Installation of the Alarm Communication Relay Card{4480} Caterpillar

Uninterruptible Power Supply:

UPSB 125 (S/N: SEP1-UP)

UPSB 130 (S/N: XTC1-UP)

Introduction

This Special Instruction provides instruction for the installation of the Alarm Communication Relay card in the Uninterruptible Power Supply (UPS) systems that are listed.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

If a tool, a procedure, a work method or operating technique that is not specifically recommended by Caterpillar is used, you must ensure that it is safe for you and for other people to use. You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Safety of Persons

Show/hide table

High voltage. Power source must be disconnected before working on equipment. Failure to disconnect power source could result in injury or death.

The relay card contains voltages that are dangerous. The protection cover of the relay card must be removed only by an installer that is qualified or by a technician that is authorized to perform maintenance.

The relay card may be connected to voltages that are dangerous. The relay card must only be installed by a person that is qualified. The relay card is connected to a network that contains a power supply. Voltages that are dangerous may be present even if there is no power to the UPS or to the module that contains the relay card.

Safety of Equipment

• The relay card must be stored in a location that is dry. The temperature in this location should be between −10° C (14° F) and 70° C (158° F).

• A Safety Extra Low Voltage (SELV) and a non-SELV circuit cannot be installed on the same relay card.

General Information

Contents

Illustration 1	g02083417
Relay card (1) and protection cover (2) for relay card

Verify that the package contains the following items:

• Relay card

• Protection cover for relay card

• Manual for installation

Overview

Illustration 2	g02088133
Detail of relay card and protection cover (3) Screws for securing the protection cover (4) Holes for securing the relay card (5) Holes for the cables (6) Hole for viewing LED for diagnostics (7) Output terminal block (8) Screws for clamping the cables (9) Input terminal block

Functions

The relay card may be used in all UPS systems that contain a UPS bus slot for communication or for systems that contain a MultiSlot module.

Note: A MultiSlot module is used in order to provide additional slots for the cards that are used for communications.

The relay card can be operated in one of the following modes:

• Standard Mode

• Programmable Mode

• Load-shedding Mode

The relay card is used in order to control six output relays. The relay card receives signals on the SELV inputs. The relays that are controlled and the signals that are received will depend on the status of the mode of operation of the UPS.

Standard Mode

The relays are controlled when the UPS changes a condition of status. The following information is transmitted:

Relay 1 - A general alarm has occurred.

Relay 2 - The battery is faulty.

Relay 3 - The load is protected.

Relay 4 - The load has been set to automatic bypass.

Relay 5 - There is a load on the power of the battery.

Relay 6 - The battery is low on power.

Programmable Mode

All six relays are controlled directly by the UPS. A change of state is transmitted to the UPS if the state of "Input A" or the state of "Input B" changes. The UPS controls the logic for the output relays. The UPS controls the management of the inputs to the relays.

Load-shedding Mode

The power from the battery in the UPS controls all relays. The following is the sequence for this operation:

1. The load is transferred to the battery. The following relays are opened: 4, 5 and 6.

2. A warning is issued in order to indicate that the battery is low on power. The following relays are opened: 1, 2 and 3.

3. The AC power is returned to the input. All relays are closed. There is two second delay between each closing of the relays.

Technical Data

Configuration of the Relay Card

Illustration 3	g02086225

The input contacts have the following characteristics:

Switched voltage - 5 VDC

Loop current - 10 mA

The output contacts have the following characteristics:

Permissible voltage - 250 VAC and 30 VDC

Permissilbe current - 2 A

Short Circuit Protection

The sources of power that are connected to the relay card must be equipped with a device for protection. The device must have a maximum breaking capacity of 2 amperes.

Installation

Setting the Mode of Operation

Standard Mode

Illustration 4	g02086230
Settings for standard mode

This is the default mode for the relay card. This mode is compatible with all UPS systems.

"SA1" is a Dual Inline Package (DIP) switch. Refer to Illustration 4 in order to set "SA1". All switches on "SA1" are set to OFF.

ReferenceIf two relay cards are installed in the same UPS, refer to ""Installing a Second Relay Card" ".

Programmable Mode

Illustration 5	g02086233
Settings for programmable mode

Refer to Illustration 5 in order to set the "SA1" DIP switch. Switch 3 of "SA1" is set to ON. All other switches are set to OFF.

Note: Not all UPS systems can use this mode. Verify in the user manual of the UPS system in order to determine if the relay contacts support this function.

ReferenceIf two relay cards are installed in the same UPS, refer to ""Installing a Second Relay Card" ".

Load-shedding Mode

Illustration 6	g02086236
Setting for Load-shedding mode

Refer to Illustration 6 in order to set the "SA1" DIP switches. Switch 2 of "SA1" is set to ON. All other switches are set to OFF.

ReferenceIf two relay cards are installed in the same UPS, refer to ""Installing a Second Relay Card" ".

Setting the Relay Contacts and Setting the Inputs

Illustration 7	g02086239
Detail of settings for relay contacts

Refer to Illustration 7. This is the default setup of the relay card. All of the relay contacts are Normally Open (NO). Switches 1 through 6 are OFF. Both of the external contacts are closed. Switch 7 and Switch 8 are OFF. In this configuration, the following actions occur:

Contact is open - The relay is not controlled.

Contact is closed - The relay is controlled.

External contact is open - The input is not activated.

External contact is closed - The input is activated.

The "SA2" DIP switch can be used in order to reverse the operation of the relay contacts and the operation of the inputs. Refer to Table 1.

Installing a Second Relay Card

Illustration 8	g02086247
Detail for setting up two relay cards

A maximum of two relay cards may be installed in a UPS system. Switch 1 on the "SA1" DIP switch must be set to ON if a second relay card is installed.

Connection

• All sources of power that will be connected to the relay card must be turned off during the installation.

• A Safety Extra Low Voltage (SELV) and a non-SELV circuit cannot be installed on separate cards.

• The position of the sources of power must be indicated on the labels of the protection cover.

• The protection cover must be installed on the relay card before the power is applied to the relay card.

• The sources of power for the relay card should not be energized until the relay card has been inserted in the correct location.

Characteristics of Cables for Connection

Outputs - 4 x 0.93 mm2, diameter equals 6.6 ± 0.3 mm (0.26 ± 0.02 inch).

Inputs - 4 x 0.34 mm2, diameter equals 5 ± 0.5 mm (0.20 ± 0.02 inch).

Installing the Relay Card

Show/hide table

Bodily contact with electrical potential can cause bodily injury or death. To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.

Illustration 9	g02086280
Detail of relay card and protection cover (2) Protection cover (5) Holes for the cables (7) Output terminal block (9) Input terminal block

1. Turn off the sources that provide power to the relay card.

2. Remove the protection cover (2) for the relay card.

3. Remove the knock-outs of the holes for cables (5) by using a screwdriver.

4. Route the cables through the holes.

5. Connect the wires to the output terminal blocks (7) .

6. Connect the wires to the input terminal blocks (9) .

7. Install the protection cover.

Show/hide table



Illustration 10	g02086285

8. Secure the protection cover by using the screws (3) .

9. Clamp the cables by using the screws (6) .

10. Mark the locations of the sources for the power on the label.

Inserting the Relay Card

Installation in a UPS

Illustration 11	g02086286
Detail of installation of the relay card

It is not necessary to shut down the UPS.

1. Unscrew the cover plate on a free slot in the UPS.

2. Insert the relay card.

3. Secure the relay card by using the screws.

MultiSlot Module

Illustration 12	g02086288
Detail of installation of the cables (10) MultiSlot module (11) UPS (12) U-Talk connection

1. Unscrew the cover plate on a free slot in the MultiSlot module (10) .

2. Insert the relay card.

3. Secure the relay card by using the screws.

Operation

Illustration 13	g02086294
Typical connection (11) UPS (12) General alarm (13) Load on battery power

1. Energize the sources of power that are connected to the relay card.

2. Verify that the circuit is operating correctly.

   The green LED on the relay card operates in the following manner:

   • During the start-up of the system, the LED flashes once per second.

   • The LED flashes rapidly during the initialization of communication with the UPS or with the MultiSlot module.

   • The LED flashes when data is being exchanged with the UPS or with the MultiSlot module.

Troubleshooting

The LED is Off

1. Ensure that the relay card is inserted in the slot.

2. Ensure that the protection cover is installed properly.

3. Verify that the UPS or the MultiSlot module is energized.

4. Remove the relay card.

5. Insert the relay card again.

The LED is On

1. Remove the relay card.

2. Insert the relay card again.

A False Alarm Occurs

1. Verify that the settings of the "SA2" DIP switch are correct. Refer to Table 1.

2. Verify that the operating mode of the "SA1" DIP switch is correct. Refer to ""Setting the Mode of Operation" ".

3. If two relay cards are installed, verify that Switch 1 is set correctly on the "SA1" DIP switch. Refer to ""Installing a Second Relay Card" ".