse Switch" for additional information.

AC Bus Fuse Removal

1. Perform steps in the Systems Operation, Testing and Adjusting, "Internal Component Preremoval Steps (Inverter Cabinet)" in order to de-energize the system and gain access to internal components.

2. Remove the two bolts that hold the fuse input and output connectors to the two red insulating spacers. Use a 229 mm (9/16 inch) socket.

3. Remove the fuse.

AC Bus Fuse Installation

1. Position fuse across input and output bus bars.

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Illustration 11	g01281177
AC Fuse Installation (40) Input Bus Bar (41) Belleville Washer (42) Output Bus Bar (43) Fuse

2. Insert two bolts, one for each of the input and output connectors, through the fuse and bus bars with appropriate washers.

   Refer to Illustration 11 for hardware connections.

3. Tighten the bolts to 95 N·m (70 lb ft).

   Note: In all cases, the side of the belleville washer that curves inward should be placed facing the bus bar.