UPSB505 Uninterruptible Power Supply UPS Battery - 50Hz Caterpillar

The information in this section is to provide the location of the various components in the UPS installation.

AC Capacitors and DC Capacitors

DC Capacitors for the 200 kVA, 300 kVA, and 400 kVA Units

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NOTICE
For installation, ensure that the torque for the mounting nuts and bus plate connections do not exceed 7 N·m (5.2 lb ft). Damage to the capacitors can occur if the required value is exceeded.

For installation, tighten the bus plate bolts first, then tighten the bolts that secure the capacitors to the mounting plate.

Illustration 1	g02566339
(1) DC capacitor location

Illustration 2	g02569399
200 kVA, 300 kVA, 400 kVA, and 500 kVA capacitor polarities (2) PFC (3) Chopper and NL (4) Inverter

DC Capacitors for the 500 kVA Unit

Illustration 3	g02566341

AC Capacitors

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NOTICE
For installation, ensure that the torque for the mounting nuts and bus plate connections do not exceed 7 N·m (5.2 lb ft). Damage to the capacitors can occur if the required value is exceeded.

For installation, tighten the bolts that secure the capacitors to the mounting plate. The bolt torque is 8 N·m (5.9 lb ft).

200 kVA AC Capacitors

Illustration 4	g02567156
(5) 500 µF output capacitors (6) 200 µF input capacitors

300 kVA and 400 kVA AC Capacitors

Illustration 5	g02568938
(10) Capacitor location in UPS (11) 400 µF output capacitors (12) 300 µF input capacitors (13) 500 µF output capacitors (14) 200 µF input capacitors

500 kVA AC Capacitors

Illustration 6	g02568939
(15) 200 µF input capacitors (16) 400 µF output capacitors

RC Star Components

Illustration 7	g02568959
RC Star module (20) F7, F8, and F9 fuses (21) K2 relay (22) F21 and F22 fuses (23) Precharge resistors (24) 30 µF capacitors (25) F7, F8, and F9 fuses (26) K2 relay (27) F21 and F22 fuses (28) 30 µF capacitors

Selector Switch Cabinet Capacitors

SSC 800 kVA Cabinet

Illustration 8	g02568978
(30) Precharge resistors (31) F7, F8, and F9 fuses (32) Capacitors (33) RC Star assembly

SSC 1200 kVA Cabinet

Illustration 9	g02568980
(34) Precharge resistors (35) F7, F8, and F9 fuses (36) Capacitors (37) RC Star assembly

SSC 2000 kVA Cabinet

Illustration 10	g02568981
(40) Precharge resistors (41) F7, F8, and F9 fuses (42) Capacitors (43) RC Star assembly

SSC 2000 kVA Light Cabinet

Illustration 11	g02568982
(40) Precharge resistors (41) F7, F8, and F9 fuses (42) Capacitors (43) RC Star assembly

Chokes

The following information provides the location of the various chokes that are used in the UPS.

200 kVA Chokes

Illustration 12	g02575076

300 kVA and 400 kVA Chokes

Illustration 13	g02576120
300 kVA and 400 kVA chokes

Illustration 14	g02575116
(45) OND31 (46) LB1 (47) OND32 (48) LB2 (49) OND33 (50) LB3 (51) LB4 (52) LN (53) PFC31 (54) PFC32 (55) LE1 (56) PFC33 (57) PFC13 (58) PFC23 (59) PFC12 (60) PFC22 (61) PFC11 (62) PFC21 (63) LB6 (64) LB5 (65) OND23 (66) OND13 (67) OND22 (68) OND12 (69) OND21 (70) OND11

500 kVA Chokes

Illustration 15	g02576199
(75) 500 kVA cabinet chokes

The 500 kVA cabinet uses the same quantity of chokes as the 300 kVA and 400 kVA cabinets and the same naming conventions. Refer to Illustration 14 for choke location and labels.

Current Transformer (CT) and LEM Component Locations

300 kVA and 400 kVA Unit CT and LEM Component Locations

Illustration 16	g02577216
(76) CT and LEM component locations

Illustration 17	g02575136
(77) PFC section (78) LEM 1 (79) LEM 2 (80) LEM 3 (81) LEM 9 (82) BN/NL (83) TI 3 (84) Output section (85) TI 2 (86) TI 1 (87) TI 7 (88) TI 6 (89) TI 5 (90) Phase 3 (91) Phase 2 (92) Phase 1 (94) TI 4 (95) Inverter section (96) LEM 6 (97) LEM 7 (98) LEM 8 (99) LEM 5 (100) Chopper1 and Chopper2 (101) LEM 4 (102) PFC Phase 3 (103) PFC Phase 2 (104) PFC Phase 1

CT and LEM Installation Positions

Refer to Illustration 17 caption for call out information.

Illustration 18	g02577219
Required mounting direction for components

Illustration 19	g02581086

500 kVA Unit CT and LEM Component Locations

Illustration 20	g02577280
(110) CT and LEM component locations

Illustration 21	g02577281
(111) PFC phase 3 (112) PFC phase 2 (113) PFC phase 1 (114) PFC (115) LEM 1 (116) LEM 2 (117) LEM 3 (118) BN/NL (119) LEM 9 (120) LEM 4 (Chopper 1) (121) LEM 5 (Chopper 2)

Illustration 22	g02577284
(125) Inverter section (126) TI 7 (127) TI 6 (128) Phase 3 (129) LEM 8 (130) LEM 7 (131) LEM 6 (132) Phase 1 (133) TI 5 (135) TI 4 (136) TI 1 (137) TI 2 (138) TI 3 (139) Phase 3 (140) Phase 2 (141) Phase 1 (142) Output section

CT and LEM Component Installation Positions

Illustration 23	g02577285
(115) LEM 1 (116) LEM 2 (117) LEM 3 (120) LEM 4 (Chopper 1) (121) LEM 5 (Chopper 2) (126) TI 7 (127) TI 6 (129) LEM 8 (130) LEM 7 (131) LEM 6 (133) TI 5 (135) TI 4

Illustration 24	g02577296
(119) LEM 9 (136) TI 1 (137) TI 2 (138) TI 3

Static Switch Cabinet (SSC) Current Transformers

800 kVA SSC Current Transformers

Illustration 25	g02589221
(139) Current transformers (CT) (TI 1, TI 2, and TI 3) (140) Current transformers (CT) (TI 4, TI 5, and TI 6)

Note: For installation, ensure that the label on each CT (TI 1, TI 2, and TI 3) is facing upward.

Note: For installation, ensure that the label on each CT (TI 4, TI 5, and TI 6) is facing downward.

1200kVA SSC Current Transformers

Illustration 26	g02589241

2000kVA SSC Current Transformers

Illustration 27	g02589256

2000kVA Light SSC Current Transformers

Illustration 28	g02589276

Fuses

200kVA, 300kVA, and 400kVA AC Power Fuses

Illustration 29	g02584282
(150) F3 (151) F2 (152) F1 (153) F6 (154) F5 (155) F4

Table 1

Input Fuses F1, F2, F3
kVA Unit	Amp
200	400
300	630
400	800
Output Fuses F4, F5, F6
200	400
300	630
400	800

500 kVA AC Power Fuses

Illustration 30	g02584379
(156) F3 (157) F2 (158) F1 (159) F6 (160) F5 (161) F4

Table 2

Input Fuses F1, F2, F3
kVA Unit	Amp
500	1000
Output Fuses F4, F5, F6
500	1000

SSC 800 kVA

Illustration 31	g02584556
(165) Q1 (166) Q2 (167) F7 (168) F8 (169) F9

Table 3

F7, F8, F9 RC Star Fuses
kVA	Amps
800	25

The SSC 800 kVA also contains the Q1 and Q2 fuses.

SSC 2000 FUSES NEXT

SSC 1200 kVA and 2000 kVA Units

Refer to Illustration 31 for the location of the fuses for the 1200 kVA and 2000 kVA cabinets. The 1200 kVA and 2000 kVA cabinets are different in some aspects, but the fuses are in the same location as the 800 kVA cabinet.

Board Fuses

DAFT Board

Illustration 32	g02585360
(172) FU8 (173) FU7 (174) FU6 (175) FU5 (176) FU4 (177) FU2 (178) FU1 (179) FU3 (180) FU17 (181) FU15 (182) FU14 (183) FU13 (184) FU12 (185) FU11 (186) FU10 (187) FU9

Table 4

Fuse	Purpose	Amp	Voltage
FU1	CPI supply phase 2	4	500
FU2	Neutral fans	12	600
FU3	CPI supply phase 2	4	500
FU4	Contactor K1 supply	4	600
FU5	ALIN V+ 400V supply DC	4	600
FU6	ALIN V- 400V supply DC	4	600
FU7	ALBT V+ 400V supply DC	4	600
FU8	ALBT V- 400V supply DC	4	600
FU9	DC caps fans supply V7, V8, V9	T1	250
FU10	PFC up or down fans supply	T1	250
FU11	PFC up or down fans supply	T1	250
FU12	INV up or down fans supply	T1	250
FU13	INV up or down fans supply	T1	250
FU14	Left choke supply fans	T1	250
FU15	Right choke supply fans, V5	T1	250
FU17	Left choke supply fans, left V3, right V4	T1	250

DAFT 2 Board Fuses

Refer to Illustration 32 for the location of the fuses for the DAFT 2 board. Refer to Table 4 for fuse information.

DALIT Board Fuses

Illustration 33	g02585365
(190) FU3 (191) FU2 (192) FU1 (193) FU12 (194) FU5 (195) FU4 (196) FU10 (197) FU11 (198) FU13 (199) FU9 (200) FU8

Table 5

Fuse	kVA Unit	Purpose	Amp	Voltage
FU1	300/400	Chokes right 1 fan supply V6	0.5	250
	500	SS ACBP 2 fans supply V6	0.5	250
FU2	300/400	CS ACBP 1 fan supply V23	0.5	250
	500	SS ACBP 2 fans supply V5	0.5	250
FU3	300/400	CS ACBP 1 fan supply V23	0.5	250
	500	SS ACBP 2 fans supply V5	0.5	250
FU4		ALIN AC Normal supply	4	500
FU5		ALIN AC Normal supply	4	500
FU8		SS ACBP Auto supply	2	500
FU9		SS ACBP Auto supply	2	500
FU10		ALIN ACBP supply	4	500
FU11		ALIN ACBP supply	4	500
FU12		Neutral fans SS ACBP	12	600
FU13		SS ACBP Auto supply TV1 secondary transformer	T2	250

VENT Board Fuses

Illustration 34	g02585366

CPI supply phase 2

Table 6

Fuse	Call Out	Purpose	Amp	Voltage
FU1	213	CPI supply phase 2	4	500
FU2	211	ALIM 1 (AC/DC) supply	4	600
FU3	212	Neutral fans	12	600
FU4	209	Contactor K1 supply	4	600
FU5	208	ALIN V+ 400V supply DC	4	600
FU6	207	ALIN V- 400V supply DC	4	600
FU7	206	ALBT V+ 400V supply DC	4	600
FU8	205	ALBT V- 400V supply DC	4	600
FU9	214	CPI supply phase 2	4	500
FU10	210	ALIM 1 (AC/C)supply	4	600
FU11	216	Power for fans that cool chokes, inverter, and DC capacitors	4	500
FU12	215	Power for fans that cool chokes and Inverter	4	500
FU13	220	Power for fans that cool the inverter	6	600
FU14	219	Power for fans that cool chokes	6	600
FU15	218	Power for fans that cool chokes, V5	6	600
FU16	217	Power for fans that cool chokes V3 and V4	6	600

RC Star Assembly Fuses

Refer to Illustration 7 for fuses in the RC star assembly.

Fans

Fans for the 200 kVA, 300 kVA, and 400 kVA Units

Illustration 35	g02585363
(225) Left choke fans V1, V2, and V3 (226) Right choke fans V4, V5, and V6 (227) PFC fans (228) Inverter fans (229) DC capacitor fans (230) SS ACBP V22 and V23 fans

Note: The DC capacitor fans are for the 300 kVA and 400 kVA units.

Fans for the 500 kVA Unit

Illustration 36	g02585376
(231) Left choke fans V1, V2, and V3 (232) Right choke fans V4, V5, and V6 (233) SS ACBP fans (234) PFC fans (235) Inverter fans (236) SS inverter fans (237) DC capacitor fans

Board LEDs

ALBT Board LEDs

Illustration 37	g02594516

Table 7

HE1 LED
LED Status	Function
On	Board OK
Off	Board not started or board fault

ALIN Board LEDs

Illustration 38	g02594536

Table 8

LED	Status	Function
HE1	On	Isolated supply OK
HE2	On	V+15 Voltage presence

CSDT Board LEDs

Illustration 39	g02594556

Table 9

LED	Status	Function
HE1	On	The static switch is controled
HE3	On	Thermal switch OK (closed)

DAFT Board LEDs

Illustration 40	g02594596
Fan LEDs

During normal operation, all of the LEDs are illuminated. A fan is faulty if the LED is off.

Refer to the Test and Adjust, UENR1799, "Troubleshooting" section of this publication for more troubleshooting information.

DALIT Board LEDs

Illustration 41	g02594598
Fan LEDs

During normal operation, all of the LEDs are illuminated. A fan is faulty if the LED is off.

Refer to the Test and Adjust, UENR1799, "Troubleshooting" section of this publication for more troubleshooting information.

DIGIT Board LEDs

Illustration 42	g02594616

Table 10

LED	Status	Function
HE1	On	3.3 V present
HE2	On	1.9 V present
HE3	On or off	Firmware normal execution stopped
	Flashing	f=0.3s downloading in progress on DPS2 (1)
	Flashing	f=1s/0.3s Initialization error (3s) (1)
	Flashing	f=1s DPS2 is running (normal execution) (1)
HE4	On or off	Firmware normal execution stopped
	Flashing	f=0.3s downloading in progress on DPS1 (1)
	Flashing	f=1s/0.3s Initialization error (3s) (1)
	Flashing	f=1s DPS1 is running (normal execution) (1)
HE5	On	Isolated 5 V is present

( 1 )

"f" refers to the length of time of the LED flash per second.

Table 11

Mode	Description	LED Status
		HE9	HE10	HE11	HE12	HE13
Normal GME	Normal running	Off	Off	Off	Off	Off
	Stopped	Off	Off	Off	Off	On
	Manual mode	Off	Off	Off	On	Off
	Downgraded mode	Off	Off	Off	On	On
	Board initiate	Off	Off	On	Off	Off
	Personalization initiate	Off	Off	On	Off	On
	UPS initiate	Off	Off	On	On	Off
	Unused	Off	Off	On	On	On
Supervision	Unused	Off	On	Off	Off	Off
	Unused	Off	On	Off	Off	On
	FPGA internal WDOG	Off	On	Off	On	Off
	WDOG Regulation	Off	On	Off	On	On
	WDOG IDLE	Off	On	On	Off	Off
	WDOG FAST	Off	On	On	Off	On
	CLK loss	Off	On	On	On	Off
	DSP Reset	Off	On	On	On	On
Trap	Board power fault NMI	On	Off	Off	Off	Off
	Stack overflow	On	Off	Off	Off	On
	Stack underflow	On	Off	Off	On	Off
	TRAP_SYSTEM/Undefined opcode	On	Off	Off	On	On
	TRAP_SYSTEM/Illegal Address	On	Off	On	Off	Off
	Reserved Interrupt	On	Off	On	Off	On
	Operating System Error	On	Off	On	On	Off
	Unused	On	Off	On	On	On
Self Tests	Unused	On	On	Off	Off	Off
	RAM Self Test Fault	On	On	Off	Off	On
	ROM_1 Self Test Fault	On	On	Off	On	Off
	ROM_2 Self Test Fault	On	On	Off	On	On
	EEPROM/Serial Flash Self Test Fault	On	On	On	Off	Off
	Unused	On	On	On	Off	On
	Unused	On	On	On	On	Off
	FPGA Self Test Fault	On	On	On	On	On

EXPUT Board LED

Illustration 43	g02594676

Table 12

HE1
Status	Function
On	+15 V present

EXTT-INTT Board LEDs

Illustration 44	g02594678
Interconnection board that also manages exchange currents

Table 13

LED	Status	Function
HE1	On	External Bus CAN OK
	Off	External Bus CAN fault
HE2	On	At least one UPS is coupled in the installation
	Off	No UPS units are coupled in the installation

GDET Board LEDs

Illustration 45	g02594679
Control-monitoring board for the display

Table 14

MODE	Description	HE1	HE2	HE3	HE4	HE5
NORMAL GME	Normal running	Flashing (0.5s)	Off	Off	Off	Off
	Unused		Off	Off	Off	On
	Manual mode		Off	Off	On	Off
	Downgraded mode		Off	Off	On	On
	Board initiate		Off	On	Off	Off
	Personalization initiate		Off	On	Off	On
	UPS initiate		Off	On	On	Off
	Unused		Off	On	On	On

Table 15

MODE	Description	HE1	HE2	HE3	HE4	HE5
Surveillance	Unused	Flashing 0.5s	On	Off	Off	Off
	Unused		On	Off	Off	On
	Unused		On	Off	On	Off
	Unused		On	Off	On	On
	Unused		On	On	Off	Off
	WDOG FAST		On	On	Off	On
	Unused		On	On	On	Off
	Unused		On	On	On	On

Table 16

MODE	Description	HE1	HE2	HE3	HE4	HE5
Trap	Board power fault NMI	On	Off	Off	Off	Off
	Unused	On	Off	Off	Off	On
	Unused	On	Off	Off	On	Off
	TRAP_SYSTEM/Undefined opcode	On	Off	Off	On	On
	Unused	On	Off	On	Off	Off
	Unused	On	Off	On	Off	On
	Unused	On	Off	On	On	Off
	Unused	On	Off	On	On	On

Table 17

MODE	Description	HE1	HE2	HE3	HE4	HE5
	Unused	On	On	Off	Off	Off
	Unused Off	On	On	Off	Off	On
	Unused	On	On	Off	On	Off
	Unused	On	On	Off	On	On
On Self Tests	Unused	On	On	On	Off	Off
	Unused	On	On	On	Off	On
	Unuse	On	On	On	On	Off
	Unused	On	On	On	On	On

Table 18

MODE	Description	HE1	HE2	HE3	HE4	HE5
Self Tests	Unused	On	On	Off	Off	Off
	Unused	On	On	Off	Off	On
	Unused	On	On	Off	On	Off
	Unused	On	On	Off	On	On
	Unused	On	On	On	Off	Off
	Unused	On	On	On	Off	On
	Unuse	On	On	On	On	Off
	Unused	On	On	On	On	On

INPUT Board LED

Illustration 46	g02594697
Input voltage and current values from the rectifier, inverter, DC bus, battery, and the neutral leg.

Table 19

HE1
Status	Function
On	+15 V present

NSDT Board LEDs

Illustration 47	g02594698

VENT Board LEDs

Illustration 48	g02594699

During normal operation, all of the LEDs are illuminated. A fan is faulty if the LED is off.

Refer to the Test and Adjust, UENR1799, "Troubleshooting" section of this publication for more troubleshooting information.

DC Supply 500kVA LEDs

Illustration 49	g02594700
DC supply (ALIM 1 and ALIM 2)

Note: Do not change the output voltage setting.

Table 20

V out
Status	Function
On	+24 V present
I (current) out
On	No current limitation

Table 21

V out LED
Status	Function
Green	21.6 V ≤ V out
Red	7 V ≤V out 21.6 V
Off	V out < 7 V
I out LED
Green	I out ≤ I in
Orange	I in ≤ I out
Red	Power supply shut off

UPSB Modules

200 kVA Modules

Illustration 50	g02601340

300 kVA and 400 kVA Modules

Illustration 51	g02601358

500 kVA

Illustration 52	g02601417

IGBT Modules

Illustration 53	g02601418

200 kVA, 300 kVA, 400 kVA CS Modules

Illustration 54	g02601420

500 kVA CS Modules

Illustration 55	g02601439

200 kVA,300 kVA, 400 kVA Freewheel Diode

Illustration 56	g02601442

500 kVA Freewheel Diode

Illustration 57	g02601456

Board Locations

200 kVA, 300 kVA, 400 kVA, and 500 kVA Boards

Illustration 58	g02602716

200 kVA, 300 kVA, and 400 kVA Boards

Illustration 59	g02602718

Illustration 60	g02603139

500 kVA Boards

Illustration 61	g02603156

Illustration 62	g02603157

Display Boards

Illustration 63	g02603158