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


Starting and Stopping

Usage:

UPS 250 APZ
Note: The following procedure should only be performed by service personnel that have been certified by Caterpillar. The procedure should be done after the system has been anchored into position and all wiring has been properly connected.

User Interface

The user interface must be used during the startup and shut down procedures.

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Illustration 1g02442956
Touchscreen panel and manual UPS controls
(1) Touchscreen
(2) USB interface
(3) Three positions keyswitch
(4) EPO button
(5) Horn silence button

Single Input with No Switches

Start Up

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Illustration 2g02846898

  1. Apply facility power to the UPS system input.

  2. Connect the UPS system output to the facility load circuits.

  3. Turn the UPS keyswitch (3) to the "Online" position.

    The three position selector switch (3) has three functions:

    • Bypass

    • Online

    • Reset

    The system enters the "Bypassed-Auto Start" state and begins charging the flywheel. When the flywheel reaches 4000 RPM, the system shifts to the "Online" mode. The system is operational.

  4. Confirm that the UPS is "Online" by observing the status line on the display.

Shut Down

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NOTICE

Before performing maintenance or service on the system, ensure that the proper lockout/tagout procedures are followed. When the flywheel is spinning, the DC bus and armature leads are energized.

  1. Turn the UPS keyswitch to the bypass position.

  2. Confirm that the UPS is in "Bypass". Press the "Home" soft key on the user interface panel. Observe the status line on the display to ensure that the system is in bypass.

    Note: The UPS system in this section is not equipped with a bypass switch. Power is lost to the supported load when the customer supplied "LOAD" circuit breaker is opened.

  3. Remove facility power from the UPS output.

  4. Remove facility power from the UPS input.

  5. Allow the capacitor banks to purge for approximately 5 minutes. The time allows any residual energy to dissipate that is in the DC bus, armature leads, and fuses.

Single Input with Three Switches

Procedure Before Applying Electrical Power

Use the following instructions before applying electrical power to the unit. The following procedure ensures that the unit is properly isolated before applying power and that the switches are in the correct positions.

  1. Turn the UPS keyswitch (3) to the "Bypass" position.

    Note: The bypass, output isolation, and input isolation switches are not intended for operator access. The switches are to be operated by personnel that are trained and qualified to service the equipment.

  2. Open (de-energize) the output isolation switch (12).

  3. Open (de-energize) the input isolation switch (13).

  4. Open (de-energize) the bypass switch (11).
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Illustration 3g02848000
Front view of cabinet
(11) Bypass switch (optional)
(12) Output isolation switch
(13) Input isolation switch
(14) Input and output connections without optional maintenance bypass

System Start Up

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    Illustration 4g02847978
    Simplified system diagram

  1. Apply facility power to the system input.

  2. Connect the system output to the facility load circuits.

  3. Confirm that the bypass switch (11) is open.

  4. Close (energize) the input isolation switch (13).

  5. Close (energize) the output isolation switch (12).

  6. Turn the UPS keyswitch (3) to the "Online" position.

    The system enters the "Bypassed-Auto Start" state and begins charging the flywheel. When the flywheel reaches 4000 RPM, the system shifts to the "Online" mode. The system is operational.

  7. Confirm that the UPS is "Online" by observing the status line on the display.

Shut Down

Note: When the flywheel is spinning, the DC bus and armature leads are energized.

  1. Turn the UPS keyswitch to the "Bypass" position.

  2. Confirm that the UPS is in bypass. Press the "Home" soft key on the user interface panel and observe the status line on the display.

    Note: Continuing with the procedure disconnects and de-energizes the critical load from the UPS output. Refer to the "Bypass" section for the proper system bypass procedure if the critical load is not suppose to be disconnected.

  3. Open (de-energize) the output isolation switch (12).

  4. Open (de-energize) the input isolation switch (13).

  5. Remove facility power from the UPS input.

  6. Allow the capacitor banks to purge for approximately 5 minutes to dissipate any residual energy in the DC bus and armature leads.

Bypass

  1. Turn the UPS key switch to the "Bypass" position.

  2. Confirm that the UPS is in bypass. Press the "Home" soft key on the user interface panel and observe the status line on the display.

    Note: If the UPS does not go to bypass, DO NOT PROCEED with the procedure. Equipment damage is possible and a load interruption is possible. Contact the technical communicator at the dealership.

    Note: Close the bypass switch to ensure that power to the critical load is not interrupted.

  3. Close (energize) the bypass switch (11).

  4. Open (de-energize) the output isolation switch (12).

  5. Open (de-energize) the input isolation switch (13).

Allow the capacitor banks to purge for approximately 5 minutes to dissipate any residual energy in the DC bus and armature leads.

Removing the System from Bypass

  1. Turn the UPS key switch to the "Bypass" position.

  2. Confirm that the UPS is in bypass. Press the "Home" soft key on the user interface panel and observe the status line on the display.

    Note: If the UPS does not go to bypass, DO NOT PROCEED with the procedure. Equipment damage is possible and a load interruption is possible. Contact the technical communicator at the dealership.

  3. Close (energize) the input isolation switch (13).

  4. Close (energize) the output isolation switch (12).

  5. Open (de-energize) the bypass switch (11).

  6. Turn the UPS keyswitch to the "Online" position.

  7. Press the "Home" soft key on the user interface panel. Ensure that the status line on the display shows that the UPS is "Online".

Emergency Shut Down

Emergency Shutdown Procedure

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Illustration 5g02849015
Touchscreen panel and manual UPS controls
(1) Touchscreen
(2) USB interface
(3) Three position key switch
(4) EPO button
(5) Horn silence button

An emergency shutdown can be initiated by the following:

  • Emergency power off (EPO) button (4)

  • Remote emergency power off (REPO) button using dry contacts

Upon activation of emergency shutdown, the entire system is secured. Power is not supplied to the load, however, voltage is still present on the input terminals.

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NOTICE

Pressing the EPO button will cause the UPS to disconnect from the load.

Refer to "Emergency Power Off Reset Circuit Breaker" in order to restart the UPS after pressing the emergency power off button.

Remote Emergency Power Off Button

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Illustration 6g00741799
Remote emergency power off (REPO) button

The remote emergency power off button is optional. The remote emergency power off button will disconnect the UPS by opening the input and the output contactors.

Note: When the remote emergency power off button is used, the entire system is secure. Power is not supplied to the load. However, voltage is still present on the input terminals.

Note: The critical load will lose power unless the customer has provided an external bypass.

Refer to "Emergency Power Off Reset Circuit Breaker" in order to restart the UPS after pressing the remote emergency power off button.

The remote emergency power off push-button functions in the same way as the emergency power off push button on the user interface panel.

Lockout/Tagout Procedure

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Illustration 7g00989668
Bypass Switch in the On (energized) Position
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Illustration 8g00989669
Bypass Switch Locked Out and in the Off (de-energized) Position

Use proper lockout/tagout procedures when you are working on the UPS in order to prevent injury to personnel and/or damage to equipment.

Emergency Power Off Reset Circuit Breaker

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NOTICE

Do not attempt to restart the UPS after an emergency shutdown until the cause of the emergency has been identified and corrected.

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Illustration 9g02849093
Emergency power off reset circuit breaker (15)

Whenever an emergency shutdown occurs, the emergency power off reset circuit breaker (15) must be reset. The circuit breaker is located behind the left door of the UPS.

Use the following procedure in order to reset the UPS:

  1. Cycle the emergency power off reset circuit breaker (15) from the "Off" position (0) to the "On" position (I) until the breaker clicks and the breaker remains in the "On" position.

  2. Cycle the UPS keyswitch (3) from the "Online" position to the "Reset" position.

    Refer to Illustration 5.

    The UPS is now reset. Follow the start-up procedure for the system in order to restart the UPS.

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