UPS 120, UPS 150, UPS 250 and UPS 300 Uninterruptible Power Supplies Caterpillar

AC Power Wiring Connections

Determine the AC currents for your system based on kVA, voltage, and installed options. Also refer to equipment nameplates for the model number, rating, and voltage.

The UPS is designed for the cables to enter the cabinet top or bottom. Removable access plates must be cut in order to accommodate the conduit size. Input cables and output cables must be run in separate conduits.

The connection terminals are drilled for 1/2 inch hardware and spaced for one or two hole NEMA lugs.

Connection terminals can be oriented for top entry or bottom entry. Orienting the terminals in the direction of cable entry will minimize the number of bends in the cables. Space limitations require smaller cables installed parallel to one another. The use of smaller cables reduces the risk of damage to the unit or the cables while pulling the cables.

Note: The lugs and the cables are not supplied. Refer to "NEC Article 210-19" and the "NEC Table 310-16" for the correct size of the cables. Refer to "NEC Article 250-95" for the correct size of the ground. Refer to "NEC Article 310-15" for the correct size of the neutral.

The torque for the wire connections is 61 N·m (45 lb ft).

Note: A service disconnect device must be installed. The disconnect device must be rated properly for the output power. The disconnect device is not supplied.

1. The following wires and cables must be housed in an individual, separate conduit or cable tray. Placing multiple cables in the same conduit with other control or power wiring may cause the system to fault.

   • All shielded cables

   • Non-shielded cables

   • Non-shielded control wires

   • Non-shielded remote control wires

2. Verify that utility power and overcurrent protection ratings will accommodate the UPS input rating.

3. A safety ground wire must be installed from building ground to the ground point in the UPS module cabinet. The grounding conductor must comply with the following conditions of installation.

   1. The insulated grounding conductor must be sized in accordance with the NEC, in the USA, and all other local and national codes. The insulated grounding conductor must be installed as part of the branch circuit that supplies power to the unit or system.

   2. The grounding conductor must have an earth ground at the service equipment. If the system is supplied by a separately derived system, the grounding conductor must have an earth ground at the supply transformer or generator set.

4. Attachment plug receptacles used in the vicinity of the unit or system must be grounding type. The grounding conductors serving the attachment plug receptacles are to be connected to earth ground at the service equipment.

5. Observe clockwise phase rotation of all power wiring. Phase A leads, Phase B leads, and Phase C leads. The phase rotation must be confirmed by a qualified electrician.

   Note: The weight of the power cables must be supported adequately to avoid stress on the bus bars and lugs.

6. The installing contractor can remove the access plates from the top or bottom of the cable access areas of the UPS in order to cut entry holes for conduit.
   Show/hide table

   NOTICE
   After cutting holes in the access plates, ensure that no foreign matter such as metal shavings, sawdust, insulation, or wire fragments remain inside the UPS. Be certain to plug any unused holes in the plates through which foreign matter could enter the UPS.

7. The following three-phase power cables are connected in the bypass cabinet:

   • Input cables

   • Output cables

   • Ground cables

   • Neutral cables

   Note: Neutral cables are used only in four-wire systems.

The Underwriters Laboratories requires that the UPS system must be installed with an appropriately rated service disconnect device. The disconnect device must be rated for the output power. The disconnect device is not supplied with the UPS. If required by local and/or national regulations, an appropriately rated service disconnect device for input and output power must be provided.

The three-phase AC input and three-phase AC output cables are connected to a copper plated bus bar. The holes are spaced for two hole NEMA lugs with barrels.

The ground cable is connected to a copper plated bus bar. The bus bars are drilled for 3/8 inch hardware. The holes are spaced for two hole NEMA lugs with barrels.

The tab on the copper plated bus bar must be inverted in order for the cable to be installed from the bottom of the cabinet.

Overcurrent protection must be provided externally to the UPS. Overcurrent protection must conform to local and national codes.

Use 75° C (167° F) wire.

Recommended wire sizes are based on NFPA 70, NEC 2002 Edition. Local, national, or other applicable codes must also be observed. Compliance with all codes is the responsibility of the installer.

Cable Connection

Ensure that proper phase rotation is maintained at all times.

1. Route the AC power cables through the holes that are intendedto be usedfor the entry of the cables. The holes are punched in the galvanized steel panel.

2. Connect the three phase AC input cables to the bus tab that is for power distribution. The bus tab is located in the bypass cabinet. Torque the fasteners for the cables to 61 N·m (45 lb ft).

3. Connect the three phase AC output cables to the bus tab that is for power distribution. The bus tab is located in the bypass cabinet. Torque the fasteners for the cables to 61 N·m (45 lb ft).

4. Connect the ground cable to the copper plated bus tab that is located in the termination cabinet. Torque the fasteners for the ground cable to 61 N·m (45 lb ft).

Control Wiring

Customer interfaces are accessible through dry contacts on the system input/output (SIO) board (2). The SIO board (2) is located in the left component panel in the UPS cabinet. The UPS has a total of six input contacts and six "form C" output contacts available for customer use. The UPS also accepts serial connection for monitoring and control.

UPS Interface Board Locations

Illustration 1	g02836417
(1) Left component panel (2) SIO board (3) SOID board (4) Access panel screw (5) Access panel (6) Access panel screw

The access panel (5) must be removed to access the dry contact in the UPS cabinet. Remove the access panel screws to remove the access panel. The dry contacts are located on the SIO board that is located on the left component panel.

Illustration 2	g02836480
Typical system input/output (SIO) board (10) J7 Remote emergency power off (EPO) contacts (11) J14 Remote Input Contacts (12) J6 Remote Output Contacts (13) J12 Device Net (14) J16 Modem DB 9 (15) J10 Modem RJ45 (16) J10a Modem RJ11 (17) J9 Ether Net (18) J1 RS-232/ RS-485 9 pin connector (19) J8 UPSNET/CAN A (20) J4 24 VDC Power in

The connections for a typical system input/output (SIO) board are shown in Illustration 2.

Illustration 3	g02836481
SIO daughter board (25) J4 24 VDC power In (26) J1 RS-485 (27) J5 Remote panel out (28) J8 Backup UPS NET

Illustration 4	g02836482
J7 contacts for the REPO (30) J7 (31) Jumper

The REPO contacts allow for connection of a button external to the UPS. The REPO button is equivalent to the local emergency power off button. The REPO contacts (J7) are located on the SIO board.

Note: The J7 terminal has two sets of contacts that operate independently of each other. Terminals 1 and 3 are normally open. Terminals 2 and 4 are normally closed.

Note: The UPS is shipped with a jumper connected across the normally closed contacts, terminals 2 and 4. If the normally closed contacts are used, remove the jumper. If the normally open contacts, terminals 1 and 3, are used, do not remove the jumper.

SIO Board Connections

Dry Contacts

Use the following steps to access the dry contacts:

1. Open the system cabinet doors.

2. The dry contacts are located on the SIO board on the left component panel.

All contacts can be configured with UPSView to indicate if certain conditions exist. Each input is intended to interface to a single-pole single-throw switch. The switch connects the pair of contacts or the switch disconnects the pair of contacts. The contacts that are user programmable have an operating parameter that is used to configure that contact.

The following list of functions can be assigned to the contacts for the remote input block. Assigning functions are done by entering the parameter in the operating parameter field for the associated remote input.

Table 2 shows the function list for the input contacts.

Table 3 shows the default function.

Table 4 shows the function list for the output contacts.

Table 5 shows the default function assignments for output contacts.